ML 2006 2011

MERCEDES ML-CLASS 2006-2011 2007 Mercedes-Benz ML350
2006-2008 HVAC Air Compressor, Belt Drives - 164 Chassis
REPAIR 2006-2008 HVAC MANUAL

TESTING & REPAIR
W164
Air Compressor, Belt Drives - 164 Chassis
TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES -
AR13.00-Z-9113AB
ENGINE 113
Remove, install poly-V- ENGINE 113... AR13.21-P-1202RVK

belt for compressor
Remove, install poly-V- ENGINE 113.990 in AR13.21-P-1202TZ
belt for compressor MODEL 219.376
Remove, install poly V- ENGINE 112, 113... AR13.22-P-1202B
belt
Remove, install poly V- ENGINE 112, 113... AR13.22-P-1202BA
belt
Remove, install poly V- ENGINE 113.964 in AR13.22-P-1202GZ
belt MODEL 164.175
Remove, install poly V- ENGINE 112, 113... AR13.22-P-1202PV
belt
Remove, install poly V- ENGINE 112, 113... AR13.22-P-1202R
belt
Remove/install poly V- ENGINE 113.971 in AR13.22-P-1202RT
belt MODELS 251.075/175
Remove/install poly V- ENGINE 113.990 in AR13.22-P-1202RV
belt MODELS 211.076 /276
Remove, install poly V- ENGINE 113.967 in AR13.22-P-1202TY
belt MODEL 219.375
Remove, install poly V- ENGINE 113.990 in AR13.22-P-1202TZ
belt MODEL 219.376
Remove/install poly-V ENGINE 112, 113... AR13.25-P-3200B
belt tensioning device
Remove/install poly V- ENGINE 112, 113... AR13.25-P-3200BA
Remove/install poly-V- ENGINE 113.964 in AR13.25-P-3200GZ
belt tensioning device MODEL 164.175
Remove/install poly-V- ENGINE 112, 113... AR13.25-P-3200R
Removing/installing the ENGINE 113.971 in AR13.25-P-3200RT
poly-V-belt tensioning MODELS 251.075 /175
device
2007 Mercedes-Benz ML350
Remove/install poly V- ENGINE 113.967 in AR13.25-P-3200TY

Remove/install poly-V- ENGINE 113.990 in AR13.25-P-3200TZ
Remove/install ENGINE 113... AR13.25-P-3217RVK
tensioning device of
compressor poly-V-belt
Remove/install ENGINE 113.990 in AR13.25-P-3217TZ
tensioning device for MODEL 219.376
compressor poly-V-belt
AR13.00-Z-9156AB
ENGINE 156
Remove/install poly V- ENGINE 156 in MODEL AR13.22-P-1202GZS

belt 164, 251
Remove/install poly-V ENGINE 156 in MODEL AR13.22-P-1202SMG
belt 216, 221
Remove/install poly V- ENGINE 156.982 in AR13.22-P-1202TMG
belt MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Remove/install poly-V ENGINE 156 in MODEL AR13.25-P-3200GZS
belt tensioning device 164, 251
Remove/install poly-V ENGINE 156 in MODEL AR13.25-P-3200SMG
belt tensioning device 216, 221
Remove/install poly-V ENGINE 156.982 in AR13.25-P-3200TMG
belt tensioning device MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
AR13.00-Z-9272AB
ENGINE 272
Remove/install ENGINE 272 in MODEL AR13.20-P-0001CV

components for belt drive 204
Remove/install ENGINE 272, 273 in AR13.20-P-0001GZA
components for belt drive MODEL 164, 251
Remove/install ENGINE 272, 273 in AR13.20-P-0001SX
components of belt drive MODEL 221 ENGINE

273 in MODEL 216
Remove/install ENGINE 272, 273 in AR13.20-P-0001TS
components of belt drive MODELS 211, 219
Remove/install poly-V- ENGINE 272, 273 ... AR13.21-P-3350QB
belt guide pulley
Remove/install poly V- ENGINE 272, 273 in AR13.21-P-3350RX
belt guide pulley MODEL 230
Remove/install poly V- ENGINE 272.942 in AR13.21-P-3350VA
belt guide pulley MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install poly V- ENGINE 272, 273 ... AR13.22-P-1202QB
belt
Remove, install poly V- ENGINE 272, 273 in AR13.22-P-1202RX
belt MODEL 230
Remove, install poly V- ENGINE 272.942 in AR13.22-P-1202VA
belt MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
belt tensioning device MODEL 230
Remove/install poly V- ENGINE 272.942 in AR13.25-P-3200VA
ENGINE 272.963 in
MODEL 171.456
AR13.00-Z-9273AB
ENGINE 273

components for belt driveMODEL 164, 251
components of belt drive MODEL 221 ENGINE
273 in MODEL 216
components of belt drive MODELS 211, 219
belt guide pulley
belt guide pulley MODEL 230
Remove/install poly V- ENGINE 272, 273 ... AR13.22-P-1202QB

belt
Remove, install poly V- ENGINE 272, 273 in AR13.22-P-1202RX
belt MODEL 230
belt tensioning device MODEL 230
REMOVE, INSTALL POLY V-BELT - AR13.22-P-1202
Remove, install poly V-belt - AR13.22-P-1202GZ
ENGINE 113.964 in MODEL 164.175
Fig. 1: Identifying Poly V-Belt Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing
Align vehicle between the columns of
the lifting platform and position the four
Risk of death caused by vehicle slipping AS00.00-Z-
support plates at the lifting platform
or toppling off of the lifting platform. 0010-01A
support points specified by the vehicle
manufacturer.
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, trunk moving parts. 0011-01A
lids, tailgates or sliding roof.
AR88.40-P-
1 Open engine hood
1000GZ
2 Remove the left and right intake air duct
AR01.10-P-
3 Remove front engine cover
2405GZ
To do this turn hexagon (3) at
tensioning pulley (2) in an anti-
4 Loosen poly-V-belt (1) and remove clockwise direction and lock tensioning
pulley (2) with pin/drift (4) (diameter 5
mm).
Checking
Inspect belt pulley sections and tensioning Check for damage, wear and dirt;
5
device replace if necessary.
6 Check guide pulley Replace if necessary.
*BA20.10-
P-1008-01C
7 Check poly-V-belt (1)
AP13.22-P-
Check poly-V-belt in visible area for wear
1352GZ
Install
Do not use belt wax or any similar
products.
8 Install poly-V-belt (1) and tighten it. Start in numerical order of the
relevant running diagram at tensioning
pulley (2), refer to: ?
AR13.22-P-
Layout diagram of poly-V-belt
3902-02GZ
Risk of accident caused by vehicle
Secure vehicle to prevent it from
starting off by itself when engine is
moving by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes.
procedure or when working near the
Do not grasp hot or rotating parts.
running engine
9 Carry out engine test run
AR88.40-P-
10 Close engine hood
1000GZ
COOLANT PUMP, COOLANT THERMOSTAT

Number Designation Engine 113.964/971
BA20.10-P-1008-01C Bolt connecting guide pulley to coolant pump housing 20
Remove/install poly V-belt - AR13.22-P-1202GZS
ENGINE 156 in MODEL 164, 251

Fig. 2: Identifying Poly V-Belt Components

Removing
Align vehicle between columns of
lifting platform and position four
support plates at lifting platform
or toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
pinched or crushed when removing, Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk of moving parts. 0011-01A
AR88.40-P-
1 Open engine hood Model 164
1000GZ
AR88.40-P-
Model 251
1000RT
2 Remove left and right intake air duct
Do not tilt front engine cover,
3 Remove front engine cover but lift upwards vertically otherwise
the retaining lugs can break off.
AR00.60-P-
4 Raise vehicle with lifting platform Model 164
1000GZ
AR00.60-P-
Model 251
1000RT
Remove lower engine compartment AR61.20-P-
5
paneling 1105GZ
Model 251 AR61.20-P-
1105RT
The tensioner pulley (2) is more
accessible from below.
To do this, turn the hexagon (3) at
6 Loosen poly-V-belt (1) and remove the tensioner pulley (2) in an anti-
clockwise direction and lock the
tensioning pulley (2) with a pin or drift
(4) (5 mm diameter).
Checking
Inspect belt pulley sections and tensioning Check for wear, damage or soiling
7
device and replace if necessary.
8 Check guide pulley Replace if necessary.
*BA13.25-P-
1003-01U
*BA13.25-P-
1004-01U
*BA13.25-P-
1005-01U
9 Check poly-V-belt (1)
Check poly-V-belt in visible range for AP13.22-P-
Model 164
wear 1352GZ
AP13.22-P-
Model 251
1352RT
Install
Do not use belt wax or any similar
products.
10 Install poly-V-belt (1) and tighten it. Start in numerical order of the
relevant running diagram at tensioner
pulley (2), refer to: ?
AR13.22-P-
Layout diagram of poly V-belt 3902-
02AMG
moving by itself.
clothes.
running engine
AR88.40-P-
12 Close engine hood Model 164
1000GZ
AR88.40-P-
Model 251
1000RT
BELT TENSIONING DEVICE

Number Designation Engine
156
BA13.25-P- Guide pulley on coolant pump housing (between power steering pump
Nm 20
1003-01U and guide pulley with grooved channel profile)
BA13.25-P- Guide pulley on coolant pump housing (between alternator and smooth
Nm 20
1004-01U guide pulley)
BA13.25-P-
Guide pulley (between poly-V-belt tensioning device and coolant pump) Nm 20
1005-01U
ROUTING DIAGRAM OF POLY V-BELT - AR13.22-P-3902
Routing diagram of poly V-belt - AR13.22-P-3902-02AMG
Fig. 3: Identifying Poly V-Belt Components Location

Running diagram of poly V-belt - AR13.22-P-3902-02GZ
6-groove single-belt drive, with AC compressor

Fig. 4: Poly V-Belt Running Diagram

Routing diagram of poly V-belt - AR13.22-P-3902-02VA
Shown on engine 272.963
Fig. 5: Routing Diagram Of Poly V-Belt (Shown On Engine 272.963)

REMOVE/INSTALL POLY-V-BELT TENSIONING DEVICE - AR13.25-P-3200
Remove/install poly-V-belt tensioning device - AR13.25-P-3200GZ
Fig. 6: Identifying Poly-V-Belt Tensioning Device Components

Remove/install
When moving components,

Risk of injury caused by fingers being jammed or
ensure that no body parts or AS00.00-Z-
pinched when removing/installing or aligning hoods,
limbs are within operating 0011-01A
doors, trunk lid/rear-end door or sliding roof.
range of moving parts.
AR88.40-P-
1 Open engine hood and raise to vertical position
1000GZ
AR01.10-P-
2405GZ
Only remove poly-V-belt
(2) from belt pulley/guide AR13.22-P-
4 Partially remove poly-V-belt (2)
pulleys until tensioning device 1202GZ
(3) is accessible.
Rotate tensioning device at hexagon (3) in an anti- Lock tensioning device with
5
clockwise direction and lock a pin/drift (5 mm diameter).
*BA13.25-P-
6 Remove bolts (1)
1001-01D
7 Remove tensioning device (3)
8 Install in the reverse order
Secure vehicle to prevent it
Risk of accident caused by vehicle starting off by from moving by itself.
itself when engine is running. Risk of injury caused by Wear closed and snug-fitting AS00.00-Z-
contusions and burns during starting procedure or when work clothes. 0005-01A
working near the running engine Do not grasp hot or rotating
parts.

113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/9
Self- Thread
tapping not Nm 35
BA13.25- bolt, belt pre-
P-1001- tensioner tapped
01D to timing Thread
case pre- Nm
cover tapped
Remove/install poly-V belt tensioning device - AR13.25-P-3200GZS

Fig. 7: Identifying Poly-V-Belt Tensioning Device Components

Remove/install
Risk of injury caused by fingers being jammed

When moving components, ensure
or pinched when removing/installing or aligning AS00.00-Z-
that no body parts or limbs are within
hoods, doors, trunk lid/rear-end door or sliding 0011-01A
operating range of moving parts.
roof.
AR88.40-P-
1 Open engine hood and raise to vertical position Model 164
1000GZ
AR88.40-P-
Model 251
1000RT
Do not tilt engine cover, but
3 Remove front engine cover lift upwards vertically otherwise
retaining lugs can break off.
Only remove poly-V-belt (2) from AR13.22-P-
4 Partially remove poly-V-belt (2) belt pulley/guide pulleys until 1202GZ
tensioning device (3) is accessible.
Rotate tensioning device at hexagon (3) in an Lock clamping device (3) with pin
5
anti-clockwise direction and lock or drift (diameter 5 mm).
*BA13.25-
6 Remove bolts (1)
P-1001-01U
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
8 Remove lower engine compartment paneling Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
Turn clamping device (3) in such a
9 Remove tensioning device (3) way that guide pulley for clamping
device (3) points towards engine!
Extend tensioner pulley in a gap in
the fan downwards.

Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of injury moving by itself.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting work
0005-01A
procedure or when working near the running clothes.
engine Do not grasp hot or rotating parts.

Number Designation Engine 156
BA13.25-P-1001-01U Bolt, poly-V belt tensioning device to timing case cover M8 Nm 20
MAINTENANCE
CHECK VISIBLE AREA OF POLY-V BELT FOR WEAR - AP13.22-P-1352
Check visible area of poly-V belt for wear - AP13.22-P-1352GZ
ENGINE 113.9, 156.9 in MODEL 164.1
ENGINE 156.9 in MODEL 209
Fig. 8: Identifying Poly V-Belt

Damage diagram
Fig. 9: Identifying V-Belts Damage Patterns

Remove/install
Risk of injury caused by Keep body parts and AS00.00-Z-0011-01A
fingers being pinched or limbs well clear of
crushed when removing, moving parts.
installing or aligning
hoods, doors, trunk lids,
tailgates or sliding roof.
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or vehicle lift columns and
toppling off of the vehicle position four support
lift. plates at vehicle lift
support points specified
by vehicle manufacturer.
1 Shut off engine and open
engine hood
Open engine hood, move Model 164 AR88.40-P-1000GZ
to upright position and
close
Model 209 AR88.40-P-1000Q
Checking
2 Check poly-V belt (1) at Replace the poly-V-
the visible points for wear belt (1) if worn: ?
and compare with damage
patterns
Remove/install poly V-
belt:
Model 164 with engine AR13.22-P-1202GZ

113
Model 164 with engine AR13.22-P-1202GZS
156
Model 209 AR13.22-P-1202TMG
3 Raise vehicle with vehicle
lift
Lift/jack up vehicle Model 164 AR00.60-P-1000GZ
Model 209 AR00.60-P-1000P
4 Remove bottom engine Installation: Install
compartment paneling engine compartment
paneling only after
completing all
maintenance jobs.
Detach/attach lower Model 164 AR61.20-P-1105GZ
engine compartment
paneling
Model 209 AR61.20-P-1105P
Checking
5 Check poly-V belt (1) at Replace the poly-V-
the points which are belt (1) if worn: ?
visible when the vehicle is
raised and compare with
damage patterns
Remove/install poly V-
belt:
Model 164 with engine AR13.22-P-1202GZ
113
Model 164 with engine AR13.22-P-1202GZS
156
Check visible area of poly-V belt for wear - AP13.22-P-1352GZC
ENGINE 272, 273 in MODEL 164.1
ENGINE 273 in MODEL 164.8

Fig. 10: Checking Poly-V Belt

Fig. 11: Identifying Poly-V Belt Damage Pattern

Remove/install
Do not touch parts which conduct high
voltages. Persons who wear electronic
Risk of death due to contact with high- AS15.10-Z-
implants (e.g. heart pacemakers) should
voltage conductive parts 0001-01A
never perform any work on the ignition
system
Align vehicle between columns of vehicle
Risk of death caused by vehicle
lift and position four support plates at AS00.00-Z-
slipping or toppling off of the lifting
vehicle lift support points specified by 0010-01A
platform.
vehicle manufacturer.
1 Open engine hood

Opening engine hood, moving to AR88.40-
upright position and closing P-1000GZ
Checking
Check poly-V belt (1) at the visible
2 points for wear and compare with Replace the poly-V-belt (1) if worn: ?
damage patterns
AR13.20-P-
Remove/install belt drive components.
0001GZA
3 Raise vehicle with vehicle lift
AR00.60-
Lift/jack up vehicle
P-1000GZ
Installation: Install engine
Remove bottom engine compartment
4 compartment paneling only after
paneling
completing all maintenance jobs.
Detach/attach lower engine AR61.20-
compartment paneling P-1105GZ
Checking
Check poly-V belt (1) at the points
which are visible when the vehicle is
5 Replace the poly-V-belt (1) if worn: ?
raised and compare with damage
patterns
AR13.20-P-
Remove/install belt drive components.
0001GZA
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - BA13.00-Z-
9999AZ
MODEL all
Multi-belt drive ENGINE BA13.21-P-

111.943 /944 /947 /955 /958 /973 /975 /983, 155 1000-01A
Single-belt drive ENGINE 112 BA13.22-P-
1000-01A
Belt tensioning ENGINE 601.942 /943 /970, BA13.25-N-
device 602.980 /982 /983 /984 /985 1000-01B
Belt tensioning ENGINE 601, 602 /, 603 /, 604, 605, 606 / BA13.25-P-
device (except, 602.98 /98) 1000-01A
Belt tensioning ENGINE 102, 103/, 104/, 111, 120 BA13.25-P-
device 1000-01B
Belt tensioning ENGINE 119 BA13.25-P-
device 1000-01C
Belt tensioning ENGINE 113, 137, 275, 285... BA13.25-P-
device 1000-01D
Belt tensioning ENGINE 166.940/960/961 /990 /991 /995 BA13.25-P-
device 1000-01E
Belt tensioning ENGINE 668.914 /940 /941 /942 BA13.25-P-
device 1000-01F
Belt tensioning ENGINE 611, 612, 613, 646, 647, 648... BA13.25-P-
device 1000-01G
Belt tensioning ENGINE 628.960 /961 /962 /963, 629 BA13.25-P-
device 1000-01H
device 1000-01I
device 1000-01L
Belt tensioning ENGINE 112... BA13.25-P-
device 1000-01M
Belt tensioning ENGINE 272, 273 BA13.25-P-
device 1000-01P
Belt tensioning ENGINE 266.920 /940 /960 /980 BA13.25-P-
device 1000-01Q
device 1000-01R
Belt tensioning ENGINE 642/ BA13.25-P-
device 1000-01T
device 1000-01U
BELT TENSIONING DEVICE - BA13.25-P-1000
Belt tensioning device - BA13.25-P-1000-01D
Engines 113, 137, 275, 285

Number Designation Engines
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/
BA13.25- Self- Thread Nm 35
P-1001- tapping not pre-
01D bolt, belt tapped
tensioner Thread Nm 25
to timing pre-
case cover tapped
BA13.25- Bolt, guide M8 x 40 Nm 20
P-1002- pulley to
01D coolant
pump
BA13.25- Shock absorber of Nm 25
P-1003- belt tensioning
01D device to belt
tensioning device
BA13.25- Shock absorber of Nm 35
P-1004- belt tensioning
01D device to coolant
pump housing
BA13.25- Bolt, belt M7x25 Nm 35
P-1005- tensioner
01D to timing
case cover
BA13.25- Self- Thread Nm -
P-1006- tapping not
01D bolt, pretapped
compressor
belt
tensioner Thread Nm -
to timing pretapped
case cover
BA13.25- Bracket for charge Nm 7
P-1007- air cooler water pipes
01D
BA13.25- Bolt, guide M8 x 78 Nm -
P-1008- pulley for
01D compressor
and major
assembly
belts to
timing case
cover

Number Designation Engine 137 Engine 275 Engine
285.950
BA13.25-P- Self-tapping bolt, belt Thread not Nm - - -
1001-01D tensioner to timing case pre-tapped
cover Thread pre- Nm - - -
tapped
BA13.25-P- Bolt, guide pulley to M8 x 40 Nm - - -
1002-01D coolant pump
BA13.25-P- Shock absorber for belt tensioning Nm - - -
1003-01D device to belt tensioning device

BA13.25-P- Shock absorber for belt tensioning Nm - - -
1004-01D device to coolant pump housing
BA13.25-P- Bolt, belt tensioner to M7 x 25 Nm 14 14 14
1005-01D timing case cover
BA13.25-P- Self-tapping bolt, Thread not Nm - - -
1006-01D compressor belt pretapped
tensioner to timing case Thread Nm - - -
cover pretapped
BA13.25-P- Bracket for charge air cooler water Nm - - -
1007-01D pipes
BA13.25-P- Bolt, guide pulley for M8 x 78 Nm - - -
1008-01D compressor and major
assembly belts to timing
case cover
Belt tensioning device - BA13.25-P-1000-01P
Engine 272, 273

Number Designation Engine Engine
272 273
BA13.25-P-1001- Bolt of poly V-belt tensioning device to timing case
Nm 35 35
01P cover
BA13.25-P-1002-
Bolt of vibration damper to coolant pump Nm 35 35
01P
BA13.25-P-1003-
Bolt of vibration damper to timing case cover Nm 25 25
01P
Belt tensioning device - BA13.25-P-1000-01U
Engine 156

BA13.25-P-1001- Bolt for poly-V-belt M8 Nm 20
01U tensioning device on
timing case cover
BA13.25-P-1002- Bolt for pulley on M6 Nm 8.5
01U coolant pump
BA13.25-P-1003- Guide pulley on Nm 20
01U coolant pump
housing (between
power steering
pump and guide
pulley with grooved
channel profile)
BA13.25-P-1004- Guide pulley on Nm 20
01U coolant pump
housing (between
alternator and
smooth guide
pulley)
BA13.25-P-1005- Guide pulley Nm 20
01U (between poly-V-
belt tensioning
device and coolant
pump)
2006-2008 ACCESSORIES & BODY, CAB Seats, Bunks, Restraint Systems - 164 Chassis
2006-2008 ACCESSORIES & BODY, CAB
Seats, Bunks, Restraint Systems - 164 Chassis
GENERAL INFORMATION
NOTES ON PERFORMING REPAIR, BODY WORK AND WELDING ON VEHICLES WITH
AIRBAGS AND ETR UNITS - AH91.00-P-0002-01M
Model 164, 169, 171, 199, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 463, 906
1. Before beginning with

 body repairs
 work on airbag or ETR units (removal, installation)
 Work on components that are associated with the airbag and emergency tensioning retractor units
or require access to their circuit, e.g. when removing the steering wheel, remove ignition key
2. Before commencing welding work
 Remove ignition key and disconnect/insulate ground line from battery
 Disconnect coupling from airbag control unit with ETR unit
3. For painting
involving force drying, there are no special safety regulations to observe.
The airbag and emergency tensioning retractor units can withstand temperatures of up to a maximum of
100°C without sustaining any damage.
4. When performing repair work

 Do not bring airbag and emergency tensioning retractor units into contact with grease, oil or
cleaning agents
 Airbag or ETR units which have fallen from a height of more than 0.5 m must be replaced and must
not be installed in a vehicle under any circumstances
 In order to be able to install emergency tensioning retractor units free from damage and dirt, they
have been provided with a PVC film protective sleeve. This protective device must be removed
after assembly. To prevent the belt from being damaged in the process, do not use any sharp-edged
tools
Following work on airbag and ETR units,
the supplemental restraint system (SRS) must always be checked using STAR DIAGNOSIS.
LEGAL REQUIREMENTS ON HANDLING AND STORING AIRBAGS AND EMERGENCY

TENSIONING RETRACTOR UNITS - AH91.00-P-0004-01A
Model 124, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221,
230, 240, 245, 251, Model 314, 316, 318, Model 414, Model 450.3/4, 451.3/4, 452.3 /4, 454, Model 461, 463,
Model 638, 639.601/603/605/701/703/ 705/711/713/811/813/815, Model 668, 670, Model 690.6, 901, 902,
903, 904, 905, 906, Model 930, 932, 933, 934, 950, 952, 953, 954, Model 970, 972, 974, 975, 976, Model
WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5,
YD6, YD7
Legal regulations on handling and storing airbags and emergency tensioning retractors
All subsequently listed legal requirements apply to the Federal Republic of Germany. In other countries, the
valid national and local legal requirements must be observed.
Airbag and emergency tensioning retractor units are class T1. pyrotechnical objects. Their handling, transport
and storage are subject to the German Act Concerning Potentially Explosive Substances "Gesetz uber
explosionsgefahrliche Stoffe". Only a limited number of class T1 pyrotechnical objects may be stored in
buildings which are used for commercial purposes.
According to appendix 6 of the annex to the 2nd explosive directive, the maximum storage volume listed in the
following is permitted in commercially used buildings under consideration of certain regulations (e.g. a steel
cabinet) without special approval by the responsible authority:
 Work room, 10 kg net

 Storage room, 100 kg net
In order to calculate it, the net mass of the explosive contained in the respective component, for which the legal
explosive permit has been granted, must be used:
 Each driver airbag, 0.1 kg

 Each front passenger airbag, 0.3 kg
 Each sidebag, 0.05 kg
 Each emergency tensioning retractor, 0.001 kg
 Each windowbag, 0.004 kg
Airbags and emergency tensioning retractor units must not be stored in the immediate vicinity of easily/highly
flammable and fire-inducing materials.
Acquiring, transport, storage, installation and removal as well as scrapping may only be performed by trained
personnel in observance of all applicable safety regulations. The use of a vehicle's passenger compartment to
transport such materials is strictly prohibited!
Always stow the airbag and emergency tensioning retractor units in their original packaging in the trunk or load
compartment of the vehicle in a secure fashion so as to prevent them from sliding around.
ASSESSMENT OF AIRBAG AND BELT TENSIONER UNITS IN ACCIDENT VEHICLES - AH91.00-

P-0006-01B
Model 129 as of 1.7.93, 163, 164, 168, 169, 170, 171, 199, 202 as of 1.7.93, 203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251, 414, 461 as of 1.4.94, 463, 638, 901, 902, 903, 904, 905, 906
Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4,
YD5, YD6, YD7
 Following an accident:
 The airbag and emergency tensioning retractor restraint system is to be checked for visual damage,
defects and if it has been triggered
 Defective or damaged components must be immediately replaced. Repair of these components is
not permitted
 The emergency tensioning retractor with airbag control unit must be replaced:
 If the housing is deformed or otherwise damaged
 If the console has been deformed, even if the emergency tensioning retractor control unit with
airbag does not appear to have suffered any damage
 If there is an electrical defect
 Or after the airbag has deployed three times
A new emergency tensioning retractor with airbag control unit must be programmed and
parameterized after installation.
 The airbag or emergency tensioning retractor units must be replaced:

 Following deployment
 If there is external damage (even without deployment)
 Or if there is an electrical defect
The steering wheel and the steering column tube must be replaced after the driver airbag has been deployed.
The instrument panel must be replaced after the front passenger airbag has deployed.
The sidebag cover in the door lining and the side paneling must be replaced after the sidebag has been deployed.
Otherwise the airbag cannot be guaranteed to function correctly.
NOTES ON CONTROLLED DEPLOYMENT OF AIRBAG, SIDEBAG AND EMERGENCY

TENSIONING RETRACTOR UNITS - AH91.60-P-0611-02P
Models 163, 164, 168, 170, 199, 202, 203, 208, 209, 210, 215, 220, 230, 240, 251, 414,461,463
The unattached airbag, sidebag, windowbag and emergency tensioning retractor units should, if possible, be
deployed in a scrapped vehicle (with doors closed).
Position the unattached airbag, sidebag, windowbag and emergency tensioning retractor units in the footwell
with the discharge hole pointing upwards.
In exceptional cases - i.e. when there is no suitable vehicle around to use - the airbag, sidebag, windowbag and
emergency tensioning retractor units can be placed in a transport container for replacement engines and
deployed there (with the cover sealed).
The adapter line and the deployment device are to be ordered through the usual replacement part channels.
The 2-pin plug connection becomes damaged when deploying the unattached airbag, sidebag, windowbag and
emergency tensioning retractor units.
Therefore, the adapter cable must be pulled out of the plug and replaced.
BASIC KNOWLEDGE
ELECTRIC SEAT ADJUSTMENT (ESA) FUNCTION - GF91.29-P-0004GZ
MODEL 164, 251 with CODE (275) Memory package (driver seat, steering column, mirrors) with CODE
(242) Electrically adjustable front passenger seat with memory
Fig. 1: Identifying Electric Seat Adjustment (ESA) Function - Shown On Model 164.8
Shown on model 164.8
The electric seat adjustment (ESA [ESV]) is made up of the following component functions:
Normalize seat adjustment.
Normalize seat adjustment.
 Normalize seat adjustment.

 Position detection
 Blockage detection
 Head restraint presetting
(up to 31.5.07, not Economic Commission for Europe (ECE))
Further partial functions are described in separate documents:
 Adjust front seat

 Save and call up seat position of front seats
 Easy entry/exit feature for driver seat
 Seat release for 2nd seat row (model 164.8, model 251)
 Folding 3rd seat row
(model 164.8 with code (845) 3rd seat row folding down electrically)
Normalization is important for the assignment between the actual adjustment position and the position recorded
by the front seat adjustment position and the position recorded by the front seat adjustment control unit.
Normalization must be performed during initial startup or in a denormalized condition.
The assignment is conducted by moving to the following end stops:
 Longitudinal adjustment, front stop

 Inclination adjustment, lower stop
 Height adjustment on lower stop
 Backrest adjustment, front stop
 Head restraint adjustment, lower stop
Upon reaching each end stop the adjustment request must remain pending for another 250 ms.
The front seat adjustment control unit recognizes each end stop due to the lack of signals from the Hall sensors
integrated into the motors and switches off the corresponding motor. The location counter in the front seat
adjustment control unit is reset to zero.
An adjustment is denormalized if the signal from the Hall sensor fails or the mechanical stop is exceeded.
Position recognition
Function requirements:
 Seat adjustment normalized
Position recognition function
The Hall sensor signals are counted in the location counter of the seat adjustment control unit. Depending on the
motor's actuation voltage they are evaluated as either positive or negative.
Lockup recognition
Function requirement
Blockage detection function
If during an active adjustment function there are no Hall sensor signals (e.g. seat mechanism blocked), the
corresponding adjustment function is switched off after t = 2 s by the front seat adjustment control unit.
Reactivation in the same adjusting direction is not permitted until the corresponding switch has been released
for approx. t 2 > or = s. Re-enabling in the opposite direction is possible immediately.
Head restraint presetting

 Circuit 15R ON or
respective front door open
Head restraint presetting function
The position of the head restraint is preset automatically by the relevant seat adjustment control unit to match
the longitudinal adjustment position. The head restraint presetting function can be switched on and off using
STAR DIAGNOSIS.
Block diagram of electric seat GF91.29-P-0004-

adjustment (ESA [ESV]) 03GZ
GF91.29-P-
Seat adjustment, function
2005GZ
GF91.29-P-
Save/call up seat position, function
2006GZ
Easy entry/exit feature driver seat, GF91.29-P-
function 2014GZ
GF91.29-P-
Seat release in 2nd seat row, function Model 164.8
2017GZ
Model 164.8 with code (845) 3rd seat row GF91.29-P-

Folding 3rd seat row, function
folding down electrically 2018GZ
Block diagram of electric seat adjustment (ESA [ESV]) - GF91.29-P-0004-03GZ
Fig. 2: Block Diagram Of Electric Seat Adjustment - Shown On Model 164.8

ELECTRIC SEAT ADJUSTMENT FUNCTION DESCRIPTION (ESV) TABLE OF CONTENTS -

GF91.29-P-0998GZ
MODEL 164, 251 with CODE (242) Electrically adjustable front passenger seat with memory with
CODE (275) Memory package (driver seat, steering column, mirrors)
GF91.29-P-
Electric seat adjustment (ESA) function
0004GZ
Block diagram of electric seat adjustment GF91.29-P-
(ESA [ESV]) 0004-03GZ
GF91.29-P-
Save/call up seat position, function
2006GZ
GF91.29-P-
Seat adjustment, function
2005GZ
Easy entry/exit feature driver seat, GF91.29-P-
function 2014GZ
GF91.29-P-
Seat release in 2nd seat row, function Model 164.8, 251.1
2017GZ
Model 164.8 with code (845) 3rd seat row GF91.29-P-
Folding 3rd seat row, function
folding down electrically 2018GZ
Overview of system components for GF91.29-P-
electric seat adjustment (ESV) 9997GZ
SEAT ADJUSTMENT, FUNCTION - GF91.29-P-2005GZ
Fig. 3: Identifying Seat Adjustment, Function

Function requirements
 Circuit 15R ON or respective front door open (up to 31.5.07)
Function
Actuation of the switch group, which is located on the front seat frame trim, is read in voltage-coded by each
front seat adjustment control unit. The front seat adjustment control unit actuates the corresponding seat
adjustment motors directly.
To adjust, press and hold down switches on the switch group until the desired position is reached.
Abort conditions:
 Overvoltage or undervoltage
Adjustment function Adjustment direction

Forward/back adjustment Forward, back
Height adjustment (rear) Up, down
Inclination adjustment Up, down
Head restraint adjustment Up, down
Backrest adjustment Forward, back
Priorities
The switch group is designed so that adjustment in group 1 is independent of any switch actuation in group 2 or
group 3. If several adjustment requests are received in a group by the front seat adjustment control unit, then the
adjustment request with the higher priority is executed. A maximum of three motors (one motor per group) can
be adjusted simultaneously
See following table.
Priorities Group 1 Group 2

High 1 Backrest forward/back Forward/back adjustment
Center 2 Head restraint adjustment Height adjustment, rear (height)
Low 3 Inclination adjustment
Front seat adjustment motor group M27/1, M27/2, M27/3, M27/4, M27/5; M28/1, M28/2,
GF91.29-P-
with memory, component M28/3, M28/4, M28/5 (with code (242) Electrically
5219GZ
description adjustable front passenger seat with memory)
Component description of driver-
N32/1 GF91.29-P-
side front seat adjustment control
Model 164 5223GZ
unit with memory
GF91.29-P-
Model 251
5223RT
Component description of
N32/2
passenger-side front seat GF91.29-P-
Model 164 with code (242) Electrically adjustable
adjustment control unit with 5224GZ
front passenger seat with memory
memory
Model 251 with code (242) Electrically adjustable GF91.29-P-
front passenger seat with memory 5224RT
S91;
Front seat adjustment switch GF91.29-P-
S92 (with code (242) Electrically adjustable front
group, component description 5220GZ
passenger seat with memory)
EASY ENTRY/EXIT FEATURE DRIVER SEAT, FUNCTION - GF91.29-P-2014GZ

MODEL 164, 251 up to 31.5.06 with CODE (275) Memory package (driver seat, steering column,
mirrors)
Fig. 4: Identifying Easy Entry/Exit Feature Driver Seat, Function

 Function activated in instrument cluster

 Normalized seat adjustment
Easy entry/exit feature for driver seat
To make it easier to leave the vehicle, the driver seat (up to 31.5.06) and the steering column are moved to the
easy entry/exit position.
Movement to the easy entry/exit position is actuated by the following given state changes:
 Transmitter key removed (A8/1)

 Driver door open with circuit 15R
 Driver door open with circuit 15C
 Driver door opened with transmitter key not inserted
Abort conditions
 Undervoltage or overvoltage
 Active seat adjustment (manual or memory)
 Manual steering column adjustment
 Circuit change up to circuit 15 ON, both with opened and closed door
 Closure of driver door (irrespective of circuit status)
 Vehicle speed > 12 km/h
Approach drive position
Movement to the last stored drive position is actuated by the following given state changes:
 The driver door is closed with circuit 15 On

 Circuit 30 to circuit 15C
 Circuit 15C to circuit 15R
 Circuit 15R to circuit 15
Evaluation of the required signals and the adjustment of the seat and steering column are performed by the
driver front seat adjustment control unit.
Repetition safeguard
Repeatedly inserting and removing the transmitter key causes the equipment to move between the easy
entry/exit positions and the drive positions every time. To prevent this, the number of cycles is limited to five.
The counter is reset when the transmitter key is turned to circuit 15R ON or the driver door status is changed.
A1
GF54.30-P-
Instrument cluster, component description Model
6000GZ
164
Model GF54.30-P-
251 6000RT
N10/8
GF54.21-P-
Rear SAM control unit, component description Model
7030GZ
164
Model GF54.21-P-
251 7030RT
N32/1
Component description of driver-side front seat adjustment control unit GF91.29-P-
Model
with memory 5223GZ
164
Model GF91.29-P-
251 5223RT
N73
Electronic ignition/starter switch control unit (EIS), component GF80.57-P-
Model
description 6000GZ
164
Model GF80.57-P-
251 6000RT
GF91.29-P-
Front seat adjustment switch group, component description S91
5220GZ
SEAT RELEASE IN 2ND SEAT ROW, FUNCTION - GF91.29-P-2017GZ
MODEL 164.8, 251 with CODE (242) Electrically adjustable front passenger seat with memory
Function conditions
 Circuit 30
 Normalized front passenger seat
Function
The scope of the functionality is integrated in the rear SAM control unit (N10/8). The microswitch access aid
for the 2nd seat row, right (S159/1) is monitored by the rear SAM control unit.
If the access aid microswitch is closed by releasing the backrest, the rear SAM control unit transmits a message
to the front passenger front seat adjustment control unit with memory (N32/2) and the instrument cluster (A1)
via the CAN-B.
If at the time of release the Controller Area Network bus Class B (interior) (CAN-B) is in bus idle, then it is
woken up by the rear SAM control unit.
If the position of the front passenger seat is preventing the seat in the second seat row from being folded and the
seat occupied recognition detects that it is unoccupied, the front passenger seat is moved forward by the front
passenger front seat adjustment control unit. If the armrest in the second seat row has been released, then the
instrument cluster shows a corresponding message at circuit 15R ON.
As soon as the seat in the 2nd seat row has been locked again (microswitch open), the relevant message is
placed on the CAN-B by the rear SAM control unit.
If the CAN-B is in bus idle when the locking takes place, it is awakened by the rear SAM control unit.
The display extinguishes in the instrument cluster.
A1 GF54.30-P-
Instrument cluster, component description
Model 164 6000GZ
GF54.30-P-
Model 251
6000RT
Rear SAM control unit, component N10/8 GF54.21-P-

description Model 164 7030GZ
GF54.21-P-
Model 251
7030RT
N32/2
Component description of passenger-side
Model 164 with code (242) Electrically GF91.29-P-
front seat adjustment control unit with
adjustable front passenger seat with 5224GZ
memory
memory
Model 251 with code (242) Electrically
GF91.29-P-
adjustable front passenger seat with
5224RT
memory
3RD SEAT ROW FOLDING FUNCTION - GF91.29-P-2018GZ
MODEL 164.8 with CODE (845) 3rd seat row, electrically folding
Illustrated on model 164.8
Fig. 5: Identifying 3rd Seat Row Folding Function - Illustrated On Model 164.8
Function conditions
 Circuit 30
 Speed <= 12 km/h

 Rear-end door or right rear door open and
 Folding backrest in park position switch detected
Actuating mechanism
The operation of the folding backrest switches is read in by the folding rear bench seat control unit.
The folding rear bench seat control unit checks whether the backrest is locked or unlocked. If the backrest is
locked, the relevant backrest release unit is actuated. If the backrest is unlocked, the folding rear bench seat
control unit actuates the relevant folding backrest motor.
If the backrest is unlocked when the folding backrest switch is operated (unlocking switch closed), the relevant
folding backrest motor is actuated immediately.
If the folding backrest switches for the left and right seats are operated simultaneously, the right seat is actuated
first. After the maximum actuation time (approx. 0.4 s) of the unlocking motor in the right seat unlocking unit,
the left seat is actuated.
The unlocking switches and the unlocking motors are integrated in the left backrest release unit and the right
backrest release unit.
The end position of the folded seat is recorded by a limit position switch in the left backrest release unit and
the right backrest release unit. This limit position switch can be used to record two possible positions: "seat
raised" and "seat lowered".
End of operation
The actuation of the folding backrest motors stops when:
 the respective folding backrest switch is released, or

 the backrest is detected as locked (unlocking switch open) and the time difference between the opening of
the unlocking switch and the end of backrest motor actuation is too great or
 the maximum actuation time of the folding backrest motor has been reached (18 s), or
 blocking is detected.
Locking monitoring
The unlocking switches in the backrest release unit are used to monitor the backrests. If a backrest is detected as
unlocked, the rear seat control unit transmits a message to the instrument cluster. The following messages are
displayed on the instrument cluster:
 LEFT BACKREST OF 3RD SEAT ROW NOT LOCKED
or
 RIGHT BACKREST OF 3RD SEAT ROW NOT LOCKED
Behavior with several switch operations
If the other switch is operated for the same seat after operating a folding backrest switch, the first function is
aborted. The second adjusting function does not start. Adjustment does not continue until it has been detected
that both switches are in the park position.
Stuck switch detection:
 Switch signal > 20 s
If a switch is detected as stuck, the relevant channel is blocked. Functions requested by the stuck switch will not
be performed until the park position has been detected.
Blockage detection
In order to prevent damage to the seat mechanism, the actuation time of the folding backrest motors is limited.
This is done by evaluating the Hall sensor signal in the motor concerned. If the signal width is greater than the
blocking detection time (can be adjusted via diagnosis), blocked status is detected and the relevant folding
backrest motor is shut off.
After blocking has been detected in a particular direction, motorized adjustment can take place again by
actuating in the same direction. The folding backrest motors are also protected from overheating using a thermo
switch.
Block diagram of electric With code 232 Electrically adjustable front passenger seat
GF91.29-P-
seat adjustment (ESA with memory, with code 275 Memory package (driver seat,
0004-03GZ
[ESV]) steering column, mirrors)
FRONT SEAT ADJUSTMENT MOTOR GROUP WITH MEMORY, COMPONENT DESCRIPTION -

GF91.29-P-5219GZ
Shown on driver seat

Fig. 6: Identifying Front Seat Adjustment Motor Group With Memory Component - Shown On Driver
Seat
Location
The seat adjustment motors are located on the seat frame of the respective front seat.
Tasks
 Seat adjustment:
 Seat longitudinal direction
 Backrest angle
 Head restraint adjustment
 Seat height
 Seat tilt
Hall sensors are integrated into the motors for recording the position.
The actuation of the motors and evaluation of the signals are performed by the driver-side front seat adjustment
control unit with memory (N32/1) or the passenger-side front seat adjustment control unit with memory (N32/2)
with code (242) Electrically adjustable front passenger seat with memory.
FRONT SEAT ADJUSTMENT SWITCH GROUP, COMPONENT DESCRIPTION - GF91.29-P-

5220GZ
MODEL 164.1 /8, 251 with CODE (242) Electrically adjustable front passenger seat with memory with
Shown on driver seat switch group
Fig. 7: Identifying Front Seat Adjustment Switch Group Component - Shown On Driver Seat Switch
Group
Location
The driver seat adjustment with memory switch group is located in the front area of the seat cushion paneling of
the driver seat on the exit side. The front passenger seat adjustment with memory switch group (S92) is located
in the front area of the seat cushion paneling of the front passenger seat on the exit side.
Tasks (indicated on the driver seat switch group)
The seat can be adjusted electrically with the driver seat adjustment with memory switch group and driver seat
adjustment switch. A previously stored position can be actuated via the memory button 1, 2, 3 switch. The
following positions can be stored with the memory switch (e.g. driver seat):
 Seat position
 Position of electrically adjustable steering column
 Position of both outside mirrors
Design (indicated on the driver seat switch group)
The driver seat adjustment with memory switch group is a composite component consisting of individual
buttons for:
 seat fore/aft switch (S22s3)

 seat rear raise/lower switch (S22s4)
 seat front raise/lower switch (S22s2)
 backrest switch (S22s5)
 Head restraint up/down (by actuating the backrest switch in the longitudinal direction)
 Memory switch
 Memory button 1, 2, 3 switch
Function (described for driver seat)

By pressing:
 the driver seat adjustment with memory switch group or the driver seat adjustment switch, the driver seat
can moved forward or back,
 the driver seat adjustment with memory switch group or the driver seat adjustment switch, the rear seat
height can be adjusted
 the driver seat adjustment with memory switch group or the driver seat adjustment switch, the front seat
height can be adjusted,
 the driver seat adjustment with memory switch group or the driver seat adjustment switch, the head
restraint can moved up or down,
 the driver seat adjustment with memory switch group or the driver seat adjustment switch, the backrest
can be adjusted,
 the memory button 1, 2, 3, switch, the stored adjustment can be called up again;
 the memory button 1, 2, 3, switch and memory switch, the adjusted seat positions can be stored;
 the memory button 1, 2, 3 switch and the memory switch, the set steering column position and the
position of the outside mirrors can be stored.
By actuating the driver seat adjustment with memory switch group, the adjustment requirements are sent to the
driver-side front seat adjustment control unit with memory, which then correspondingly actuates the motors for
driver seat adjustment, the steering column and the outside mirror (via the left front door control unit (N69/1)).
Function (described for passenger seat)
By pressing:
 the front passenger seat adjustment with memory switch group or the front passenger seat adjustment
switch (S23), the front passenger seat can be moved forward or back;
switch, the rear seat height can be adjusted:
switch, the front seat height can be adjusted;
switch, the head restraint can be moved up or down;
switch, the backrest angle can be adjusted;
 the memory button 1, 2, 3 switch (S92s14), the stored settings can be called up again;
 the memory button 1, 2, 3, switch and the memory switch (S92s9), the adjusted seat positions can be
stored.
When the passenger seat adjustment with memory switch group is actuated, adjustment requests are transmitted
to the front passenger front seat adjustment control unit with memory (N32/2), which actuates the passenger
seat adjustment motors correspondingly.
COMPONENT DESCRIPTION OF DRIVER-SIDE FRONT SEAT ADJUSTMENT CONTROL UNIT

WITH MEMORY - GF91.29-P-5223GZ
MODEL 164.1 /8 with CODE (275) Memory package (driver seat, steering column, mirrors)
Fig. 8: Identifying Driver Front Seat Adjustment Control Unit With Memory
Location
The driver-side front seat adjustment control unit with memory is located under the seat frame of the driver seat;
the front passenger front seat adjustment control unit with memory (N32/2) is located under the seat frame of
the front passenger seat.
Purpose (described for driver seat)
The driver front seat adjustment control unit with memory is responsible for:
 5-seat adjustment functions.

 the 2-steering column adjustment functions;
 Driver entry/exit aid through automatic seat and steering column adjustment into a position specified by
the driver
 Sensing and storing actual position (last mode); can be performed key-related (depending on memory
block number).
 Actuation of positions stored for adjustment functions
Design (described on driver seat)
Discrete inputs:
 Circuit 15R
 Terminal 30
 Terminal 31
 Hall sensors for seat adjustment motors on driver seat/steering column
Discrete outputs:
 Power supply 12 V (+ and -) for all seat adjustment motors

 Power supply 12 V (+ and -) for all steering column adjustment motors
Function (described for driver seat)
The driver front seat adjustment control unit with memory has the following functions:
Reading in sensors
 seat front raise/lower switch (S22s2)

 seat rear raise/lower switch (S22s4)
 backrest switch (S22s5)
 seat fore/aft switch (S22s3)
 Head restraint adjustment switch (by actuating the backrest switch in longitudinal direction)
 Memory switch (S91s9)
 memory button 1, 2, 3 switch (S91s14)
 Hall sensors for steering column forward/back as well as up/down
 Hall sensors for driver seat height at front or back
 Hall sensors for driver seat longitudinal adjustment or backrest adjustment
 Hall sensors for driver seat head restraint
Switching consumers using relays
 Steering column in/out motor (M20/1)

 Steering column up/down motor (M20/2)
 Driver seat longitudinal adjustment motor (M27/1)
 Driver rear seat height adjustment motor (M27/2)
 Driver front seat height adjustment motor (M27/3)
 Driver head restraint motor (M27/4)
 Driver backrest angle adjustment motor (M27/5)
CAN signals
The driver front seat adjustment control unit with memory is a subscriber on the passenger compartment CAN
bus.
COMPONENT DESCRIPTION OF PASSENGER-SIDE FRONT SEAT ADJUSTMENT CONTROL

UNIT WITH MEMORY - GF91.29-P-5224GZ
MODEL 164 with CODE (242) Electrically adjustable front passenger seat with memory
Fig. 9: Identifying Front Passenger Front Seat Adjustment Control Unit With Memory
Task
The front passenger front seat adjustment control unit with memory is responsible for:
 Sensing the sensor signals (memory block number, circuit status)

 Sensing the switch statuses (seat adjustment switch);
 Control of motors for front passenger seat adjustment
Design
Discrete inputs:
 Circuit 15R
 Terminal 30
 Circuit 31
 Hall sensor for seat adjustment motors
Discrete outputs:
 Power supply 12 V (+ and -) for all seat adjustment motors
Function
The front passenger front seat adjustment control unit with memory has the following functions:
Reading in sensors
 Height adjustment switch, driver

 Inclination adjustment switch
 Fore/aft adjustment switch
 Head restraint adjustment switch
 Memory switch (S92s9)
 memory button 1, 2, 3 switch (S92s14)

 Hall sensors for front passenger seat height at front or back
 Hall sensors for front passenger seat longitudinal adjustment or backrest adjustment
 Hall sensors for front passenger seat head restraint
Switching consumers using relays
 Front passenger seat longitudinal adjustment motor(M28/1)

 Front passenger rear seat height motor (M28/2)
 Front passenger front seat height motor (M28/3)
 Front passenger head restraint motor (M28/4)
 Front passenger backrest angle adjustment motor (M28/5)
CAN signals
The front passenger front seat adjustment control unit with memory is a subscriber on the passenger
compartment CAN bus
FOLDING BACKREST MOTOR, COMPONENT DESCRIPTION - GF91.29-P-5225GZ
Fig. 10: Identifying Folding Backrest Motor Component

Location
The left folding backrest motor and the right folding backrest motor are beneath the seat in the third row of
seats.
Task
The backrests of the left and right seats in the 3rd seat row are folded down and moved upright using the left
folding backrest motor and the right folding backrest motor.
BACKREST RELEASE UNIT COMPONENT DESCRIPTION - GF91.29-P-5226GZ
Fig. 11: Identifying Backrest Release Unit Component

Location
The left backrest release unit and the right backrest release unit are at the side behind the seat paneling of the
relevant seat in the 3rd seat row.
Task
 The end position of the relevant folded-over seat is read in using a limit position switch
 Unlocking switch actuation
 Unlocking motor actuation
FOLDING REAR BENCH SEAT CONTROL UNIT, COMPONENT DESCRIPTION - GF91.29-P-

5251GZ
Fig. 12: Identifying Folding Rear Bench Seat Control Unit

Location
The folding rear bench seat control unit is beneath the left-hand seat in the 2nd seat row.
Task
 Read in two folding backrest switches per seat

 Unlocking switch actuation
 Unlocking motor actuation
 Actuation of folding backrest motors
OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRIC SEAT ADJUSTMENT (ESV) - GF91.29-

P-9997GZ
Instrument cluster, component A1 GF54.30-P-

GF54.30-P-
Model 251
6000RT
Backrest release unit component A93/1, A93/2 GF91.29-P-
description Model 164.8 with code (845) 3rd seat row folding 5226GZ
down electrically
M27/1, M27/2, M27/3, M27/4, M27/5; M28/1,
Front seat adjustment motor group
M28/2, M28/3, M28/4, M28/5 (with code (242) GF91.29-P-
with memory, component
Electrically adjustable front passenger seat with 5219GZ
description
memory)
M53/10, M53/11
Folding backrest motor, component GF91.29-P-
Model 164.8 with code (845) 3rd seat row folding
description 5225GZ
down electrically
Rear SAM control unit, component N10/8 GF54.21-P-
GF54.21-P-
Model 251
7030RT
Component description of driver-
N32/1 GF91.29-P-
side front seat adjustment control
Model 164 5223GZ
unit with memory
GF91.29-P-
Model 251
5223RT
Component description of N32/2
GF91.29-P-
passenger-side front seat adjustment Model 164 with code (242) Electrically adjustable
5224GZ
control unit with memory front passenger seat with memory
Model 251 with code (242) Electrically adjustable GF91.29-P-
front passenger seat with memory 5224RT
N32/26
Folding rear bench seat control unit, GF91.29-P-
Model 164.8 with code (845) 3rd seat row folding
component description 5251GZ
down electrically
Electronic ignition/starter switch
N73 GF80.57-P-
control unit (EIS), component
Model 164 6000GZ
description
GF80.57-P-
Model 251
6000RT
S91;
Front seat adjustment switch group, GF91.29-P-
S92 (with code (242) Electrically adjustable front
passenger seat with memory)
Electric seat adjustment function GF91.29-P-
description (ESV) table of contents 0998GZ
ELECTRIC SEAT VENTILATION, FUNCTION - GF91.30-P-0002GZ
MODEL 164, 251 with CODE (401) Front comfort seats, incl. seat heating and seat ventilation
Fig. 13: Identifying Electric Seat Ventilation, Function - Shown On Model 164.8
Function
The seat ventilation integrated into the driver/front passenger seat enables the seat cushions and the backrests to
be ventilated in three ventilation stages.
The seat ventilation switch in the upper control panel control unit (N72/1) can be used to switch the seat
ventilation on and off or to regulate ventilation output.
Each actuation of the seat ventilation switch is read in by the upper control panel control unit and sent over the
interior CAN to the HS [SIH], seat ventilation and steering wheel heater control unit. This then actuates the
respective blower regulator. The blower regulators in turn then actuate the respective motor groups with the
desired seat ventilation output.
 C. 15R On
Switching seat ventilation on and over

Feedback of the set ventilation output is provided via three blue LEDs in the seat ventilation switch.
 Operating the seat ventilation switch once activates stage 3 of the seat ventilation. All 3 LEDs in the seat
ventilation switch are actuated.
 Operating the seat ventilation switch again switches over to stage 2. 2 LEDs are actuated in the seat
ventilation switch.
 Operating the seat ventilation switch again switches over to stage 1. 1 LED is actuated in the seat
ventilation switch.
During comfort opening with the transmitter key (A8/1) (infrared signal), the seat ventilation of the driver
seat is switched on in stage 3 for 5 min.
Manual seat ventilation cutout
Seat ventilation can be switched off manually by operating the seat ventilation switch.
To this end, the respective seat ventilation switch must be repeatedly actuated until the LEDs are all off.
Switching the seat ventilation on, over or off by operating the respective seat ventilation switch is possible at
any given time.
Automatic seat ventilation switch-off
Seat ventilation is automatically switched off if one of the following criteria is fulfilled:
 Switching off as under terminal 15R OFF
If circuit 15C remains On, the timer control runs for another 5 min.
If circuit 15R is switched on again, then the seat ventilation is also switched on at the stage active
according to the timer control.
 Switching off in the event of undervoltage
The timer control continues to run if the seat ventilation is switched off due to undervoltage. The LEDs in
the switches flash on and off while undervoltage is applied.
 Switching off in the event of overvoltage
The timer control continues to run if the seat ventilation is switched off due to overvoltage.
Electric seat ventilation, location of components GF91.30-P-0002-02GZ

Electrical seat ventilation block diagram GF91.30-P-0002-03GZ
Electric seat ventilation, location of components - GF91.30-P-0002-02GZ

Fig. 14: Identifying Electric Seat Ventilation Components Location - Illustrated On Model 164.8
Electrical seat ventilation block diagram - GF91.30-P-0002-03GZ
Fig. 15: Electrical Seat Ventilation Block Diagram

HEATED SEATS (HS) FUNCTION - GF91.30-P-0003GZ
MODEL 164 with CODE (873) Heated left and right front seats with CODE (401) Front deluxe seats,
incl. seat heating and seat ventilation with CODE (872) Electrically heated left and right rear seats
Fig. 16: Identifying Heated Seats Function - Shown On Model 164.8

 Circuit 15R or circuit 15 "ON".
Actuation of seat heating elements
The heating elements in the front seats are actuated by the front SAM control unit.
For vehicles with code 872, the heating elements in the 2nd seat row are actuated by the HS [SIH], seat
ventilation and steering wheel heater control unit.
Actuation is performed by way of a duty cycle, which is implemented as follows:
 Stage 1= Low heat output with a duty cycle of approx. 0 to 40 %, here one LED is lit.
 Stage 2= Medium heat output with a duty cycle of approx. 41 to 70 %, here two LEDs are lit.
 Stage 3= High heat output with a duty cycle of approx. 71 to 100 %, here three LEDs are lit.
Time control
A timer control for the heated seats is located in the front SAM control unit and the HS [SIH], seat ventilation
and steering wheel heater control unit:
 Switch-on of stage 3 for t = 5 min

 Switchover to stage 2 for t = 10 min
 Heated seats shutoff
On vehicles with code 401, the heated seats remain active in stage 1 when seat ventilation is active.
The times of the three heating stages can be parameterized using STAR DIAGNOSIS in the front SAM
control unit and the HS [SIH], seat ventilation and steering wheel heater control unit.
Front heated seats
With the integrated heated seats function, it is possible to heat the seat cushions and backrests in three heating
stages. The left front HS [SIH] switch and the right front HS [SIH] switch are designed as buttons. They are
located on the upper control panel control unit. The left front HS [SIH] switch and the right front HS [SIH]
switch change the respective switching state ("ON" or "OFF") depending on the number of actuations. Each
actuation is sent by the upper control panel control unit over the interior CAN to the front SAM control unit.
The front SAM control unit in response actuates the respective heated cushion of the front seats. If the heated
seats are switched on, the LED indicator lamps indicate the corresponding actuation on the upper control panel
control unit.
Rear heated seat (with code 872)
With the integrated heated seats, it is possible to heat the seat cushions and backrests in the 2nd seat row in
three heating stages. The left HS [SIH] switch, 2nd seat row and the right HS [SIH] switch, 2nd seat row are
designed as buttons. They are located on the RCP [HBF] control unit. The left HS [SIH] switch, 2nd seat row
and the right HS [SIH] switch, 2nd seat row change the respective switching state ("ON" or "OFF") depending
on the number of actuations. Each actuation is sent by the RCP [HBF] control unit over the interior CAN to the
HS [SIH], seat ventilation and steering wheel heater control unit. The HS [SIH], seat ventilation and steering
wheel heater control unit actuates in response the respective heated cushions in the 2nd seat row. If the heated
seats are switched on, the LED indicator lamps indicate the corresponding actuation on the RCP [HBF] control
unit.
Heated seats (HS), networking of components GF91.30-P-0003-01GZ

Heated seats (HS) block diagram GF91.30-P-0003-03GZ
Switch heated seats on, off, over GF91.30-P-5217GZ
Heated seats (HS), networking of components - GF91.30-P-0003-01GZ
Fig. 17: Identifying Networking Of Heated Seats Components - Shown On Model 164.8
Heated seats (HS) block diagram - GF91.30-P-0003-03GZ

Fig. 18: Heated Seats Block Diagram - Illustrated On Model 164.8

ELECTRONIC SEAT VENTILATION FUNCTION DESCRIPTION, TABLE OF CONTENTS -

GF91.30-P-0997GZ
MODEL 164, 251 with CODE (401) Front deluxe seats, incl. seat heating and seat ventilation
Electric seat ventilation, function GF91.30-P-0002GZ

Electric seat ventilation, location of components GF91.30-P-0002-02GZ
Electrical seat ventilation block diagram GF91.30-P-0002-03GZ
Overview of seat ventilation system components GF91.30-P-9993GZ
HEATED SEATS (SIH) FUNCTION DESCRIPTION TABLE OF CONTENTS - GF91.30-P-0998GZ
Heated seats (HS) function GF91.30-P-0003GZ

Heated seats (HS), networking of components GF91.30-P-0003-01GZ
Heated seats (HS) block diagram GF91.30-P-0003-03GZ
Switch heated seats on, off, over GF91.30-P-5217GZ
Overview of system components for heated seats HS [SIH] GF91.30-P-9999GZ
FRONT SEAT VENTILATION MOTOR COMPONENT DESCRIPTION - GF91.30-P-5200GZ
Fig. 19: Identifying Front Seat Ventilation Motor Component - Shown On Model 164.8
Location
The seat cushion ventilation motor groups, which consist of three 3 motors each, are integrated into the
respective seat cushion of the driver/front passenger seat.
The seat backrest ventilation motor groups, which consists of 2 motors each, are integrated into the respective
backrest of the driver/front passenger seat.
Task
The two motor groups are divided up into backrest and seat cushion. Each motor drives a small ventilator that
produces a flow of air. The motors in each motor group are connected in parallel. Actuation takes place over the
HS [SIH], seat ventilation and steering wheel heater control unit (N25/7). The actuation signal on the control
unit output is amplified over the left front seat ventilation blower regulator (N29/5) and the right front seat
ventilation blower regulator (N29/6).
HEATED SEATS/SEAT VENTILATION CONTROL UNIT, COMPONENT DESCRIPTION -

GF91.30-P-5209GZ
MODEL 164, 251 with CODE (401) Front comfort seats, incl. seat heating and seat ventilation with
CODE (872) Electrically heated left and right rear seats
Fig. 20: Identifying Heated Seats/Seat Ventilation Control Unit Component - Shown On Model 164.8
Location
The HS [SIH], seat ventilation and steering wheel heater control unit is located in the 2nd seat row under the
seat cushion on the passenger side.
Tasks
Voltage supply
 of the 2nd seat row heated cushions

 of the seat ventilation blower regulators
 of the steering wheel heater
Actuation
 of the 2nd seat row heated seats relay

 of the steering wheel heater relay
 of the seat ventilation blower regulators
 of the 2nd seat row heated cushions
 of the steering wheel heater
FRONT HEATED SEAT SWITCH, COMPONENT DESCRIPTION - GF91.30-P-5211GZ

incl. seat heating and seat ventilation
Fig. 21: Identifying Front Heated Seat Switch Component

Tasks
Manual switching on, over and off of heated seat for driver and front passenger. Display of actuated output
stage by an optical signal (LED).
Design (Described on switch on driver side, left)
The left front HS [SIH] switch is designed as a push-push switch. This switch changes the respective switching
status depending on the number of actuations.
The left front HS [SIH] switch and right front HS [SIH] switch are located on the upper control panel control
unit (N72/1).
Heated seat function
An actuation of the left front HS [SIH] switch or the right front HS [SIH] switch is read in by the upper control
panel control unit and sent over the interior CAN to the front SAM control unit (N10). If the heated seat is
switched on, then red LED indicator lamps indicate the corresponding actuation in the left front HS [SIH]
switch or the right front HS [SIH] switch.
SWITCH HEATED SEATS ON, OFF, OVER - GF91.30-P-5217GZ
Fig. 22: Identifying Switch Heated Seats On, Off, Over Function
 No undervoltage or overvoltage
 Circuit 15R "ON"
 Terminal 15 "ON"
Switching off the heated seats during the starting procedure
During the starting procedure, the power supply to the heated cushions is switched off. The timer control
continues to run if the heated seats are switched off during the starting procedure.
Switching off after circuit 15R "OFF"
After switching off the ignition, the heated seats are also switched off. However, the timer control continues to
run for another 5 min as long as circuit 15C is "ON". If the ignition is switched on again, then the heated seats
are switched on again in the stage active in accordance with the timer control.
Switching off the heated seats (cancel conditions)
If one of the following criteria occurs, the heated seats are switched off.
The criteria are listed in the order of decreasing priority; i.e. if the heated seats are switched off due to a
criterion with a low priority and then another switch-off criterion with a higher priority occurs, this is treated as
described for the criterion with the higher priority.
Switching off in the event of a hardware defect
If an actuation of the heated cushions is detected without any current switch request pending or function
condition fulfilled, then the supply for the respective seating is switched off by canceling the load actuation.
The timer control is switched off by the front SAM control unit and, on vehicles with code 872, by the HS
[SIH], seat ventilation and steering wheel heater control unit.
If, when the heated seats are switched on, a temperature which is too high to guarantee reliable operation is
detected on the printed circuit board of the front SAM control unit or for vehicles with code 872, of the HS
[SIH], seat ventilation and steering wheel heater control unit, then the respective heated cushions are switched
off. The front SAM control unit and, for vehicles with code 872, the HS [SIH], seat ventilation and steering
wheel heater control unit, continue to run through the timer function.
Switching off in the event of undervoltage
The undervoltage cutout for all control units and consumers is monitored globally by the battery control unit
(N82). If the front SAM control unit and, for vehicles with code 872, the HS [SIH], seat ventilation and steering
wheel heater control unit, receives the emergency mode message of the battery control unit, the heated seats
(load only) are switched off. The same applies when the undervoltage cutout threshold is reached.
If an undervoltage is recognized, the corresponding LEDs in the switches flash on and off at a frequency of 1.5
Hz and a brightness of 50 %. The timer control continues to run if the heated seats are switched off due to
undervoltage.
If the control units detect an impermissible actuation of the heat mats, a fault is stored in the fault memory.
Switching off in the event of overvoltage
When the overvoltage threshold of 15.5 V is exceeded, the heated seats (load only) are switched off. The timer
control continues to run if the heated seats are switched off due to overvoltage. Switching on again is only
possible when a permissible voltage of 15 V is applied.
Exceeding the switch-off threshold temperature
If the interior temperature - or the outside temperature if there is no interior temperature - is higher than the
defined switch-off threshold, then specific stages or the complete heated seats function cannot be switched on.
Switching over with switch
By actuating the switch for the heated seats repeatedly, the heated seats can be manually switched over.
The front SAM control unit and the HS [SIH], seat ventilation and steering wheel heater control unit reduce the
power output for the respective heated cushions in the seat accordingly.
Automatic switching over and switching off of the heated seats
A timer control for the heated seats is located in the front SAM control unit and in the HS [SIH], seat ventilation
and steering wheel heater control unit :
 Switching on of stage 3 for t = 5 min

 Heated seats shutoff
If on vehicles with code 401, the seat ventilation is active, the heated seats are switched to stage 1.
The heating periods can be programmed using STAR DIAGNOSIS.
Switching off using switches (front seats)
The heated seats can be switched off by actuating the switches in the upper control panel.
Actuation of the switches is read in by the upper control panel control unit and forwarded via the interior CAN
to the front SAM control unit. This then switches off the selected seat cushions in the front seats. At the same
time the function LEDs in the upper control panel are switched off.
Switching off using the switches of the over 2nd seat row (for vehicles with code 872)
The heated seats of the 2nd seat row can be switched off by actuating the switches in the RCP [HBF] control
unit. Actuation of the switches is read in by the RCP [HBF] control unit and forwarded via the interior CAN to
the HS [SIH], seat ventilation and steering wheel heater control unit. This then switches off the selected seat
cushions in the 2nd seat row. At the same time the function LEDs in the RCP [HBF] control unit are switched
off.
Heated seat switch, component description GF91.30-P-5211GZ
FRONT SEAT VENTILATION BLOWER REGULATOR, COMPONENT DESCRIPTION - GF91.30-

P-5220GZ

Fig. 23: Identifying Front Seat Ventilation Blower Regulator Component - Shown On Model 164.8
Location
The left front seat ventilation electronic blower controller and the right front seat ventilation electronic blower
controller are located in the backrest of the driver and front passenger seats.
Task
The left front seat ventilation electronic blower controller and the right front seat ventilation electronic blower
controller regulate the seat ventilation motors depending on the actuation voltage from the HS [SIH], seat
ventilation and steering wheel heater control unit (N25/7). The overload resistant blower regulators are
connected between the HS [SIH], seat ventilation and steering wheel heater control unit and the motors.
OVERVIEW OF SEAT VENTILATION SYSTEM COMPONENTS - GF91.30-P-9993GZ
Front seat ventilation motor GF91.30-P-

Front seat ventilation blower GF91.30-P-
regulator, component description 5220GZ
Model 164.1 /8 with AIRmatic (air suspension with
Upper control panel control GF54.21-P-
level adjustment and adaptive damping system ADS),
module component description 6040GZ
code 489, except offroad package, code 430
GF54.21-P-
Model 251
6040RT
Heated seats/seat ventilation With electrically heated left and right rear seats, code GF91.30-P-
control unit, component 872 5209GZ

description
GF80.57-P-
control unit (EIS) component Model 164.1 /8
6000GZ
description
GF80.57-P-
Model 251.0 /1
6000RT
Electronic seat ventilation
GF91.30-P-
function description, table of
0997GZ
contents
OVERVIEW OF SYSTEM COMPONENTS FOR HEATED SEATS HS [SIH] - GF91.30-P-9999GZ
Front heated seat switch, GF91.30-P-

Upper control panel control With adaptive damping system (ADS) with skyhook GF54.21-P-
module component description and level control, except offroad package, code 430 6040GZ
With comfort automatic air conditioning, code 581,
Rear control panel control unit, GF83.40-P-
with USA version, code 494, with rear AC system,
component description 3020RTU
code 582, with rear audio system, code 519
Heated seats/seat ventilation
GF91.30-P-
control unit, component
5209GZ
description
Front SAM control unit, GF54.21-P-
GF80.57-P-
control unit (EIS) component
6000GZ
description
Heated seats (SIH) function GF91.30-P-
description table of contents 0998GZ
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), FUNCTION - GF91.60-P-0002GZ
MODEL 164 with CODE (494) USA version
General information
The supplemental restraint system (SRS) provides passive passenger protection. Depending on the strength of a
detected impact in the event of an accident, the corresponding airbag units, front buckle emergency tensioning
retractors and rear emergency tensioning retractors are deployed. An automatic emergency call is also generated
when an airbag is deployed.
 The supplemental restraint system (SRS) must be programmed to the vehicle (left or right-hand drive
vehicle, equipment programming and configuration parameters)
 Circuit 15R On
 Circuit 30 ON
Function
The supplemental restraint system (SRS) can record and differentiate between the following types of accident:
 Head-on collision
 Rear end collision
 Side-on collision
 Roll-over along the longitudinal vehicle axis
The restraint systems control unit (N2/7) has sensors integrated into it. This is why it must not be removed
when the power supply is active, as otherwise restraint equipment may be triggered. All work performed on or
with the restraint systems control unit may only be conducted when the battery (G1) has been disconnected and
after a waiting time of approx. > or = 60 s.
The following restraint equipment can be triggered depending on the type of accident involved:
 Driver airbag (two-stage)

 Front passenger airbag (two-stage)
 Driver/front passenger sidebag
 Left/right rear sidebag (with code (293) Left and right rear sidebag)
 Left/right windowbag
 Driver/front passenger buckle emergency tensioning retractor
 Driver/front passenger belt force limiter
 2nd seat row emergency tensioning retractor, left/right
 Left/right 3rd seat row emergency tensioning retractor (model 164.8)
 Front NECK-PRO head restraints
Collision detection and ignition time determination
The restraint systems control unit determines the level of acceleration using its own integrated sensors and the
following external sensors:
 Driver-side frontal acceleration sensor (B48/1)

 Passenger-side frontal acceleration sensor (B48/2)
 Drive sidebag sensor (A53)
 Front passenger sidebag sensor (A54)
Information from the following components is also evaluated:
 Driver door pressure sensor (B48/7)

 Front passenger door pressure sensor (B48/8)
 Rear door pressure sensor, driver-side (B48/9) (with code (293) Left and right rear sidebag)
 Rear door pressure sensor, passenger-side (B48/10) (with code (293) Left and right rear sidebag)
 Driver seat belt buckle and seat belt warning switch (S68/1)
 Front passenger seat belt buckle and seat belt warning switch (S68/2)
 Left rear belt buckle switch (S68/11) (up to 31.5.06)
 Right rear belt buckle switch (S68/12) (up to 31.5.06)
 Center rear seat belt buckle switch (S68/14) (up to 31.5.06)
 Left seat belt buckle switch on 3rd seat row (S68/16) (model 164.8 up to 31.5.06)
 Right seat belt buckle switch on 3rd seat row (S68/17) (model 164.8 up to 31.5.06)
 WSS (Weight Sensing System) control unit (N2/13)
The WSS control unit determines whether the front passenger seat is occupied or not. If a weight is deemed
to be low (child seat), then front passenger airbag activation is suppressed.
If a threshold is exceeded, the ignition stages for the corresponding restraint equipment are actuated. Actuation
is for at least 2 ms. This serves to ensure that the corresponding restraint system is actuated reliably.
More detailed information is available in the following separate subfunctions:
 Head-on collision, function

 Rear end collision, function
 Side impact, function
Roll-over along the longitudinal vehicle axis
A rollover is detected by the restraint systems control unit by means of a separate, integrated rollover sensor. In
addition to this, the data of the frontal acceleration sensors and the sidebag sensors are also used for evaluation
purposes.
The following restraint equipment is triggered accordingly:
 Window airbags
 Front buckle emergency tensioning retractors
 Emergency tensioning retractors in 2nd seat row
 Emergency tensioning retractors in 3rd seat row
The seat belts in the 2nd and 3rd seat rows are not checked. The emergency tensioning retractors for the 2nd
and 3rd seat rows will also be triggered even if seat belts are not buckled.
System monitoring
The system monitors itself permanently automatically and transmits errors immediately to the driver via the
multifunction display (A1p13) in the instrument cluster (A1) The airbag indicator and warning lamp (A1e15) in
the instrument cluster is also switched on. Faults are stored in the nonvolatile memory of the restraint systems
control unit.
Airbag indicator and warning lamp
The airbag indicator and warning lamp is irreversibly actuated by the restraint systems control unit when
malfunctions occur in the following instances:
 Immediately after the entry of the 5th crash telegram.

 Through a malfunction detected in the restraint systems control unit, in the external ignition circuits or the
remote sensors (e.g. frontal acceleration sensor)
 If the instrument cluster recognizes an interruption in the flow of data to the restraint systems control unit,
the airbag indicator and warning lamp are automatically switched on by the instrument cluster and a fault
stored in the memory.
In this case a fault is not written to the restraint systems control unit.
The supplemental restraint system has a capacitor in the restraint systems control unit. After a battery
disconnection, the system is provided with power for at least 300 ms. The peripheral acceleration sensors (e.g.
frontal acceleration sensor) have power supplied to them for at least 30 ms.
Front passenger seat occupied recognition
The seat occupied and automatic child seat recognition operates by means of weight sensing. The following
sensors enable the weight applied to the front passenger seat to be determined:
 Left front WSS sensor (Weight Sensing System) (B48/11)

 Right front WSS sensor (Weight Sensing System) (B48/12)
 Left rear WSS sensor (Weight Sensing System) (B48/13)
 Right rear WSS (Weight Sensing System) sensor (B48/14)
The WSS control unit performs the weight classification process and transmits it via the Controller Area
Network bus Class B (interior) (CAN-B) to the central gateway control unit (N93). This routes the data over the
Controller Area Network bus Class C (engine compartment) (CAN-C) to the restraint systems control unit.
It then decides on the basis of the weight class whether to suppress or to trigger the 1- or 2-stage front passenger
airbag. Apart from this, a CAN-B signal with the weight class is sent to the instrument cluster to be displayed in
the multifunction display.
If the system recognizes that the front passenger seat is not occupied (person/child seat), the automatic child
seat recognition airbag OFF indicator lamp (N71/1e1) is switched on in addition to the multifunction display in
the instrument cluster via the upper control panel control unit (N72/1) as long as the system recognizes that no
seat is occupied, and the front passenger airbag is switched off by the restraint systems control unit. When a low
weight is recognized, it is considered to be a child seat.
The automatic child seat recognition airbag OFF indicator lamp is switched on and the front passenger airbag is
switched off. If the airbag indicator and warning lamp and the automatic child seat recognition OFF indicator
lamp illuminate at the same time, an error is present in the weight determination.
Seat belt warning light (A1e9)
The seat belt buckle switch and seat belt reminder warning are read in by the restraint systems control unit and
shown on the seat belt warning lamp display in the instrument cluster. The seat belt warning lamp is
extinguished, when the monitoring conditions are fulfilled.
Special features in event of crash
Crash telegrams are stored in a designated memory area in the restraint systems control unit when a crash
threshold is exceeded. When a crash threshold is reached, it is notified to other control units (e.g. to switch off
the engine).
A separate, digital crash output of the restraint systems control unit is used to send a message to the emergency
call system control unit (N123/4) to initiate an automatic emergency call.
If the CAN-C malfunctions (e.g. short circuit in the event of a crash) and a crash signal is to be sent to the
ME control unit (N3/10) and the rear SAM control unit (N10/8), the restraint systems control unit on vehicles as
of 1.6.07 is also connected with these control units by way of a discrete line (redundant crash signal).
Hazard warning flashers
The hazard warning system is automatically switched on in the event of a crash. The crash signal is generated
by the restraint systems control unit and sent via CAN C over the central gateway control unit and made
available to the rear SAM control unit, which acts as a turn-signal master.
The hazard warning flashing can be switched off at any time via the hazard warning system switch (N72/1s5).
Automatic emergency opening of the central locking (CL)
If the vehicle is subject to negative acceleration greater than 6 times the normal g force, the "Emergency
opening" function is actuated by the restraint systems control unit.
The signal is sent over CAN-C to the central gateway control unit and forwarded from there over CAN-B to the
following control units:
 Rear SAM control unit

Front SAM control unit (N10)
 Left front door control unit (N69/1)

 Right front door control unit (N69/2)
More information on this is available in the separate function description for the central locking.
Crash ventilation
After a crash, the restraint systems control unit may prompt the side windows and the tilting/sliding roof (with
code (414) Power glass tilting/sliding sunroof) to open to a gap of approx. 50 mm to enable any smoke particles
from the pyrotechnical restraint systems to be vented. The signal is sent over CAN-C to the central gateway
control unit and forwarded from there over CAN-B to the following control units:
 Front SAM control unit

 Front door control unit
 Overhead control panel control unit (N70)
More detailed information on this is available in the separate function descriptions for the power windows
and tilting/sliding roof.
Foresighted accident protection (PRE-SAFE) (with code (299) PRE-SAFE)
The supplemental restraint system is extended to the extent that any unintended movements of the driver or
front passenger under vehicle braking and skidding are reduced and the driver and front passenger are moved to
an ideal seating position prior to a possible accident.
Pyrotechnical separating element (K88) (model 164.822/825)
The separating element is located under the footwell plate at the right on the battery positive terminal, and is
used to protect the line to the front prefuse box (F32), starter (M1) and the alternator (G2). The separating
element is triggered - starting from the crash instance - by the restraint systems control unit.
The triggered separating element may only be exchanged or replaced by an authorized workshop.
Supplemental restraint system GF91.60-P-

(SRS), location of components 0002-01GZ
Supplemental restraint system GF91.60-P-
(SRS), block diagram 0002-03GZ
GF91.60-P-
Rear end collision, function
2004GZ
GF91.60-P-
Side impact, function
2005GZ
GF91.60-P-
Head-on collision, function
2006GZ
With code (299) PRE-SAFE and code (242)
Foresighted occupant protection Electrically adjustable front passenger seat with GF91.60-P-
function memory 2010GZ
TABLE OF CONTENTS: FUNCTION DESCRIPTION OF SUPPLEMENTAL RESTRAINT SYSTEM

(SRS) - GF91.60-P-0999GZ
Supplemental restraint system (SRS), GF91.60-P-

function 0002GZ
Supplemental restraint system (SRS), GF91.60-P-
location of components 0002-01GZ
Supplemental restraint system (SRS), block GF91.60-P-
diagram 0002-03GZ
GF91.60-P-
Rear end collision, function
2004GZ
GF91.60-P-
Side impact, function
2005GZ
GF91.60-P-
Head-on collision, function
2006GZ
With code (299) PRE-SAFE and with (code
GF91.60-P-
Foresighted occupant protection function 242) Electrically adjustable front passenger
2010GZ
seat with memory
Overview of system components for
GF91.60-P-
supplemental restraint system (SRS),
9997GZ
component description
REAR END COLLISION, FUNCTION - GF91.60-P-2004GZ
MODEL 164
Fig. 24: Identifying Rear End Collision, Function (1 Of 2)

Sequence of emergency tensioning retractor activities and the NECK-PRO head restraints in the event of
a rear end collision for the driver and passenger-sides
Sequence of emergency tensioning retractor activities and the NECK-PRO head restraints in the event of
a rear end collision for the driver and passenger-sides
Fig. 25: Identifying Rear End Collision, Function (2 Of 2)

If the restraint systems control unit (N2/7) registers high vehicle acceleration and deceleration as a consequence
of a rear end collision, a trigger pulse is issued to the following components:
 Driver ETR [GUS] squib (R12/1)

 Passenger ETR squib (R12/2)
 Left 2nd row ETR [GUS] squib (R12/6)
 Right 2nd row ETR [GUS] squib (R12/7)
 Left 3rd seat row emergency tensioning retractor squibs (R12/35)
 Right 3rd seat row emergency tensioning retractor squibs (R12/36)
If the seat belt on the driver or passenger side is not engaged in the seat belt buckle, then this fact is registered
by the restraint systems control unit.
Registration is performed via the driver seat belt buckle and seat belt warning switch (S68/1) or via the front
passenger seat belt buckle and seat belt warning switch (S68/2) and does not trigger the corresponding driver
ETR [GUS] squib or the front passenger ETR [GUS] squib.
Seat belt buckle scan up to production period 31.05.06
If the driver seat belt buckle and seat belt warning switch, front passenger seat belt buckle and seat belt warning
switch, left rear seat belt buckle switch (S68/11) and right rear seat belt buckle switch (S68/12), left 3rd seat
row seat belt buckle switch (S68/16) (model 164.8) and right 3rd seat row seat belt buckle switch (S68/17)
(model 164.8) signal that a seat belt has not been engaged, then the respective emergency tensioning retractors
are not triggered by the restraint systems control unit.
Seat belt buckle scan as of production period 01.06.06
If the driver seat belt buckle and seat belt warning switch, front passenger seat belt buckle and seat belt warning
switch signal that a seat belt has not been engaged, then the respective emergency tensioning retractors are not
triggered by the restraint systems control unit.
There is no seat belt buckle scan for the 2nd seat row at left/right and seat belt buckle scan for the 3rd seat
row at left/right (model 164.8). The emergency tensioning retractors for the 2nd and 3rd seat rows are triggered
if the latch plate is not inserted.
Only for USA version, code 494
There is no seat belt buckle scan for the left and right rear seats, this means that the left and right rear ETR
squibs are always deployed.
In the event of a collision and if the corresponding triggering threshold is exceeded, then a signal is additionally
sent from the restraint systems control unit to the emergency call system control unit (N123/4) and an automatic
emergency call is made.
Front emergency tensioning retractor GF91.60-P-

Rear emergency tensioning retractor GF91.60-P-
Seat belt buckle switch, component GF91.60-P-
description 4045GZ
Restraint systems control unit, component GF91.60-P-
description 4048GZ
Reversible belt emergency tensioning GF91.60-P-
retractor, component description 4050GZ
Driver/passenger-side NECK-PRO head GF91.60-P-
restraints 4053GZ
Rear seat belt buckle switch component Model 164.1 except USA version, code GF91.60-P-
description 494, up to production period 31.05.06 4054GZ
3rd seat row emergency tensioning GF91.60-P-
Model 164.8
retractor, component description 4063GY
SIDE IMPACT, FUNCTION - GF91.60-P-2005GZ
MODEL 164
Sequence of a front sidebag deployment in the event of a side impact

Fig. 26: Identifying Side Impact, Function - Sequence Of Front Sidebag Deployment In Event Of Side
Impact
Sequence of a rear sidebag deployment in the event of a side impact
Fig. 27: Identifying Side Impact, Function - Sequence Of Rear Sidebag Deployment In Event Of Side
Impact
Location of windowbag
The sequence of the windowbag deployment runs parallel to deployment of the front and rear sidebags and
protects the occupants on each side in the event of a side impact in the area of the windows from the A- to the
C-pillars against injury.
Fig. 28: Identifying Windowbag Location

If the driver sidebag sensor (A53), front passenger sidebag sensor (A54), driver door pressure sensor (B48/7),
front passenger door pressure sensor (B48/8), rear door pressure sensor, driver-side (B48/9) and rear door
pressure sensor, passenger-side (B48/10) recognize a side impact, then the corresponding acceleration data or
pressure values are transmitted to the restraint systems control unit.
If the triggering threshold is exceeded, the restraint systems control unit sends trigger pulses to the
corresponding restraint systems.
The following squibs are ignited in the event of a side collision from the left:
 driver sidebag squib (R12/9)

 left 2nd row sidebag squib (R12/11)
 left windowbag squib (R12/16)
The following squibs are ignited in the event of a side collision from the right:
 front passenger sidebag squib (R12/10)

 right 2nd row sidebag squib (R12/12)
 right windowbag squib (R12/17)
Only with CODE (494) USA version
In the event of a collision and if the corresponding triggering threshold is exceeded, then a signal is sent from
the restraint systems control unit to the emergency call system control unit (N123/4) and an automatic
emergency call is made.
Sidebag sensor component description GF91.60-P-4034GZ

Driver/front passenger sidebag component description GF91.60-P-4039GZ
Rear sidebag component description GF91.60-P-4040GZ
Windowbag component description GF91.60-P-4041GZ
Restraint systems control unit, component description GF91.60-P-4048GZ
Pressure sensor, component description GF91.60-P-4109GZ
HEAD-ON COLLISION, FUNCTION - GF91.60-P-2006GZ
Sequence of emergency tensioning retractor activities in the event of moderately severe frontal impact for
the driver and passenger-side
Fig. 29: Identifying Head-On Collision, Function (1 Of 2)

Sequence of front airbag deployment in the event of severe frontal impact for the driver and passenger-
side
Fig. 30: Identifying Head-On Collision, Function (2 Of 2)

Moderately severe frontal impact (1st triggering stage)
If the 1st triggering threshold is exceeded in the event of a moderately severe head-on collision, only the seat
belts are activated.
The restraint systems control unit (N2/7) registers medium deceleration via the driver-side frontal acceleration
sensor (B48/1) or the passenger-side frontal acceleration sensor (B48/2) and activates the following squibs:
 Driver ETR [GUS] squib (R12/1)

 Passenger ETR squib (R12/2)
 Left 2nd row ETR [GUS] squib (R12/6)
 Right 2nd row ETR [GUS] squib (R12/7)
 Left 3rd seat row emergency tensioning retractor squibs (R12/35)
 Right 3rd seat row emergency tensioning retractor squibs (R12/36)
WSS (Weight Sensing System)
The seat occupied and child seat recognition is determined by the weight sensing system (WSS).
A weight measurement of the WSS (Weight Sensing System) control unit (N2/13) in the front passenger seat
enables a weight class to be determined which is then sent to the restraint systems control unit. The restraint
systems control unit uses the weight class to determine whether a suppression, a 1-stage or 2-stage triggering of
the front passenger airbag is necessary. If a seat belt on the passenger-side is not engaged in the seat belt buckle,
the restraint systems control unit registers this via the front passenger seat belt buckle and seat belt warning
switch (S68/2) and does not trigger the front passenger ETR [GUS] squib.
There is no seat belt buckle scan for the left/right seats in the 2nd seat row and in the 3rd seat row; therefore, the
left/right 2nd seat row emergency tensioning retractor squibs and the left/right 3rd seat row emergency
tensioning retractor squibs are always triggered.
Severe head-on collision (2nd and 3rd triggering threshold)
If in the event of a severe frontal impact, the 2nd triggering stage is exceeded, then the seat belts and front
airbags are activated. The restraint systems control unit registers severe deceleration via the driver or passenger-
side frontal acceleration sensor and activates the following squibs:
 Driver ETR [GUS] squib and front passenger ETR [GUS] squib
 Left 2nd row ETR [GUS] squib and right 2nd row ETR [GUS] squib
 Left/right 3rd row ETR [GUS] squibs
 Driver airbag squib 1 (R12/13)
 Passenger airbag squib 1 (R12/4)
 Driver belt force limiter (R12/27)
 Front passenger belt force limiter (R12/26)
If in the event of a severe frontal impact, the 3rd triggering stage is exceeded, then the restraint systems control
unit activates the following squibs too:

WSS (Weight Sensing System)
The seat occupied and child seat recognition is determined by the weight sensing system (WSS). A weight
measurement in the front passenger seat enables a weight class to be determined and this is sent to the restraint
systems control unit. The restraint systems control unit uses the weight class to determine whether a
suppression, a 1-stage or 2-stage triggering of the front passenger airbag is necessary.
A seat belt on the driver or passenger-side that is not engaged in the seat belt buckle, is registered by the
restraint systems control unit via the driver seat belt buckle and seat belt warning switch or the front passenger
seat belt buckle and seat belt warning switch, whereupon the corresponding driver or passenger-side ETR
[GUS] squib and the driver or passenger-side driver belt force limiters are not deployed.
There is no seat belt buckle scan for the left/right seats in the 2nd seat row and in the 3rd seat row; therefore, the
left/right 2nd seat row emergency tensioning retractor squibs and the left/right 3rd seat row emergency
tensioning retractor squibs are always triggered.
In the event of a collision and when the corresponding triggering threshold is exceeded, an additional signal
is transmitted to the emergency call system control unit (N123/4) by the restraint systems control unit and an
automatic emergency call is completed
Driver-side/front passenger frontal acceleration sensor component GF91.60-P-

description 4033GZ
GF91.60-P-
WSS sensor (Weight Sensing System), component description
4036GZ
GF91.60-P-
Driver airbag component description
4037GZ
GF91.60-P-
Front passenger airbag component description
4038GZ
GF91.60-P-
Front emergency tensioning retractor component description
4042GZ
GF91.60-P-
Rear emergency tensioning retractor component description
4043GZ
GF91.60-P-
Seat belt buckle switch, component description
4045GZ
GF91.60-P-
WSS (Weight Sensing System) control unit, component description
4046GZ
GF91.60-P-
Restraint systems control unit, component description
4048GZ
Model GF91.60-P-
3rd seat row emergency tensioning retractor, component description
164.8 4063GY
FORESIGHTED OCCUPANT PROTECTION FUNCTION - GF91.60-P-2010GZ
MODEL 164 with CODE (299) PRE-SAFE with CODE (242) Electrically adjustable front passenger seat
with memory
Fig. 31: Identifying Foresighted Occupant Protection Function - Shown On Model 164.8

Fig. 32: Block Diagram For PRE-SAFE System

Block diagram for the PRE-SAFE system shown with electrically adjustable front passenger seat with
memory, code 242, and power glass tilting/sliding roof, code 414
Block diagram continued
General
The "PRE-SAFE foresighted occupant protection" safety system is both an active and passive safety device. As
soon as a critically dangerous driving situation is detected by the brake system's sensor system, precautionary
measures are introduced.
Foresighted occupant protection is effective as from a speed >30 km/h (20 mph).
The PRE-SAFE safety system encompasses the following functions:
 Left/right front reversible emergency tensioning retractor

 Front passenger seat conditioning
 Automatic closing of all side windows
 Automatic closing of tilting/sliding roof (with power glass tilting/sliding roof, code 414)
The control units for the predicative passenger protection are located in the left front reversible emergency
tensioning retractor and right front reversible emergency tensioning retractor installed in the B-pillars. Data are
exchanged over the Controller Area Network bus Class C (engine compartment) (CAN-C).
Function
PRE-SAFE is triggered in the following critical driving situations:
PRE-SAFE longitudinal dynamics
 Emergency stop: Driver shocked into pressing all the way down on the brake pedal.
 Panic follow-up braking: Vehicle fails to decelerate sufficiently due to weather conditions (ice, snow,
etc.). The driver panics and depresses the brake pedal.
 Powerful targeted braking: Brake Assist System introduces powerful targeted braking.
PRE-SAFE lateral dynamics
 Excessive oversteer: A major rear axle slip angle occurs and cannot be stabilized by the Electronic
Stability Program (ESP).
 Excessive understeer: A significant, pending front axle slip angle occurs for an extended period and
cannot be stabilized by ESP.
 Critical steering wheel motion: Driver's steering wheel motion, which may point to a startled response
and which may result in vehicle instability. Triggering only occurs at speeds > 140 km/h (90 mph).
For all the above-mentioned conditions the left front reversible emergency tensioning retractor and right front
reversible emergency tensioning retractor are activated. In the process, the "seat belt slack" of the driver or front
passenger seat belt is drawn in until the seat belt is fitted snug to the occupant's body, provided that the
particular driver/front passenger seat belt latch plate is engaged.
Front passenger seat conditioning
The driver seat does not have any PRE-SAFE adjustment (conditioning).
Seat positioning serves to move the occupants to a position that will lessen the effects of an accident.
Conventional restraint systems can act ideally in this position.
The left front/right front reversible emergency tensioning retractors send the conditioning request of the front
passenger seat cyclically over CAN-C, the central gateway control unit, the Controller Area Network bus class
B (interior) (CAN-B) to the passenger-side front seat adjustment control unit with memory.
Only when an unfavorable seat position is given and the front passenger seat is recognized as occupied (CAN-C
signal from restraint systems control unit), is an adjustment made to the seats for the duration of the PRE-SAFE
situation.
The following adjustments must be normalized:
 Height adjustment, longitudinal adjustment, inclination adjustment

 Backrest
This automatic adjustment of the front passenger seat can be interrupted at any time by actuating the passenger-
side seat adjustment switch.
A memory reset regulation of the passenger-side seat does not take place after the PRE-SAFE situation is over.
The PRE-SAFE function for the passenger-side seat can be switched off using the diagnosis in the
passenger-side front seat adjustment control unit with memory.
Vehicle skidding (lateral dynamics)
If vehicle skidding is recognized, then the previously described functions are executed. Additionally the side
windows and tilting/sliding roof (SHD) are closed to within a gap of 50 mm.
The closing process for the side windows can be interrupted by pressing any of the switches. If, with an active
automatic closing of the windows, a request is received, the process is not interrupted, i.e. the windows are fully
closed.
The closing process of the SHD can be interrupted at any given time by actuating the roof switch (N70s1). If the
overhead control panel control unit continues to recognize the transmitted "PRESAFE message", the
tilting/sliding roof closing process is continued with. A memory reset regulation of the tilting/sliding roof does
not take place after the PRE-SAFE situation is over.
The anti-pinch protection is operative during the closing process and if activated will cause the drive to be
reversed.
End PRE-SAFE function
The following adjustments are interrupted by the respective control units, insofar as they have not reached their
PRE-SAFE positions:
 The left front reversible emergency tensioning retractor and right front reversible emergency tensioning
retractor only release the tensioned belts from the driver and front passenger, once the vehicle
acceleration (irrespective of direction) drops below a value of 0.3 g and PRE-SAFE longitudinal or lateral
dynamics are no longer pending. If the initial release process is not successful, a second one is initiated.
 Adjustment of passenger-side seat
 Power window and SHD run to the end of their automatic sequence, i.e. they move to their PRE-SAFE
position even after the PRE-SAFE situation is over.
Error message
Faults are stored in the left front reversible emergency tensioning retractor and right front reversible emergency
tensioning retractor and displayed in the instrument cluster.
Reversible belt emergency tensioning retractor, component description GF91.60-P-4050GZ
DRIVER/FRONT PASSENGER-SIDE FRONTAL ACCELERATION SENSOR, COMPONENT

DESCRIPTION - GF91.60-P-4033GZ
MODEL 164
Fig. 33: Identifying Driver/Front Passenger-Side Frontal Acceleration Sensor Component

The driver-side frontal acceleration sensor (B48/1) and passenger-side frontal acceleration sensor (B48/2) are
mounted at the side of the front module.
The restraint systems control unit (N2/7) can also be triggered on reception of the data of just one frontal
acceleration sensor. In the event of the failure of one sensor, the signal of the second sensor continues to be
evaluated.
The frontal acceleration sensors determine the acceleration values in the area of the left and right front sections.
The acceleration sensors support the restraint systems control unit for calculation of the triggering characteristic
in the event of a head-on collision (if or if not airbag is to be triggered).
SIDEBAG SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4034GZ
MODEL 164
Fig. 34: Identifying Sidebag Sensor Component

Measuring range and sensitivity are checked for conformity with programmed equipment. The production
date can be read out via the diagnosis.
The driver sidebag sensor (A53) and front passenger sidebag sensor (A54) are each located in the B-pillars.
They determine the acceleration values in the area of the left and right B-pillars and serve for an early detection
of a side impact.
The basic functions are:
 constant transmission of a digital "OK" signal on successfully completing self-test

 transmission of "Sensor faulty" following fourth successive self-test failures
 transmission of identification (measuring range, sensitivity) on request from restraint systems control unit
(N2/7)
 periodic transmission of acceleration values as digital values
WSS (WEIGHT SENSING SYSTEM) SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4036GZ
Fig. 35: Identifying WSS (Weight Sensing System) Sensor Component

The WSS (Weight Sensing System) sensors,
 left front WSS sensor (Weight Sensing System) (B48/11),

 right front WSS sensor (Weight Sensing System) (B48/12),
 left rear WSS sensor (Weight Sensing System) (B48/13) and

 right rear WSS (Weight Sensing System) sensor (B48/14),
are located in the front passenger seat frame.
The sensors record the applied weight. The recorded values are sent to the WSS (Weight Sensing System)
control unit (N2/13) and called on and evaluated for the triggering of the restraint system.
DRIVER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P-4037GZ
MODEL 164
Fig. 36: Identifying Driver Airbag Component

The driver airbag with its squibs (driver airbag squib 1 (R12/13) and driver airbag squib 2 (R12/14)) is located
in the steering wheel's impact absorber; it protects the driver in the event of a head-on collision.
The driver airbag is bolted to the steering wheel and upholstered on the side facing the driver. The upholstery is
equipped with a predetermined fracture point to enable the airbag to deploy fully.
The electric connection of the squibs from the rotatable steering wheel to the restraint systems control unit is
ensured by the steering column module (N80).
To avoid any malfunctions, the squibs are equipped with short circuit bridges. If the coupling is detached, the
squib connections are short circuited.
The housing contains the gas generator, which is equipped with two acid-free solid fuel units and is connected
to the airbag via a filter. For ignition, each solid-propellant charge is equipped with its own squib.
Function
The restraint systems control unit (N2/7) sends an electrical ignition pulse to either one or both of the squibs of
the gas generator, depending on the severity of the impact. The type of crash involved determines whether the
squibs are ignited simultaneously or in stages.
The squibs then ignite the solid propellant in the gas generator. As the solid fuel burns, it generates a gas that
flows explosively under high pressure through a filter and into the interior of the air sack, i.e. the airbag.
The folded airbag on the gas generator then inflates, the pressure of the in flowing gas forcing open the steering
wheel cover along a predetermined fracture point.
As gas enters the airbag, it pushes through the predetermined fracture point and fills to maximum volume.
The airbag reaches its full volume within approximately 30 msec.
It begins to deflate immediately after attaining maximum volume. The gas escapes from the airbag through a
filter and the airbag collapses.
FRONT PASSENGER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P-4038GZ
MODEL 164
Fig. 37: Identifying Front Passenger Airbag Component

The front passenger airbag with its squibs (front passenger airbag squib 1 (R12/4) and front passenger airbag
squib 2 (R12/5)) is located in the instrument panel on the passenger side; it protects the front passenger against
injury in the event of a head-on collision.
In the event of a severe enough impact, the front passenger airbag is triggered - depending on the seat occupied
recognition of the front passenger seat and the WSS (Weight Sensing System) control unit (N2/13).
The airbag consists of a two-stage compressed gas generator and an air sack, i.e. the airbag.
Function
The restraint systems control unit (N2/7) delivers an electrical ignition pulse to either one or both of the squibs
of the gas generator, depending on the severity of the impact.
The type of crash involved determines whether the squibs are ignited simultaneously or in stages. If the squib is
ignited, a high pressure is generated which is transmitted to the corresponding pressure chamber.
The pressure rise in the pressure chamber fractures a bursting disk, enabling the gas mixture to flow into the
airbag. The airbag is inflated.
The pressure of the incoming gas causes the airbag to deploy. The airbag flap is ripped apart along the
predetermined fracture points and the airbag deploys fully.
The airbag reaches its maximum volume within approximately 35 msec.
The bag begins to deflate immediately after reaching its maximum volume. The gas escapes from the airbag
through a filter and the airbag collapses.
DRIVER/FRONT PASSENGER SIDEBAGS, COMPONENT DESCRIPTION - GF91.60-P-4039GZ
MODEL 164
Fig. 38: Identifying Driver/Front Passenger Sidebags Component

The left and right front sidebags with their respective squibs (driver sidebag squib (R12/9) and front passenger
sidebag squib (R12/10)) are located in the respective lateral support cushion of the driver and front passenger
seats.
In the event of a side impact in the area of the door and the B-pillar, the sidebag protects the upper thorax and
the head of driver or the front passenger against injuries.
The protective effect of the sidebag is augmented and improved by the windowbag.
The sidebag unit is located in a housing, which contains the folded up airbag, the gas generator and the squib.
Located on the front side of the housing is a predetermined fracture point to allow the airbag to expand.
The electrical connection for the squib is located at the rear of the housing.
Function
In the event of a side collision, the restraint systems control unit (N2/7) together with the driver sidebag sensor
(A53) or front passenger sidebag sensor (A54) measures the acceleration in the area of the B-pillar. If the
triggering threshold is exceeded, then the sidebag in question is triggered by an electrical ignition pulse.
The squib ignites the solid fuel in a fuel chamber.
The solid fuel is burned off. A bursting disk bursts open and the compressed gas escapes from the pressure
container and is routed over discharge holes into the airbag.
As the gas flows into the bag under pressure, the airbag rapidly inflates, tearing open the sidebag housing and
thrusting through the seam in the lateral support cushion and into the passenger compartment. The airbag
reaches its full volume within approximately 20 msec.
The bag begins to deflate immediately after reaching its maximum volume. The gas escapes from the airbag
through a filter and the airbag collapses.
REAR SIDEBAG COMPONENT DESCRIPTION - GF91.60-P-4040GZ
MODEL 164
Fig. 39: Identifying Rear Sidebag Component

The left or right 2nd row sidebag with the left 2nd row sidebag squib (R12/11) or right 2nd row sidebag squib
(R12/12) is located in the respective lateral support cushion of the left or right 2nd row and protects the rear
occupants against injury in the event of a side impact in the area of the door and C-pillar.
The sidebag unit is located in a housing which contains the folded up airbag, the gas generator and the squib.
Located on the front side of the housing is a predetermined fracture point to allow the airbag to expand. The
electrical connection for the squib is located at the rear of the housing.
Function
In the event of a side impact, the restraint systems control unit (N2/7) together with the driver sidebag sensor
(A53) or front passenger sidebag sensor (A54) measures the acceleration in the area of the B-pillar.
If the triggering threshold is exceeded, then the sidebag in question is triggered by an electrical ignition pulse.
The squib ignites the solid fuel in a fuel chamber.
The solid fuel is burned off. A bursting disk bursts open and the compressed gas escapes from the pressure
container and is routed over discharge holes into the airbag.
As the gas flows into the bag under pressure, the airbag rapidly inflates, tearing open the sidebag housing and
thrusting through the seam in the lateral support cushion and into the passenger compartment. The airbag
reaches its full volume within approximately 20 msec.
The bag begins to deflate immediately after reaching its maximum volume. The gas escapes through a filter.
The sidebag collapses.
WINDOWBAG, COMPONENT DESCRIPTION - GF91.60-P-4041GZ
MODEL 164
Fig. 40: Identifying Windowbag Component

When folded up, the corresponding air hose is located in the side roof frame and extends from the A-pillar to
the C-pillar.
The windowbag unit consists of a hybrid-type gas generator with the left windowbag squib (R12/16) or right
windowbag squib (R12/17) and an air hose. The air hose is divided into multiple air chambers.
The gas generator with the left windowbag squib and the gas generator with the right windowbag squib are
located in the left and right A-pillars.
The windowbag supplements the effect of the sidebag in the event of a side-impact collision. It protects the
head area of front and rear passengers in the event of a side impact collision or an angled collision.
In inflated state, the windowbag on the driver or passenger side fills up the area between the side windows and
occupants.
It prevents the head from oscillating wildly immediately after an impact and thus reduces any acceleration
forces that act on the body.
In addition, the air cushion holds back glass splinters and other objects that could penetrate into the passenger
compartment in the event of a side impact or a subsequent rollover.
Function
The restraint systems control unit (N2/7) sends an ignition pulse to the squib in the hybrid gas generator. The
solid fuel in the fuel chamber is ignited by the squib, which is burning off.
A pressure builds up in the fuel chamber. This pressure causes a bursting disk to be destroyed.
The compressed inert gas mixture can escape from the pressure reservoir through the discharge holes. The gas
flowing out is guided at a high pressure in the air hose folded and stored in the roof frame.
The air hose, which is now inflating, tears open the inner paneling at the side roof frame and penetrates into the
passenger compartment.
The air hose reaches its full volume within approximately 25 ms This volume remains for approx. 3 to 5 s,
ensuring that the protective effect is retained for a sufficiently long period also in the event of subsequent
rollovers.
The pressure now begins to drop. The gas escapes from the airbag through a filter and the airbag collapses.
FRONT EMERGENCY TENSIONING RETRACTOR, COMPONENT DESCRIPTION - GF91.60-P-

4042GZ
MODEL 164
Fig. 41: Identifying Front Emergency Tensioning Retractor Component

The driver/front passenger buckle emergency tensioning retractor with the relevant squibs (driver buckle ETR
squib (R46) and front passenger buckle ETR squib (R46/1)) are located at each seat frame.
The emergency tensioning retractors in the event of a
 head-on collision,
 a rear-end collision or a
 Rolling along the longitudinal vehicle axis
reels in the seat belt slack and avoids any free travel, the seat belt's so-called film reel effect.
The close-fitting seat belt means that vehicle occupants are exposed to the deceleration forces acting on the
body at an earlier stage.
When deployed, a solid fuel is ignited by the squib. The resulting excess pressure in the cylinder mechanically
retracts the seat belt buckle.
REAR EMERGENCY TENSIONING RETRACTOR, COMPONENT DESCRIPTION - GF91.60-P-

4043GZ
MODEL 164
Fig. 42: Identifying Rear Emergency Tensioning Retractor Component

The emergency tensioning retractor of the left and right 2nd rows with their squibs (left 2nd row ETR squib
(R12/6) and right 2nd row ETR squib (R12/7)) are located in the respective C-pillar.
The emergency tensioning retractor in the event of a
 head-on collision,
 a rear-end collision or a
 Rolling along the longitudinal vehicle axis
reels in the seat belt slack and avoids any free travel, the seat belt's so-called film reel effect.
The close-fitting seat belt means that vehicle occupants are exposed to the deceleration forces acting on the
body at an earlier stage.
The burn-off gas of the squib generated upon ignition creates a gas pressure and thus turns a piston. This
rotation induces the emergency tensioning.
SEAT BELT BUCKLE SWITCH, COMPONENT DESCRIPTION - GF91.60-P-4045GZ
MODEL 164
Fig. 43: Identifying Seat Belt Buckle Switch Component

The driver seat belt buckle and seat belt warning switch (S68/1) and the front passenger seat belt buckle and
seat belt warning switch (S68/2) are assigned to the respective seat; they monitor the tight seat of the driver and
front passenger three-point seat belts.
Feedback is displayed in the multifunction display (A1p13) of the instrument cluster (A1) concerning the
switching states of the seat belt buckles.
WSS (WEIGHT SENSING SYSTEM) CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-

4046GZ
Fig. 44: Identifying WSS (Weight Sensing System) Control Unit Component
The WSS (Weight Sensing System) control unit (N2/13) is located on the front passenger seat frame. It
measures the applied weight of a person or a mounted child seat on the front passenger seat via the sensors
 B48/11 Left front WSS (Weight Sensing System) sensor,

 B48/12 Right front WSS (Weight Sensing System) sensor,
 B48/13 Left rear WSS (Weight Sensing System) sensor,
 B48/14 Right rear WSS (Weight Sensing System) sensor,
which are mounted on the seat frame.

The measured values are used to determine a weight class for the applied weight and made available to the
restraint systems control unit (N2/7) for exact control of the airbag stages.
The WSS control unit tasks are:
 evaluation and voltage supply of the four WSS sensors

 calculation of the weight class of an applied weight of a person or a mounted child seat on the front
passenger seat
 provision of weight class data via the Controller Area Network bus Class B (interior) (CAN-B)
 self-test of WSS control unit and WSS sensors. In the event of a defect, an entry is made to the fault
memory
RESTRAINT SYSTEMS CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-4048GZ
MODEL 164
Fig. 45: Identifying Restraint Systems Control Unit Component

Location
The restraint systems control unit is located on the center tunnel between the front seats.
Task
The restraint systems control unit is used to ensure passive occupant protection. The restraint systems control
unit deploys the restraint systems in the event of an accident. These include, e.g. the airbag units and emergency
tensioning retractors. The restraint systems control unit has self-monitoring and fault monitoring features. Head-
on, rear-end, and side impact collisions are recorded, and a distinction is made between the different types of
collision.
Roll-overs around the longitudinal vehicle axis can also be detected.
For code (494) USA version:
In the event of an accident, an automatic emergency call is also sent over the emergency call system control unit
(N123/4).
Scope of task
 Crash recognition and ignition point recognition

 To trigger ignition stages in event of collision, taking crash evaluation during a collision into
consideration
 Evaluation of front passenger seat occupied and child seat recognition sensor (B48) (not with code (494)
USA version)
 Evaluation of Weight Sensing System (WSS) (with code (494) USA version)
 Actuation of digital crash output, separately and via Controller Area Network Bus Class C (engine
compartment) (CAN-C) (with code (494) USA version)
 Output of redundant crash signal over discrete lines to ME control unit (N3/10) and rear SAM control
unit (N10/8) (as of 1.6.07)
 Power supply and evaluation of following sensors:
 Driver sidebag sensor (A53)
 Front passenger sidebag sensor (A54)
 Driver frontal acceleration sensor (B48/1)
 Passenger-side frontal acceleration sensor (B48/2)
 Driver door pressure sensor (B48/7)
 Front passenger door pressure sensor (B48/8)
With code (293) Left and right rear sidebag:
 Rear door pressure sensor, passenger side (B48/10)

 Rear door pressure sensor, driver-side (B48/9)
 To be a power backup in a "self-sufficiency instance", in the event of a battery failure after a collision
 Self-testing and permanent monitoring of system and fault display with nonvolatile storage of faults and
failure time
 Storage of nonvolatile crash telegrams
 Programming capability in terms of equipment and crash parameters
 Fault output via interface after initiating diagnosis communication
 System readiness display over CAN-C to the instrument cluster (A1)
 Evaluation of integrated rollover sensor
 Support of automatic seat belt reminder warning over CAN-C
 Sleep function
Seat belt warning lamp function (A1e9)
The seat belt warning lamp is located in the instrument cluster.
After starting the engine, the seat belt warning lamp lights up for a maximum of 6 seconds and a buzzer sounds
in order to remind the driver or front passenger (if available) to buckle up.
If the driver or front passenger is not belted after these 6 seconds and a speed of 25 km/h (15 mph) has not been
exceeded, the seat belt warning lamp lights up until the driver and front passenger are belted.
If a speed of 25 km/h (15 mph) has been exceeded (driver or front passenger not belted), the seat belt warning
lamp starts to flash on and off for a maximum of 60 s after the speed has been exceeded and a warning sound is
emitted.
If the driver or front passenger is still not belted after these 60 seconds, the warning sound goes off and the seat
belt warning lamp stops flashing on and off. The seat belt warning lamp stays on until the driver and front
passenger are belted.
The seat belt warning lamp will only go out, if the driver and the front passenger are belted or the vehicle is
standing and one front door is open.
Objects on the front passenger seat can be identified as person due to their weight and lead to a warning.
Indicator and warning lamp airbag function (A1e15)
The airbag indicator and warning lamp is located in the instrument cluster. If the airbag indicator and warning
lamp lights up during the journey the supplemental restraint system is faulty. In such a case the restraint
equipment may be unintentionally deployed or not at all in the event of an accident.
Automatic child seat recognition airbag OFF indicator lamp function (N72/1e1)
The Airbag OFF indicator lamp is located in the upper control panel control unit.
The airbag OFF indicator lamp indicates the functional availability of the automatic child seat recognition
system and that the front passenger airbag has been turned off if a special child seat is detected.
Self-test, function
When c. 15R is activated, the restraint systems control unit performs a self-test for restraint system.
In the process, the airbag indicator and warning lamp in the instrument cluster and the airbag OFF indicator
lamp in the upper control panel control unit are actuated for 4 seconds via the central gateway control unit
(N93). If the self-test was successful, both indicator lamps are switched off.
If the self-test was not successful, the airbag indicator and warning lamp remains switched off. However, the
restraint systems control e. unit remains ready for triggering.
If the airbag OFF indicator lamp and the airbag indicator and warning lamp light up at the same time, there is
a malfunction in the weight sensing system and the front passenger airbag is deactivated (only with code (494)
USA version).
Discrete inputs
 Circuit 15R
 Circuit 31
 Circuit 30
 Driver sidebag sensor
 Front passenger sidebag sensor
 Front passenger seat occupied and child seat recognition sensor
 Driver-side frontal acceleration sensor
 Passenger-side frontal acceleration sensor
 Driver door pressure sensor
 Front passenger door pressure sensor
 Rear door pressure sensor, driver-side
 Rear door pressure sensor, passenger-side
 Driver seat belt buckle and seat belt warning switch (S68/1)
 Front passenger seat belt buckle and seat belt warning switch (S68/2)
 Left rear belt buckle switch (S68/11) (up to 31.5.06)
 Right rear belt buckle switch (S68/12) (up to 31.5.06)
 Center rear seat belt buckle switch (S68/14) (up to 31.5.06)
 Left seat belt buckle switch on 3rd seat row (S68/16) (model 164.8 up to 31.5.06)
 Right seat belt buckle switch on 3rd seat row (S68/17) (model 164.8 up to 31.5.06)
Discrete outputs

 Driver sidebag squib (R12/9)
 Front passenger sidebag squib (R12/10)
 Left windowbag squib (R12/16)
 Right windowbag squib (R12/17)
 Left sidebag squib for 2nd seat row (R12/11) (with code (293) Left and right rear sidebag)
 Right sidebag squib for 2nd seat row (R12/12) (with code (293) Left and right rear sidebag)
 Left 3rd seat row emergency tensioning retractor squib (R12/35) (model 164.8)
 Right 3rd seat row emergency tensioning retractor squib (R12/36) (model 164.8)
 Left 2nd row emergency tensioning retractor squib (R12/6)
 Right 2nd row emergency tensioning retractor squib (R12/7)
 Drive buckle ETR squib (R46)
 Front passenger ETR squib (R46/1)
 Solenoid for NECK-PRO head restraint, driver (Y24/12) (with code (494) USA version or with code
(438) NECK-PRO)
 Solenoid for NECK-PRO head restraint, front passenger (Y24/13)
(with code (494) USA version or with code (438) NECK-PRO)
 Digital crash output via emergency call system control unit (with code (494) USA version)
 ME control unit (redundant crash signal as of 1.6.07)
 Rear SAM control unit (redundant crash signal as of 1.6.07)
The restraint system control unit has integrated sensors. For this reason, do not remove the restraint
equipment control unit when the power supply is activated, as otherwise airbags and emergency
tensioning retractors trigger. All work performed on or with the restraint systems control unit may only be
conducted when the battery (G1) has been disconnected and after a waiting time of approx. > or = 60 s.
REVERSIBLE EMERGENCY TENSIONING RETRACTOR, COMPONENT DESCRIPTION -

GF91.60-P-4050GZ
MODEL 164
Fig. 46: Identifying Left/Right Front Reversible Emergency Tensioning Retractor

The left front reversible emergency tensioning retractor (A76) and right front reversible emergency tensioning
retractor (A76/1) are located in the B-pillars. The reversible emergency tensioning retractors have their own
integrated PRE-SAFE control unit.
General
The left and right front reversible emergency tensioning retractors are also known as "reversible electrical reel
retractors". The reversible emergency tensioning retractors are the core of a PRESAFE system. An activation of
the PRE-SAFE control unit occurs in a critical driving situation, i.e. in a potential accident situation.
The PRE-SAFE adjustment just prior to the actual impact should help to provide an improved situation for the
occupants prior to a collision.
Fig. 47: Identifying Left/Right Front Reversible Emergency Tensioning Retractor

Control unit task scope:
 Detection of a critical driving situation such as an emergency stop or a skidding situation

 Triggering of the electrical reel retractor
 Transmission of the emergency stop or skidding message to the Controller Area Network bus Class C
(engine compartment) (CAN-C)
 Actuation of the overhead control panel control unit (N70) to close the power sliding roof, only when
equipped with glass electric power sliding roof (Code 414)
The necessary information is received by the PRE-SAFE control unit over the CAN-C.
Electric reel retractor, task scope:
 Rolling up belt
 (Electric) belt tensioning
 Releasing belt
Variations
There are different mechanical variants, e.g. manual child safety lock in retractor on passenger-side in USA
version.
There are different variant codings for left-hand and right-hand drive vehicles.
DRIVER/PASSENGER-SIDE NECK-PRO HEAD RESTRAINTS - GF91.60-P-4053GZ
MODEL 164, 251

Fig. 48: Identifying Driver And Front Passenger NECK-PRO Head Restraint Solenoid
The solenoids are integrated in the head restraints.
Function diagram for NECK-PRO head restraint
Fig. 49: Identifying NECK-PRO Head Restraint In Basic Position And NECK-PRO Head Restraint In
Position After Rear End Collision
Tasks
The solenoid of the driver NECK-PRO head restraint and of the front passenger NECK-PRO head restraint
activates a mechanism in the head restraint in the event of a rear end collision. The head restraint impact
cushion then moves forward by approx. 40 mm and upward by approx. 30 mm thus reducing the distance
between the head and the head restraint during the accident.
Function
The sensor electronics of the restraint systems control unit (N2/7) senses the vehicle acceleration and, if
required, switches the solenoid in the head restraints on after a delay period of approx. 20 ms.
This releases a mechanic locking mechanism which activates the NECK-PRO function in the head restraints
through spring force.
The cable of the restraint systems control unit that is used to activate the head restraint is routed through the
head restraint bracket. Therefore, the head restraint can no longer be removed by the customer.
Triggered head restraints can be recognized by the fact that they are moved forward and cannot be adjusted.
They can be reset with the available vehicle tool kit.
REAR SEAT BELT BUCKLE SWITCH, COMPONENT DESCRIPTION - GF91.60-P-4054GZ
MODEL 164.1 up to 31.5.06 except CODE (494) USA version
Rear seat belt buckle switches, location
Fig. 50: Identifying Rear Seat Belt Buckle Switch Component Location
Location
The left rear seat belt buckle switch, right rear seat belt buckle switch and center rear seat belt buckle switch,
are each located at the rear bench seat.
Task
The left rear seat belt buckle switch, right rear seat belt buckle switch and center rear seat belt buckle switch
monitor whether the rear passengers have been buckled up with the three-point seat belt. Corresponding to the
switching state of the seat belt buckles, a feedback appears in the multifunction display (A1p13) of the
instrument cluster (A1).
3RD SEAT ROW EMERGENCY TENSIONING RETRACTOR, COMPONENT DESCRIPTION -

GF91.60-P-4063GY
MODEL 164.8, 251

Fig. 51: Identifying 3rd Seat Row Emergency Tensioning Retractor Component (Shown On Model 164.8)
Location
The left and right 3rd seat row emergency tensioning retractor with its left and right 3rd seat row emergency
tensioning retractor squib are each located at the D-pillar behind the side window.
Task
The left and right 3rd seat row emergency tensioning retractor prevents seat belt slack and thus the seat belt film
reel effect. The close-fitting seat belt means that vehicle occupants are exposed to the deceleration forces acting
on the body at an earlier stage.
PRESSURE SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4109GZ
MODEL 164, 251
Fig. 52: Identifying Pressure Sensor Component - Shown On Model 164.1

Location
The pressure sensors are located behind the respective door trim.
Task
To detect a side impact in the door area, the pressure sensors measure the air pressure values inside the doors. If
the air pressure value increases significantly in one door (e.g. when the door skin is pressed in from outside), the
restraint systems control unit (N2/7) triggers the respective sidebag or windowbag in the impact area.
Scope of tasks
 After a successful self-test, the pressure sensors confirm success by transmitting a signal to the restraint
systems control unit.
 Upon request of the restraint systems control unit, the measuring range and the sensitivity of the pressure
sensors are transmitted, and the system checks whether they match the programmed equipment. The
production data can be output via STAR DIAGNOSIS.
OVERVIEW OF SYSTEM COMPONENTS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS),

COMPONENT DESCRIPTION - GF91.60-P-9997GZ
GF91.60-P-
Driver airbag, component description
4037GZ
GF91.60-P-
Front passenger airbag, component description
4038GZ
Driver-side/front passenger-side sidebag, component GF91.60-P-
description 4039GZ
GF91.60-P-
Rear sidebag, component description
4040GZ
GF91.60-P-
Windowbag, component description
4041GZ
Front emergency tensioning retractor, component GF91.60-P-
description 4042GZ
GF91.60-P-
Rear emergency tensioning retractor, component description
4043GZ
GF91.60-P-
Driver/passenger-side NECK-PRO head restraints
4053GZ
3rd seat row emergency tensioning retractor, component GF91.60-P-
Model 164.8
description 4063GY
GF91.60-P-
Sidebag sensor, component description A53, A54
4034GZ
Reversible belt emergency tensioning retractor, component GF91.60-P-

A76, A76/1
description 4050GZ
Driver-side/front passenger frontal acceleration sensor GF91.60-P-
B48/1, B48/2
B48/7, B48/8, B48/9, GF91.60-P-
Pressure sensor, component description
B48/10 4109GZ
WSS (Weight Sensing System) sensor, component B48/11, B48/12, B48/13, GF91.60-P-
description B48/14 4036GZ
WSS (Weight Sensing System) control unit, component GF91.60-P-
N2/13
description 4046GZ
GF91.60-P-
Restraint systems control unit, component description N2/7
4048GZ
GF91.60-P-
Seat belt buckle switch component description S68/1, S68/2
4045GZ
Table of contents: Function description of supplemental GF91.60-P-
restraint system (SRS) 0999GZ
SAFETY PRECAUTIONS
RISK OF INJURY CAUSED BY PERFORMING TESTING OR REPAIR WORK ON AIRBAG OR
EMERGENCY TENSIONING RETRACTOR UNITS. - AS91.00-Z-0001
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. -
AS91.00-Z-0001-01A
Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C.
When working on these units, disconnect the power supply.
Risk of injury
caused by flying objects if an airbag or emergency tensioning retractor (ETR) unit is triggered accidentally or if
an airbag unit is stored with its deployment side face down. A danger also exists if the units are scrapped or
opened using cutting torches or other cutting equipment, smelted, or if parts that have not ignited end up in fires
or smolder files on landfills.
Safety instructions/precautions
 Always store removed airbag units with the deployment face up.
 Acquisition, transportation, storage, testing and assembly work should only be performed or supervised
by properly trained personnel.
 Install airbag or seat belt emergency tensioning retractor units immediately after taking them from the
storage room.
 Airbag and seat belt emergency tensioning retractor units must be protected from flying sparks, open
flames and temperatures of >100°C.
 Do not transport airbags and emergency tensioning retractors in the passenger compartment, but rather
stow them securely in the load compartment of the vehicle in their original replacement part packaging so
as to prevent any slippage.
 Do not bring airbag and emergency tensioning retractor units into contact with grease, oil or cleaning
agents.
 Perform system tests using approved testing equipment only and only when the units are properly
installed and the vehicle is unoccupied.
 Initial hook-up of the battery or an external power supply may only be done when the ignition is switched
on and when the vehicle is unoccupied.
 Airbags and emergency tensioning retractors that have dropped from a height of more than 0.5 m must be
replaced.
 The airbag and emergency tensioning retractor units must be disposed of in their original
packaging through the MeRSy (Renz) disposal channel in a professional and environmentally acceptable
manner.
 In all countries except national regulations governing proper disposal must be complied
with.
The following steps must be taken before performing body work or retrofitting operations, work on airbag or
ETR units, or work on components connected to airbag or ETR units or work that involves the airbag or ETR
circuitry (e.g. removal of the steering wheel):
 Withdraw ignition key.

 Disconnect any external power sources (e.g. chargers).
 Pull plug from control unit prior to performing work inside the passenger compartment and prior to any
welding work.
On vehicles with Keyless Go (KG)
Ensure that no circuit is on.
Risk of injury. Injuries may result when performing testing or repair work on airbag or emergency tensioning retractor
units. - AS91.00-Z-0001-01B
Store airbag unit with expulsion area on top, do not subject to temperatures above 100 °C. When
working on these units, disconnect power supply and unplug the SRS test connector (X11/13).
Risk of injury
Injuries may be caused by flying objects if an airbag or emergency tensioning retractor (ETR) unit is triggered
accidentally or if an airbag unit is stored with its deployment face down.
 Always store removed airbag units with the discharge opening facing upwards.
 Purchase, transport, storage, and checking and assembly operations may only be performed or supervised
by specifically trained personnel.

 Install airbag or emergency belt tensioner units immediately after taking them from the storage room.
 Airbag and emergency tensioning retractor units must be protected from flying sparks, open flames and
temperatures of > 100° C.
 Do not transport airbags and emergency tensioning retractors in the passenger compartment, but rather
stow them securely in the load compartment of the vehicle in their original replacement part packaging so
as to prevent any sliding.
 Do not allow grease, oil or cleaning agents to come into contact with airbag or ETR units.
 Only perform system tests using the approved testing equipment (e.g. hand-held tester) when installed
and without passengers .
 Initial hook-up of the battery or an external power supply may only be done when the ignition is switched
on and when the vehicle is unoccupied .
 Airbag and emergency belt tensioner units which have fallen from a height of more than 0.5 m must be
replaced
 For proper disposal return airbags and emergency tensioning retractors in the original
package through the usual disposal channel MeRSy (Renz company).
 In all countries except proper and safe scrapping shall be done in compliance with the
applicable regulations of the country concerned.
The following steps must be taken before performing body work or retrofitting operations, work on airbag or
ETR units, or work on components connected to airbag or ETR units or that involves the airbag or ETR
circuit (e.g. when removing the steering wheel):
 Remove key from starter switch

 Disconnect and isolate the battery ground cable.
 Disconnect the SRS test connector.
 Disconnect external power sources (e.g. charging equipment).
 Pull plug from control module prior to performing work inside the passenger compartment and prior to
any welding work.
RISK OF INJURY. INJURY MAY RESULT WHEN THE TENSION IN THE SPRING IN THE
AUTOMATIC BELT RETRACTOR IS RELEASED. - AS91.00-Z-0002-01A
Never disassemble automatic belt retractors.
Risk of injury
Disassembling an automatic belt retractor may cause the sudden release of spring tension and result in injuries.
Safety guidelines/precautions
Never disassemble automatic belt retractors!

TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: SEATS, BUNKS, RESTRAINT SYSTEMS -
AR91.00-Z-9164AA
MODEL 164
AR91.10-P-
Remove/install front seat MODEL 164
1000GZ
AR91.10-P-
Remove/install front seat backrest MODEL 164
1060GZ
Remove/install front seat backrest AR91.10-P-
MODEL 164
upholstery 1090GZ
AR91.10-P-
Remove/install front seat frame trim panels MODEL 164
1200GZ
Remove/install back shell from front seat AR91.10-P-
MODEL 164
backrest 1915GZ
AR91.10-P-
Remove/install seat cushion MODEL 164
3310GZ
AR91.10-P-
Remove/install front seat backrest frame MODEL 164
3331GZ
AR91.10-P-
Remove/install seat cushion frame MODEL 164
3334GZ
MODEL 164, 251 with CODE (864) Rear AR91.10-P-
Remove/install monitor frame on front seat
entertainment system 3510GZ
AR91.12-P-
Removing and installing rear seat MODEL 164.8 40 % rear seat
1000GY
AR91.12-P-
Removing and installing rear seat MODEL 164.8 60 % rear seat
1000GYA
AR91.12-P-
Remove/install rear seat MODEL 164.8 3rd seat row
1000GYB
MODEL 164.8 Rear seat cushion of 40 % AR91.12-P-
Remove/install rear seat cushion
rear seat 1020GY
MODEL 164.8 Rear seat cushion of 60 % AR91.12-P-
Remove/install rear seat cushion
rear seat 1020GYA
AR91.12-P-
Remove/install rear seat cushion MODEL 164.8 3rd seat row
1020GYB
AR91.12-P-
Remove/install rear seat cushion MODEL 164.1 40 % rear seat
1020GZ
AR91.12-P-
Remove/install rear seat cushion MODEL 164.1 60 % rear seat
1020GZA
Remove/install upholstery for rear seat AR91.12-P-
MODEL 164.8 3rd seat row
backrest 1030GY
Remove/install upholstery for rear seat MODEL 164.8 Padding of rear seat AR91.12-P-
backrest backrests in 2nd seat row 1030GYA

MODEL 164.1 40 %
backrest 1030GZ
MODEL 164.1 60 %
backrest 1030GZA
AR91.12-P-
Remove and install rear seat cushion frame MODEL 164.8 3rd seat row
1110GY
AR91.12-P-
Remove and install rear seat cushion frame MODEL 164.8 2nd seat row rear seat, 40 %
1110GYA
AR91.12-P-
Remove and install rear seat cushion frame MODEL 164.1 40 %
1110GZ
Remove/install cable for unlocking easy AR91.12-P-
MODEL 164.8
entry 1120GY
Remove/install paneling of rear seat AR91.12-P-
backrest 1131GY
Removing and installing paneling of rear AR91.12-P-
MODEL 164 40 % rear seat
seat backrest 1131GZ
Removing and installing paneling of rear AR91.12-P-
seat backrest 1131GZA
AR91.12-P-
Remove/install rear seat backrest MODEL 164.8 40 %
1620GY
AR91.12-P-
Remove/install rear seat backrest MODEL 164.8 60 % rear seat backrest
1620GYA
AR91.12-P-
Remove/install rear seat backrest MODEL 164.8 3rd seat row
1620GYB
AR91.12-P-
Remove/install rear seat backrest MODEL 164.1 40% rear seat
1620GZ
AR91.12-P-
Remove/install rear seat backrest MODEL 164.1 60% rear seat
1620GZA
Remove and install locking mechanism for AR91.12-P-
MODEL 164.1
folding rear seat backrest 1730GZA
Remove/install buckle of rear seat backrest AR91.12-P-
MODEL 164.1
lock 1731GZ
Remove/install release lever of rear seat AR91.12-P-
MODEL 164.8
backrest 1732GY
Remove/install rear seat backrest release MODEL 164.8 Rear seat backrest of 60 % AR91.12-P-
cable rear seat 1734GY
Remove/install rear seat backrest release AR91.12-P-
MODEL 164.1
cable 1734GZ
Remove/install split rear seat backrest arm AR91.12-P-
MODEL 164
rest 1750GZ
MODEL 164.8 40 % and 60 % rear seat AR91.12-P-
Remove/install seat frame in rear
frame 6000GY
Remove/install gas-operated strut on seat AR91.12-P-
frame MODEL 164.8 40 % rear seat 6005GY

MODEL 164 Electrically adjustable head AR91.16-P-
Remove/install head restraint on front seat
restraint 0040GZ
MODEL 164 Mechanically adjustable head AR91.16-P-
Remove/install head restraint on front seat
restraint 0040GZA
Remove/install head restraint guide on AR91.16-P-
MODEL 164.1
front seat 0050GZ
Remove/install head restraint guide on AR91.16-P-
MODEL 251, 164.8
front seat 0050RT
AR91.16-P-
Removing rear head restraint MODEL 164.8 3rd seat row
1770GY
AR91.16-P-
Removing rear head restraint MODEL 164.1 MODEL 164.8 2nd seat row
1770GZ
Remove/install rear seat backrest head AR91.16-P-
MODEL 164.1 MODEL 164.8 2nd seat row
restraint guides 1775GZ
Remove/install rear seat backrest head AR91.16-P-
MODEL 164.8, 251 3rd seat row
restraint guides 1775RTA
AR91.18-P-
Remove/install front seat cushion covering MODEL 164
1800GZ
AR91.18-P-
Remove front seat backrest cover MODEL 164
1820GZ
Remove and install cover on rear seat AR91.18-P-
MODEL 164.8 Cover on 40 % rear seat
cushion 1850GY
cushion 1850GYA
MODEL 164.1 Covering on 40% rear seat
cushion 1850GZ
cushion 1850GZA
AR91.18-P-
Remove and install rear seat backrest cover MODEL 164.8 3rd seat row
1870GY
Remove/install left rear seat backrest AR91.18-P-
MODEL 164
upholstery 1874GZ
Remove/install right rear seat backrest AR91.18-P-
MODEL 164
upholstery 1878GZ
MODEL 164 with CODE (404) Left
Remove/install air pump for multicontour AR91.25-P-
multicontour seat with CODE (405) Right
seat 1430GZ
multicontour seat
Removing and installing multicontour seat AR91.25-P-
switch 1720GZ
multicontour seat
Remove/install multicontour backrest air AR91.25-P-
cushion 1740GZ
multicontour seat

Remove/install multicontour backrest side AR91.25-P-
air cushions 1741GZ
multicontour seat
Remove/install multicontour backrest seat AR91.25-P-
cushion air cushion 1770GZ
multicontour seat
Replace seat adjustment control unit with AR91.29-P-
MODEL 164 ...
memory 0002GZ
MODEL 164 with CODE (275) Memory
Remove/install seat adjustment switch unit AR91.29-P-
package (driver seat, steering column,
on front seat 0003GZ
mirrors)
Remove/install seat adjustment drive motor AR91.29-P-
MODEL 164
(forward/back) 1425GZ
Remove/install backrest motor for front AR91.29-P-
MODEL 164
seat 1431GZ
AR91.29-P-
Remove/install front seat headrest motor MODEL 164
1432GZ
MODEL 164 Front seat height adjustment AR91.29-P-
Remove/install front seat adjustment motor
motor 1434GZ
MODEL 164 Rear seat height adjustment AR91.29-P-
Remove/install front seat adjustment motor
motor 1434GZA
AR91.29-P-
Remove/install folding rear backrest motor MODEL 164.8 3rd seat row
7050GY
AR91.29-P-
Replace folding backrest switch MODEL 164.8
7060GY
Remove/install heated seats and seat AR91.30-P-
MODEL 164 ...
ventilation control unit 0031GZ
MODEL 164, 251 with CODE (401) Front
Remove/install the seat ventilation motors AR91.30-P-
comfort seats, incl. seat heating and seat
on the front seat backrest 1900GY
ventilation
Remove/install blower regulator for seat AR91.30-P-
ventilation motors in front seat 1910GY
ventilation
Remove/install front seat cushion AR91.30-P-
ventilation motors 1950GZ
ventilation
Render emergency tensioning retractor AR91.40-P-
MODEL 164, 251
units unusable 0611RT
Checking recognition of actuation state of AR91.40-P-
MODEL 164
emergency/compact tensioning retractors 0612GZ
AR91.40-P-
Remove/install rear seat belts MODEL 164
0681GZ
Remove, replace and install rear center seat AR91.40-P-
MODEL 164
belt 0683GZ
AR91.40-P-
Remove/install seat belt (front seat) MODEL 164
1010GZ
Seat belt height adjustment mechanism AR91.40-P-
MODEL 164
(front seat) removal and installation 1100GZ
AR91.40-P-
Remove/install seat belt buckle (front seat) MODEL 164
1515GZ
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164.8 40 % rear seat
1516GY
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164.8 60 % rear seat, center
1516GYA
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164.8 3rd seat row
1516GYB
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164.1 40% rear seat
1516GZ
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164.1 center seat 60% rear seat
1516GZA
AR91.40-P-
Remove/install rear seat belt buckle MODEL 164 60 % rear seat, outside
1516GZB
Remove/install seat belts for third row of AR91.40-P-
MODEL 164.8, 251
seats 2000RT
AR91.60-P-
Make airbag units unusable MODEL 164 Not valid for K B d
0611GZ
AR91.60-P-
Remove/install airbag control unit MODEL 164
0615GZ
Remove/install airbag unit on the steering AR91.60-P-
MODEL 164
wheel 0660GZ
AR91.60-P-
Remove/install passenger airbag unit MODEL 164
0680GZ
AR91.60-P-
Removing, installing windowbag MODEL 164
0693GZ
MODEL 164 with CODE (808) Model year AR91.60-P-
Removing, installing windowbag
2008 0693GZA
AR91.60-P-
Remove/install front seat sidebag unit MODEL 164
0695GZ
MODEL 164 with CODE (293) Left and AR91.60-P-
Remove/install rear seat sidebag unit
right rear sidebag 0696GZ
Remove/install sensor for AR91.60-P-
MODEL 164
sidebag/windowbag 0730GZ
AR91.60-P-
Remove/install frontal acceleration sensor MODEL 164
0750GZ
Remove/install side deployment pressure AR91.60-P-
MODEL 164, 251
sensor 0760GZ
Remove/install WSS control unit MODEL 164 with CODE (494) USA
version Only vehicles with WSS (weight AR91.60-P-
sensing system) 0800GZ

AR91.60-P-
Remove/install WSS sensor MODEL 164 ...
0810GZ
AR91.60-P-
Remove/install WSS sensor MODEL 164 ...
0810GZA
Remove/install dust excluder at WSS MODEL 164 with CODE (494) USA AR91.60-P-
sensor version Passenger-side only 0820GZ
REMOVE/INSTALL FRONT SEAT - AR91.10-P-1000GZ
MODEL 164
Fig. 53: Identifying Front Seat Components - Shown On Driver Seat With Memory Package Code 275
Shown on driver seat with memory package (driver seat, steering column, mirror), code 275, without left
multicontour seat, code 404
MODIFICATION NOTES
Disconnect/connect ground line of battery and perform basic programming, Steps 10 and
26.7.06
removed 19
Remove/install
Electrically adjustable head AR91.16-P-
1 Remove front seat head restraint
restraint 0040GZ
Mechanically adjustable head AR91.16-P-
restraint 0040GZA
2 Move backrest into upright position
3 Move front seat forward
4 Unclip cover (1) from belt end fitting Long wedge Fig. 54
*BA91.40-P-
5 Remove bolt (2)
1001-01H
6 Move front seat to rear
Installation: Replace bolts
7 Remove screws (5)
(5), align seat rails.
*BA91.10-P-
1001-01L
Installation: Replace bolts
8 Remove bolts (3)
(3), align seat rails.
*BA91.10-P-
1001-01L
9 Remove seat rail covers (4)
Lift up front of front seat, carefully tilt toward
10
rear
Disconnect electrical connector (6, 7) from left The number of connectors
11 front seat contacting strip (X55/3) on vehicle varies according to vehicle
side equipment.
Only vehicles with memory
Disconnect electrical connectors (8, 9) from package (driver seat, steering
12 driver-side front seat adjustment control unit column, mirror), code 275 and
with memory (N32/1) electrically adjustable passenger
seat with memory, code 242.
Disconnect compressed air connection for Only vehicles with left
13 multicontour seat from main coupling below multicontour seat, code 404 and
seat (gray air hose) right multicontour seat, code 405.
14 Lift out front seat Use helper
Calibrate left front WSS sensor (weight sensing
system), right front WSS sensor (weight
Only front seat on passenger side
sensing system), left rear WSS sensor (weight
16 in vehicles with USA version,
sensing system) and right rear WSS sensor
code 494.
(weight sensing system) with STAR diagnosis
system
Plates Fig. 55
Connect STAR DIAGNOSIS and read out fault AD00.00-P-

memory 2000-04A
STAR DIAGNOSIS diagnosis *WH58.30-
system Z-1048-13A
Carry out function test, return seat to the
17
original position again
FRONT SEATS
Number Designation Model 164.1/8
BA91.10-P-1001-01L Bolt of seating mounting bracket to vehicle floor Nm 45
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

BA91.40-P-1001-01H Bolt at seat belt fitting Nm 35
Fig. 54: Identifying Long Wedge (115 589 03 59 00)

Fig. 55: Identifying Plates (211 589 00 32 00)

COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL FRONT SEAT BACKREST - AR91.10-P-1060GZ
MODEL 164
Fig. 56: Identifying Front Seat Backrest Components - Shown On Driver Seat With Memory Package
Code 275
Shown on driver seat with memory package (driver seat, steering column, mirror), code 275, without left
multicontour seat, code 404
Remove/install
AR91.10-P-
1 Remove front seat
1000GZ
AR91.10-P-
2 Remove paneling on front seat frame
1200GZ
The number of connectors varies
Disconnect electrical connectors (1, 2, 3)
3.1 from left front seat contacting strip according to vehicle equipment.
Disconnect all connectors of the seat wiring
(X55/3)
harness.
Only on seat with memory package
Disconnect electrical connectors (4, 5, 6)
4.1 from driver-side front seat adjustment (driver seat, steering column, mirror), code
275 and with electrically adjustable
control unit with memory (N32/1)
passenger seat with memory, code 242.
Disconnect electrical connector from

At the left front seat contacting strip
5 driver seat belt buckle and seat belt
(X55/3).
warning switch (S68/1)
Disconnect electrical connectors from
driver seat fore/aft adjustment motor
6.1
(M27/1) and from driver front seat height
adjustment motor (M27/3)
Only on vehicles with left multicontour
Detach air hoses from switch for
7.1 seat, code 404 and right multicontour seat,
multicontour seat backrest
code 405, refer to: ?
Removing and installing multicontour seat AR91.25-P-
switch 1720GZ
Observe routing of cable for seat wiring
8 Unscrew bolts (7, 8), remove seat backrest harness and air hoses (on vehicles with left
multicontour seat, code 404 and right
multicontour seat, code 405).
*BA91.10-P-
1002-01L
FRONT SEATS
BA91.10-P-1002-01L Screw, backrest to seat frame Nm 40
REMOVE/INSTALL FRONT SEAT BACKREST UPHOLSTERY - AR91.10-P-1090GZ
MODEL 164
Shown on removed front seat with memory package (driver seat, steering column, mirror), code 275,
with mechanical lumbar support
Fig. 57: Identifying Front Seat Backrest Upholstery Components - Shown On Removed Front Seat With
Memory Package Code 275
Remove/install
Store airbag units with deployment side facing
Risk of injury caused by performing
up; do not expose to temperatures greater than AS91.00-Z-
testing or repair work on airbag or
100°C. When working on these units, 0001-01A
disconnect the power supply.
Remove backrest shell from front AR91.10-P-
1
Front seat with electrically adjustable head AR91.16-P-
restraint. 0040GZ
Front seat with mechanically adjustable AR91.16-P-
head restraint. 0040GZA
Remove front seat head restraint AR91.16-P-
3 Model 164.1
guide 0050GZ
AR91.16-P-
Model 164.8
0050RT
4.1 Detach lever (1) Front seat with mechanical lumbar support.
5.1
motor 1432GZ
6 Unclip clips (2)
Unhook front seat backrest cover (8)
7
from hook (3)
8 Remove spreading clip (4) Push out airbag rescue line upwards.
9 Unhook retaining rails (5)
Remove front seat backrest cover (8)
10 with padding
11 Unclip clips (6, 7)
12
from padding
REMOVE/INSTALL FRONT SEAT FRAME TRIM PANELS - AR91.10-P-1200GZ
MODEL 164
Shown on vehicle with memory package (driver seat, steering column, mirrors), Code 275
Fig. 58: Identifying Front Seat Frame Trim Panels Components - Shown On Vehicle With Memory
Package Code 275
MODIFICATION NOTES
20.12.04 Bolt at seat belt fitting *BA91.40-P-1001-01H
Remove/install
1 Pry off trim panel at belt mount (1) Long wedge Fig. 54
2 Unscrew belt mount bolt (2) *BA91.40-P-1001-01H
3 Unclip seat trim panel (3) Long wedge Fig. 54
4 Unclip seat trim panel (4) Long wedge Fig. 54
5 Remove screw (5)
6 Unclip seat trim panel (6)


REMOVE/INSTALL BACK SHELL FROM FRONT SEAT BACKREST - AR91.10-P-1915GZ
MODEL 164
Fig. 60: Identifying Back Shell From Front Seat Backrest Components
Remove/install
1 Move front seat forward

2 Move front seat backrest forward
3 Remove bolts (1)
Remove seat-back lining on front seat
Slide seat-back lining on front seat backrest (2)
4 backrest (2) carefully to prevent damage to
downwards out of guides and remove
guides.
REMOVE/INSTALL SEAT CUSHION - AR91.10-P-3310GZ
MODEL 164
Fig. 61: Identifying Seat Cushion Components - Shown On Vehicle With Memory Package (Driver Seat,
Steering Column, Mirrors), Code 275
Fig. 62: Identifying Seat Cushion Components - Shown On Vehicle With Memory Package (Driver Seat,
MODIFICATION NOTES
20.12.04 Bolt at seat belt fitting *BA91.40-P-1001-01H
Remove/install
On vehicles with Keyless Go, code 889:

Turn key in ignition switch to position
1 Press keyless go start/stop button
"0".
repeatedly until ignition is switched off
2 Unclip cover (1) Mounting wedge Fig. 63
*BA91.40-P-
3 Remove bolt (2)
1001-01H
4 Unclip covers (3, 4) Mounting wedge Fig. 63
5 Remove screws (5)
6 Remove bracket (6) Place next to seat.
7 Remove bolts (7)
8 Lift up seat cushion (8) (arrow)
9 Unclip brackets (9)
Disconnect electrical connectors (10)
10 from driver seat belt buckle and seat belt
warning switch (S68/1)
11 Remove seat cushion (8) (arrow)

Fig. 63: Identifying Wedge Tool (110 589 03 59 00)

REMOVE/INSTALL FRONT SEAT BACKREST FRAME - AR91.10-P-3331GZ
MODEL 164
Shown on removed, complete front seat with memory package (driver seat, steering column, mirror),
code 275 and with mechanical lumbar support
Fig. 64: Identifying Front Seat Backrest Frame Components - Shown On Removed, Complete Front Seat
With Memory Package Code 275
Remove/install
AR91.10-P-
1 Remove front seat
1000GZ
Remove head restraint and head AR91.16-P-
2 Model 164.1
restraint guide from front seat 0050GZ
AR91.16-P-
Model 164.8
0050RT
3.1
motor 1432GZ
AR91.10-P-
4 Remove front seat backrest
1060GZ
Removing front seat backrest AR91.10-P-
5
upholstery 1090GZ
AR91.60-P-
6 Remove sidebag on front seat
0695GZ
AR91.29-P-
7 Remove front seat backrest motor
1431GZ
Remove multicontour seat backrest On left multicontour seat, code 404 or AR91.25-P-
8.1
air cushion right multicontour seat, code 405. 1740GZ
Remove multicontour backrest side On left multicontour seat, code 404 or AR91.25-P-
9.1
air cushions right multicontour seat, code 405. 1741GZ
10.1 Detach cable (1) For mechanical lumbar support.
11.1 Unclip lumbar support (2) For mechanical lumbar support.
12 Unhook crosswise stapling (3)
For mechanical lumbar support.
13.1 Drill out rivets (4)
Installation: Use new rivets (4).
*WH58.30-Z-
Hand riveter 1003-29A
*WH58.30-Z-
Rechargeable drill / screwdriver
1007-20A
Remove lumbar support adjustment
14.1 For mechanical lumbar support.
mechanism (5)

Number Designation
WH58.30-Z-1007-20A Cordless drill/driver
WH58.30-Z-1003-29A Hand riveter
REMOVE/INSTALL SEAT CUSHION FRAME - AR91.10-P-3334GZ
MODEL 164
Shown on seat cushion with heated seats
Fig. 65: Identifying Seat Cushion Frame Components - Shown On Seat Cushion With Heated Seats
Remove/Install
Remove cover of front seat Only remove cover with upholstery from seat AR91.18-P-
1
cushion cushion frame (1). 1800GZ
REMOVE/INSTALL MONITOR FRAME ON FRONT SEAT - AR91.10-P-3510GZ
MODEL 164, 251 with CODE (864) Rear entertainment system

Fig. 66: Identifying Monitor Frame - Shown On Model 164.8

Fig. 67: Identifying Monitor Frame On Front Seat Components (1 Of 2)

Fig. 68: Identifying Monitor Frame On Front Seat Components (2 Of 2)

Remove/install

1 Press keyless go start/stop button repeatedly
"0".
until ignition is switched off
Model 164 with electrically adjustable head AR91.16-P-
restraint. 0040GZ
Model 164 with mechanically adjustable AR91.16-P-
head restraint. 0040GZA
AR91.16-P-
Model 251.
0040RT
3 Unclip cover (2) Unclip at bottom left and right (arrows A).
4 Detach clamping plates (3)
5 Separate electrical connectors (4)
6 Unclip cover (5) Unclip at bottom left and right (arrows B).
7 Loosen bolts (7) Do not remove completely.
Pull monitor frame unit (6) out Pay attention to electrical lines, risk of
8
upwards breakage!
9 Unclip clips (8)
10 Remove bolts (9)
11 Remove bracket (10)
12 Pull out pin (11)
13 Remove locking pin (12)
Remove left rear display (A40/5) or
14 right rear display (A40/6) from
monitor frame (1)
REMOVE/INSTALL REAR SEAT - AR91.12-P-1000
Removing and installing rear seat - AR91.12-P-1000GY
MODEL 164.8
40 % rear seat
Fig. 69: Identifying Rear Seat Components - 40 % Rear Seat

Remove/install
1 Fold over 40 % rear seat

Unscrew left bolt and right
2
bolt on covering (5)
Unclip covering (5) to front
3
(arrows)
Remove gas-operated strut on AR91.12-P-
4
seat frame of 40 % rear seat 6005GY
Switch off ignition and On vehicles with Keyless Go, code 889: Press
Keyless Go start/stop button repeatedly until ignition is
remove the transmitter key
5 switched off. Remove transmitter key from vehicle and
from the EIS [EZS] control
store it in a location beyond its transmission range (at
unit
least 2 m).
Disconnect electrical
6
connector (1)
7 Remove bolts (3)
8 Remove fabric trim (4)
*BA91.12-P-
9 Remove bolts (6)
1002-03F
*BA91.12-P-
1003-03F
10 Remove 40% rear seat
REAR SEATS
Number Designation Model 164.8
BA91.12-P-1002-03F Bolt, rear seat console to front of vehicle floor Nm 50
BA91.12-P-1003-03F Bolt, rear seat console to rear of vehicle floor Nm 90
Removing and installing rear seat - AR91.12-P-1000GYA
MODEL 164.8
60 % rear seat
Fig. 70: Identifying Rear Seat Components - 60 % Rear Seat

Remove/install
On vehicles with Keyless Go, code 889: Press

Switch off ignition and
store it in a location beyond its transmission range (at
unit
least 2 m).
2 Unclip cover (1)
3 Remove release lever (2) Note lock washer.
4 Fold up seat cushion (3)
5
connector (4)
6 Remove foam material (5)
7 Remove bolts (6)

8 Remove covers (7)
Remove interior Keyless Go On vehicles with keyless go code 889. AR82.62-P-
9.1
antenna (A2/61) Do not disconnect electrically 8000GZ
*BA91.12-P-
10 Remove screws (8)
1001-02D
*BA91.12-P-
11 Remove bolts (9)
1002-03F
*BA91.12-P-
1003-03F
12 Remove 60% rear seat
REAR SEAT BACKREST

BA91.12-P-1001-02D Bolt for rear seat backrest to vehicle floor Nm 90
REAR SEATS
BA91.12-P-1002-03F Bolt, rear seat console to front of vehicle floor Nm 50
BA91.12-P-1003-03F Bolt, rear seat console to rear of vehicle floor Nm 90
Remove/install rear seat - AR91.12-P-1000GYB
MODEL 164.8
3rd seat row

Fig. 71: Identifying Rear Seat Components - 3rd Seat Row

Remove/install
Long
1 Unclip covers (1). Fig. 54
wedge
*BA91.12-P-1001-
2 Unscrew bolt (2)
03F
3 Fold rear seat forward
*BA91.12-P-1001-
4 Remove bolt (3)
03F
5 Fold up rear seat
*BA91.12-P-1001-
6 Unscrew bolt (4)
03F
*BA91.12-P-1001-
7 Remove screws (5)
03F
Release connector on folding rear backrest motor and
8
detach
9 Remove rear seat
REAR SEATS
Number Designation Type 164.8
BA91.12-P-1001-03F Bolt, rear seat console to vehicle floor Nm 50

REMOVE/INSTALL REAR SEAT CUSHION - AR91.12-P-1020
Remove/install rear seat cushion - AR91.12-P-1020GY
MODEL 164.8 Rear seat cushion of 40 % rear seat
Fig. 73: Identifying Rear Seat Cushion Components - Shown On Removed Rear Seat Without
Electrically Heated Left And Right Rear Seats, Code 872
Shown on removed rear seat without electrically heated left and right rear seats, code 872
Remove/install
Only for vehicles with electrically

heated left and right rear seats, code 872.
1 On vehicles with Keyless Go, code
"0".
889: Press keyless go start/stop button
2 Fold up seat cushion of 40 % rear seat
3 Drill out rivets (1) Installation: use new rivets (1).
*WH58.30-Z-
Handymaster cordless drill/driver 1007-20A

*WE58.40-Z-
PowerBird blind rivet tool 1003-14A
*BR00.45-Z-
Rivet
1009-13A
4 Unscrew bolt (2)
Localize and disconnect electrical
6 connector of heated cushion, expose wire
harness up to rear seat cushion Expose wiring harness far enough until
the rear seat cushion can be removed.
*BA91.12-P-
7 Remove bolts (4)
1004-03F
8 Remove rear seat cushion
REAR SEATS
BA91.12-P-1004-03F Bolt, rear seat cushion to rear seat console Nm 25


Number Designation
WORKSHOP EQUIPMENT
WE58.40-Z-1003-14A Blind rivet tool
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-13A Rivet A 003 990 38 97
Remove/install rear seat cushion - AR91.12-P-1020GYA
MODEL 164.8 Rear seat cushion of 60 % rear seat
Fig. 75: Identifying Rear Seat Cushion Components - Shown On Removed Rear Seat Without
Electrically Heated Left And Right Rear Seats, Code 872
Shown on removed rear seat without electrically heated left and right rear seats, code 872
Remove/install

1 On vehicles with Keyless Go, code
"0".
AR91.12-P-
2 Remove 60 % rear seat
1000GYA
3 Drill out rivets (1) Installation: use new rivets (1).
*WH58.30-Z-
Handymaster cordless drill/driver
1007-20A
*WE58.40-Z-
PowerBird blind rivet tool 1003-14A
*BR00.45-Z-
Rivet
1009-13A
4 Unscrew bolt (2)
6 Unclip covers (4) Mounting wedge Fig. 63
Localize and disconnect electrical
7 connector of heated cushion, expose
wiring harness up to rear seat cushion
*BA91.12-P-
8 Remove bolts (5)
1004-03F
REAR SEATS


Number Designation
WORKSHOP EQUIPMENT
REPAIR MATERIALS
BR00.45-Z-1009-13A Rivet A 003 990 38 97
Remove/install rear seat cushion - AR91.12-P-1020GYB
MODEL 164.8
3rd seat row

Fig. 77: Identifying Rear Seat Cushion Components - 3rd Seat Row
Remove/install
1 Remove 3rd seat row rear seat AR91.12-P-1000GYB
2 Remove bolts (1) *BA91.12-P-1004-03F
3 Remove rear seat cushion (2)
REAR SEATS
Number Designation Type 164.8
Remove/install rear seat cushion - AR91.12-P-1020GZ
MODEL 164.1
40 % rear seat
Fig. 78: Identifying Rear Seat Cushion Components - 40 % Rear Seat

Remove/install
Pull up release handle (1) and move 40 % rear Installation: 40 % rear seat
1
seat (2) to the vertical position (2) must latch.
*BA91.12-P-
2 Remove bolts (3)
1001-03F
3 Remove 40 % rear seat (2)
REAR SEATS
Remove/install rear seat cushion - AR91.12-P-1020GZA
MODEL 164.1 60 % rear seat
Fig. 79: Identifying Rear Seat Cushion Components - 60 % Rear Seat

Remove/install
Pull release handle (1) up and move 60 % rear Installation: 60 % rear seat
1
seat (2) to the vertical position (2) must latch.
*BA91.12-P-
2 Remove bolts (3)
1001-03F
3 Remove 60 % rear seat (2)
REAR SEATS

REMOVE/INSTALL UPHOLSTERY FOR REAR SEAT BACKREST - AR91.12-P-1030
Remove/install upholstery for rear seat backrest - AR91.12-P-1030GY
Fig. 80: Identifying Upholstery For Rear Seat Backrest Components - 3rd Seat Row
Removing
AR91.12-P-
1 Remove 3rd seat row rear seat
1000GYB
AR91.12-P-
2 Remove 3rd seat row rear seat cushion
1020GYB
Remove 3rd seat row rear seat backrest AR91.12-P-
3
paneling (6) 1131GY
Remove head restraint guides and concealed AR91.16-P-
4
cover 1775RT
5 Unclip covers (1). Mounting wedge Fig. 63
Unhook 3rd seat row rear seat backrest cover
6
(5) from lug (2)
Unhook 3rd seat row rear seat backrest cover
7
(5) from bolt (3)
Remove 3rd seat row rear seat backrest

8 cover (5) with 3rd seat row rear seat backrest
padding (6) from rear seat backrest frame
Unhook 3rd seat row rear seat backrest cover Place 3rd seat row rear seat backrest
9 (5) from attachment lugs (4) in 3rd seat row cover (5) down onto a clean surface to
rear seat backrest padding (6) avoid contamination or damage.
10 cover (5) from 3rd seat row rear seat
backrest padding (6)
Install
Fold in 3rd seat row rear seat backrest cover
11 (5) at side, place onto 3rd seat row rear seat
backrest padding (6) and align
Place 3rd seat row rear seat backrest
Hook attachment lugs (4) into 3rd seat row
12 cover (5) down onto a clean surface to
rear seat backrest cover (5)
avoid contamination or damage.
Pull 3rd seat row rear seat backrest cover (5) Ensure that the corner brackets of the
13 over corners of 3rd seat row rear seat 3rd seat row rear seat backrest padding (6)
backrest padding (6) are correctly seated.
Pull 3rd seat row rear seat backrest cover (5)
14
over corners of rear seat backrest frame
Hook 3rd seat row rear seat backrest cover
15
(5) into lug (2)
16
(5) onto bolt (3)
Install 3rd seat row rear seat backrest AR91.12-P-
17
paneling (6) 1131GY
18 Clip in covers (1)
Install head restraint guides and cover AR91.16-P-
19 Note installation position of cover.
underneath 1775RT
AR91.12-P-
20 Install 3rd seat row rear seat cushion
1020GYB
AR91.12-P-
21 Install 3rd seat row rear seat
1000GYB

Remove/install upholstery for rear seat backrest - AR91.12-P-1030GYA
MODEL 164.8
Padding of rear seat backrests in 2nd seat row
Remove/install
The removal/installation procedure for the rear set backrest

padding is identical to the removal/installation procedure for the
rear seat backrest cover. The rear seat backrest padding remains
after removal of the cover.
Padding of left rear seat backrest
1 Remove padding of left rear seat backrest See: ?
Remove/install left
AR91.18-P-
rear seat backrest
1874GZ
upholstery
Padding of right rear seat backrest
2 Remove padding of right rear seat backrest See:?
Remove/install right
AR91.18-P-
rear seat backrest
1878GZ
cover
Remove/install upholstery for rear seat backrest - AR91.12-P-1030GZ
MODEL 164.1 40 %
Fig. 82: Identifying Upholstery For Rear Seat Backrest Components - 40 %

Remove
Place rear seat backrest with the cover of the
rear seat backrest (2) downwards on a suitable

Remove cover of the right rear seat AR91.18-P-
1 clean base in order to avoid dirt or damage to the
backrest (2) 1878GZ
rear seat backrest.
Unhook hooking-in lugs (1) from
2
cover of rear seat backrest (2)
Remove cover of rear seat backrest
3 (2) from upholstery of rear seat
backrest (3)
Install
Hammer in the cover of the rear seat
backrest (2) at the side, put on
4
upholstery of rear seat backrest (3)
and align
Pull the cover of the rear seat
backrest (2) over the edge of the Pay attention to correct seating of corner
5
upholstery of the rear seat backrest bracket of upholstery of rear seat backrest (3)
(3)
Install cover of right rear seat AR91.18-P-
6
backrest 1878GZ
Remove/install upholstery for rear seat backrest - AR91.12-P-1030GZA
MODEL 164.1 60 %
Fig. 83: Identifying Upholstery For Rear Seat Backrest Components - 60 %

Remove
Put rear seat backrest with the rear seat backrest

Remove left rear seat backrest cover cover (3) facing down onto an appropriate clean AR91.18-P-
1
(3) base to avoid soiling or damaging the rear seat 1874GZ
backrest.
2 Open Velcro fastener (1)
Unhook securing lugs (2) from rear
3
seat backrest cover (3)
Remove rear seat backrest cover (3)
4 from rear seat backrest upholstery
(4)
Install
Fold rear seat backrest cover (3) to
5 one side, place on rear seat backrest
upholstery (4) and straighten out
Pull rear seat backrest cover (3) over
Pay attention that the corner brackets of the rear
6 the edge of the rear seat backrest
upholstery (4) seat backrest upholstery (4) are properly seated.
7 Close Velcro fastener (1)
Install rear seat backrest cover on AR91.18-P-
8
left 1874GZ
REMOVE AND INSTALL REAR SEAT CUSHION FRAME - AR91.12-P-1110
Remove and install rear seat cushion frame - AR91.12-P-1110GY
Shown on removed rear seat
Fig. 84: Identifying Rear Seat Cushion Frame Components - Shown On Removed Rear Seat
Remove/install
Remove front bolts for 3rd seat row rear seat to

1 See: ?
vehicle floor
Remove/install 3rd seat row AR91.12-P-

rear seat 1000GYB
2 Unhook shackles (1)
*BA91.12-P-1004-
3 Remove bolts (2)
03F
4 Remove rear seat from fastening arms (3)
Remove cover (4) on rear seat cushion frame AR91.18-P-
5
(5) 1850GY
REAR SEATS
BA91.12-P-1004-03F Bolt, rear seat cushion frame to 3rd seat row rear seat backrest Nm 30
Remove and install rear seat cushion frame - AR91.12-P-1110GYA
MODEL 164.8 2nd seat row rear seat, 40 %
Remove/install
1 Remove 40 % rear seat cushion. AR91.12-P-1020GY
2 Remove cover from 40 % rear seat cushion AR91.18-P-1850GY
Remove and install rear seat cushion frame - AR91.12-P-1110GZ
MODEL 164.1 40 %
Fig. 85: Identifying Rear Seat Cushion Frame Components - 40 %

Remove/Install
Only on right-hand AR91.12-P-

1 Remove rear seat cushion (1).
side. 1020GZ
AR91.18-P-
2 Remove cover of right seat backrest
1878GZ
3 Push release handle (2) down
4 Unclip clip (3)
5 Remove release handle (2)
Unclip retaining bracket (4) from rear seat cushion
6
frame (5)
REMOVE/INSTALL CABLE FOR UNLOCKING EASY ENTRY - AR91.12-P-1120GY
MODEL 164.8
Fig. 86: Identifying Cable For Unlocking Easy Entry Components (1 Of 2)

Fig. 87: Identifying Cable For Unlocking Easy Entry Components (2 Of 2)

Remove/install
1 Remove fabric trim (1)

2 Remove bolts (2)
3 Remove covers (3) Mounting wedge Fig. 63
Remove release lever (5) on 2nd seat row right AR91.12-P-
5
rear seat 1732GY
6 Remove cover (6). Mounting wedge Fig. 63
7 Remove bolts (7)
9 Remove bolts (9)
11 Unhook control cable (11, 13, 15, 16, 18, 20)
12 Unclip guide (12, 14, 17, 19, 21)
Installation: Use new tie
13 Separate tie strap (22)
strap (22).
14 Unhook and remove release shackle (23)
15 Remove cables

REMOVE/INSTALL PANELING OF REAR SEAT BACKREST - AR91.12-P-1131
Remove/install paneling of rear seat backrest - AR91.12-P-1131GY
Fig. 89: Identifying Paneling Of Rear Seat Backrest Components - 3rd Seat Row
Remove/install
Remove rear seat cushion of 3rd seat AR91.12-P-

1
row 1020GYB
2 Unclip cover (1) Long wedge Fig. 54
Pull out rear backrest cover plug-in
3
fold (arrows)
Installation: Replace double-sided
4 Remove paneling (2)
adhesive tape.
5 Install in the reverse order.

Removing and installing paneling of rear seat backrest - AR91.12-P-1131GZ
Fig. 91: Identifying Paneling Of Rear Seat Backrest Components - Shown On Model 164.1
Remove/install
Fold up rear seat

1 Fold 40 % rear seat backrest to front
cushion first.
Unclip coverings of cargo retainers (1) and unscrew
2.1 Only model 164.1.
concealed bolt
*BA68.50-P-
1001-03F
3.1 Unclip load compartment floor (2) and remove. Only on model
164.1.
Long wedge Fig. 54
4 Unclip coverings (3) of 40 % rear seat backrest Long wedge Fig. 54

Pull out rear backrest cover side lip (arrows) on back of
5 Long wedge Fig. 54
the 40 % rear seat backrest
6 Remove trim, 40 % rear seat backrest (4)
CARGO RETAINERS
BA68.50-P-1001-03F Bolt, cargo retainers to body Nm 24

Removing and installing paneling of rear seat backrest - AR91.12-P-1131GZA
Fig. 93: Identifying Paneling Of Rear Seat Backrest Components - Shown On Model 164.1
Remove/install
1 Fold 60 % rear seat backrest forward

Unclip covers of cargo retainers (1) and unscrew concealed Only on model
2.1
bolts 164.1.
*BA68.50-P-1001-
03F
Long wedge Fig. 54
Only on model
3.1 Unclip and remove load compartment floor (2)
164.1.
Long wedge Fig. 54
4 Unclip covers (3) on 60 % rear seat backrest Long wedge Fig. 54
Pull out rear backrest cover side lip (arrows) on back of 60
% rear seat backrest
6 Remove trim, 60 % rear seat backrest (4)
CARGO RETAINERS

REMOVE/INSTALL REAR SEAT BACKREST - AR91.12-P-1620
Remove/install rear seat backrest - AR91.12-P-1620GY
MODEL 164.8 40 %
Fig. 95: Identifying Rear Seat Backrest Components - Shown On Rear Seat Without Left And Right Rear
Sidebag, Code 293)
Shown on rear seat without left and right rear sidebag, code 293, and without electrically heated left and
right rear seats, code 872
Remove/install
Store airbag units with deployment
Risk of injury caused by performing testing side facing up; do not expose to
AS91.00-Z-
or repair work on airbag or emergency temperatures greater than 100°C.
0001-01A
tensioning retractor units. When working on these units,
Risk of explosion caused by oxyhydrogen No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns smoking. Wear acid-resistant
caused by swallowing battery acid. Risk of gloves, clothing and safety glasses. AS54.10-Z-
injury caused by burns to skin and eyes from Only pour battery acid into suitable 0001-01A
battery acid or when handling damaged lead- and appropriately marked
acid batteries containers.
Notes on performing repair, body work and
AH91.00-P-
welding on vehicles with airbags and ETR
0002-01M
units
Assessment of airbag and belt tensioner units AH91.00-P-
in accident vehicles 0006-01B
Legal regulations on handling and storing AH91.00-P-
airbags and emergency tensioning retractors 0004-01A
Disconnect jump-start sources or battery
1 If connected.
charger
2.1 Disconnect battery ground cable On vehicles with left and right AR54.10-P-
rear sidebag, code 293. 0003GZ
On vehicles without left and

right rear sidebag, code 293, with
electrically heated left and right
rear seats, code 872.

On vehicles with Keyless Go,
2.2 Turn key in ignition switch to position "0". code 889: Press keyless go
start/stop button repeatedly until
ignition is switched off
AR91.12-P-
3 Remove paneling of rear seat backrest
1131GZ
On vehicles with left and right
rear sidebag, code 293: expose
4 Detach cover and pull it to the side
connector and wiring harness for
sidebag.
Only on vehicles with left and
5 Disconnect sidebag connector from squib
right rear sidebag, code 293.
Remove sidebag wiring harness from rear seat Only on vehicles with left and
6
backrest right rear sidebag, code 293.
Disconnect connector of backrest heated Only on vehicles with
7 cushion, remove wiring harness of backrest electrically heated left and right
heated cushion rear seats, code 872.
*BA91.12-P-
8 Remove bolts (1)
1003-02D
9 Remove rear seat backrest (2)
Check restraint system using STAR STAR DIAGNOSIS diagnosis *WH58.30-
11
DIAGNOSIS diagnostic system system Z-1048-13A
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
REAR SEAT BACKREST

BA91.12-P-1003-02D Bolt, rear seat backrest bracket to 40 % rear seat backrest Nm 35

Number Designation
Remove/install rear seat backrest - AR91.12-P-1620GYA
MODEL 164.8 60 % rear seat backrest

Fig. 96: Identifying Rear Seat Backrest Components - 60 % Rear Seat Backrest
Remove/install
Fold up seat cushion on 60 % rear

1 Only on model 164.1.
seat
Unscrew bolt on belt end fitting of Model 164.8: The bolt is located at the
2
center seat belt rear of the rear seat.
*BA91.40-P-
1003-01H
*BA91.12-P-
2 Remove bolts (1)
1004-02D
3 Remove rear seat backrest (2)
REAR SEAT BACKREST

BA91.12-P-1004-02D Bolt of rear seat backrest to 60 % rear seat backrest bracket Nm 43

BA91.40-P-1003-01H Screw at belt end fitting Nm 35
Remove/install rear seat backrest - AR91.12-P-1620GYB
Remove/install
1 Remove 3rd seat row rear seat AR91.12-P-1000GYB
2 Remove 3rd seat row rear seat cushion AR91.12-P-1020GYB
3 Remove 3rd seat row folding rear seat backrest motors AR91.29-P-7050GY
Remove/install rear seat backrest - AR91.12-P-1620GZ
MODEL 164.1 40% rear seat
Fig. 97: Identifying Rear Seat Backrest Components - 40% Rear Seat (1 Of 2)
Remove/install
AR91.16-P-
1 Remove head restraint from 40% rear seat
1770GZ
2 Pull release handle (1) upwards and move Installation: 40% rear seat (2)
40% rear seat (2) to an upright position must latch in place.

*BA91.12-P-
3 Remove screw (3)
1001-02D
See Operator's Manual
4 Fold 40% rear seat backrest (4) forwards Installation: 40% rear seat
backrest (4) must latch in place.
Unclip covers from cargo retainers (5) and
unscrew bolts beneath
*BA68.50-P-
1001-03F
Unclip and remove load compartment cover
(6)
*BA91.12-P-
7 Remove screw (7)
1001-02D
Release lock (9) and remove 40% rear seat Installation: Lock (9) must latch
9
backrest (4) in place
LOAD RETAINER
Number Designation Models 164.1/8
REAR SEAT BACKREST

BA91.12-P-1001-02D Bolt of rear seat backrest to vehicle floor Nm 90

Remove/install rear seat backrest - AR91.12-P-1620GZA
MODEL 164.1 60% rear seat

MODIFICATION NOTES
20.12.04 Screw at belt end fitting *BA91.40-P-1003-01H
Remove/install
Remove head restraint from 60% AR91.16-P-

1
rear seat 1770GZ
2 Pull release handle (1) upwards

and move 60% rear seat (2) to an Installation: 60% rear seat (2) must latch in
upright position place.

*BA91.12-P-
3 Remove bolts (3)
1001-02D
*BA91.40-P-
1003-01H
Installation: Check rear seat belt buckle for
Release rear seat belt buckle (4)
damage. Ensure that belt end fitting (5), rear seat
4 with bracket from belt end fitting
belt buckle (4) and spring (6) are in correct
(5)
installation position.
See Operator's Manual
Fold 60% rear seat backrest (7)
5 Installation: 60% rear seat backrest (7) must
forwards
latch in place.
Unclip covers from cargo
6 retainers (8) and unscrew bolts Long wedge Fig. 54
beneath
*BA68.50-P-
1001-03F
Unclip and remove load
compartment cover (9)
*BA91.12-P-
8 Remove screw (10)
1001-02D
Release lock (12) and remove
10 Installation: Lock (12) must latch in place
60% rear seat backrest (7)
LOAD RETAINER
REAR SEAT BACKREST

BA91.12-P-1001-02D Bolt of rear seat backrest to vehicle floor Nm 90


REMOVE AND INSTALL LOCKING MECHANISM FOR FOLDING REAR SEAT BACKREST -
AR91.12-P-1730GZA
MODEL 164.1
Fig. 103: Identifying Locking Mechanism For Folding Rear Seat Backrest Components
Remove/Install
AR91.12-P-
1 Remove upholstery for rear seat backrest
1030GZA
2 Unscrew bolt (1)
In order to enable access to the
3 Fold cover (2) upward
locking mechanism (5).
4 Disconnect connection (3) Upward.
Unclip catch lugs (4) on both sides of the Locking mechanism (5) is spring-
5
locking mechanism (5) loaded, risk of injury!
7 Perform a function test
REMOVE/INSTALL BUCKLE OF REAR SEAT BACKREST LOCK - AR91.12-P-1731GZ

MODEL 164.1
Shown on left rear seat backrest
Fig. 104: Identifying Buckle Of Rear Seat Backrest Lock Components - Shown On Left Rear Seat
Backrest
Remove/install
1 Fold rear seat backrest forward Left or right as required.

Unclip cover directly from clip (arrow A), to
avoid damaging the cover (1).
2 Unclip cover (1)
Unclip the cover (1) on the left or right rear
seat backrest as required.
Long wedge Fig. 54
Detach rear seat backrest
3 In area of B arrow
upholstery (2)
Remove rear seat backrest
4 upholstery (2) in area of rear seat Long wedge Fig. 54
backrest lock buckle (4)
5 Pull foam (3) to one side. To ensure that access to bolts (6) is given.
Use suitable tool to help rear seat backrest lock
buckle (4) latch into place.
Unhook cable (5) for rear seat Installation: Before installation of the buckle,
6
backrest lock buckle (4) the cable (5) has to be inserted first, as otherwise
the cable (5) can be unhooked at the bottom.
Installation: Use suitable tool to help rear seat
backrest lock buckle (4) latch into place. Carry out

function test.
*BA91.12-P-
7 Unscrew bolts (6)
1002-02D
Remove rear seat backrest lock
8
buckle (4)
REAR SEAT BACKREST

BA91.12-P-1002-02D Bolt for buckle to rear seat backrest Nm 25

REMOVE/INSTALL RELEASE LEVER OF REAR SEAT BACKREST - AR91.12-P-1732GY
MODEL 164.8
Fig. 106: Identifying Release Lever Of Rear Seat Backrest Components

Remove/install
Installation: First insert retaining clip (1) into right

1 Remove retaining clip (1)
release lever (2) or left release lever (3).
Detach right release lever (2) or left

2
release lever (3)
REMOVE/INSTALL REAR SEAT BACKREST RELEASE CABLE - AR91.12-P-1734
Remove/install rear seat backrest release cable - AR91.12-P-1734GY
MODEL 164.8 Rear seat backrest of 60 % rear seat
Fig. 107: Identifying Rear Seat Backrest Release Cable Components - 60 % Rear Seat (1 Of 2)
Fig. 108: Identifying Rear Seat Backrest Release Cable Components - 60 % Rear Seat (2 Of 2)
Remove/install

2 Remove bolts (2)
3 Unclip covers (3, 4) Mounting wedge Fig. 63
4 Remove bolts (5)
6 Separate tie strap (7) Installation: Replace tie straps (7).
7 Unhook cable (8, 10)
8 Unclip cable guide (9, 11)
9 Remove cable (8, 10)

Remove/install rear seat backrest release cable - AR91.12-P-1734GZ
MODEL 164.1
Fig. 110: Identifying Rear Seat Backrest Release Cable Components

Remove/Install
Remove left rear seat backrest AR91.18-P-

1
covering 1874GZ
Installation: Carefully screw in bolt (1), risk
2 Unscrew bolt (1)
of cracks and fracture on cover (2).
Slide to the right side.
3 Take off cover (2)
Installation: Note installation position.
4 Detach connection (3) Up
5 Separate cable strap (4) Installation: Replace tie straps (4).
Unhook hook (5) from rear seat Engage rear seat backrest lock (6) using
6
backrest lock (6) suitable tool.
Remove release cable (7) from
7
rear seat backrest
REMOVE/INSTALL SPLIT REAR SEAT BACKREST ARM REST - AR91.12-P-1750GZ
MODEL 164
Shown on rear seat backrest which has been removed

Fig. 111: Identifying Split Rear Seat Backrest Arm Rest Components - Shown On Rear Seat Backrest
Which Has Been Removed
Remove/install
1 Fold out armrests (1) from rear seat backrest (3)
2 Unlock retaining bracket (2) (in direction of arrow) On left and right.
REMOVE/INSTALL SEAT FRAME IN REAR - AR91.12-P-6000GY
MODEL 164.8 40 % and 60 % rear seat frame
Remove/install
1 Remove rear seat cushion Rear seat cushion of 40 % rear seat AR91.12-P-1020GY
Rear seat cushion of 60 % rear seat AR91.12-P-1020GYA
2 Remove rear seat backrest Rear seat backrest of 40 % rear seat AR91.12-P-1620GY
Rear seat backrest of 60 % rear seat AR91.12-P-1620GYA
3 Reinstall in opposite order
REMOVE/INSTALL GAS-OPERATED STRUT ON SEAT FRAME - AR91.12-P-6005GY
MODEL 164.8 40 % rear seat

Fig. 112: Identifying Gas-Operated Strut On Seat Frame Components

Remove/install
Only remove and install gas-operated
Risk of injury caused by body parts
struts when they are not under tension AS00.00-Z-
being pinched or crushed when working
and when the components are properly 0012-01A
on gas-operated struts under tension
secured.
Do not remove retainers (1),
otherwise tension can be lost.
Observe installation position of gas-
Lift up retainers (1) at gas-operated strut
1 operated strut (2).
(2), unhook gas-operated strut (2)
If required, replace gas-operated strut
(2) and dispose of gas-operated strut (2)
(old part), see: ?
OS00.00-P-
Degas and drain gas-operated strut
1001-01A
REMOVE/INSTALL HEAD RESTRAINT ON FRONT SEAT - AR91.16-P-0040
Remove/install head restraint on front seat - AR91.16-P-0040GZ
MODEL 164 Electrically adjustable head restraint

Fig. 113: Identifying Head Restraint On Front Seat Components - Electrically Adjustable Head Restraint
(1 Of 2)
Fig. 114: Identifying Head Restraint On Front Seat Components - Electrically Adjustable Head Restraint
(2 Of 2)
MODIFICATION NOTES
26.7.06 "Disconnect/connect battery ground line" removed Step 2
Remove/install
Notes on avoiding damage to electronic AH54.00-P-

components due to electrostatic discharge 0001-01A
Remove back shell (2) on front seat backrest AR91.10-P-
1
(4) 1915GZ
2 Unclip clip (3) from guide (5)
Vehicles with code 438 NECK-
3 Disconnect electrical connector
PRO.
4 Tilt front seat backrest to the rear (4)
Carefully remove head restraint

5 Pull head restraint (1) out upward
(1) to avoid damaging the headliner.
Remove/install head restraint on front seat - AR91.16-P-0040GZA
MODEL 164 Mechanically adjustable head restraint
Fig. 115: Identifying Head Restraint On Front Seat Components - Mechanically Adjustable Head
Restraint (1 Of 2)
Fig. 116: Identifying Head Restraint On Front Seat Components - Mechanically Adjustable Head
Restraint (2 Of 2)
MODIFICATION NOTES
Remove/install

Remove back shell (4) from the front seat AR91.10-P-
1
backrest 1915GZ
Unclip clip (5) from guide (6) of head
2
restraint
Vehicles with code 438 NECK-
PRO.
4 Tilt front seat backrest (3) backwards
Press release button (2) and pull out head Carefully remove head restraint
5
restraint (1) upwards (1) to avoid damaging the headliner.
REMOVE/INSTALL HEAD RESTRAINT GUIDE ON FRONT SEAT - AR91.16-P-0050
Remove/install head restraint guide on front seat - AR91.16-P-0050GZ
MODEL 164.1
Fig. 117: Identifying Head Restraint Guide On Front Seat Components - Model 164.1
Remove/install
AR91.16-P-
1 Remove front seat head restraint Driver side. 0040GZ
AR91.16-P-
Passenger side. 0040GZA
Press in catch tabs (3) of right head restraint guide
Release right head restraint guide
2 (1) or left head restraint guide (2) (1) or left head restraint guide (2) carefully in order
to prevent damage to the backrest cover and the head
at the catch tabs (3)
restraint guides.
Pull out right head restraint guide Installation: Note the installation position of the
3 (1) or left head restraint guide (2) right head restraint guide (1) or the left head restraint
upwards guide (2).
Remove/install head restraint guide on front seat - AR91.16-P-0050RT
MODEL 251, 164.8
Fig. 118: Identifying Head Restraint Guide On Front Seat Components - Model 251, 164.8
Remove/install
AR91.16-P-
1 Remove head restraint Model 164.8, electrically adjustable head restraint
0040GZ
AR91.16-P-
Model 164.8, mechanically adjustable head restraint
0040GZA
AR91.16-P-
Model 251
0040RT
Press in catch tabs (3) of right head restraint guide
Release right head restraint guide
(1) or left head restraint guide (2) carefully in order
2 (1) or left head restraint guide (2)
to prevent damage to the backrest cover and the head
at the catch tabs (3)
restraint guides.
Pull out right head restraint guide Installation: Note the installation position of the
3 (1) or left head restraint guide (2) right head restraint guide (1) or the left head restraint
upwards guide (2).
REMOVING REAR HEAD RESTRAINT - AR91.16-P-1770
Removing rear head restraint - AR91.16-P-1770GY

Fig. 119: Identifying Head Restraint And Lock

Remove, Install
Fold backrest of 3rd seat row rear seat

1
forward
2 Press lock (2) Press and hold lock (2).
Installation: head restraint (1) must audibly
3 Extend head restraint (1) along the brackets
engage.
Removing rear head restraint - AR91.16-P-1770GZ
MODEL 164.1
MODEL 164.8 2nd seat row

Fig. 120: Identifying Lock - Shown On Model 164.1

Remove/install
1 Fold rear seat backrest to front Do not fold rear seat cushion forward.
2 Press lock (1) Press and hold lock (1).
To avoid damage to the headliner, carefully move head restraints
Move head restraints on upwards.
3
brackets upwards Installation: Head restraints must latch audibly into place. Note
installation position of center head restraint.
REMOVE/INSTALL REAR SEAT BACKREST HEAD RESTRAINT GUIDES - AR91.16-P-1775
Remove/install rear seat backrest head restraint guides - AR91.16-P-1775GZ
MODEL 164.1
MODEL 164.8 2nd seat row
Fig. 121: Identifying Rear Seat Backrest Head Restraint Guides Components - Shown On Model 164.1
Remove/install
Remove head restraint on 2nd AR91.16-P-

1
seat row 1770GZ
Use pulling hook to carefully release catch tabs (3)
Release right head restraint
2 guide (1) and left head restraint of right head restraint guide (1) and left head restraint
guide (2), to avoid damage to the backrest covering and
guide (2) at catch tabs (3)
the head restraint guides.
Pulling hook Fig. 122
Remove right head restraint Installation: Check installation position of right
3 guide (1) and left head restraint head restraint guide (1) and left head restraint guide
guide (2) upwards (2).
Fig. 122: Identifying Pulling Hook (140 589 02 33 00)

Remove/install rear seat backrest head restraint guides - AR91.16-P-1775RTA
MODEL 164.8, 251 3rd seat row
Fig. 123: Identifying Rear Seat Backrest Head Restraint Guides Components - 3rd Seat Row
Remove/install
AR91.16-P-
1 Remove head restraint of 3rd seat row Model 164.8
1770GY
AR91.16-P-
Model 251
1770RTA
Unlock left head restraint guide (1) and
2 right head restraint guide (2) at the Pulling hook Fig. 122
catch lugs (3)
Pull left head restraint guide (1) and Installation: Pay attention to installation
3 right head restraint guide (2) up and position of left head restraint guide (1) and
out right head restraint guide (2).

REMOVE/INSTALL FRONT SEAT CUSHION COVERING - AR91.18-P-1800GZ
MODEL 164
Shown with heated left and right front seats, code 873
Fig. 125: Identifying Front Seat Cushion Covering Components - Shown With Heated Left And Right
Front Seats, Code 873
Remove/install
1 Remove seat cushion AR91.10-P-3310GZ
2 Unhook retaining rails (1) and retaining rail (2)
3 Unhook cover (3)
4 Unhook hooks (4, 5)
5 Remove cover (6)
Remove SRS airbag emblem from rear seat cover - AR91.18-P-1800-01GZ
Models 164, 251
Fig. 126: Removing SRS Airbag Emblem From Rear Seat Cover
In order to minimize variety, the cover of the rear seat backrest can only be obtained with the "SRS Airbag"
emblem (1). In order to avoid mix-ups, the emblem must be removed on vehicles without sidebag at the left and
right rear, code 293.
1. Cut out the "SRS Airbag" emblem (1) on the outside of the rear seat backrest cover as close to the seam
as possible.
2. Remove the remainder of the "SRS Airbag" emblem (1) on the inside of the rear seat backrest cover (3).
Do not separate or damage the seam, as the rear seat backrest cover will then be unusable.
REMOVE FRONT SEAT BACKREST COVER - AR91.18-P-1820GZ
MODEL 164
Shown on removed front seat with memory package (driver seat, steering column, mirror), code 275,
with mechanical lumbar support
Fig. 127: Identifying Front Seat Backrest Cover Components - Shown On Removed Front Seat With
Memory Package Code 275
Remove/install
100°C. When working on these units, 0001-01A
Remove backrest shell from front AR91.10-P-
1
Front seat with electrically adjustable head AR91.16-P-
2 Remove front seat head restraint restraint 0040GZ

Front seat with mechanically adjustable head AR91.16-P-
restraint 0040GZA
3 Model 164.1
guide 0050GZ
AR91.16-P-
Model 164.8
0050RT
4.1 Detach lever (1) Front seat with mechanical lumbar support.
5.1
motor 1432GZ
6 Unclip clips (2)
Unhook front seat backrest cover (8)
7
from hook (3)
8 Remove spreading clip (4) Push out airbag rescue line upwards.
10
with padding
12
from padding
REMOVE AND INSTALL COVER ON REAR SEAT CUSHION - AR91.18-P-1850
Remove and install cover on rear seat cushion - AR91.18-P-1850GY
Fig. 128: Identifying Cover On Rear Seat Cushion Components - Cover On 40 % Rear Seat
Remove/install
Remove rear seat cushion of Place rear seat cushion with cover facing down onto AR91.12-P-
40 % rear seat a suitable clean surface to avoid soiling or damaging 1020GY

1
the rear seat cushion.
Unhook cover (1) from
2
cushion frame (arrows)
Remove cover (1) with
3 cushion (2) from cushion
frame
4 Turn back cover (1)
Unhook clevis-type shackles
5
(3) from cover (1)
Remove cover (1) from
6
upholstery (2)
Remove and install cover on rear seat cushion - AR91.18-P-1850GYA
Fig. 129: Identifying Cover On Rear Seat Cushion Components - Cover On 60 % Rear Seat
Remove/install
Place rear seat cushion with cover facing down onto a AR91.12-P-
Remove rear seat cushion of
1 suitable clean surface to avoid soiling or damaging the
60 % rear seat 1020GY
rear seat cushion.
Unhook cover (1) from
cushion frame (arrows)
3 Turn back cover (1)
Unhook clevis-type shackles
4
(3) from cover (1)
Remove cover (1) with For vehicles with code (872) Electrically heated left
5 cushion (2) from cushion and right rear seats: Expose connector in padding,
frame separate it and then thread out of padding.
Remove cover (1) from
6 upholstery (2)

Remove and install cover on rear seat cushion - AR91.18-P-1850GZ
Shown on rear seat, model 164.1 without electrically heated left and right rear seats, code 872
Fig. 131: Identifying Cover On Rear Seat Cushion Components - Shown On Rear Seat, Model 164.1 (1 Of
2)
2)
Removing
Only on right-hand side.
Place rear seat cushion upholstery down AR91.12-P-
onto suitably clean surface, to avoid causing 1020GZ
any contamination or damage.
Press out catch tab (1), lift release handle
2 Unclip release handle (2).
(2).
Long wedge Fig. 54
If necessary, relieve load from rear seat
Unhook rear seat cushion covering (4)
3 cushion covering (4) by pressing down from
(arrows).
rear seat cushion frame (6).
Remove rear seat cushion covering (4)
4 with rear seat cushion upholstery (5)
from rear seat cushion frame (6)
5 Pull over rear seat cushion covering (4)
Unhook securing lugs (3) from rear seat
6
cushion covering (4).
7
from rear seat cushion upholstery (5).
Install
Fold in rear seat cushion covering (4) at
8 side, position on rear seat cushion
upholstery (5) and align.
Hook securing lug hooks (3) into rear If necessary, relieve load from rear seat
9 cushion covering (4) by pressing down rear
seat cushion upholstery (5).
Pull rear seat cushion covering (4) over Ensure that corner brackets of rear seat
10
edge of rear seat cushion upholstery. cushion upholstery (5) are seated correctly.
Hook rear seat cushion covering (4) into If necessary, relieve load on rear seat
11 clip groove on rear seat cushion frame cushion covering (4) by pressing down rear
(6). seat cushion frame (6).
AR91.12-P-
12 Install rear seat cushion
1020GZ

Remove and install cover on rear seat cushion - AR91.18-P-1850GZA
2)
Shown on rear seat, model 164.1 without electric heated seat for left and right rear seat, code 872
2)
Removing
Only on left side.

Place rear seat cushion upholstery down AR91.12-P-
onto suitably clean surface, to avoid causing 1020GZA
2 Unclip release handle (2). Press out catch tab (1), lift release handle
(2).
Long wedge Fig. 54
Unhook rear seat cushion covering (4) If necessary, relieve load on rear seat
(arrows).
seat cushion frame (5).
5 with rear seat cushion upholstery (7)
from rear seat cushion frame (5)
6 Pull over rear seat cushion covering (4).
Unhook securing lugs (6) from rear seat
7
cushion covering (4).
8
from rear seat cushion upholstery (7).
Install
Fold in rear seat cushion covering (4) at
9 side, position on rear seat cushion
upholstery (7) and align.
If necessary, relieve load from rear seat
Hook securing lugs (6) into rear seat
cushion upholstery (7).
Pull rear seat cushion covering (4) over Ensure that corner brackets of rear seat
11
edge of rear seat cushion upholstery. cushion upholstery (7) are seated correctly.
Hook rear seat cushion covering (4) into If necessary, relieve load on rear seat
12 clip groove on rear seat cushion frame cushion covering (4) by pressing down rear
(5). seat cushion frame (5).
AR91.12-P-
13 Install rear seat cushion
1020GZA

REMOVE AND INSTALL REAR SEAT BACKREST COVER - AR91.18-P-1870GY
Fig. 137: Identifying Rear Seat Backrest Cover Components

Removing
AR91.12-P-
1000GYB
AR91.12-P-
2 Remove 3rd seat row rear seat cushion
1020GYB
Remove 3rd seat row rear seat backrest AR91.12-P-
3
paneling (6) 1131GY
Remove head restraint guides of rear seat Installation: Observe installation AR91.16-P-
4
backrest and covering underneath position of cover. 1775RTA
5 Unclip covers (1). Long wedge Fig. 54
Unhook 3rd seat row rear seat backrest
6
cover (5) from lug (2)
Unhook 3rd seat row rear seat backrest
7
cover (5) from bolt (3)
8 Remove 3rd seat row rear seat backrest

cover (5) with 3rd seat row rear seat
backrest (6) from frame

Unhook 3rd seat row rear seat backrest Place 3rd seat row rear seat backrest
9 cover (5) from attachment lugs (4) in 3rd cover (5) down onto a clean surface to avoid
seat row rear seat backrest (6) contamination or damage.
10 cover (5) from 3rd seat row rear seat
backrest (6)
Install
Fold in 3rd seat row rear seat backrest
11 cover (5) at side, place onto 3rd seat row
rear seat backrest (6) and align
Place 3rd seat row rear seat backrest
Hook attachment lugs (4) into 3rd seat
12 down onto a clean surface to avoid
row rear seat backrest cover (5) cover (5)
contamination or damage.
Pull 3rd seat row rear seat backrest cover Ensure that the corner brackets of the 3rd
13 (5) over corners of 3rd seat row rear seat seat row rear seat backrest (6) are correctly
backrest (6) seated.
Pull 3rd seat row rear seat backrest cover
14 (5) over corners of rear seat backrest
frame
15
(5) into lug (2)
16
(5) onto bolt (3)
Install 3rd seat row rear seat backrest AR91.12-P-
17
paneling (6) 1131GY
18 Clip in covers (1)
Install head restraint guides of 3rd seat AR91.16-P-
19
row rear seat backrest (6) 1775RTA
AR91.12-P-
20 Install 3rd seat row rear seat cushion
1020GYB
AR91.12-P-
21 Install 3rd seat row rear seat
1000GYB


REMOVE/INSTALL LEFT REAR SEAT BACKREST UPHOLSTERY - AR91.18-P-1874GZ
MODEL 164
Fig. 140: Identifying Left Rear Seat Backrest Upholstery Components - Shown On Rear Seat, Model
164.1 (1 Of 3)
164.1 (2 Of 3)
164.1 (3 Of 3)
Removing
AR91.12-P-
1 Remove 60% rear seat backrest Model 164.1
1620GZA
Model 164.8 AR91.12-P-
1620GYA
Remove armrest for divided rear seat AR91.12-P-
2
backrest 1750GZ
Remove head restraint guides of rear AR91.16-P-
3
Remove paneling for left rear seat AR91.12-P-
4
backrest 1131GZA
Carefully unclip belt passage for
center seat belt at top of rear seat
backrest, remove center seat belt to
side.
Guide center seat belt through rear seat
6
backrest covering (7).
7.1 Unclip cover (1) Only on model 164.1.
Long wedge Fig. 54
Unclip center armrest shell (2) (arrow
8
A)
Model 164.8: Only unclip lower covers
9 Unclip covers (3)
(3).
Long wedge Fig. 54
Only on model 164.1.
Pull rear seat backrest upholstery (7)
10.1 Pull carefully, to avoid damaging the rear
over pivot bearing (4)
seat backrest upholstery (7).
Unhook rear seat backrest cover (7)
11
(arrows B).
Remove rear seat backrest covering (7) Place rear seat backrest covering (7) with
12 with rear seat backrest upholstery (8) rear seat backrest upholstery down onto clean
from frame on rear seat backrest. subsurface to prevent soiling or damage.
13 Open Velcro fastener (5).
Unhook rear seat backrest upholstery
14 (7) from insertion tabs (6) in the rear
seat backrest padding (8)
Remove rear seat backrest cover (7)
15
from rear seat backrest upholstery (8)
Install
Cut off "sidebag" insert as close as
Only on vehicles without sidebag in left AR91.18-P-
16.1 possible along rear seat backrest
and right rear, code 293. 1800-01GZ
covering (7) seam.
Fold the rear seat backrest cover (7) at
17 the side, put on rear seat backrest
upholstery (8) and align
Fit insertion tabs (6) into rear seat Place rear seat backrest covering (7) with
backrest upholstery (7) rear seat backrest upholstery down onto clean
18
subsurface to prevent soiling or damage.
Check that corner brackets of rear seat
19.1 over corners of rear seat backrest
padding (8)
20 Pull carefully, to avoid damaging the rear
Pull rear seat backrest covering (7)
21 over corners of rear seat backrest
frame.
22 Close Velcro fastener (5).
If necessary, relieve load on rear seat
Hook rear seat backrest covering (7)
23 backrest covering (7) by pushing down rear
into rear seat backrest frame.
seat backrest frame downwards.
First hook in center armrest shell (2) at
24 Clip in center armrest shell (2).
top, then clip in at bottom.
25 Clip in covers (3) Observe installation position.
26.1 Clip on cover (1) Only on model 164.1.
Guide center seat belt through rear seat
27
backrest covering (7).
Install center seat belt in belt passage
28
at top side, clip in belt passage.
Install paneling for left rear seat AR91.12-P-
29
backrest. 1131GZA
Install head restraint guides of rear seat AR91.16-P-
30
backrest 1775GZ
Install armrest for divided rear seat AR91.12-P-
31
backrest. 1750GZ
AR91.12-P-
32 Install 60% rear seat backrest. Model 164.1
1620GZA
AR91.12-P-
Model 164.8
1620GYA


REMOVE/INSTALL RIGHT REAR SEAT BACKREST UPHOLSTERY - AR91.18-P-1878GZ
MODEL 164
Fig. 145: Identifying Right Rear Seat Backrest Upholstery Components - Shown On Rear Seat, Model
164.1 (1 Of 2)
Fig. 146: Identifying Right Rear Seat Backrest Upholstery Components - Shown On Rear Seat, Model
164.1 (2 Of 2)
Removing
AR91.12-P-
1.1 Remove rear seat backrest Only on model 164.1. 1620GZ
Remove head restraint guides of AR91.16-P-
2
right rear seat backrest. 1775GZ
Remove paneling of rear seat AR91.12-P-
3
backrest 1131GZ
4 Unclip covers (1). Long wedge Fig. 54
5.1 Remove bolt (2) Only on model 164.1.
6.1 Remove bracket (3) Only on model 164.1.
Detach rear seat backrest upholstery
8.1 Only on model 164.1.
(8) from hooks (5)
9 upholstery (8) from rear seat
backrest frame (6)
Unhook rear seat backrest
Place rear seat backrest covering (8) down
upholstery (8) from insertion tabs
10 onto suitably clean surface, to avoid causing
(7) in the rear seat backrest padding
(9)
11 upholstery (8) from rear seat
backrest padding (9)
Install
Cut off "sidebag" insert as close as
Only on vehicles without sidebag in left and AR91.18-P-
12.1 possible along rear seat backrest
right rear, code 293. 1800-01GZ
covering (8) seam.
Fold rear seat backrest upholstery Place rear seat backrest covering (8) with
(8) to one side, place onto rear seat rear seat backrest upholstery down onto clean
13
backrest padding (9) and align subsurface to prevent soiling or damage.
Fit insertion tabs (7) into rear seat
14
backrest upholstery (8)
Check that corner brackets of rear seat
padding (9)
frame (6)
If necessary, relieve rear seat backrest
Insert rear seat backrest upholstery
18 upholstery (8) by pushing rear seat backrest
(8) into rear seat backrest frame (6)
frame (6) downwards.
19.1 Install bracket (3) Only on model 164.1.
20.1 Screw in bolts (2) Only on model 164.1.
*BA91.12-P-
1003-02D
21 Install covers (1) Observe installation position.
AR91.12-P-
22 Install paneling of rear seat backrest
1131GZ
Install head restraint guides of rear AR91.16-P-
23
AR91.12-P-
24.1 Install rear seat backrest Only on model 164.1. 1620GZ
REAR SEAT BACKREST

BA91.12-P-1003-02D Bolt for rear seat backrest bracket to rear seat backrest 40% Nm 35


REMOVE/INSTALL AIR PUMP FOR MULTICONTOUR SEAT - AR91.25-P-1430GZ
MODEL 164 with CODE (404) Left multicontour seat with CODE (405) Right multicontour seat
Fig. 149: Identifying Air Pump For Multicontour Seat Components - Shown On Model 164.1
Remove/install

1 Turn key in ignition switch to position "0". keyless go start/stop button repeatedly until ignition is
switched off
Remove flap in left side paneling in load
2 Remove stowage compartment, if necessary.
compartment
Installation: Pay attention to the correct seat of the
3 Remove front half of damping material (1)
two halves of the soundproofing (1).
4 Fold up rear half of damping material (1)
Remove multicontour seat pneumatic pump
5
(M40) from damping material (1)
Disconnect electrical connector (2) from the

6
multicontour seat pneumatic pump (M40)
Detach pneumatic lines (3) from the
7 Installation: Do not mix up pneumatic lines (3).
multicontour seat pneumatic pump (M40)
REMOVING AND INSTALLING MULTICONTOUR SEAT SWITCH - AR91.25-P-1720GZ
Fig. 150: Identifying Right/Left Front Multicontour Backrest Switch Group

Shown on removed seat
Fig. 151: Identifying Upper Part Of Bracket, Catch Lugs, Connection Strip And Bracket
Fig. 152: Identifying Upper Part Of Bracket, Catch Lugs, Mounting Holes And Right/Left Front
Multicontour Backrest Switch Group
Shown on removed seat
Remove/install
Fig.
1 Unclip upper part of bracket (1) Long wedge 54
Do not pull it out too far, as
Pull out upper part of bracket (1) from bracket (2) to allow
2 this could damage the pneumatic
access to the catch lugs (3)
lines.
Press catch lugs (3) together and remove multipoint connector
(4) from the right front multicontour backrest switch group Installation: Catch lugs (3)
3 must audibly engage into the
(S108) or from the left front multicontour backrest switch
group (S109) multipoint connector.
Remove upper part of bracket (1) with right front
4 multicontour backrest switch group (S108) or left front
multicontour backrest switch group (S109)
Unclip right front multicontour backrest switch group (S108) Installation: Ensure that the
5 or left front multicontour backrest switch group (S109) on the catch lugs (5) are correctly seated
catch lugs (5) in the mounting holes (6).
Fig.
Long wedge 54

7 Carry out a multicontour backrest function test

REMOVE/INSTALL MULTICONTOUR BACKREST AIR CUSHION - AR91.25-P-1740GZ
Fig. 154: Identifying Multicontour Backrest Air Cushion Components

Remove/install
Remove padding of backrest from AR91.10-P-

1
left or right front seat 1090GZ
2 Remove tie straps (1) Installation: Replace tie straps (1).
Open multipoint connector on the Installation: Catch lugs must audibly (2)
3
catch lugs (2) engage into the multipoint connector.
Remove pneumatic line (3, 4) on Installation: Ensure that pneumatic lines (3, 4)
4
the air cushion side are seated correctly.
Detach retainer tabs (5) from the
5 multicontour seat backrest tension
wire (6)
Remove multicontour backrest air Installation: Note the installation position of

6 cushion (7) by lifting it upwards the multicontour seat backrest air cushion (7) on
and pulling it out the multicontour seat backrest tension wire (6).
Carry out multicontour seat
8 backrest air cushion (7) function
test
REMOVE/INSTALL MULTICONTOUR BACKREST SIDE AIR CUSHIONS - AR91.25-P-1741GZ
Fig. 155: Identifying Multicontour Backrest Side Air Cushions Components (1 Of 2)

Fig. 156: Identifying Multicontour Backrest Side Air Cushions Components (2 Of 2)

Remove/install
Remove padding of backrest from left or AR91.10-P-

1
right front seat 1090GZ
2 Remove tie straps (1, 2) Installation: Replace cable ties (1, 2).
Installation: Catch lugs (3) must
Open multipoint connector on the catch
3 audibly engage into the multipoint
lugs (3)
connector.
Detach pneumatic line (4, 5) from the

4
multipoint connector on air cushion side
AR91.60-P-
5 Remove sidebag on front seat
0695GZ
Drill out right and left rivets (6) on the
6 Installation: Use new rivets (6).
backrest
*WH58.30-Z-
*WH58.30-Z-
1007-20A
7 Remove air cushion (7)
Carry out a multicontour seat backrest
9
function test

Number Designation
REMOVE/INSTALL MULTICONTOUR BACKREST SEAT CUSHION AIR CUSHION - AR91.25-P-

1770GZ
Shown on removed front seat
Fig. 157: Identifying Multicontour Backrest Seat Cushion Air Cushion Components - Shown On
Removed Front Seat

Remove/install
In addition, separate pneumatic line connection AR91.10-P-

1 Remove seat cushion
(1). 3310GZ
Pull back seat cushion cover (3) in
To allow access to the multicontour seat air
2 the area of the multicontour seat air
cushion (4).
cushion (4)
Remove multicontour seat air cushion (4)
carefully. The multicontour seat air cushion (4) is
Detach multicontour seat air cushion
3 stuck to the seat cushion upholstery.
(4) from the seat cushion upholstery.
Installation: Multicontour seat air cushion (4)
must be replaced.
4 Lift protective mat (2)
Pull out pneumatic line from the seat Installation: Ensure that the pneumatic line is
5 correctly seated in the guide groove (arrow) in the
cushion upholstery
seat cushion upholstery.
REPLACE SEAT ADJUSTMENT CONTROL UNIT WITH MEMORY - AR91.29-P-0002GZ
MODEL 164 with CODE (275) Memory package (driver seat, steering column, mirrors) with CODE
(242) Electrically adjustable front passenger seat with memory
Shown on removed front seat, front seat cushion removed for clearer illustration
Fig. 158: Identifying Seat Adjustment Control Unit With Memory Components - Shown On Removed
Front Seat, Front Seat Cushion Removed For Clearer Illustration
Remove/install
Information on preventing damage to electronic components due to All AH54.00-P-

electrostatic discharge models 0001-01A
1 Move seat upwards
Disconnect electrical connectors (1, 2) from driver-side front seat
2
adjustment control unit with memory (N32/1)
Press lever (3) inwards and remove driverside front seat adjustment
3
control unit with memory (N32/1)
Disconnect electrical connectors (4, 5, 6) from driver-side front seat
4
adjustment control unit with memory (N32/1)
REMOVE/INSTALL SEAT ADJUSTMENT SWITCH UNIT ON FRONT SEAT - AR91.29-P-0003GZ
MODEL 164 with CODE (275) Memory package (driver seat, steering column, mirrors)
Shown on driver seat on model 164.1

Fig. 159: Identifying Seat Adjustment Switch Unit On Front Seat Components - Shown On Driver Seat
On Model 164.1
Remove/install
On vehicles with Keyless Go code 889: Press

Keyless Go start/stop button repeatedly until the ignition
Switch off ignition and remove
1 is switched off. Remove transmitter key from vehicle
transmitter key from EIS control unit
and store it in a location beyond its transmission range
(at least 2 m).
Fig.
2 Unclip cover (1) Mounting wedge 63
3 Disconnect electrical connector (2)
4 Remove bolts (3)
Remove driver seat adjustment with
memory switch group (S91) or front
5
passenger seat adjustment with
memory switch group (S92)
Fig. 160: Identifying Mounting Wedge (110 589 03 59 00)

REMOVE/INSTALL SEAT ADJUSTMENT DRIVE MOTOR (FORWARD/BACK) - AR91.29-P-

1425GZ
MODEL 164
Shown on removed front seat with memory package (driver seat, steering column, mirrors), code 275
Fig. 161: Identifying Seat Adjustment Drive Motor (Forward/Back) Components - Shown On Removed
Front Seat With Memory Package Code 275
Remove/install
AR91.10-P-
3310GZ
3 Lift driver seat fore/aft adjustment motor (M27/1) on left (arrow A)
Remove driver seat fore/aft adjustment motor (M27/1) upward at an angle

4
(arrow B)
6 Carry out function check
REMOVE/INSTALL BACKREST MOTOR FOR FRONT SEAT - AR91.29-P-1431GZ
MODEL 164
Fig. 162: Identifying Backrest Motor For Front Seat Components - Shown On Front Seat With Memory
Package Code 275
Shown on front seat with memory package (driver seat, steering column, mirror), code 275
Remove/install
AR91.10-P-
1 Remove front seat
1000GZ
AR91.10-P-
2 Remove padding for front seat backrest
1090GZ
3 Remove covers (1)
4 Remove circlip (2)
5 Slide drive shaft (3) through motor (4)
Disconnect electrical connector (5) from backrest angle adjustment motor, driver
6
(M27/5) or backrest angle adjustment motor, front passenger (M28/5)
7 Remove screw (6)
REMOVE/INSTALL FRONT SEAT HEADREST MOTOR - AR91.29-P-1432GZ

MODEL 164
Fig. 163: Identifying Front Seat Headrest Motor Components - Shown On Removed Front Seat
Remove/install
AR91.10-P-
1 Remove backrest shell from front seat backrest
1915GZ
AR91.16-P-
0040GZ
Slide head restraint motor, driver (M27/4) or head restraint motor, front passenger
3
(M28/4) to the right
Remove head restraint motor, driver (M27/4) or head restraint motor, front
4
passenger (M28/4) downwards
Disconnect electrical connector (1) from head restraint motor, driver (M27/4) or
5
head restraint motor, front passenger (M28/4) and remove motor
REMOVE/INSTALL FRONT SEAT ADJUSTMENT MOTOR - AR91.29-P-1434
Remove/install front seat adjustment motor - AR91.29-P-1434GZ
MODEL 164
Front seat height adjustment motor

Fig. 164: Identifying Bolts - Shown On Removed Front Seat With Memory Package (Driver Seat,
Fig. 165: Identifying Electrical Connector And Front Seat Height Adjustment Motor, Driver - Shown On
Removed Front Seat With Memory Package Code 275
Remove/install
Turn key in ignition switch to position On vehicles with Keyless Go, code 889:
"0".
AR91.10-P-
3310GZ
3 Remove bolts (1)
Detach driver front seat height

4 adjustment motor (M27/3) from drive
rod (arrow)
5 driver front seat height adjustment
motor (M27/3)
Remove/install front seat adjustment motor - AR91.29-P-1434GZA
MODEL 164
Rear seat height adjustment motor
Fig. 166: Identifying Bolts, Electrical Connector And Rear Seat Height Adjustment Motor, Driver -
Shown On Removed Front Seat With Memory Package Code 275
Remove/install

"0".
AR91.10-P-
3310GZ
Position front seat in center height

3
position
4 Remove bolt (1)
Disconnect electrical connector (3) from
5 driver rear seat height adjustment motor
(M27/2)
6 Unscrew bolt (2)
Remove driver rear seat height In doing this, push front seat at backrest
7 downward in order to counteract the
adjustment motor (M27/2)
pretension of the spring!
REMOVE/INSTALL FOLDING REAR BACKREST MOTOR - AR91.29-P-7050GY
MODEL 164.8
3rd seat row
Fig. 167: Identifying Folding Rear Backrest Motor Components

Remove/install
AR91.12-P-
1000GYB
Detach electrical connector (1) from left folding backrest motor (M53/10) or
2
from right folding backrest motor (M53/11)
3 Unscrew nuts (2).
Remove left folding backrest motor (M53/10) or right folding backrest motor
4
(M53/11)
REPLACE FOLDING BACKREST SWITCH - AR91.29-P-7060GY

MODEL 164.8
Fig. 168: Identifying Folding Backrest Switch Components

Remove/install
Unclip front switch for left folding backrest (158/1), rear switch for left folding
Long Fig.
1 backrest (158/2), front switch for right folding backrest (158/3) or rear switch for
wedge 54
right folding backrest (158/4)
Detach electrical connector (1) of front switch for left folding backrest (158/1), rear
2 switch for left folding backrest (158/2), front switch for right folding backrest (158/3)
or rear switch for right folding backrest (158/4)

REMOVE/INSTALL HEATED SEATS AND SEAT VENTILATION CONTROL UNIT - AR91.30-P-

0031GZ
MODEL 164 with CODE (401) Front comfort seats, incl. seat heating and seat ventilation with CODE
(872) Electrically heated left and right rear seats
Fig. 170: Identifying Heated Seats And Seat Ventilation Control Unit Components
Remove/install

1 Turn key in ignition switch to position "0". keyless go start/stop button repeatedly until ignition is
switched off
2 Fold up seat cushion (60 %)
3 Remove cover (1)
5 Unscrew nuts (3).
Remove HS [SIH], seat ventilation and
6
steering wheel heater control unit (N25/7)
REMOVE/INSTALL THE SEAT VENTILATION MOTORS ON THE FRONT SEAT BACKREST -

AR91.30-P-1900GY
Fig. 171: Identifying Seat Ventilation Motors On Front Seat Backrest Components
Remove/install
Model 164: AR91.16-P-

1 Remove head restraint (2) on front seat electrically adjustable
0040GZ
head restraint.
Model 164: AR91.16-P-
mechanically adjustable 0040GZA
head restraint.
AR91.16-P-
Model 251. 0040RT
AR91.29-P-
2 Remove head restraint motor (1) on front seat Model 164. 1432GZ
AR91.29-P-
Model 251. 1432RT
3 Unclip clip (3)
5 Unclip retaining clip (5)
Carefully remove retaining frame (6) with left front seat
6 backrest ventilation motor group (M18/10) and right front
seat backrest ventilation motor group (M18/11)
REMOVE/INSTALL BLOWER REGULATOR FOR SEAT VENTILATION MOTORS IN FRONT

SEAT - AR91.30-P-1910GY
Fig. 172: Identifying Blower Regulator For Seat Ventilation Motors In Front Seat Components
MODIFICATION NOTES
Remove/install
Model AR91.10-P-
1 Remove back shell from front seat backrest
164 1915GZ
Model AR91.10-P-
251 1915RT
2 Unhook cover (1)
4 Remove screw (3)
Remove left front seat ventilation blower regulator (N29/5) or right front
5
seat ventilation blower regulator (N29/6)
REMOVE/INSTALL FRONT SEAT CUSHION VENTILATION MOTORS - AR91.30-P-1950GZ
Fig. 173: Identifying Front Seat Cushion Ventilation Motors Components

Remove/install
Remove cover of AR91.18-P-

1 Model 164.
front seat cushion 1800GZ
AR91.18-P-
Model 251. 1800RT
Lift up rubberized
2
fiber matting (1)
3 Remove louver (2)
Observe electrical line (4).
Remove motor (3) It is not possible to replace individual motors (3) of the left
4
from cushion front seat cushion ventilation motor group (M18/9) or of the
right front seat cushion ventilation motor group (M18/11).
Install in the reverse
5 order
RENDER EMERGENCY TENSIONING RETRACTOR UNITS UNUSABLE - AR91.40-P-0611RT
MODEL 164, 251
Figure Work instructions

item,
etc.
Store airbag units with deployment side
facing up; do not expose to temperatures AS91.00-Z-
greater than 100°C. When working on 0001-01A
these units, disconnect the power supply.
Ignition of removed emergency AR91.40-P-
tensioning retractors 0611-02RT
AR91.60-P-
Operating the deployment device
0611-04RT
Deployment of emergency tensioning
AR91.40-P-
retractor units when no deployment
0611-05RT
device is present
Checking recognition of actuation
AR91.40-P-
state of emergency/compact Model 251
0612RT
tensioning retractors
AR91.40-P-
Model 164
0612GZ
Ignition of removed emergency tensioning retractors - AR91.40-P-0611-02RT
Risk of injury caused by Store airbag units with deployment side facing
performing testing or repair work up; do not expose to temperatures greater than AS91.00-Z-
on airbag or emergency tensioning 100°C. When working on these units, 0001-01A
retractor units. disconnect the power supply.
Notes on controlled deployment of
AH91.60-P-
airbag, sidebag and emergency
0611-02P
tensioning retractor units
Notes on disposing of airbag and
OS91.00-P-
emergency tensioning retractor All models
0001-01A
units
Fig. 174: Identifying Pressure Switch, Battery Control And Deployment, Rotary Switch And 2-Pin Plug
Connector
Using the deployment device
1. Plug the 2-pin plug connector (8) into the unit to be scrapped.
2. Dial the rotary switch (4) to position "1".
3. Press the battery control pressure switch (2) and deployment pressure switch (3) simultaneously.
Keep a distance of 10 m for safety.
After a successful deployment, the deployment indicator lamp (5) flashes.
Firing removed emergency tensioning retractors when ignition device is not present - AR91.40-P-0611-05RT
Notes on controlled deployment
AH91.60-P-
of airbag, sidebag and emergency
0611-02P
Ignition cable for firing airbag and
WF58.50-P-
emergency tensioning retractor
9160-02A
units
OS91.00-P-
0001-01A
units
Application of shop-made ignition cables
1. Fabricate ignition cables at least 10 m long with a pressure switch at the end.
2. Plug the 2-pin plug connector into the corresponding emergency tensioning retractor unit.
3. Connect ignition cables to the battery.
4. Press both pressure switches simultaneously.
Keep a distance of 10 m for safety.
CHECKING RECOGNITION OF ACTUATION STATE OF EMERGENCY/COMPACT

TENSIONING RETRACTORS - AR91.40-P-0612GZ
MODEL 164
Components removed to simplify illustration
Fig. 175: Identifying Driver/Front Passenger And Left 2nd Seat Row/Right 2nd Seat Row Automatic Belt
Retractor
Components removed to simplify illustration

Fig. 176: Identifying Driver/Font Passenger GUS Squib, And Left/Right 2nd Row ETR [GUS] Squib
Checking
Driver/front passenger emergency
tensioning retractor squibs:
Test driver ETR squib (R12/1) and
Check driver automatic belt retractor (1), front passenger ETR squib (R12/2)
front passenger automatic belt retractor (2), electrically using the STAR
left 2nd seat row automatic belt retractor (3),
DIAGNOSIS diagnosis system to
1 right 2nd seat row automatic belt retractor (4) see if triggering has occurred.
as well as driver seat belt buckle (7) and front
passenger seat belt buckle (8) using STAR If triggering of the driver ETR
squib (R12/1) or front passenger
DIAGNOSIS
ETR squib (R12/2) is determined in
the test, then the corresponding
component must be replaced, see: ?
AR91.40-P-
Remove/install seat belt (front seat)
1010GZ
Driver/front passenger belt force
limiter:
Test driver belt force limiter
(R12/27) and front passenger belt
force limiter (R12/26) electrically
using the STAR DIAGNOSIS
diagnosis system to determine if
triggering has occurred.
If triggering of the driver belt
force limiter (R12/27) or front
passenger belt force limiter
(R12/26) is determined in the test,
then the corresponding component

must be replaced, see: ?
AR91.40-P-
Remove/install seat belt (front seat)
1010GZ
Left or right 2nd seat row
squibs:
Test left 2nd seat row ETR squib
(R12/6) and right 2nd seat row ETR
squib (R12/7) electrically using the
STAR DIAGNOSIS diagnosis
system to see if triggering has
occurred.
If triggering of the left 2nd seat
row ETR squib (R12/6) or right 2nd
seat row ETR squib (R12/7) is
determined in the test, then the
corresponding component must be
replaced, see: ?
AR91.40-P-
Remove/install rear seat belts
0681GZ
Driver/front passenger buckle
squibs:
Test driver buckle ETR squib (R46)
and front passenger buckle ETR
squib (R46/1) electrically using the
system to see if triggering has
occurred.
If triggering of the driver buckle
ETR squib (R46) or the front
passenger buckle ETR squib
(R46/1) is determined in the test,
then the corresponding component
must be replaced, see: ?
Remove/install seat belt buckle AR91.40-P-
(front seat) 1515GZ
system Z-1048-13A
Check left 3rd seat row automatic belt
2 retractor (5) and right 3rd seat row automatic Only on model 164.8.
belt retractor (6) using STAR DIAGNOSIS
Left or right 3rd row emergency
tensioning retractor squib:

Check electrical deployment of left
3rd row ETR [GUS] squib (R12/35)
and right 3rd row ETR [GUS] squib
(R12/36) with STAR DIAGNOSIS
diagnosis system.
If deployment of the left 3rd row
ETR [GUS] squib (R12/35) or the
right 3rd row ETR [GUS] squib
(R12/36) is detected during the
check, the relevant component must
be replaced, see:?
Remove/install seat belts for third AR91.40-P-
row of seats 2000RT
system Z-1048-13A

Number Designation
REMOVE/INSTALL REAR SEAT BELTS - AR91.40-P-0681GZ
MODEL 164
Fig. 177: Identifying Rear Seat Belts Components - Shown On Model 164.1
MODIFICATION NOTES
20.12.04 Screw in rear seat belt guide bracket *BA91.40-P-1004-01H
Bolt to rear inertia reel *BA91.40-P-1005-01H
Remove/install
AS91.00-Z-
0001-01A
Risk of injury caused by release of spring in Never disassemble automatic belt AS91.00-Z-
the automatic belt retractor is released. retractors. 0002-01A
AH91.00-P-
0002-01M
units
AR54.10-P-
1 Disconnect battery ground cable
0003GZ
Detach bottom belt end fitting at entrance of *BA91.40-P-
2
rear door 1003-01H
AR68.30-P-
3 Remove moldings from C-pillar
4490GZ
Unscrew bolt (1) from seat belt guide bracket *BA91.40-P-
4
(2) 1004-01H
Detach electrical connector (3) from left 2nd
row emergency tensioning retractor squib
5
(R12/6) or from right 2nd row emergency
tensioning retractor squib (R12/7)
Unscrew bolt (4) at automatic belt retractor *BA91.40-P-
6
(5) 1005-01H
Automatic belt retractor (5)
7 Detach automatic belt retractor (5) must not be disassembled. On no
account should oil or grease be
used to help eliminate noise.
If the emergency tensioning
8 Check seat belt for signs of damage retractor is replaced, the defective
unit must be disposed of
properly: ?
Render emergency tensioning AR91.40-P-
retractor units unusable 0611RT
Notes on disposing of airbag and emergency OS91.00-P-

All models
tensioning retractor units 0001-01A
Installation: Pay attention to
different emergency tensioning
9 Install in the reverse order retractor versions (left/right) and
ensure that they are correctly
seated in their catches.
Read out/clear fault memory and test restraint STAR DIAGNOSIS diagnosis *WH58.30-
10
system using STAR DIAGNOSIS system Z-1048-13A

BA91.40-P-1004-01H Screw in rear seat belt guide bracket Nm 35
BA91.40-P-1005-01H Bolt to rear inertia reel Nm 35

Number Designation
REMOVE, REPLACE AND INSTALL REAR CENTER SEAT BELT - AR91.40-P-0683GZ
MODEL 164
Shown on model 164.1 without sidebag in left and right rear, code 293
Fig. 178: Identifying Rear Center Seat Belt Components - Shown On Model 164.1 Without Sidebag In
Left And Right Rear, Code 293
Fig. 179: Identifying Rear Center Seat Belt Components - Shown On Model 164.1
MODIFICATION NOTES
20.12.04 Screw at belt end fitting *BA91.40-P-1003-01H
Screw, rear automatic belt retractor to 2/3 seat bench *BA91.40-P-1006-01H
Remove/install
Risk of injury caused by release
AS91.00-Z-
of spring in the automatic belt Never disassemble automatic belt retractors.
0002-01A
retractor is released.
Pull up release handle (1) and Model 164.8: Grip strap in place of release
1
fold up seat cushion handle (1).
Unscrew bolt (3) from belt end Model 164.8: Bolt (3) on belt end fitting (4)
2
fitting (4) is found at the rear of the rear seat.
*BA91.40-P-
1003-01H
Detach electrical connector for On vehicles with left and right rear sidebag,
3.1
seat belt buckle code 293.
Model 164.1.
Remove rear seat belt buckle (5) Installation: Ensure correct installation
4.1
together with bracket position of belt end fitting (4), rear seat belt
buckle (5) and spring (6).
Remove rear-seat seat belt Model 164.8.

4.2 Installation: Ensure correct installation
buckle (5)
position of belt end fitting (4), rear seat belt
buckle (5) and spring (6).

Remove trim, 60 % rear seat AR91.12-P-
5
backrest (7) 1131GZA
Carefully unclip the belt opening
6 of the center seat belt and Long wedge Fig. 54
laterally feed out seat belt
Guide seat belt through the rear
7
backrest cover
8 Unclip cover (8) Push cover (8) up (arrow).
Unscrew bolt (9) at automatic *BA91.40-P-
9
belt retractor (10) 1006-01H
Installation: Pay attention to catch and
Remove automatic belt retractor correct installation position of the automatic belt
10
(10) retractor (10). Make sure seat belt is not twisted
when installed.
Check seat belt and rear seat belt
11
buckle (5) for damage
Check seat belts and seat belt
AP91.40-P-
buckles for external damage and
9150GZ
operation

BA91.40-P-1006-01H Bolt, automatic belt retractor at the rear of 2/3 seat bench Nm 35

REMOVE/INSTALL SEAT BELT (FRONT SEAT) - AR91.40-P-1010GZ
MODEL 164
Fig. 181: Identifying Seat Belt (Front Seat) Components (1 Of 2)

Fig. 182: Identifying Seat Belt (Front Seat) Components (2 Of 2)

Remove/install
Risk of injury caused by release of
AS91.00-Z-
spring in the automatic belt retractor Never disassemble automatic belt retractors.
0002-01A
is released.
greater than 100°C. When working on these 0001-01A
units, disconnect the power supply.
Notes on performing repair, body
AH91.00-P-
work and welding on vehicles with
0002-01M
airbags and ETR units
Legal regulations on handling and

AH91.00-P-
storing airbags and emergency
0004-01A
Move front seat all the way forward
1 and move seat backrest to upright
position.
Risk of explosion caused by
oxyhydrogen gas. Risk of poisoning No fire, sparks, open flames or smoking.
and caustic burns caused by Wear acid-resistant gloves, clothing and
AS54.10-Z-
swallowing battery acid. Risk of safety glasses. Only pour battery acid into
0001-01A
injury caused by burns to skin and suitable and appropriately marked
eyes from battery acid or when containers.
handling damaged lead-acid batteries
AR54.10-P-
0003GZ
Remove cover (7) from belt end Installation: Ensure that arresting lug
3
fitting (8) and unscrew bolt (9) (10) is seated correctly.
*BA91.40-
P-1003-01H
AR68.30-P-
4 Remove B-pillar trim (1)
4700GZ
Unscrew bolt (2) from upper belt *BA91.40-
5
guide fitting P-1009-01H
Unscrew bolt (3) at automatic belt *BA91.40-
6
retractor (4) P-1010-01H
Installation: Note different versions
(left, right) of emergency tensioning
retractor and its proper location in the catch.
Noises from the automatic belt reel when
rolling up belt are normal. In the event of
complaint annoying noises can only be
eliminated by replacing seat belt together
7 Remove automatic belt retractor (4) with emergency tensioning retractor.
On no account should oil or grease be
used to help eliminate noise. Inertia reels
that have been opened are no longer under
warranty. If the seat belt with emergency
tensioning retractor is replaced, the
defective one must be properly rendered
unusable and disposed of: ?
Render seat belt tensioning retractor AR91.40-P-
unusable 0611RT
Notes on disposing of airbag and OS91.00-P-
All models
emergency tensioning retractor units 0001-01A
Disconnect electrical connector (5)

from driver ETR squib (R12/1) or

8
passenger ETR squib (R12/2)
Read out/clear fault memory and test
*WH58.30-
11 restraint system using STAR STAR DIAGNOSIS diagnosis system
Z-1048-13A
DIAGNOSIS
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A

BA91.40-P-1009-01H Screw on front upper belt guide fitting Nm 35
BA91.40-P-1010-01H Screw on front automatic belt reel Nm 35

Number Designation
SEAT BELT HEIGHT ADJUSTMENT MECHANISM (FRONT SEAT) REMOVAL AND

INSTALLATION - AR91.40-P-1100GZ
MODEL 164
Fig. 183: Identifying Seat Belt Height Adjustment Mechanism (Front Seat) Components
Remove/install
Completely move front seat to

the foremost position and move
1
seat backrest to vertical
position.
Switch off ignition and remove Keyless Go start/stop button repeatedly until ignition
2 the transmitter key from the EIS is switched off. Remove transmitter key from vehicle
[EZS] control unit and store it in a location beyond its transmission range
(at least 2 m).
AR68.30-P-
3 Remove B-pillar paneling Only remove the top part of the B-pillar paneling 4700GZ
Unscrew bolt (1) from upper *BA91.40-P-
4
belt guide fitting 1009-01H
Release sliding block (3) and
slide toward center of belt
5 For this purpose, press release button (6) (arrow).
height adjuster until nut (4, 5) is
accessible
Unscrew nut (4, 5) and remove *BA91.40-P-
6
belt height adjuster (2) 1011-01H

BA91.40-P-1011-01H Nut for belt height adjuster to B-pillar Nm 24
REMOVE/INSTALL SEAT BELT BUCKLE (FRONT SEAT) - AR91.40-P-1515GZ
MODEL 164
Fig. 184: Identifying Seat Belt Buckle (Front Seat) Components

MODIFICATION NOTES
Disconnect/connect ground line for battery and carry out basic programming Steps 1 and
26.7.06
removed 10
Remove/install
Risk of injury caused by Store airbag units with deployment side
performing testing or repair work on facing up; do not expose to temperatures AS91.00-Z-
airbag or emergency tensioning greater than 100°C. When working on these 0001-01A
retractor units. units, disconnect the power supply.
work and welding on vehicles with AH91.00-P-
airbags and emergency tensioning 0002-01M
retractor units
AH91.00-P-
0004-01A
AR91.10-P-
1 Remove front seat
1000GZ
2 Remove bolt (2)
*BA91.40-P-
4 Unscrew bolt (4)
1002-01H
Disconnect electrical connector (5,
5 6) from seat belt buckle and seat belt
reminder warning switch
If the seat belt buckle (1) with squib is
6 Remove buckle (1) replaced, the squib must be properly
rendered unusable and disposed of:?
Render seat belt tensioning retractor AR91.40-P-
unusable 0611RT
Read out/clear fault memory and test
*WH58.30-Z-
8 restraint system using STAR STAR DIAGNOSIS diagnosis system
1048-13A
DIAGNOSIS

BA91.40-P-1002-01H Bolt, seat belt buckle to front seat Nm 35


Number Designation
REMOVE/INSTALL REAR SEAT BELT BUCKLE - AR91.40-P-1516
Remove/install rear seat belt buckle - AR91.40-P-1516GY
MODEL 164.8
40 % rear seat
Fig. 186: Identifying Rear Seat Belt Buckle Components - Shown With Removed Rear Seat Without Left
And Right Rear Sidebag, Code 293
Shown with removed rear seat without left and right rear sidebag, code 293
Remove/install
1 Release rear seat and fold forward

2 Unclip cover (1)

3 Unscrew bolt (2)
Fold rear seat all the way down, fully retract head
4 restraint, fold up seat cushion, fold rear seat backrest
forwards
5 Remove cover (3).
*BA91.40-P-
6 Unscrew bolt (4)
1007-01H
On vehicles with left and
7.1 Detach electrical connector for seat belt buckle
right rear sidebag, code 293.
Installation: Note
8 Remove rear-seat seat belt buckle (5) installation position of springs
(arrow).

BA91.40-P-1007-01H Bolt, belt buckle to rear seat Nm 35
Remove/install rear seat belt buckle - AR91.40-P-1516GYA
MODEL 164.8
60 % rear seat, center
Shown on vehicle without left and right rear sidebag, code 293
Fig. 187: Identifying Rear Seat Belt Buckle Components - Shown On Vehicle Without Left And Right
Rear Sidebag, Code 293

Remove/install
Release 40 % rear seat and

1 The 60 % rear seat must be accessible from the side.
set upright
2 Lift up cover (1) Swivel upwards and lock.
*WH58.30-Z-
3 Unscrew bolt (2) Power screwdriver/drill 1007-20A
4 Unclip cover (3)
Detach electrical connector On vehicles with left and right rear sidebag, code
5.1
for seat belt buckle 293.
Unscrew bolt (4) from rear *BA91.40-P-
6
seat belt buckle (5) 1007-01H
Installation: Check rear seat belt buckle (5) for
Remove rear seat-seat belt
7 signs of damage. Ensure correct installation position of
buckle (5)
springs (6).


Number Designation
Remove/install rear seat belt buckle - AR91.40-P-1516GYB
MODEL 164.8
3rd seat row
Fig. 188: Identifying Rear Seat Belt Buckle Components - 3rd Seat Row
Remove/install
1 Remove rear seat for 3rd seat row at left or right AR91.12-P-1000GYB
2 Remove screw (1) *BA91.40-P-1007-01H
3 Remove rear seat belt buckle (2)

Remove/install rear seat belt buckle - AR91.40-P-1516GZ
MODEL 164.1
40% rear seat
Fig. 189: Identifying Rear Seat Belt Buckle Components - 40% Rear Seat
MODIFICATION NOTES
Remove/install
Pull up release handle (1) and move

40% rear seat (2) to the vertical Installation: 40% rear seat (2) must latch into
1
position place.
2 Lift up cover (3) Swivel out of working area and secure.
Detach electrical connector (4) and
3
unclip from bracket (5)
Unscrew bolt (6) from rear seat belt *BA91.40-P-
4
buckle (7) 1007-01H
Installation: Check rear seat belt buckle (7)
5 Remove rear seat belt buckle (7) for signs of damage. Ensure that spring (8) has
correct installation position.

Remove/install rear seat belt buckle - AR91.40-P-1516GZA
MODEL 164.1
center seat 60% rear seat
Fig. 190: Identifying Rear Seat Belt Buckle Components - Center Seat 60% Rear Seat
MODIFICATION NOTES
20.12.04 Bolt, belt buckle to rear seat *BA91.40-P-1007-01H
Remove/install
Switch off ignition and On vehicles with Keyless Go, code 889: Press Keyless
Go start/stop button repeatedly until the ignition is switched
1 remove transmitter key
from EIS control unit off. Remove transmitter key from vehicle and store it in a
location beyond its transmission range (at least 2 m).
Pull release handle (1)
2 upwards and set 60% rear Installation: 60% rear seat (2) must latch into place.
seat (2) upright
Detach electrical connector
4 (4) and unclip from
bracket (5)
Unscrew bolt (6) from rear *BA91.40-P-
5
seat belt buckle (7) 1007-01H
Remove rear seat belt Installation: Check rear seat belt buckle for damage.
6
buckle (7) Ensure that spring (8) has correct installation position.

Remove/install rear seat belt buckle - AR91.40-P-1516GZB
MODEL 164
60 % rear seat, outside
Shown on model 164.1 with sidebag in left and right rear, code 293
Fig. 191: Identifying Rear Seat Belt Buckle Components - Shown On Model 164.1 With Sidebag In Left
And Right Rear, Code 293
MODIFICATION NOTES
20.12.04 Bolt, belt buckle to rear seat *BA91.40-P-1007-01H
Remove/install
On vehicles with Keyless Go, code 889: Press Keyless

Switch off ignition and Go start/stop button repeatedly until the ignition is
1 remove transmitter key switched off. Remove transmitter key from vehicle and
from EIS control unit store it in a location beyond its transmission range (at least
2 m).
Pull release handle (1) up
2 and fold up 60 % rear seat Model 164.8: Grip strap in place of release handle (1).
cushion (2)
Detach electrical
4.1 connector (4) and unclip On vehicles with left and right rear sidebag, code 293.
from bracket (5)
Remove bolt (6) from belt Model 164.8: Remove bolt (6) at the back of the seat
5
end fitting (7) frame.
*BA91.40-P-
1007-01H
Model 164.1.
6.1 Remove rear seat belt Installation: Check rear seat belt buckle (8) for signs of
buckle (8) together with damage. Ensure correct installation position of belt end
bracket fitting (7), rear seat belt buckle (8) and spring (9).
Model 164.8.
Remove rear seat-seat belt Installation: Check rear seat belt buckle (8) for signs of
6.2
buckle (8) damage. Ensure correct installation position of belt end
fitting (7), rear seat belt buckle (8) and spring (9).

REMOVE/INSTALL SEAT BELTS FOR THIRD ROW OF SEATS - AR91.40-P-2000RT
MODEL 164.8, 251
Fig. 192: Identifying Seat Belts For Third Row Of Seats Components - Illustrated On Model 251.1
MODIFICATION NOTES
Remove/install
Risk of injury caused by Store airbag units with deployment side facing up;
performing testing or repair do not expose to temperatures greater than 100°C. AS91.00-Z-
work on airbag or emergency When working on these units, disconnect the power 0001-01A
tensioning retractor units. supply.
Risk of injury caused by

release of spring in the AS91.00-Z-
Never disassemble automatic belt retractors.
automatic belt retractor is 0002-01A
released.
Notes on performing repair,
body work and welding on AH91.00-P-
vehicles with airbags and 0002-01M
ETR units
Assessment of airbag and
AH91.00-P-
belt tensioner units in
0006-01B
accident vehicles
Legal regulations on
handling and storing airbags AH91.00-P-
and emergency tensioning 0004-01A
retractors
Remove moldings from D- AR68.30-P-
1 Model 251.
pillar 4495RT
AR68.30-P-
Model 164.
4495GZ
Detach electrical connector
(1) from left 3rd row ETR
2 [GUS] squib (R12/35) or
right 3rd row ETR [GUS]
squib (R12/36)
3 Remove screw (3) Model 251.
*BA91.40-P-
Model 164. 1007-01N
*BA91.40-P-
1005-01H
4 Unscrew bolt (4) Model 251.
*BA91.40-P-
Model 164. 1005-01N
*BA91.40-P-
1004-01H
Installation: Note different version (left/right) of
emergency tensioning retractor and proper seating in
catches (5). Noises from the automatic belt reel
Remove automatic belt
5 when rolling up belt are normal. In the event of
retractor (2)
complaint annoying noises can only be eliminated
by replacing seat belt together with emergency
tensioning retractor.
On no account should oil or grease be used to
help eliminate noise. Inertia reels that have been
opened are no longer under warranty. If the seat belt
with emergency tensioning retractor is replaced, the
defective one must be properly rendered unusable

and disposed of:?
AR91.40-P-
Render seat belt tensioning retractor unusable
0611RT
Notes on disposing of airbag
OS91.00-P-
and emergency tensioning
0001-01A
retractor units
Faults stored due to simulations or cables being
Read out fault memory and disconnected for assembly or testing operations,
8
erase must be processed and erased from the fault
memories after work is completed.
Connect STAR DIAGNOSIS AD00.00-P-
and read out fault memory 2000-04A
*WH58.30-
STAR DIAGNOSIS diagnosis system
Z-1048-13A

Number Designation Model 251
BA91.40-P-1005-01N Bolt to rear seat belt guide bracket Nm 35
BA91.40-P-1007-01N Screw of rear seat automatic belt retractor to C-pillar/D-pillar Nm 35

BA91.40-P-1004-01H Screw in rear seat belt guide bracket Nm 35
BA91.40-P-1005-01H Bolt to rear inertia reel Nm 35

Number Designation
MAKE AIRBAG UNITS UNUSABLE - AR91.60-P-0611GZ
MODEL 164
Not valid for
Fig. Work instructions

item,
etc.
Risk of injury. Injuries may result Store airbag units with deployment side
when performing testing or repair facing up; do not expose to temperatures AS91.00-Z-
work on airbag or emergency greater than 100°C. When working on these 0001-01A
tensioning retractor units. units, disconnect the power supply.
AH91.60-P-
0611-02P
AR91.60-P-
Deployment of removed airbag units
0611-02GZ
AR91.60-P-
Operating the deployment device
0611-04GZ
Deployment of airbag units when no AR91.60-P-
deployment device is present 0611-05GZ
All models
Deployment of removed airbag units - AR91.60-P-0611-02GZ

Risk of injury. Injuries may result when side facing up; do not expose to
AS91.00-Z-
performing testing or repair work on airbag temperatures greater than 100°C.
0001-01A
or emergency tensioning retractor units. When working on these units,
Notes on controlled deployment of airbag, Models 163, 164, 168, 170, 199, 202,
AH91.60-P-
sidebag and emergency tensioning retractor 203, 208, 209, 210, 215, 220, 230,
0611-02P
units 240, 414, 461, 463
All models
Fig. 193: Identifying Pressure Switch, Battery Control And Deployment, Rotary Switch And 2-Pin Plug
Connector
Using the deployment device
1. Plug the 2-pin plug (8) into the unit to be scrapped.

2. Dial the rotary switch (4) to position "1".
3. Press the battery control pressure switch (2) and deployment pressure switch (3) simultaneously.
4. For airbag units with 2 squibs, both must be triggered. To do this, repeat steps 1 through 3 after plugging
the ignition cable into the second squib.
Keep to a safety distance of 10 meters, to avoid being injured.
After a successful deployment, the deployment indicator lamp (5) flashes.
Operating the deployment device - AR91.60-P-0611-04GZ

Risk of injury. Injuries may result when side facing up; do not expose to
AS91.00-Z-
performing testing or repair work on airbag temperatures greater than 100°C.
0001-01A
or emergency tensioning retractor units. When working on these units,
Notes on controlled deployment of airbag, Models 163, 164, 168, 170, 199, 202,
AH91.60-P-
sidebag and emergency tensioning retractor 203, 208, 209, 210, 215, 220, 230,
0611-02P
units 240, 414, 461, 463
All models
For testing Cable Test of Press: Keys Specified Possible causes

arrangement, turn set value: LED for deviation
rotary switch of plug, from specified
deployment device to no. value
position
If necessary,
1 Internal battery test Press ON replace battery
set for igniter:
Deployment Green
2 Baby cells (1.5
device not Indicator ON
V each)
connected lamp
Actuation of driver Press both 1. Before Trigger circuit is
1 10+11
side squib pushbuttons actuation defective
ON
Deployment of
emergency Press both Deployment Trigger circuit is
2 1+2
tensioning retractor pushbuttons makes a bang defective
squib, left seat
Deployment of
emergency
3+4
tensioning retractor
squib, right seat
Ignition Front Press both 2. After Trigger circuit is
3 13+14
passenger squib pushbuttons deployment defective
ON
Green
Indicator ON
lamp
Operating the deployment device - AR91.60-P-0611-04RT
AH91.60-P-
0611-02P
OS91.00-P-
0001-01A
units
For testing Cable set Test of Press: keys Specified value: LED Possible
arrangement, plug, no. causes for
turn rotary deviation
switch of from
deployment specified
device to value
position
1 Internal Press ON Replace any
battery test battery set for
ignition
device:
Deployment Green ON 2 baby cells
device not Indicator lamp (each 1.5 V)
connected
1 10+11 Actuation of Press both 1. Before actuation Triggering
driver side pushbuttons circuit is
squib defective
ON
2 1+2 Ignition of Press both Deployment makes a bang Triggering
emergency pushbuttons circuit is
tensioning defective
retractor
squib, left seat
3+4 Ignition of
emergency
tensioning
retractor
squib, right
seat
3 13+14 Ignition Front Press both 2. After deployment Triggering

passenger pushbuttons circuit is
squib defective
ON
Green ON
Indicator lamp
Deployment of airbag units when no deployment device is present - AR91.60-P-0611-05GZ
Risk of injury. Injuries may

result when performing testing
or repair work on airbag or
100°C. When working on these units, disconnect 0001-01A
the power supply.
units.
Notes on controlled deployment
of airbag, sidebag and Models 163, 164, 168, 170, 199, 202, 203, 208, AH91.60-P-
emergency tensioning retractor 209, 210, 215, 220, 230, 240, 414, 461, 463 0611-02P
units
Models 164, 168, 170, 199, 202, 203, 208, 210,
Ignition cable for firing airbag 220, 230, 414, 463, 901, 902, 903, 904, 905,
WF58.50-
and emergency tensioning WD1, WD2, WD3, WD6, WD7, XD1, XD2,
P-9160-02A
retractor units XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3,
YD4, YD5, YD6, YD7
OS91.00-P-
0001-01A
units
Application of ignition cable to be shop made
1. Make the ignition cables at a length of at least 10 m with a pressure switch.

2. Plug the 2-pin plug into the corresponding airbag unit.
3. Connect ignition cables to the battery.
4. Press both pressure switches simultaneously.
5. For airbag units with 2 squibs, both must be triggered. To do this, repeat steps 2 through 4 after plugging
the ignition cable into the second squib.
Keep to a safety distance of 10 meters to avoid being injured.
REMOVE/INSTALL AIRBAG CONTROL UNIT - AR91.60-P-0615GZ
MODEL 164
Fig. 194: Identifying Airbag Control Unit Components

Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic All models
0001-01A
discharge
AR54.10-P-
0003GZ
AR68.20-P-
2 Remove front beverage holder (1).
2240GZ
3 Lift rubber cover (2) Swivel out of working area.
*BA91.60-P-
4 Unscrew nuts (3).
1002-01H
Installation: Make sure that the
ground line on the restraint systems
5 Lift restraint systems control unit (N2/7) control unit (N2/7) (under right
front corner) is properly fastened in
place.
AR00.19-P-
8 Perform basic programming
0200GZ
Check restraint system using STAR
9
DIAGNOSIS

system Z-1048-13A
AIRBAG
BA91.60-P-1002-01H Nut, control unit to vehicle floor Nm 10

Number Designation
REMOVE/INSTALL AIRBAG UNIT ON THE STEERING WHEEL - AR91.60-P-0660GZ
MODEL 164
Fig. 195: Identifying Airbag Unit On The Steering Wheel Components

Remove/install
AS91.00-Z-
0001-01A

AH91.00-P-
0002-01M
units
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Disconnect jump-start sources or battery
1.1 If connected.
charger
Move steering wheel (1) to straight-ahead AR54.10-P-
2
position, disconnect battery ground line 0003GZ
Insert screwdriver bit into openings (arrows)
*BA91.60-P-
3 at back of steering wheel (1) and remove
1003-01H
screws from driver airbag unit (2)
Screwdriver bit Fig. 196
Installation: The electrical
Lift driver airbag unit (2) from steering wheel
4 connector (3, 4) must audibly latch
(1) and disconnect electrical connector (3, 4)
into place when being plugged in.
If the driver airbag unit (2) is
Remove driver airbag unit (2) from steering
5 replaced, the defective unit must be
wheel (1)
disposed of properly. ?
All models
7
DIAGNOSIS diagnostic system
system Z-1048-13A
AIRBAG
BA91.60-P-1003-01H Bolt, airbag to steering wheel Nm 8
Fig. 196: Identifying Screwdriver Bit (126 589 00 10 00)


Number Designation
REMOVE/INSTALL PASSENGER AIRBAG UNIT - AR91.60-P-0680GZ
MODEL 164
Fig. 197: Identifying Passenger Airbag Unit Components - Shown On Model 164.1 (1 Of 2)
Shown on model 164.1 with Parktronic system (PTS), code 220

Fig. 198: Identifying Passenger Airbag Unit Components - Shown On Model 164.1 (2 Of 2)
Remove/install
Risk of injury caused by performing facing up; do not expose to
AS91.00-Z-
testing or repair work on airbag or temperatures greater than 100°C. When
0001-01A
emergency tensioning retractor units. working on these units, disconnect the
power supply.
Notes on performing repair, body work
AH91.00-P-
and welding on vehicles with airbags and
0002-01M
ETR units
AH54.00-P-
0001-01A
discharge
Assessment of airbag and belt tensioner AH91.00-P-
units in accident vehicles 0006-01B
Legal regulations on handling and storing
AH91.00-P-
airbags and emergency tensioning
0004-01A
retractors
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. Risk AS54.10-Z-
clothing and safety glasses. Only pour
of injury caused by burns to skin and 0001-01A
battery acid into suitable and
eyes from battery acid or when handling
appropriately marked containers.
damaged lead-acid batteries
AR54.10-P-
0003GZ
AR68.10-P-
2 Remove instrument panel top section (1)
1020GZ
Installation: The electrical
Detach electrical connector (5, 6) from
front passenger airbag squib 1 (R12/4) connector (5, 6) must be correctly
3 plugged in and the clamping element
and front passenger airbag squib 2
(R12/5) must slide all the way into the
connector housing.
Handle the front passenger airbag
unit (2) carefully to ensure that the
printed paper covering of the front
passenger airbag unit (2) is not
Unscrew nuts (4) and remove the front damaged.
4 passenger airbag unit (2) from the upper Installation: The wiring harness for
section of the instrument panel (1) the front passenger airbag unit (3) must
be routed correctly. It must not be
jammed in nor routed between the front
passenger airbag unit (2) and the upper
section of the instrument panel (1)!
*BA91.60-P-
1009-01H
If the front passenger airbag unit (2)
is replaced, the defective unit must be
disposed of properly:?
All models
AR00.19-P-
0200GZ
7
DIAGNOSIS
*WH58.30-
Z-1048-13A
AIRBAG
BA91.60-P-1009-01H Nut, front passenger airbag unit to instrument panel Nm 8

Number Designation
REMOVING, INSTALLING WINDOWBAG - AR91.60-P-0693GZ

MODEL 164
Fig. 199: Identifying Check Strap, Windowbag Unit, Gas Generator And Left/Right Windowbag Squib -
Shown On Model 164.1
Shown on vehicle with power glass tilting/sliding roof, code 414
Fig. 200: Identifying Electrical Connector And Left/Right Windowbag Squib - Shown On Vehicle With
Power Glass Tilting/Sliding Roof, Code 414
Fig. 201: Identifying Check Strap, Bolts, Nuts, Lug, Clamps And Windowcab Unit - Shown On Vehicle
With Power Glass Tilting/Sliding Roof, Code 414
Shown on vehicle with power glass tilting/sliding roof, code 414
Remove/install
Risk of injury caused by performing testing or side facing up; do not expose to
AS91.00-Z-
repair work on airbag or emergency tensioning temperatures greater than 100°C.
0001-01A
retractor units. When working on these units,
AH91.00-P-
0002-01M
units
All models
Legal requirements on handling and storing
AH91.00-P-
airbags and emergency tensioning retractor
0004-01A
units
Push front seat all the way back and fully

1
extend the head restraints on the front seats
Pull steering column all way out and move all
2
way down
Risk of explosion caused by oxyhydrogen gas.
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant
by swallowing battery acid. Risk of injury AS54.10-Z-
gloves, clothing and glasses. Only
caused by burns to skin and eyes from battery 0001-01A
pour battery acid into suitable and
acid or when handling damaged lead-acid
batteries
AR54.10-P-
3 Disconnect battery ground line
0003GZ
AR68.30-P-
4 Remove headliner
4300GZ
AR68.10-P-
5 Remove upper instrument panel section
1020GZ
Detach electrical connector (4) from left
Pull up clamping element and
6 windowbag squib (R12/16) or the right
windowbag squib (R12/17) detach electrical connector (4).
Installation: The clamping
element of the electrical connector
(4) must latch audibly into place
when pressed in.
Installation: Insert tab (5) of
Unscrew bolt (7) and remove check strap clip check strap clip (6) into cutout on *BA91.60-
7
(6) from D-pillar D-pillar. P-1005-01H
Only if windowbag unit (2) to

be used again.
8.1 Remove check strap (1) from clip (arrow A)
Installation: Do not twist
check strap (1) when installing!
Only when replacing the
windowbag unit (2).
8.2 Remove clip (arrow A) from roof frame Installation: Do not twist clip
and check strap (1) when
installing!
9 Unscrew four bolts (9) of windowbag unit (2) Model 164.8: Six bolts (9).
*BA91.60-
P-1006-01H
10 Remove bracket for grab handle on roof Only model 164.8.
*BA91.60-
11 Unscrew nut (10)
P-1008-01H
12 Remove right air duct on instrument panel Only when removing

windowbag unit (2) on right side
of vehicle.
*BA91.60-
13 Unscrew nuts (11)
P-1007-01H
Insert assembly wedge between
Undo clamps (8) of windowbag unit (2) using inner roof frame and windowbag
14 the mounting wedge carefully from inside roof unit (2) and detach clamps (8). The
frame clamps (8) remain on the
windowbag unit (2)!
Mounting wedge Fig. 63
Do not damage components in
instrument panel of vehicle interior
or the seat covers. Use suitable
15 Remove windowbag unit (2) carefully covers for protection.
If the windowbag unit (2) is
replaced, the defective unit must
be disposed of properly:
All models
Check restraint system using STAR STAR DIAGNOSIS diagnosis
17
DIAGNOSIS diagnostic system system
memory 2000-04A
AR00.19-P-
0200GZ
AIRBAG
BA91.60-P-1005-01H Bolt of bracket for windowbag check strap to body Nm 8
BA91.60-P-1006-01H Bolt, windowbag to body Nm 8
BA91.60-P-1007-01H Nut, windowbag to A-pillar at bottom Nm 8
BA91.60-P-1008-01H Nut, gas generator for windowbag to upper A-pillar Nm 8

REMOVE/INSTALL FRONT SEAT SIDEBAG UNIT - AR91.60-P-0695GZ
MODEL 164
Fig. 203: Identifying Front Seat Sidebag Unit Components - Shown On Removed Front Seat
Remove/install
AS91.00-Z-
0001-01A
injury caused by burns to skin and eyes from Pour battery acid only into suitable 0001-01A
AH91.00-P-
0002-01M
units

1 Move rear seat all the way forward
2 Move rear seat backrest to vertical position
AR54.10-P-
0003GZ
Remove backrest shell from front seat AR91.10-P-
4
backrest 1915GZ
5 Pull out spreading rivet (1)
6 Pull out check strap (2) downward
7 Detach backrest upholstery (3)
Disconnect electrical connector (4) from the
8 driver sidebag squib (R12/9) or from the front
passenger sidebag squib (R12/10)
Installation: Use new rivets
(5).
9 Drill out rivets (5) Installation: Ground line (6)
must be riveted between rivets (5)
and bracket.
Remove drill shavings with
vacuum cleaner.
*WE58.40-
Wet/dry vacuum cleaner
Z-1005-03A
Installation: Ensure correct
Detach driver sidebag squib (R12/9) or front
10 seating of the guides (7) to ensure
passenger sidebag squib (R12/10) downward
function of sidebag squibs.
Pull driver sidebag squib (R12/9) or front
11
passenger sidebag squib (R12/10) toward you
When replacing the driver
Take driver sidebag squib (R12/9) or front
12 passenger sidebag squib (R12/10) out of check sidebag squib (R12/9) or the front
passenger sidebag squib
strap
(R12/10):?
All models
WORKSHOP EQUIPMENT
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
REMOVE/INSTALL REAR SEAT SIDEBAG UNIT - AR91.60-P-0696GZ
MODEL 164 with CODE (293) Left and right rear sidebag
Fig. 204: Identifying Rear Seat Sidebag Unit Components - Shown On Model 164.1
Fig. 205: Identifying Rear Seat Sidebag Unit Components - Shown On Model 164.1
Remove/install
Risk of injury caused by performing testing or side facing up; do not expose to AS91.00-
repair work on airbag or emergency tensioning temperatures greater than 100°C. Z-0001-
retractor units. When working on these units, 01A
Risk of explosion caused by oxyhydrogen gas. No fire, sparks, open flames or

Risk of poisoning and caustic burns caused smoking. Wear acid-resistant
AS54.10-
by swallowing battery acid. Risk of injury gloves, clothing and safety glasses.
Z-0001-
caused by burns to skin and eyes from battery Only pour battery acid into suitable
01A
acid or when handling damaged lead-acid and appropriately marked
batteries containers.
Notes on performing repair, body work and AH91.00-
welding on vehicles with airbags and ETR P-0002-
units 01M
AH91.00-
Assessment of airbag and ETR units in
P-0006-
accident vehicles
01B
AH91.00-
Legal regulations on handling and storing
P-0004-
airbags and emergency tensioning retractors
01A
1 Fold back rear seat backrest
AR54.10-
P-0003GZ
3 Unclip cover (1) (arrow A) Only on model 164.1.
Detach rear seat backrest cover (2) from
backrest frame (arrows B)
Separate electrical connector (3) from left 2nd
5 row sidebag squib (R12/11) or from right 2nd
row sidebag squib (R12/12)
6 Drill out rivets (4) Installation: Use new rivets (4).
Installation: Ensure that the
Pull rear seat sidebag unit (5) downwards guides (6) are correctly seated, as
7 otherwise correct functioning of the
(arrow C)
rear seat sidebag unit (5) is not
guaranteed!
8 Pull out rear seat sidebag unit (5) (arrow D)
When replacing the rear seat
sidebag unit (5): Observe
Remove rear seat sidebag unit (5) upwards
9 information on disposal of airbag
(arrow E) out of the check strap
and emergency tensioning retractor
units.
OS91.00-
Notes on disposing of airbag and emergency
P-0001-
01A


REMOVE/INSTALL SENSOR FOR SIDEBAG/WINDOWBAG - AR91.60-P-0730GZ
MODEL 164
MODIFICATION NOTES
Remove/install
Notes on avoiding damage to

AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
Remove front and rear door sill AR68.30-P-
1 Left or right side.
moldings 4100GZ
AR68.30-P-
2 Remove paneling on B-pillar Bottom left or right. 4700GZ
Disconnect electrical connector
3
(1)
Push floor covering to one side *BA91.60-P-
4
and unscrew bolt (2) 1004-01H
Remove left sidebag and Installation: Insert the pin from the left sidebag
windowbag sensor (A53/1) or and windowbag sensor (A53/1) or the right sidebag
5
right sidebag and windowbag and windowbag sensor (A54/1) for positioning into
sensor (A54/1) the bore of the inner longitudinal member (arrow).
AIRBAG
Number Designation Model
164.1/8
BA91.60-P-1004- Bolt, sidebag and windowbag sensor to inner longitudinal
Nm 8
01H member

REMOVE/INSTALL FRONTAL ACCELERATION SENSOR - AR91.60-P-0750GZ

MODEL 164
Fig. 210: Identifying Frontal Acceleration Sensor Components

MODIFICATION NOTES
Remove/install
Risk of death caused by high
voltage levels present at xenon
headlamps.
Risk of explosion/fire due to Do not come into contact with parts that are under
highly flammable materials in high voltage. Persons with active electronic
the area of damaged xenon implants (e.g. heart pacemakers) must never work
bulbs on xenon headlamps. Switch off entire lighting
AS82.10-Z-
Risk of injury caused by UV system. Wear insulating safety shoes, safety glasses,
0001-01A
light, hot components on xenon and protective gloves. Remove highly inflammable
headlamps and glass splinters materials from the hazard area. Ensure that the
when xenon bulbs are bursting working area is sufficiently vapors and when
Risk of poisoning due to swallowing/coming in ventilated.
inhaling mercury contact with
toxic salts and mercury
compounds
Notes on avoiding damage to AH54.00-
electronic components due to P-0001-
electrostatic discharge 01A
AR82.10-
1 Remove lamp unit
P-4730GZ
2
(1)
*BA91.60-
P-1001-
3 Remove bolt (2)
01H
Installation: The white plastic plate on the
Remove driver-side frontal
acceleration sensor (B48/1) or driver-side frontal acceleration sensor (B48/1) must
4 point up.
passenger-side frontal
acceleration sensor (B48/2) The white plastic plate on the passenger-side frontal
acceleration sensor (B48/2) must point down.
AIRBAG
BA91.60-P-1001-01H Bolt, frontal acceleration sensor to front module support Nm 8
REMOVE/INSTALL SIDE DEPLOYMENT PRESSURE SENSOR - AR91.60-P-0760GZ
MODEL 164, 251
Fig. 211: Identifying Side Deployment Pressure Sensor Components - Shown On Model 251.1
MODIFICATION NOTES
Remove/install
For work on the driver door
pressure sensor (B48/7), or
front passenger door pressure
1.1 Remove door lining from left or right front door
sensor (B48/8).
Replace damaged door
module seal with butyl cord.
AR72.10-P-
Model 164
1000GZ
AR72.10-P-
Model 251
1000RT
*BR00.45-Z-
Sealing cord
1021-01A
For work on the rear door
pressure sensor, driver-side
(B48/9), or rear door pressure
sensor, passenger-side
1.2 Remove door lining from left or right rear door (B48/10).
Vehicles with code 293,
sidebags in rear
Replace damaged door module
seal with butyl cord.
AR72.12-P-
Model 164
1010GZ
AR72.12-P-
Model 251
1010RT
*BR00.45-Z-
Sealing cord
1021-01A
Disconnect electrical connector (2) from driver
door pressure sensor (B48/7), front passenger
2 door pressure sensor (B48/8), rear door pressure
sensor, driver-side (B48/9), or rear door pressure
sensor, passenger-side (B48/10)
Installation: Use new rivets
3 Drill out rivets (1) with a dia. 4.8 mm drill bit (1). Polygrip aluminum/steel
hollow rivet dia. 4.8 x 15 mm.
Handymaster cordless *WH58.30-
drill/driver Z-1007-20A
*WE58.40-
PowerBird blind rivet tool Z-1003-14A
Remove driver door pressure sensor (B48/7), or
4
front passenger door pressure sensor (B48/8)
Remove rear door pressure sensor, driver-side
(B48/9), or rear door pressure sensor, passenger- Vehicles with code 293,
5
side (B48/10) sidebags in rear
For work on the driver door
pressure sensor (B48/7), or
front passenger door pressure
6.1 Remove front door loudspeakers
sensor (B48/8).
In order to remove the rest of
the rivets.
AR82.62-P-
Model 251
7845RT
AR82.62-P-
Model 164 7845GZ
For work on the rear door
pressure sensor, driver-side
(B48/9), or rear door pressure
sensor, passenger-side
6.2 Remove speakers in rear doors (B48/10).
sidebags in rear
In order to remove the rest of
the rivets.
AR82.62-P-
Model 251
7874RT
AR82.62-P-
Model 164 7874GZ
Check the restraint system with STAR
8
DIAGNOSIS
memory 2000-04A
system Z-1048-13A

Number Designation
WORKSHOP EQUIPMENT
REPAIR MATERIALS
BR00.45-Z-1021-01A Sealing cord A 001 987 73 46
REMOVE/INSTALL WSS CONTROL UNIT - AR91.60-P-0800GZ
Only vehicles with WSS (weight sensing system)
Fig. 212: Identifying WSS Control Unit Components (1 Of 2)

Fig. 213: Identifying WSS Control Unit Components (2 Of 2)

MODIFICATION NOTES
26.7.06
removed 8
Remove/install
Store airbag units with
deployment side facing up; do not
Risk of injury caused by performing testing or
expose to temperatures greater AS91.00-Z-
repair work on airbag or emergency tensioning
than 100°C. When working on 0001-01A
retractor units.
these units, disconnect the power
supply.
AR91.10-P-
1 Remove front seat (1) on passenger side
1000GZ
2 Unscrew bolt (2)
Do not damage electrical
Disconnect all electrical connectors from WSS
connectors and cable!
3 control unit (weight sensing system) (N2/13)
(arrow A) Installation: Ensure that cable
is routed correctly!
Remove WSS control unit (weight sensing
4
system) (N2/13)
Calibrate left front WSS sensor (weight
sensing system), right front WSS sensor
(weight sensing system), left rear WSS sensor
6 Plates Fig. 55
(weight sensing system) and right rear WSS
sensor (weight sensing system) with STAR
diagnosis system
system Z-1048-13A


Number Designation
REMOVE/INSTALL WSS SENSOR - AR91.60-P-0810
Remove/install WSS sensor - AR91.60-P-0810GZ
Only front seat on passenger side, left front WSS sensor and right front WSS sensor
Fig. 215: Identifying Front Seat, Pin, Nut, Bolts And Left/Right Front WSS Sensor - Shown On Right
Front WSS Sensor (B48/12)
Shown on right front WSS sensor (weight sensing system) (B48/12)

Fig. 216: Identifying Front Seat, Nut, Bolts And Left/Right Front WSS Sensor - Shown On Right Front
WSS Sensor (B48/12)
Shown on right front WSS sensor (weight sensing system) (B48/12)
MODIFICATION NOTES
26.7.06
removed 12
Remove/install
Notes on avoiding damage to electronic
AH54.00-P-
components due to electrostatic
0001-01A
discharge
AR91.10-P-
1000GZ
2 Loosen connector block bracket (6) Unscrew two bolts (arrow A) and place
the connector block bracket (6) outside of
the working area.

Unclip electrical connector from right
front WSS sensor (weight sensing Do not damage electrical connector on
3
system) (B48/12) from circlips (arrows right front WSS sensor (weight sensing
B) system) (B48/12).
4 from WSS control unit (weight sensing
system) (N2/13) (arrow C)
Install bolt (2) only with associated left
front WSS sensor (weight sensing system)
(B48/11) or right front WSS sensor
5 Unscrew nut (3) and remove bolts (2) (weight sensing system) (B48/12).
Installation: Lightly grease bolt (2)
before installing and hold when tightening
nut (3).
*BA91.60-
P-1011-01H
*BA91.60-
6 Remove bolts (4)
P-1012-01H
Never loosen or remove bracket from
left front WSS sensor (weight sensing
Remove left front WSS sensor (weight system) (B48/11) or bracket from right
sensing system) (B48/11) or right front front WSS sensor (weight sensing system)
7 WSS sensor (weight sensing system) (B48/12)! This would render the left front
(B48/12) together with installed bracket WSS sensor (weight sensing system)
(7) (B48/11) or right front WSS sensor
(weight sensing system) (B48/12)
unusable.
If required, remove retaining ring (8)
and drive out plastic bearing with suitable
Check plastic bearing (9) for wear and tool.
8
replace if necessary Installation: Install new plastic
bearing by hand and fasten with circlip
(8).
sensing system) (B48/11), right front
WSS sensor (weight sensing system)
10 (B48/12), left rear WSS sensor (weight Plates Fig. 55
sensing system) (B48/13) and right rear
(B48/14) with STAR diagnosis system.
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
STAR DIAGNOSIS diagnosis system *WH58.30-
Z-1048-13A
AIRBAG
BA91.60-P-1011-01H Nut for bolts on WSS sensor (Weight Sensing System) Nm 5
BA91.60-P-1012-01H Bolt, front WSS sensor (weight sensing system) at seat rail Nm 8


Number Designation
Remove/install WSS sensor - AR91.60-P-0810GZA
Only front seat on passenger side, left rear WSS sensor and right rear WSS sensor
Fig. 218: Identifying Front Seat, Bolts, Electrical Connector And Left/Right Front WSS Sensor - Shown
On Right Rear WSS Sensor (B48/14)
Shown on right rear WSS sensor (weight sensing system) (B48/14)

Fig. 219: Identifying Front Seat, Bolts, WSS Control Unit And Left/Right Front WSS Sensor - Shown On
Right Rear WSS Sensor (B48/14)
Shown on right rear WSS sensor (weight sensing system) (B48/14)
MODIFICATION NOTES
26.7.06
removed 11
Remove/install
AH54.00-P-
0001-01A
discharge
AR91.10-P-
1000GZ
Unclip electrical line from right rear Do not damage electrical line on right
2 WSS sensor (weight sensing system) rear WSS sensor (weight sensing system)
(B48/14) from circlips (arrow A and (B48/14).
arrow B)
3 WSS control unit (weight sensing
system) (N2/13) (arrow C)
Install bolt (2) only with associated
left rear WSS sensor (weight sensing
system) (B48/13) or right rear WSS
4 Unscrew nut (3) and remove bolts (2) sensor (weight sensing system) (B48/14).
Installation: Lightly grease bolt (2)
before installing and hold when
tightening nut (3).
*BA91.60-
P-1011-01H
*BA91.60-
5 Remove screws (5)
P-1013-01H
Never loosen or remove mount from
left rear WSS sensor (weight sensing
Remove left rear WSS sensor (weight
sensing system) (B48/13) or right rear system) (B48/13) or right rear WSS
sensor (weight sensing system) (B48/14)!
6 WSS sensor (weight sensing system)
(B48/14) together with installed bracket This would render the left rear WSS
(6) sensor (weight sensing system) (B48/13)
or right rear WSS sensor (weight sensing
system) (B48/14) unusable
If required, remove retaining ring (8)
and drive out plastic bearing with suitable
Check plastic bearing (7) for wear and
7 tool.
replace if necessary
Installation: Install new plastic
bearing by hand and fasten with circlip.
sensing system) (B48/11), right front
9 (B48/12), left rear WSS sensor (weight Plates Fig. 55
sensing system) (B48/13) and right rear
(B48/14) with STAR diagnosis system.
*WH58.30-
Z-1048-13A
AIRBAG
BA91.60-P-1011-01H Nut for bolts on WSS sensor (Weight Sensing System) Nm 5
BA91.60-P-1013-01H Bolt, rear WSS sensor (weight sensing system) at seat rail Nm 20


Number Designation
REMOVE/INSTALL DUST EXCLUDER AT WSS SENSOR - AR91.60-P-0820GZ
Passenger-side only
Fig. 221: Identifying Dust Excluder At WSS Sensor Components

MODIFICATION NOTES
26.7.06 removed 7
Remove/install
Remove front passenger seat and set down on a
AR91.10-P-
1 suitable support surface leaning forward on the
1000GZ
seat backrest
Unclip dust cap (1) from the retaining tab (2)
using a suitable screwdriver (3) at the
2
corresponding WSS (Weight Sensing System)
sensor and remove dust cap (1)
The gap (arrow) on the WSS
Check gap (arrow) on corresponding WSS (Weight Sensing System)
(Weight Sensing System) sensor for sensor must not have any
3
contamination, if necessary clean gap (arrow) contamination otherwise the
with a lint free cloth function is not longer
guaranteed.
Calibrate left front WSS sensor (weight sensing
system) (B48/11), right front WSS sensor (weight
sensing system) (B48/12), left rear WSS sensor
5 Plates Fig. 55
(weight sensing system) (B48/13) and right rear
WSS sensor (weight sensing system) (B48/14)
with STAR diagnosis system.
memory 2000-04A
system Z-1048-13A


Number Designation
MAINTENANCE
CHECK SEAT BELTS AND SEAT BELT BUCKLES FOR EXTERNAL DAMAGE AND OPERATION
- AP91.40-P-9150GZ
MODEL 164
Fig. 223: Checking Seat Belts And Seat Belt Buckles For External Damage And Operation
Checking
If any fibers are cut through or if there are any chafing
Pull seat belt all the way marks or any other signs of damage, replace affected seat
1 out and check for belt with new seat belt as a separate order. If a customer
damage refuses replacement of a damaged seat belt, an appropriate
endorsement must be made on the repair order.
Replace seat belt with
2.1 emergency tensioning If the seat belt is damaged.
retractor at front seat
Remove/install seat belt AR91.40-P-
(front seat) 1010GZ
3.1 Replace seat belt in rear If the seat belt is damaged.
Remove/install rear seat AR91.40-P-
belts 0681GZ
Replace middle seat belt
4.1 If the seat belt is damaged.
in rear
Remove, replace and
AR91.40-P-
install rear center seat
0683GZ
belt
Check seat belt for
5
twisting
Correct the installation
6.1 If seat belt is twisted 180° behind trim.
position of the seat belt
(front seat) 1010GZ

belts 0681GZ
Remove, replace and
AR91.40-P-
0683GZ
belt
Inspect lock function of
7 inertia reel by pulling
sharply on belt webbing
Replace seat belt with
8.1 emergency tensioning If lock function of inertia reel is defective.
retractor at front seat
(front seat) 1010GZ
9.1 Replace seat belt in rear If lock function of inertia reel is defective.
belts 0681GZ
Replace middle seat belt
10.1 If lock function of inertia reel is defective.
in rear
Remove, replace and
AR91.40-P-
0683GZ
belt
Check catch mechanism
11 Install new seat belt buckle if necessary.
of seat belt buckles
buckle (front seat) 1515GZ
Remove/install rear seat
Model 164.1, see: ?
belt buckle
AR91.40-P-
40 % rear seat
1516GZ
AR91.40-P-
Center seat 60% rear seat
1516GZA
60% outer rear seat AR91.40-P-
Model 164.8, see:? 1516GZB
AR91.40-P-
40 % rear seat
1516GY
AR91.40-P-
Center seat 60% rear seat
1516GYA
AR91.40-P-
60% outer rear seat
1516GZB
TIGHTENING TORQUES: PASSENGER CARS: SEATS, BUNKS, RESTRAINT SYSTEMS -
BA91.00-Z-9999AZ
MODEL all
Front seats MODEL 168, 170, 171, BA91.10-P-1000-01A

202, 203, 208, 209, 210,
211, 230, 240, 414.700
Front seats MODEL 163 BA91.10-P-1000-01B
Front seats MODEL 215 BA91.10-P-1000-01C
Front seats MODEL 140 BA91.10-P-1000-01D
Front seats MODEL 220 BA91.10-P-1000-01H
Front seats MODEL 199.376 BA91.10-P-1000-01I
Front seats MODEL 169.0 /3, 245.2 BA91.10-P-1000-01K
Front seats MODEL 164.1 /8 BA91.10-P-1000-01L
Front seats MODEL 219 BA91.10-P-1000-01M
Front seats MODEL 251 BA91.10-P-1000-01N
Front seats MODEL 216, 221 BA91.10-P-1000-01O
Front seats MODEL 204 BA91.10-P-1000-01Q
Rear seat backrest lock MODEL 202, 203, 209 BA91.12-P-1000-01A
Rear seat backrest lock MODEL 169.0 /3, 245.2 BA91.12-P-1000-01B
Rear seat backrest MODEL 202, 211 BA91.12-P-1000-02A
Rear seat backrest MODEL 168 BA91.12-P-1000-02B
Rear seat backrest MODEL 215, 220, 240 BA91.12-P-1000-02C
Rear seat backrest MODEL 164.1 /8 BA91.12-P-1000-02D
Rear seats MODEL 163, 168 BA91.12-P-1000-03A
Rear seats MODEL 220 BA91.12-P-1000-03B
Rear seats MODEL 203, 209 BA91.12-P-1000-03C
Rear seats MODEL 203 BA91.12-P-1000-03D
Rear seats MODEL 169.0 /3, 245.2 BA91.12-P-1000-03E
Rear seats MODEL 164.1 /8 BA91.12-P-1000-03F
Rear seats MODEL 251.0 /1 BA91.12-P-1000-03G
Rear seats MODEL 221 BA91.12-P-1000-03H
Rear seats MODEL 204 BA91.12-P-1000-03I
Head restraints MODEL 202, 210, 215, BA91.16-P-1000-01A
220
Child seats MODEL 163 BA91.20-P-1000-01A
Child seats MODEL 240 with CODE BA91.20-P-1000-01B
(573) ISOFIX (child seat
attachment) in rear
Seat adjustment MODEL 170, 202, 203, BA91.29-P-1000-01A
208, 209, 210, 215, 220
Seat adjustment MODEL 240 BA91.29-P-1000-01C
Seat belts/emergency MODEL 171, 199.376, BA91.40-P-1000-01A
tensioning retractors 202, 203, 208.3 /4,
209.3 /4, 210, 211.0 /2 /6,
215, 220, 230
Seat belts/emergency MODEL 140 BA91.40-P-1000-01B

Safety belts/emergency MODEL 163 BA91.40-P-1000-01D
Seat belts/emergency MODEL 168, 414.700 BA91.40-P-1000-01E
Seat belts/emergency MODEL 170 BA91.40-P-1000-01F
Seat belts/emergency MODEL 164.1 /8 BA91.40-P-1000-01H
Seat belts/emergency MODEL 240 BA91.40-P-1000-01I
Seat belts/emergency MODEL 169.0 /3, 245.2 BA91.40-P-1000-01K
Seat belts/emergency MODEL 219 BA91.40-P-1000-01M
Seat belts/emergency MODEL 251 BA91.40-P-1000-01N
Seat belts/emergency MODEL 216, 221 BA91.40-P-1000-01O
Seat belts/emergency MODEL 204 BA91.40-P-1000-01P
Rollover bar mechanical MODEL 170, 171, 208.4, BA91.50-P-1000-01A
system 209.4, 230
Airbag MODEL 163, 168, 170, BA91.60-P-1000-01A
171, 202, 203, 208,
209.3 /4, 210, 211.0 /2 /6,
215, 220, 230, 240,
414.700
Airbag MODEL 199.376 BA91.60-P-1000-01E
Airbag MODEL 169.0 /3, 245.2 BA91.60-P-1000-01F
Airbag MODEL 211.0 /2, 219.3 BA91.60-P-1000-01G
with CODE (494) USA
version
Airbag MODEL 164.1 /8 BA91.60-P-1000-01H
Airbag MODEL 219.3 BA91.60-P-1000-01J
Airbag MODEL 251 BA91.60-P-1000-01K
Airbag MODEL 204 BA91.60-P-1000-01M
FRONT SEATS - BA91.10-P-1000-01L
Model 164
MODIFICATION NOTES
17.3.05 Bolt of seating mounting bracket to vehicle floor Model 164.1
FRONT SEATS
BA91.10-P-1001-01L Bolt of seating mounting bracket to vehicle floor Nm 45
BA91.10-P-1002-01L Screw, backrest to seat frame Nm 40
REAR SEATS - BA91.12-P-1000
Rear seat backrest - BA91.12-P-1000-02D
Model 164
REAR SEAT BACKREST

BA91.12-P-1001-02D Bolt for rear seat backrest to vehicle floor Nm 90
BA91.12-P-1002-02D Bolt for buckle to rear seat backrest Nm 25
BA91.12-P-1003-02D Bolt, rear seat backrest bracket to 40 % rear seat backrest Nm 35
BA91.12-P-1004-02D Bolt, rear seat backrest to 60 % rear seat backrest bracket Nm 43
Rear seats - BA91.12-P-1000-03F
Model 164
REAR SEATS
Number Designation Model 164.1 Model 164.8
BA91.12-P-1001-03F Bolt, rear seat console to vehicle floor Nm 50 50
BA91.12-P-1002-03F Bolt, rear seat console to front of vehicle floor Nm - 50
BA91.12-P-1003-03F Bolt, rear seat console to rear of vehicle floor Nm - 90
BA91.12-P-1004-03F Bolt, rear seat cushion to rear seat console Nm - 25
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS - BA91.40-P-1000-01H
Model 164
MODIFICATION NOTES
Bolt at seat belt fitting
Bolt, seat belt buckle to front seat
Screw at belt end fitting
20.12.04 Bolt, rear seat belt guide bracket
Bolt to rear automatic belt retractor
Screw rear automatic belt retractor to
2/3 seat bench
Bolt, belt buckle to rear seat
Bolt, seat belt fitting to front seat

BA91.40-P-1002-01H Bolt, seat belt buckle to front seat Nm 35
BA91.40-P-1004-01H Bolt, rear seat belt guide bracket Nm 35
BA91.40-P-1005-01H Bolt to rear automatic belt retractor Nm 35
BA91.40-P-1006-01H Screw rear automatic belt retractor to 2/3 seat bench Nm 35
BA91.40-P-1008-01H Bolt, seat belt fitting to front seat Nm 35
BA91.40-P-1010-01H Screw on front automatic belt reel Nm 35
BA91.40-P-1011-01H Nut for belt height adjuster to B-pillar Nm 24
AIRBAG - BA91.60-P-1000-01H
Model 164
AIRBAG
164.1/8
BA91.60-P-1001-
Bolt, frontal acceleration sensor to front module support Nm 8
01H
BA91.60-P-1002-
Nut, control unit to vehicle floor Nm 10
01H
BA91.60-P-1003-
Bolt, airbag to steering wheel Nm 8
01H
BA91.60-P-1004- Bolt, sensor for sidebag and windowbag to inner longitudinal
Nm 8
01H member
BA91.60-P-1005-
Bolt of bracket for windowbag check strap to body Nm 8
01H
BA91.60-P-1006-
Bolt, windowbag to body Nm 8
01H
BA91.60-P-1007-
Nut, windowbag to lower A-pillar Nm 8
01H
BA91.60-P-1008-
Nut, gas generator for windowbag to upper A-pillar Nm 8
01H
BA91.60-P-1009-
Nut, front passenger airbag unit to dashboard Nm 8
01H
BA91.60-P-1010-
Nut, passenger airbag to dashboard crossmember Nm 20
01H
BA91.60-P-1011-
Nut for bolts on WSS sensor (Weight Sensing System) Nm 5
01H
BA91.60-P-1012-
Bolt, front WSS sensor (weight sensing system) at seat rail Nm 8
01H
BA91.60-P-1013-
Bolt, rear WSS sensor (weight sensing system) at seat rail Nm 20
01H
BA91.60-P-1014-
Bolt, windowbag guide rail bracket Nm 23
01H
MISCELLANEOUS NOTES
NOTES ON DISPOSING OF AIRBAG AND EMERGENCY TENSIONING RETRACTOR UNITS -
OS91.00-P-0001-01A
All models
In the Federal Republic of Germany, the airbag and emergency tensioning retractor units must be rendered
unusable according to the accident prevention and safety regulations and the EU Directive on End-of-life
Vehicles.
Airbag and emergency tensioning retractor units must be forwarded in their original packaging,
via the familiar MeRSy disposal channel (Renz), for proper and environmentally-friendly scrapping.
In all countries except national regulations governing proper disposal need to be complied with.
These safety precautions are necessary because pyrotechnic devices can inflict injuries when activated
improperly.
2006-2008 ENGINE Air Intake, Turbo Charging - 164 Chassis
2006-2008 ENGINE
Air Intake, Turbo Charging - 164 Chassis
BASIC KNOWLEDGE
TURBOCHARGING, FUNCTION - GF09.00-P-2000P
ENGINE 642.9 in MODEL 164.1 /8, 203.0 /2, 204.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
Charging serves to make an appropriate boost pressure available to the engine in every operating phase and thus
to increase engine performance and engine torque. For exhaust gas turbocharging, the flow energy of the
exhaust gases is used to drive the turbocharger. The turbocharger draws in fresh air at the compressor intake,
compresses it and directs it through the compressor outlet, the charge air pipe, the charge air cooler and the air
intake manifold to the engine's individual cylinders.
Turbocharging is regulated by the boost pressure control.
Model 164.8, 203.0/2, 209.3/4,

Component description for the charge air GF07.04-P-
211.0/2/6, 219.3, 221.0/1, 251.0/1, 463
temperature sensor 6050P
B17/8
Model 461 GF07.04-P-
B17/8 6050GX
Component description for the charge air Model 204.0 GF07.04-P-
temperature sensor B17/8 6052CO
Engine 642.920 in model 211.022 with
Component description for the temperature GF07.16-P-
code (494) USA version
sensor upstream of the turbocharger 3021SX
Engine 642 in model 221
Model 204.0 GF07.16-P-
B19/11 3021CO
Model 164.1/8, 203.0/2, 209.3/4,
Component description for the boost pressure GF07.04-P-
211.0/2/6, 219.3, 221.0/1, 251.0/1, 463
sensor 6051P
B5/1
B5/1 6051GX
Component description for the boost pressure Model 204.0 GF07.04-P-
sensor B5/1 6053CO
Component description for the CDI control N3/9 GF07.16-P-
unit Model 203, 209 6000P
N3/9 GF07.16-P-
Model 211, 219 6000T
N3/9 GF07.16-P-
Model 164, 463 6000GZ
N3/9 GF07.16-P-
Model 221 6000SX
N3/9 GF07.16-P-
Model 251 6000RT
N3/9 GF07.16-P-
Model 204.0 6000CO
N3/9 GF07.16-P-
Model 461 6000GX
Model 203.0/2, 209.3/4, 221.0/1
Model 211.0/2/6, 219.3 to 31.5.06
Model 164.1/8, 251.0/1 except code GF09.40-P-
Component description for the turbocharger
(494) 4010P
USA version
Model 461, 463
Model 211.0/2/6, 219.3 from 1.6.06
GF09.40-P-
Model 164.1/8, 251.0/1 with code (494)
4010TU
USA version
GF09.40-P-
Model 204.0
4010CO
Model 203.0/2, 204.0, 209.3/4, 221.0/1
Model 211.0/2/6, 219.3 to 31.5.06
Component description for the boost pressure GF09.40-P-
Model 164.1/8, 251.0/1 except code
positioner 4020P
(494) USA version
Model 461, 463
Model 211.0/2/6, 219.3 from 1.6.06
GF09.40-P-
Model 164.1/8, 251.0/1 with code (494)
4020TU
USA version
Component description for the charge air GF09.41-P-
Model 203, 209, 211, 219
cooler 5000P
GF09.41-P-
Model 164, 251, 463
5000GZ
GF09.41-P-
Model 221
5000SX
GF09.41-P-
Model 204.0
5000CW
GF09.41-P-
Model 461
5000GX
COMPONENT DESCRIPTION FOR THE VENT LINE HEATER ELEMENT - GF09.00-P-4010P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
ENGINE 642 in MODEL 461.3, 463.3

Fig. 1: Identifying Vent Line Heater Element

Shown except code (494) USA version and except model 461.3
Location
The vent line heater element is located in the crankcase ventilation hose on the intake line to turbocharger.
Task
The vent line heater element prevents freezing of the crankcase ventilation system.
Design
The vent line heater element consists of a plastic housing in which a heating resistor is integrated.
Function
The vent line heating element is switched on and off by the CDI control unit (N3/9) depending on the outside
temperature.
COMPONENT DESCRIPTION FOR THE VARIABLE INTAKE MANIFOLD SWITCHOVER

VALVE - GF09.20-P-6001AMG
ENGINE 156.980 in MODEL 164, 251

Location
The switchover valve is mounted at the front of variable intake manifold.
Fig. 2: Identifying Variable Intake Manifold Switchover Valve

Task
The switchover valve applies vacuum to variable intake manifold vacuum unit to intake manifold switchover
(long intake routes) or ventilates it again (short intake routes).
Function
Design
The switchover valve is an electromagnetic switchover valve which is cast in a plastic housing.
The coil resistance about 30 ohms at 20°C.

Fig. 3: Identifying Variable Intake Manifold Vacuum Capsule Connection And Wiring Connector
The switchover valve is actuated by the ME-SFI control unit (N3/10) from the ground side via its own output
stage. The voltage supply takes place from "circuit 87 M2e".
In an activate condition a valve plate is pulled by solenoids and a rubber seal closes the connection (3). The
connection between the connection (2) and connection (1) is released in this way and the vacuum from the
vacuum reservoir is built up to the vacuum unit.
In the deenergized state the link again exists between connection 2 and 3 through which
Connection 1 is supplied with air again.

VALVE - GF09.20-P-6001BK
Location
The variable intake manifold switchover valve is mounted at the front of the variable intake manifold.
Fig. 4: Identifying Variable Intake Manifold Switchover Valve

Task
Pressurize intake manifold switchover aneroid capsule with vacuum or admitting air.
Design
Electromagnetic switchover valve in plastic housing, coil resistance approx. 25 ohms.
Fig. 5: Identifying Intake Manifold Switchover Diaphragm Unit And Variable Intake Manifold
Switchover Valve
Switched states of intake manifold switchover valve
Fig. 6: Identifying Switched States Of Intake Manifold Switchover Valve

Function
The variable intake manifold switchover valve is actuated at the ground side by the engine control unit through
its own output stage.
The voltage is supplied through circuit 87.
A valve plate actuated by the coil armature switches between the atmospheric memory and the vacuum
memory.

VALVE - GF09.20-P-6001V

Fig. 7: Identifying Variable Intake Manifold Switchover Valve - Shown On Engine 272.963
Location
The variable intake manifold switchover valve is mounted at the front of the variable intake manifold.
Task
Pressurize intake manifold switchover aneroid capsules with vacuum or admitting air.
Design
Electromagnetic switchover valve in the plastic housing, coil resistance approx. 30 t. Ventilation via cap.
Fig. 8: Identifying Variable Intake Manifold Switchover Valve Design - Shown On Engine 272.963
Function
The variable intake manifold switchover valve is actuated on the earth side by the engine control unit through
its own output stage.
The voltage is supplied through circuit 87.
A valve plate operated by a coil armature shifts between atmosphere and vacuum storage.
COMPONENT DESCRIPTION FOR THE VARIABLE INTAKE MANIFOLD - GF09.20-P-6002AMG
Location
The variable intake manifold is located in the middle between the cylinder heads.
Fig. 9: Identifying Variable Intake Manifold

Task
Switching between long and short intake routes can occur with the variable intake manifold. The vibration
response of the intake air for different operating conditions is used in a specific way to achieve internal
charging.
External structure
The variable intake pipe lengths also allows better distribution of the mixture which leads to better combustion
and thus to a higher engine torque.
Fig. 10: Identifying Variable Intake Manifold Components

Internal structure
The variable intake manifold consists of a number of magnesium pressure castings.
When fitted together, they produce the individual intake manifolds and the air collecting volume. The parts are
sealed off to each other by plastic.
The variable intake manifold must not be disassembled down to the housing bottom section and the throttle
valve actuator.
Fig. 11: Identifying Throttle Valves, Variable Flaps And Air Guide Duct
Function Short intake routes (Switch flaps opened)
Short intake routes improve the engine torque at low rotational speeds and low loads. Short intake routes also
achievement of high motor speeds.
Fig. 12: Short Intake Routes Rotation Function

The variable intake manifold switchover valve is de-energized and the aneroid capsule is ventilated. The switch
flaps are or will be opened through the spring force of the vacuum unit via the gearshift linkage and releases the
short intake routes.
The switch flap shafts of the right and left cylinder head are connected at the rear in the variable intake manifold
via a further gearshift linkage.
Long intake routes (Switch flaps closed)
Long intake routes improve the engine torque at low rotational speeds and high loads.
Fig. 13: Long Intake Routes Rotation Function

The variable intake manifold switchover valve is actuated at the ground end from the ME-SFI [ME] control unit
(N3/10) and switches off the vacuum from the vacuum reservoir through to the vacuum unit. The aneroid
capsule actuates the gearshift linkage of the switch flap shafts and the switch flaps close the short intake routes.
COMPONENT DESCRIPTION FOR THE INTAKE MANIFOLD - GF09.20-P-6010BK
Location
The intake manifold is located between the cylinder banks.
Fig. 14: Identifying Intake Manifold

Task
Optimizes engine torque curve by means of two different intake manifold lengths
Fig. 15: Intake Manifold Operation Diagram

Design
The intake manifold is assembled out of several pressure castings. When fitted together, they produce the
individual intake manifolds and the air collecting volume. The parts are sealed off to each other by plastic. The
intake manifold cannot be disassembled.
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air
collecting volume. A single intake manifold is assigned to each cylinder.
Each single intake manifold has a further opening to the air collecting volume in the middle. These can be
opened or closed by means of variable flaps which pivot through approx. 60°.
The variable flaps are attached to steel shafts. One shaft is installed for each bank of cylinders. The flap shafts
which are connected together are turned by the aneroid capsule for intake manifold switchover in such a way
that the variable flaps close (the longer air intake way).
When the variable intake manifold switchover valve is open, the vacuum is supplied from a vacuum reservoir
with check valve in the intake manifold. The reservoir volume is designed for about 5 operations without
renewed evacuation.
The switch flaps open due to spring force (short intake route).
Section through variable intake manifold in cylinder plane

Fig. 16: Switch Flaps Operation

Function
When the engine is started and at low engine speeds the variable flaps are open. The intake air flows along the
shortest path and thus reaches the cylinder with low friction losses from the distributor volume.
At an engine load of more than 50% from approx. 1750 rpm up to approx. 3900 rpm the variable flaps are
closed. The intake air must flow through the whole intake pipe. Its length is selected in such a way that the
pressure waves produced by the inducting pistons, arrive at the right moment at the open inlet valves for the
next induction stroke. The result is improved cylinder charge and thus an increase in torque.
At higher engine speeds (e.g. from 3900 rpm) the actuation to the variable intake manifold switchover valve is
interrupted - the variable flaps open as a result of the spring force. Through the shortened route the pressure
waves arrive in time even at higher rotational speeds before the closing of the intake valves to the combustion
chamber.
INTAKE MANIFOLD COMPONENT DESCRIPTION - GF09.20-P-6010V

Shown on ENGINE 272

Fig. 17: Identifying Intake Manifold Components - Shown On Engine 272

Location
The intake manifold is located between the cylinder banks.
Task
Optimizes engine torque curve by means of two different intake manifold lengths
Improves flow via swing-out tumble flaps in the intake port.
Design
The intake manifold is assembled out of several magnesium pressure castings. During assembly, the individual
intake manifolds for each cylinder and the air manifold collecting sections are in the center. The intake manifold
cannot be disassembled. A total of four shafts are stored in the intake manifold.
The vacuum pressure for the aneroid capsules is supplied by a vacuum reservoir in the intake manifold when the
switchover valves are actuated. The reservoir volume is designed for several operations without renewed
evacuation.
Shown on ENGINE 272

Fig. 18: Identifying Intake Manifold Design - Shown On Engine 272

Shown on ENGINE 273
Fig. 19: Identifying Intake Manifold Design - Shown On Engine 273

Intake manifold switchover, function
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air
collecting volume. Each single intake manifold has a further opening to the air collecting volume somewhere in
the middle. These can be opened or closed by rotating longitudinal switch flap shafts. The switch flaps of a
engine 272 BOTH aneroid capsules for the intake manifold switchover are connected to the variable intake
manifold switchover valve via hose pipes. Engine 273 has only one aneroid capsule. The flap shafts are
connected in the intake manifold. The switch flaps open by spring force without actuation and enable the short
suction way.
Cut at intake manifold at cylinder level, short intake route
Fig. 20: Identifying Longitudinal Switch Flap Open

At higher speeds (from approx. 3500/min) the intake manifold switchover aneroid capsules are ventilated and
the switch flaps opened by the spring force. The intake air takes the short intake route.
Cut at intake manifold at cylinder level, long intake route
Fig. 21: Identifying Longitudinal Switch Flap Closed And Tumble Flap
At lower speed (up to approx. 3500/min) the intake manifold aneroid capsules are pressurized with vacuum
pressure and the longitudinal switch flaps closed. The intake air takes the long intake route. The result is
improved cylinder charge and thus an increase in torque.
Tumble flap switchover function
At partial load, tumble flaps can be fully swung out in each cylinder intake port in the intake manifold. This
closes the intake manifold by around 50 %.
The flow speed of the intake air is increased and allows for improved distribution of the fuel/air mixture in the
combustion chamber. The tumble flaps are actuated via an aneroid capsule and linkage.
COMPONENT DESCRIPTION FOR THE INTAKE PORT SHUTOFF MOTOR - GF09.20-P-6110P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
ENGINE 642 in MODEL 463
Fig. 22: Identifying Intake Port Shutoff Motor

Shown except code (494) USA version
Location
The intake port shutoff motor is located between both engine cylinder heads behind the main fuel filter.
Task
The intake port shutoff motor adjusts the flaps in the intake ports in the charge air manifold according to
actuation by the CDI control unit (N3/9).
Design
Fig. 23: Intake Port Shutoff Motor Operation Diagram

Function
The CDI control unit specifies the set value for the flap position by means of a PWM signal. The signal is
analyzed by the integrated electronics. The DC motor pushes the adjusting lever into the corresponding
position.
The potentiometer serves as an angle sensor, so that a specified / actual value comparison of the adjusting lever
position takes place. In the event of a malfunction or an open circuit in the supply voltage, the adjusting lever is
moved into the rest position by the spring. The flaps are open in the reclining position.
BOOST PRESSURE CONTROL, FUNCTION - GF09.40-P-3000P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
The boost pressure control controls turbocharger charging and is regulated by the CDI control unit (N3/9)
depending on the following associated components:
 Coolant temperature via the coolant temperature sensor (B11/4).

 Charge air temperature via the charge air temperature sensor (B17/8).
 Atmospheric pressure, via the pressure sensor downstream of air filter (B28/5) (except model 463) or
pressure sensor downstream of air filter, right cylinder bank (B28/5) (model 463).
 Engine speed via the crankshaft Hall sensor (B70).
 The injection quantity which is determined via the injection time of fuel injectors (Y76) and the fuel
pressure in the rail.
The fuel pressure in the rail is detected by the rail pressure sensor (B4/6).
After evaluating the input signals, the CDI control unit actuates depending on the charge pressure performance
map of the boost pressure positioner (Y77/1) by means of a pulse width modulation (PWM) signal. The position
of the guide vanes in the turbocharger are altered via the control linkage on the boost pressure positioner.
The adjustable guide vanes modify the flow cross-section through which the exhaust gas flows to the turbine.
The guide vanes thus match the gas pressure present at the turbine to the required boost pressure. The
turbocharger speed is used to determine the quantity of compress air and thus the boost pressure. The boost
pressure is constantly monitored by the boost pressure sensor (B5/1) and transmitted to the CDI control unit.
B17/8
Component description for the charge GF07.04-P-
Model 164.8, 203.0/2, 209.3/4, 211.0/2/6,
air temperature sensor 6050P
219.3, 221.0/1, 251.0/1, 463
B17/8 GF07.04-P-
Model 461 6050GX
Model 164.1/8, 203.0/2, 209.3/4, 211.0/2/6,
Component description for the boost GF07.04-P-
219.3, 221.0/1, 251.0/1, 463
pressure sensor 6051P
B5/1
B5/1 6051GX
Component description for the CDI Model 203, 209 GF07.16-P-
control unit N3/9 6000P
Model 211, 219 GF07.16-P-
N3/9 6000T
Model 164, 463 GF07.16-P-
N3/9 6000GZ
N3/9 6000SX
N3/9 6000RT
N3/9 6000GX
Model 203.0/2, 209.3/4, 221.0/1
Model 211.0/2/6, 219.3 to 31.5.06 Model
Component description for the GF09.40-P-
164.1/8, 251.0/1 except code (494)
turbocharger 4010P
USA version
Model 461, 463
Model 211.0/2/6, 219.3 from 1.6.06
GF09.40-P-
Model 164.1/8, 251.0/1 with code (494)
4010TU
USA version
Model 203.0/2, 209.3/4, 221.0/1
Model 211.0/2/6, 219.3 to 31.5.06
Component description for the boost GF09.40-P-
Model 164.1/8, 251.0/1 except code (494)
pressure positioner 4020P
USA version
Model 461, 463 Y77/1
Model 211.0/2/6, 219.3 from 1.6.06

GF09.40-P-
Model 164.1/8, 251.0/1 with code (494)
4020TU
USA version Y77/1
Component description for the charge GF09.41-P-
Model 203, 209, 211, 219
air cooler 5000P
GF09.41-P-
Model 164, 251, 463
5000GZ
GF09.41-P-
Model 221
5000SX
GF09.41-P-
Model 461
5000GX
COMPONENT DESCRIPTION FOR THE TURBOCHARGER - GF09.40-P-4010P
ENGINE 642 in MODEL 203.0 /2, 209.3 /4, 221.0 /1
ENGINE 642 up to 31.5.06 in MODEL 211.0 /2 /6, 219.3 up to 31.5.06
ENGINE 642 in MODEL 164.1 /8, 251.0 /1 except CODE (494) USA version
Fig. 24: Identifying Turbocharger

Location
The turbocharger sits at the rear between the two cylinder heads.
Task
The turbocharger has the task of pre-compressing the suctioned in air depending on the operating condition of
the engine.
Design
Fig. 25: Identifying Turbocharger Components And Operation

Function
The exhaust gases of the engine are directed through the exhaust manifold into the turbine housing onto the
turbine wheel. The flow energy of the exhaust gases sets the turbine wheel in rotation. As a result, the
compressor wheel, which is connected to the turbine wheel by the turbine shaft, is also driven at the same speed.
The fresh air inducted by the compressor wheel is compressed and passed to the engine. The boost pressure is
regulated by adjusting the guide vanes which means changing the turbine geometry. The pilot studs on the boost
pressure positioner control rods (Y77/1) turn the adjusting ring in the turbine housing. As the pilot studs of the
guide vanes also latch into the adjusting ring, all guide vanes are thus adjusted simultaneously.
At a lower engine speed the flow cross-section is downsized by closing the guide vanes. As a result, the flow
rate of the exhaust gas at the turbine wheel is increased, which in turn increases the speed of the exhaust
turbocharger and thus boosts the boost pressure.
At higher engine speeds, the guide vanes are opened increasingly and thus the flow cross-section increased. As
a result, the flow rate of the exhaust gas at the turbine wheel is decreased, which in turn decreases the speed of
the exhaust turbocharger and thus lowers the boost pressure.
Adjustment of the turbine geometry of the turbocharger takes place via the boost pressure positioner.
BOOST PRESSURE POSITIONER, COMPONENT DESCRIPTION - GF09.40-P-4020P
ENGINE 642.9 in MODEL 203.0 /2, 204.0 /2, 209.3 /4, 221.0 /1
ENGINE 642.9 up to 31.5.06 in MODEL 211.0 /2 /6, 219.3 up to 31.5.06
ENGINE 642.9 in MODEL 164.1 /8, 251.0 /1 except CODE (494) USA version
ENGINE 642.9 in MODEL 461.3, 463.3
Fig. 26: Identifying Boost Pressure Positioner

Location
The boost pressure positioner is located at the turbocharger.
Task
The boost pressure positioner is actuated by the CDI control unit (N3/9) and changes the position of the guide
vanes in the turbocharger and thus the boost pressure. Boost pressure control of the turbocharger improves the
torque characteristic in full load operation and the gas cycle in the partial load range. The specified value for the
boost pressure depends on the following variables:
 Engine speed
 Quantity injected
 Coolant temperature
 Intake temperature
Design
The boost pressure positioner consists of an actuator motor and an electronics unit.
Function
An adjustment shaft is turned by a worm drive, which is connected to the guide vanes in the turbocharger.
COMPONENT DESCRIPTION FOR THE CHARGE AIR COOLER - GF09.41-P-5000GZ
ENGINE 642 in MODEL 164.1 /8, 251.0 /1
Fig. 27: Identifying Charge Air Cooler

Location
The charge air cooler is located at the front under the radiator.
Task
The charge air cooler cools the incoming intake air. This improves the fill level in the cylinder.
Design
The charge air cooler consists of 2 side-mounted air intake cases with connections and the radiator block which
contains the corrugated rib-pipe-system.
Function
During the charging process the charge air is led through the charge air cooler. The air stream present in driving
mode which flows through the corrugated rib-pipe-system cools off the charge air.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AR09.00-
Z-9113AB
ENGINE 113
Removing/installing air ENGINE 113... AR09.10-P-1150AC

cleaner housing
Remove/install air ENGINE 113.964 in AR09.10-P-1150GZ
cleaner housing MODEL 164.175
Remove/install air filter ENGINE 113.971 in AR09.10-P-1150RT
housing MODEL 251.075 /175
Remove/install air filter ENGINE 112, 113... AR09.10-P-1150SVK
housing
Remove/install air ENGINE 113.967 in AR09.10-P-1150TY
cleaner housing MODEL 219.375
Removing/installing the ENGINE 113.990 in AR09.10-P-1150TZ
air cleaner housing MODEL 219.376
Remove/install intake ENGINE 112, 113... AR09.20-P-1310A
manifold
Remove/install intake ENGINE 113.964 in AR09.20-P-1310GZ
manifold MODEL 164.175
Remove/install intake ENGINE 113.971 in AR09.20-P-1310RT
manifold MODELS 251.075 /175
Remove/install intake ENGINE 113.967 in AR09.20-P-1310TY
manifold MODEL 219.375
Remove/install top ENGINE 112, 113... AR09.41-P-1320SVK
charge air distributor
top charge air distributor MODEL 219.376
Remove/install charge ENGINE 113.990 in AR09.41-P-6817RVK
air cooler MODEL 211.076 /276
ENGINE 113.991 in
MODEL 215.374, 220.074
Remove/install charge ENGINE 112, 113... AR09.41-P-6817SVK
air cooler
charge air cooler MODEL 219.376
Remove/install low ENGINE 113... AR09.41-P-6831RVK
temperature radiator
low temperature radiator MODEL 219.376
Remove/install charge ENGINE 112, 113... AR09.41-P-6832SVK
air cooler circulation
pump
Removing and installing ENGINE 113.990 in AR09.41-P-6925TX

the circulation pump for MODEL 219.376
the low temperature
water circuit
Remove compressor, ENGINE 112, 113... AR09.50-P-4705SVK
install
Remove/install ENGINE 113.990 in AR09.50-P-4705TZ
compressor MODEL 219.376
Remove and install ENGINE AR09.50-P-4786R
electromagnetic clutch 113.990 /991 /992 /995
compressor
Remove/install ENGINES 112.960 /961, AR09.50-P-4787R
compressor belt pulley 113.990 /991 /992 /995
Remove/install ENGINE 113... AR09.50-P-8843T
recirculated air flap
actuator
Z-9156AB
ENGINE 156
Remove/install air filter ENGINE 156 in

housing MODEL 164, 251 AR09.10-P-1150GZS
Remove/install air filter ENGINE 156 in MODEL AR09.10-P-1150SMG
housing 216, 221
Remove/install air filter ENGINE 156.982 in AR09.10-P-1150TMG
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove, install resonance ENGINE 156 in MODEL AR09.20-P-1961GZS
intake manifold 164, 251
Remove, install resonance ENGINE 156 in MODEL AR09.20-P-1961SMG
intake manifold 216, 221
Remove, install resonance ENGINE 156.982 in AR09.20-P-1961TMG
intake manifold MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Z-9272AB
ENGINE 272
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150GZA

housing MODEL 164, 251
Removing/installing air filter ENGINE 272, 273 ... AR09.10-P-1150QB
housing
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150RX
housing MODEL 230
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150SX
housing MODEL 221 ENGINE
273 in MODEL 216
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150TS
housing MODELS 211, 219
Removing/installing air cleaner ENGINES AR09.10-P-1150VA
housing 272.942 /963 in
MODEL 171.4
Remove/install air duct housing ENGINE 272 in AR09.20-P-0080CV
MODEL 204
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080GZA
Remove/install the air duct ENGINE 272, 273 ... AR09.20-P-0080QB
housing
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080RX
housing MODEL 230
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080TS
Removing/installing the air ENGINE 272.942 in AR09.20-P-0080VA
duct housing MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove, install resonance ENGINE 272 in AR09.20-P-1961CV
intake manifold MODEL 204
Remove, install resonance ENGINE 272, 273 in AR09.20-P-1961GZA
intake manifold MODEL 164, 251
Remove, install the resonance ENGINE 272, 273 ... AR09.20-P-1961QB
intake manifold
Remove, install the resonance ENGINE 272, 273 in AR09.20-P-1961RX
Remove, install resonance ENGINE 272, 273 in AR09.20-P-1961SX
intake manifold MODEL 221 ENGINE
273 in MODEL 216
Remove, install the resonance ENGINE 272, 273 in AR09.20-P-1961TS
272.964, 273 in
MODEL 219
Remove, install the resonance ENGINE 272.985 in AR09.20-P-1961TX

Removing and installing the ENGINE 272.942 in AR09.20-P-1961VA
resonance intake manifold MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove, install tumble flap ENGINE 272 in AR09.20-P-1990CV
and resonance flap switchover MODEL 204
valve to intake manifold
Remove, install the tumble flap ENGINE 272, 273 in AR09.20-P-1990GZD
and resonance flap switchover MODEL 164, 251
valve at the intake manifold
Remove/install the tumble flap ENGINE 272, 273 in AR09.20-P-1990RX
Remove, install tumble flap ENGINE 272, 273 in AR09.20-P-1990SX
and resonance flap switchover MODEL 221 ENGINE
valve to intake manifold 273 in MODEL 216
Remove, install the tumble flap ENGINE 272, 273 in AR09.20-P-1990TS
valve at the intake manifold 272.964, 273 in
MODEL 219
Removing/installing the ENGINE 272, 273 ... AR09.20-P-1993QB
resonance flap switchover
valve on the intake manifold
Remove/install resonance flap ENGINE 272.985 in AR09.20-P-1993TX
switchover valve at the intake MODEL 219
manifold
Remove/install the resonance ENGINE 272.942 in AR09.20-P-1993VA
flap switchover valve at the MODEL 171.454
intake manifold ENGINE 272.963 in
MODEL 171.456
Removing/installing the tumble ENGINE 272, 273 ... AR09.20-P-1994QB
flap switchover valve at the
intake manifold
Remove/install the tumble flap ENGINE 272.942 in AR09.20-P-1994V
switchover valve at the intake MODEL 171.454
manifold ENGINE 272.963 in
MODEL 171.456
Remove, install tumble flap ENGINE 272 in AR09.20-P-1995CV
position sensor to intake MODEL 204
manifold
Remove, install tumble flap ENGINE 272, 273 in AR09.20-P-1995GZA
position sensor to intake MODEL 164, 251
manifold
Remove, install tumble flap ENGINE 272, 273 ... AR09.20-P-1995QB
position sensor at intake

manifold
position sensor at the intake MODEL 230
manifold
position sensor to intake MODEL 221 ENGINE
manifold 273 in MODEL 216
Remove, install tumble flap ENGINE 272, 273 in AR09.20-P-1995TS
position sensor at the intake MODEL 211 ENGINE
manifold 272.964, 273 in
MODEL 219
Removing/installing the tumble ENGINE 272.942 in AR09.20-P-1995V
flap position sensor on intake MODEL 171.454
manifold ENGINE 272.963 in
MODEL 171.456
Remove/install low ENGINE 272.985 in AR09.41-P-6831TX
temperature radiator MODEL 219
Z-9273AB
ENGINE 273
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150GZA

Removing/installing air filter ENGINE 272, 273 ... AR09.10-P-1150QB
housing
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150RX
housing MODEL 230
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150SX
273 in MODEL 216
Remove/install air filter ENGINE 272, 273 in AR09.10-P-1150TS
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080GZA
Remove/install the air duct ENGINE 272, 273 ... AR09.20-P-0080QB
housing
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080RX
housing MODEL 230
Remove/install the air duct ENGINE 272, 273 in AR09.20-P-0080TS
Remove, install resonance ENGINE 272, 273 in AR09.20-P-1961GZA
intake manifold MODEL 164, 251
Remove, install the resonance ENGINE 272, 273 ... AR09.20-P-1961QB

intake manifold
Remove, install the resonance ENGINE 272, 273 in AR09.20-P-1961RX
Remove, install resonance ENGINE 272, 273 in AR09.20-P-1961SX
273 in MODEL 216
Remove, install the resonance ENGINE 272, 273 in AR09.20-P-1961TS
272.964, 273 in
MODEL 219
Remove, install the tumble flap ENGINE 272, 273 in AR09.20-P-1990GZD
and resonance flap switchover MODEL 164, 251
valve to intake manifold 273 in MODEL 216
Remove, install the tumble flap ENGINE 272, 273 in AR09.20-P-1990TS
valve at the intake manifold 272.964, 273 in
MODEL 219
Removing/installing the ENGINE 272, 273 ... AR09.20-P-1993QB
resonance flap switchover
valve on the intake manifold
Removing/installing the tumble ENGINE 272, 273 ... AR09.20-P-1994QB
flap switchover valve at the
intake manifold
Remove, install tumble flap ENGINE 272, 273 in AR09.20-P-1995GZA
position sensor to intake MODEL 164, 251
manifold
Remove, install tumble flap ENGINE 272, 273 ... AR09.20-P-1995QB
position sensor at intake
manifold
position sensor at the intake MODEL 230
manifold
position sensor to intake MODEL 221 ENGINE
manifold 273 in MODEL 216
Remove, install tumble flap ENGINE 272, 273 in AR09.20-P-1995TS
position sensor at the intake MODEL 211 ENGINE
manifold 272.964, 273 in
MODEL 219
REMOVE/INSTALL AIR CLEANER HOUSING - AR09.10-P-1150GZ
Fig. 28: Identifying Air Cleaner Housing Remove/Install Components

Remove/Install
Risk of injury caused by fingers being When moving components, ensure

jammed or pinched when removing, that no body parts or limbs are AS00.00-Z-
installing or aligning hoods, doors, trunk within the operating range of 0011-01A
lid/rear-end door or sliding roof. moving parts.
AR88.40-P-
1 Open engine hood
1000GZ
AR01.10-P-
2 Remove engine trim panel
2405GZ
3 Remove intake air ducts (1)
Detach the air cleaner housing (4) upwards
4 from the mounts (2) at the left and right
cylinder head cover
Detach the air cleaner housing (4) upwards In order to avoid
scratches and damage, the air
5 from the mounts (3) at the left and right
cylinder head cover cleaner housing (4) must be put
down on a padded base.
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 29: Identifying Air Filter Housing Remove/Install Components

Remove/install
Remove reinforcement between AR62.30-P-

1.1 Model 164.8
wheel assemblies 2500GY
Remove partition wall between AR62.30-P-
1.2 Model 251
wheelhouses 2400RT
Pull off the front engine cover (1)
2
from above.
Remove left and right engine intake
3
air duct (2)
Installation: The arrows on hose (3) and
Detach hose (3) for air pump at air
4 air filter housing (4) must point towards
filter housing (4)
each other.
Lever out clamp (5) from air filter
5
housing (4)
In order to avoid scratches and damage,
the air filter housing (4) must be put down
Detach air filter housing (4)
on a padded base.
6 upwards from mounts (4a) on left
and right cylinder head cover Installation: Put air filter housing (4) in
position carefully so that the sealing ring in
the air filter housing (4) is not damaged.
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150GZS

Shown on model 164
Fig. 30: Identifying Air Filter Housing Remove/Install Components (Shown On Model 164)
Remove/install

pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk lids, clear of moving parts. 0011-01A
Open engine hood and move to vertical AR88.40-P-
1 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
AR62.30-P-
2 Remove partition wall between wheelhouses Model 251
2400RT
Do not tilt front engine cover
(1) but instead lift it off vertically,
3 Remove front engine cover (1)
otherwise retaining lugs can break
off.
4 Remove intake air ducts (2)
5 Unclip covers (3)
Disconnect electrical connectors (4) at hot
6
film mass air flow sensor
7 Loosen clamps at air filter housing (5)
Check sealing ring on intake

port; replace if necessary.
Installation: If the intake port

8 Unclip retaining clips (6) at intake port is damage, install an altered
intake port.
BT09.10-P-
Intake port altered
0001-01A
For model 251 the air filter
housing (5) must be installed
individually.
9 Remove both air filter housings (5).
Installation: Coat rubber
mounts on valve covers with
antifriction agent.
Lubricating paste *BR00.45-Z-
Cover intake opening. 1002-06A
REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricating paste A 000 989 01 60
REMOVE/INSTALL THE AIR DUCT HOUSING - AR09.20-P-0080GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 31: Identifying Air Duct Housing Remove/Install Components

Remove/install
Risk of injury caused by fingers being pinched

or crushed when removing, installing or Keep body parts and limbs AS00.00-Z-
aligning hoods, doors, trunk lids, tailgates or well clear of moving parts. 0011-01A
sliding roof
Information on preventing damage to electronic AH54.00-P-


AR09.10-P-
1 Remove air filter housing
1150GZA
AR07.07-P-
2 Remove hot film mass air flow sensor (B2/5)
1453GZA
Do not use pointed or
3 Detach hose (1) at centrifuge cover (2) sharp-edged tools to detach the
hose (1); they will damage the
hose.
Detach retaining clamp (3) on electric wiring
4
harness from air duct housing (4)
Push notch (4a) downwards and swing away air
5 duct housing (4) from under the throttle valve
actuator (M16/6)
Raise notch (4b) and remove air duct housing (4)
6
from throttle valve actuator (M16/6)
Detach hose (1) at air duct housing (4) Only
when replacing the air duct housing (4).
Do not use pointed or sharp-edged tools to
7 detach the hose (1); they will damage the hose.
Installation: Replace clamp (A). Never use
screw and nut clamps or spring bracket clamps;
otherwise, there is a possibility of leaks.
Checking
Check seals (5) for wear
8 Check seals (5) and damage; replace if
necessary.
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01GZ
Intake manifold connection diagram
Engine 113
Fig. 32: Intake Manifold Connection Diagram

REMOVE/INSTALL INTAKE MANIFOLD - AR09.20-P-1310GZ
Fig. 33: Identifying Intake Manifold Remove/Install Components

Remove/install
Risk of explosion caused by fuel No fire, sparks, open flames or smoking.

igniting, risk of poisoning caused by Only pour fuels into suitable and
AS47.00-Z-
inhaling and swallowing fuel as well appropriately marked containers.
0001-01A
as risk of injury to eyes and skin Wear protective clothing when handling
caused by contact with fuel. fuel.
Risk of injury caused by fingers
being jammed or pinched when When moving components, ensure that no
AS00.00-Z-
removing, installing or aligning body parts or limbs are within operating
0011-01A
hoods, doors, trunk lid/rear-end door range of moving parts.
or sliding roof.
On vehicles with code 889 Keyless Go:
Press Keyless Go start/stop button
Switch ignition off, remove ignition repeatedly until the ignition is switched off.
1 Remove the Keyless Go transmitter card or
key (transmitter key).
transmitter key from the vehicle and store
beyond the reach of the transmitter (at least
2 m).
Open engine hood and raise to AR88.40-P-
2
vertical position 1000GZ
AR09.10-P-
1150GZ
Remove hot film mass air flow AR07.07-P-
4
sensor with air intake pipe 1454GZ
Dismount fuel line (3) from fuel *BA07.52-
5
distributor P-1001-01A
Removing fuel rail with injection AR07.03-P-
6
valves 1451GZ
*BA07.52-
P-1002-01A
Remove vacuum lines from intake
Installation: Observe intake manifold AR09.20-P-
7 manifold (1) and variable intake
connection diagram. 1310-01GZ
manifold switchover valve (Y22/6)
Disconnect electrical connector at
8 variable intake manifold switchover
valve (Y22/6)
Screw down union nut (5) on line to Counterhold connection fitting when
9
exhaust gas recirculation valve (4) unscrewing.
10 Remove combination valves (6)
Remove intake manifold (1) bolts on *BA09.20-
11
cylinder head P-1001-01D
Plug intake ducts.

The intake manifold must not be
disassembled.
Installation: Replace seals (2). When

mounting observe correct seating of bore for
combination valve (see arrow).
12 Remove intake manifold (1) upwards
Installation: Use centering pin to
achieve exact bottoming of intake manifold
as well as centering of seals (2).
Set of dowel bolts Fig. 34
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near a Do not grasp hot or rotating parts.
running engine
In the event of a leak, determine and
Carry out engine test run and check
14 eliminate cause, otherwise malfunctions and
intake manifold (1) for leaks
serious environmental pollution may occur.
FUEL RAIL
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/97
Disconnect
BA07.52-
fuel feed
P-1001- Nm 38
line at fuel
01A
rail
Bolt, fuel
BA07.52-
rail to
P-1002- Nm 10
intake
01A
manifold
INTAKE MANIFOLD
Number Designation Engines 112, 113
BA09.20-P-1001-01D Bolt, intake manifold to cylinder head M8 Nm 20
Fig. 34: Identifying Set Of Dowel Bolts (112 589 02 62 00)

REMOVE, INSTALL RESONANCE INTAKE MANIFOLD - AR09.20-P-1961GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 35: Identifying Resonance Intake Manifold Remove/Install Components (1 Of 2)

Fig. 36: Identifying Resonance Intake Manifold Remove/Install Components (2 Of 2)

Remove/install

Risk of explosion caused by fuel igniting, smoking.
risk of poisoning caused by inhaling and Only pour fuels into suitable and AS47.00-Z-
swallowing fuel and risk of injury to eyes appropriately marked containers. 0001-01A
and skin caused by contact with fuel Wear protective clothing when
handling fuel.
AH54.00-P-
0001-01A
discharge
AR09.10-P-
1150GZA
Remove right connector (R) at ME-SFI
2
[ME] control unit (N3/10)
3 Disconnect electrical connectors (1a, 1b)
Remove jack for electrical connector (1b)
4 Installation: Install new cable ties.
on fuel distributor (2)
Remove electrical feed line (1c) from left
5 Installation: Install new cable ties.
control unit bracket (3)
Pull ME-SFI [ME] control unit (N3/10) Do not disconnect left connector
6 out of left control unit bracket (3) and (L) at ME-SFI [ME] control unit
place to one side (N3/10).
Remove hot film mass air flow sensor AR07.07-P-
7
(B2/5) 1453GZA
AR09.20-P-
8 Remove air guide housing (4)
0080GZA
Disconnect hoses (5a, 5b) from crankcase
9
ventilation system
*BA07.08-
10 Remove right control unit holder
P-1002-01A
Detach feed line duct (6a) from cylinder
*BA15.18-
11 head cover and resonance intake manifold
P-1001-01B
(7)
*BA15.18-
P-1002-01B
Remove feed line duct (6b) from *BA15.18-
12
resonance intake manifold (7) P-1001-01B
*BA01.30-
13 Remove left rear motor suspension lug (8)
P-1005-01O
*BA15.18-
P-1003-01B
Remove feed line duct (6c) from cylinder *BA15.18-
14
head cover P-1002-01B
Release and disconnect the electrical
15
connectors on fuel injection valves (Y62)
connectors on the left intake manifold
16 tumble flap position sensor (B28/9) and
right intake manifold tumble flap position
sensor (B28/10)
18 connector at the throttle valve actuator
(M16/6)
19
electrical air pump (M33)
Reduce fuel pressure with the pressure AR07.03-P-
20
hose via the service valve (10) 1460-01GZ
*BA07.03-
P-1004-01B
Fig. 40
21 Catch escaping fuel with an

Disconnect fuel line (11) from fuel absorbent rag!
distributor (2) Seal connections immediately with

stop plugs.
*BA07.03-
P-1001-01B
Fig. 38
*BA09.20-
22 Remove bolts (7a)
P-1001-01N
Lift resonance intake manifold (7) to the
front and detach pneumatic lines (12) from
23
connection fittings at the resonance intake
manifold (7)
24 Remove resonance intake manifold (7) Installation: Replace gaskets (7b).
Installation: Objects that have
found their way into the intake tract
must always be removed before fitting
25 Cover openings in cylinder heads
the resonance intake manifold (7);
otherwise there may be engine
damage.
Only perform steps 26 to 29 when
replacing the resonance intake manifold
(7)
Remove left control unit bracket (3) from *BA07.08-
26
resonance intake manifold (7) P-1002-01A
Detach fuel distributor (2) with the fuel
*BA07.03-
27 injection valves (Y62) from the resonance
P-1002-01B
intake manifold (7)
Remove throttle valve actuator (M16/6) *BA07.61-
28
from resonance intake manifold (7) P-1001-01D
Remove left intake manifold tumble flap
position sensor (B28/9) and right intake
*BA09.20-
29 manifold tumble flap position sensor
P-1002-01N
(B28/10) from resonance intake manifold
(7)
Checking
moving by itself.
clothes.
Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
31
intake tract and fuel system for leaks
CONTROL UNIT
Number Designation Engine 272 Engine 273
BA07.08-P-1002-01A Bolt, control unit holder to resonance intake manifold Nm 8 8
ENGINE WIRING HARNESS

BA15.18-P-1001-01B Bolt, feed line duct to resonance intake manifold Nm 8 8
BA15.18-P-1002-01B Bolt, feed line duct to cylinder head cover Nm 8 8
BA15.18-P-1003-01B Bolt, feed line duct to motor suspension lug Nm 8 8
CYLINDER HEAD
BA01.30-P-1005-01O Bolt connecting suspension lug to cylinder head M8 Nm 20 20
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 272 Engine 272 with Engine
without code 917 code 917 273
BA07.03-P- Union nut, fuel feed line to fuel
Nm 20 20 20
1001-01B distributor
BA07.03-P- Bolt connecting fuel distributor to
Nm 9 9 9
1002-01B resonance intake manifold
BA07.03-P-
Protective cap to service valve Nm - 15 -
1004-01B
INTAKE MANIFOLD
272 273
BA09.20-P-1001- Bolt connecting resonance intake manifold to cylinder
Nm 9 9
01N head
BA09.20-P-1002- Bolt connecting tumble flap position sensor to resonance
Nm 6 6
01N intake manifold
ME GASOLINE INJECTION AND IGNITION SYSTEM

272 273
BA07.61-P-1001- Bolt connecting throttle valve actuator to resonance
Nm 9 9
01D intake manifold
Fig. 37: Identifying Pressure Hose (119 589 04 63 00)

Fig. 38: Identifying Set Of Stop Plugs (129 589 00 91 00)

REMOVE, INSTALL RESONANCE INTAKE MANIFOLD - AR09.20-P-1961GZS

Fig. 39: Identifying Resonance Intake Manifold Remove/Install Components

MODIFICATION NOTES
19.10.06 Bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Remove/install

igniting, risk of poisoning caused by Only pour fuels into suitable and
AS47.00-Z-
inhaling and swallowing fuel and risk appropriately marked containers.
0001-01A
of injury to eyes and skin caused by Wear protective clothing when handling
contact with fuel fuel.
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning hoods,
moving parts. 0011-01A
doors, trunk lids, tailgates or sliding
roof.
Vehicles with Keyless Go, code 889:
Switch ignition off, remove ignition repeatedly until ignition is switched off.
1
key (transmitter key). Remove keyless go transmitter card or
transmitter key from vehicle and store
outside of transmission range (min. 2 m)
Open engine hood and raise to vertical AR88.40-P-
2 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
3 Model 251
wheelhouses 2400RT
Do not tilt front engine cover, but lift AR09.10-P-
4 Remove air filter housing upwards vertically otherwise retaining 1150GZS
lugs can break off.
AR07.03-P-
Release fuel pressure with pressure
5 1460-
hose via service valve
01TMG
Pressure hose Fig. 40
Dismount fuel line from fuel
6 Installation: Install new sealing rings.
distributor (4)
*BA07.03-
P-1001-01C
Disconnect connectors (2) at intake
7
pipe (1) at front
8 Detach vacuum line (3)
Detach brake booster vacuum line at
9
connection (11)
10 Remove insulating cover
Disconnect connectors for injection
11 Place wiring hardness to side.
valves
Remove bolt (6) and place purge line *BA07.03-
12
(5) to one side P-1002-01C
Detach vacuum hose (9) from intake
13 Detach hose to vacuum reservoir.
manifold (1) or from vacuum unit (13)
14 Remove vacuum line (10).
Unscrew fuel line (7) from intake pipe
15
(1)
16 Disconnect connector (12)
Close off intake ports in doing so
Remove bolts (8) from intake pipe (1) Injection valves is not damaged.
17
then remove intake pipe (1) upwards Installation: Clean sealing surfaces;
replace gasket and bolts.
*BA09.20-
P-1002-01R
Secure vehicle to prevent it from moving
by itself.
clothes.
In the event of a leak, determine and

Carry out engine test run and check eliminate cause, otherwise malfunctions
19
intake manifold (1) for leaks and serious environmental pollution may
occur.

BA07.03-P-1001-01C Union nut, fuel feed line to fuel distributor Nm 20
BA07.03-P-1002-01C Bolt connecting fuel distributor to resonance intake manifold Nm 9
INTAKE MANIFOLD
Stage 1 Nm 8
BA09.20-P-1002-01R Bolt, intake manifold to cylinder head Stage 2 Nm 10
Stage 3 Angle° 90

REMOVE, INSTALL THE TUMBLE FLAP AND RESONANCE FLAP SWITCHOVER VALVE AT
THE INTAKE MANIFOLD - AR09.20-P-1990GZD
ENGINE 272, 273 in MODEL 164, 251

Fig. 41: Identifying Tumble Flap And Resonance Flap Switchover Valve Remove/Install Components
Remove/install

the lifting platform and position the
Risk of death caused by vehicle slipping or AS00.00-Z-
four support plates at the lifting
toppling off of the lifting platform. 0010-01A
platform support points specified by
the vehicle manufacturer.
discharge
Vehicles with Keyless Go, Code
1 Turn key in ignition switch to position "0". 889: Press Keyless Go start/stop
button repeatedly until ignition is
switched off.
AR09.10-
2 Remove air filter housing P-
1150GZA
AR09.20-
3 Remove the resonance intake manifold (7) P-
1961GZA
Never use pointed or sharp tools to

Pull pneumatic line (1 or 2) out of remove the pneumatic line (1 or 2),
4 otherwise these may be damaged.
switchover valve (Y22/6 or Y22/9)
Installation: Check pneumatic
line (1 or 2) for damage and replace if
necessary.
5 Remove lock washer (3 or 4) Installation: Replace lock washer
(3 or 4).
Disconnect the electrical connector (X205)
6
at the switchover valve (Y22/6 or Y22/9)
Remove switchover valve (Y22/6 or Y22/9)
7
from resonance intake manifold (7)
Checking
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk moving by itself.
AS00.00-Z-
of injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes.
near the running engine Do not grasp hot or rotating parts.
Carry out an engine test run and check the
9
intake tract and fuel system for leaks
REMOVE, INSTALL TUMBLE FLAP POSITION SENSOR TO INTAKE MANIFOLD - AR09.20-P-

1995GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 42: Identifying Tumble Flap Position Sensor To Intake Manifold Remove/Install Components
Remove/install

AH54.00-P-
0001-01A
AR09.10-P-
1150GZA
Release and disconnect electrical
connector (1) at left intake manifold
2 tumble flap position sensor (B28/9) or
right intake manifold tumble flap
position sensor (B28/10)
*BA09.20-
3 Remove bolt (2)
P-1002-01N
Remove left intake manifold tumble flap
position sensor (B28/9) or right intake
4 manifold tumble flap position sensor Installation: Replace the gaskets.
(B28/10) from the resonance intake
manifold (3)
Stored faults which may be caused
by disconnecting cables or by
Connect STAR DIAGNOSIS and read
6 simulation during test operations, must
fault memory
be erased in the fault memory after
completing the work.
INTAKE MANIFOLD
272 273
BA09.20-P-1002- Bolt connecting tumble flap position sensor to resonance
Nm 6 6
01N intake manifold
OPEN AND CLOSE COUPLING - AR09.41-P-1311-01AL
Open
1. Slide nose (2) of catch spring (3) to position (B).
Do not pull on the eyelet (1) as the catch spring (3) will lose pretension.
2. Detach hose on component.

3. Replace seal.
Close
4. Slide nose (2) of catch spring (3) to position (A).

5. Slide hose onto component until the catch spring (3) latches.
6. Check connection by pulling slightly.
Fig. 43: Identifying Open And Close Coupling Position

MAINTENANCE
REPLACE AIR FILTER ELEMENT - AP09.10-P-0980GZ
Fig. 44: Identifying Air Filter Element Components

MODIFICATION NOTES
16.5.07 Notes on avoiding damage through contamination and foreign objects, added
Remove/install and replace
Notes on avoiding damage through AH00.00-P-

contamination and foreign objects 5000-01A
In order to avoid scratches and
1 Remove air filter housing (1). damage, put down air filter housing (1)
on a padded base.
AR09.10-P-
Remove/install air filter housing
1150GZ
The bolts (2) remain in the lower
2 Slacken bolts (2)
sections of the housing (1a, 1b).
Remove lower sections (1a, 1b)
3
from the air filter housing (1)
Installation: Replace air filter
4 Take out air filter element (3)
elements (3), do not clean.
Clean
Clean housing lower parts (1a, 1b)
*BR00.45-Z-
5 and air filter housing (1) on the LU cleaner
1028-04A
inside
AUXILIARY REPAIR MATERIALS

Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
BR00.45-Z-1028-04A LU cleaner Germany
Tel. +49-7940-15-0
Fax +49-7940-15-1000
www.wuerth.de
REPLACE AIR FILTER ELEMENT - AP09.10-P-0980GZC

Fig. 45: Identifying Air Filter Element Components

MODIFICATION NOTES

In order to avoid scratches and
1 Remove air filter housing (1). damage, put down air filter housing (1)
on a padded base.
AR09.10-P-
1150GZA
2 Slacken bolts (2) The bolts (2) remain in the lower
sections of the housing (1a, 1b).
Remove lower sections (1a, 1b)
3
from the air filter housing (1)
Installation: Replace air filter
4 Take out air filter elements (3)
elements (3), do not clean.
Clean
Clean housing lower parts (1a, 1b)
*BR00.45-Z-
5 and air filter housing (1) on the LU cleaner
1028-04A
inside

Tel. +49-7940-15-0
Fax +49-7940-15-1000
www.wuerth.de
REPLACE AIR FILTER ELEMENT - AP09.10-P-0980GZS
ENGINE 156.9 in MODEL 164.1, 251.0 /1
ENGINE 156.9 in MODEL 209 except CODE (P98) Black Series
Fig. 46: Identifying Top And Bottom Section Of Air Filter Housing, Air Filter Element And Screws
MODIFICATION NOTES
12.2.07 Notes on avoiding
damage through
contamination and
foreign objects, added
Remove/install

Notes on avoiding AH00.00-P-5000-01A
damage through
contamination and foreign
objects
1 Open engine hood
Open engine hood, move Model 164 AR88.40-P-1000GZ
to upright position and
close
Model 209 AR88.40-P-1000Q
Model 251 AR88.40-P-1000RT
2 Remove air filter housing In order to avoid
scratches and damage,
place air filter housing on
a padded base.
Remove/install air filter Model 164, 251 AR09.10-P-1150GZS
housing
3 Remove bolts (3) The bolts (3) remain
in the air filter housing
top sections (2).
top sections (2) from air
filter housing bottom
sections (5)
5 Take out air filter element Installation: Replace
(4) air filter elements (4), do
not clean.
Clean
6 Clean inside of air filter LU cleaner *BR00.45-Z-1028-04A
housing top sections (2)
and air filter housing
bottom sections (5)

BR00.45-Z-1028-04A LU cleaner Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17 74653
Kunzelsau-Gaisbach Germany
Tel. +49-7940-15-0
Fax +49-7940-15-1000
www.wuerth.de
TIGHTENING TORQUES: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - BA09.00-Z-
9999AZ
MODEL all
Air filter ENGINE 668.914 /940 /941 /942 BA09.10-P-1000-

01A
Air cleaner ENGINE 611.960 /961 /962 /980 BA09.10-P-1000-
01B
Air filter ENGINE 271 BA09.10-P-1000-
01C
Air filter ENGINE 155.980, 275, 285.950 BA09.10-P-1000-
01E
Air filter ENGINE 640 BA09.10-P-1000-
01F
Air filter ENGINE 266.920 /940 /960 /980 BA09.10-P-1000-
01G
Air filter ENGINE 642, 629, 642 BA09.10-P-1000-
01H
Air filter ENGINE 646.8 BA09.10-P-1000-
01I
Intake manifold ENGINE 604, 605, 606 /, BA09.20-P-1000-
611.960 /961 /980 01A
Intake manifold ENGINE 104 /, 111 BA09.20-P-1000-
01B
Intake manifold ENGINE 119, 120 BA09.20-P-1000-
01C
Intake manifold ENGINE 112 / /, 113 / BA09.20-P-1000-
01D
Intake manifold ENGINE 166.940 /960 /961 /990 /991 /995 BA09.20-P-1000-
01E
Intake manifold ENGINE 668.914 /940 /941 /942 BA09.20-P-1000-
01F
Intake manifold ENGINE 137 BA09.20-P-1000-
01G
01I
01L
01N
Intake manifold ENGINE 266.920 /940 /960 /980 BA09.20-P-1000-
01O
01P
Intake manifold ENGINE 629, 642 / BA09.20-P-1000-
01Q
01R
Turbocharger ENGINE 602.982 /983, 605.960 /962, BA09.40-P-1000-
606.961 /964 01A
Turbocharger ENGINE 668.914 /940 /941 /942 BA09.40-P-1000-
01B
Turbocharger ENGINE 611, 612, 613, 647... BA09.40-P-1000-
01C
Turbocharger ENGINE 628.960 /961 /962 /963, 629 BA09.40-P-1000-
01D
Turbocharger ENGINE 646.951 /961 /962 /963 /966, BA09.40-P-1000-
647, 648 01E
Turbocharger ENGINE 275, 285 BA09.40-P-1000-
01H
Turbocharger ENGINE 640 BA09.40-P-1000-
01J
Turbocharger ENGINE 642 / BA09.40-P-1000-
01K
Turbocharger ENGINE 266.980 BA09.40-P-1000-
01M
Turbocharger ENGINE 646.8 BA09.40-P-1000-
01N
Charge air ENGINE 602, 605, 606, 611, 612, 613, BA09.41-P-1000-
pipe/charge air 646, 647, 648... 01A
cooling
Charge air ENGINE 111.943 /944 /947 /973 /975 BA09.41-P-1000-
pipe/charge air 01B
cooler
Charge air ENGINE 112, BA09.41-P-1000-
pipe/charge air 113.990 /991 /992 /993 /995, 155 01C
cooling
Charge air ENGINE 271 BA09.41-P-1000-
pipe/charge air 01D
cooling
Charge air ENGINE 275, 285 BA09.41-P-1000-
pipe/charge air 01G
cooling
Charge air ENGINE 628.960 /961 /962 /963 BA09.41-P-1000-
pipe/charge air 01H
cooling
pipe/charge air 01I
cooling
Charge air ENGINE 642 / BA09.41-P-1000-
pipe/charge air 01J
cooling
pipe/charge air 01M
cooling
Charge air duct ENGINE 271 BA09.41-P-1000-
02A
Charge air duct ENGINE 271, 275, 285 BA09.41-P-1000-
02B
Charge air cooler ENGINE 275, 285 BA09.41-P-1000-
03A
Boost pressure ENGINE 646.8 BA09.41-P-1000-
sensor 04B
Compressor-type ENGINE 111 BA09.50-P-1000-
supercharger 01A
Compressor ENGINE 112, BA09.50-P-1000-
113.990 /991 /992 /993 /995, 155 01B
Compressor ENGINE 271 BA09.50-P-1000-
01C
Compressor ENGINE 271.950 /952 in MODEL 204 BA09.50-P-1000-
01D
INTAKE MANIFOLD - BA09.20-P-1000-01D
Engines 112, 113
INTAKE MANIFOLD
BA09.20-P-1001- Bolt, intake M8 Nm 20
01D manifold to cylinder
head
INTAKE MANIFOLD - BA09.20-P-1000-01N
Engine 272, 273B
INTAKE MANIFOLD
272 273
BA09.20-P-1001-
Bolt of resonance intake manifold to cylinder head Nm 9 9
01N
BA09.20-P-1002- Bolt for tumble flap position sensor to resonance intake
Nm 6 6
01N manifold
INTAKE MANIFOLD - BA09.20-P-1000-01R
Engine 156
MODIFICATION NOTES
19.10.06 Bolt, intake manifold to
cylinder head
INTAKE MANIFOLD
BA09.20-P-1001- Bolt, pressure sensor/fuel to fuel Nm 5
01R distributor
BA09.20-P-1002- Bolt, intake Stage 1 Nm 8
01R manifold to cylinder Stage 2 Nm 10
head Stage 3 Angle ° 90
BA09.20-P-1003- Bolt, reservoir to M6 Nm 6.5
01R crankcase M8 Nm 20
BA09.20-P-1004- Bolt, collector to Initial installation Nm 9
01R intake manifold Follow-up Nm 7
operations
2006-2008 TRANSMISSION Automatic Transmission - Maintenance - 164 Chassis
2006-2008 TRANSMISSION
Automatic Transmission - Maintenance - 164 Chassis
MAINTENANCE
AUTOMATIC TRANSMISSION - OIL AND FILTER CHANGE - AP27.00-P-2702W
TRANSMISSIONS 722.9
Fig. 1: Identifying Automatic Transmission Oil And Filter Components - Transmissions 722.9
MODIFICATION NOTES
2.8.05 Reference to modified Step 2.1
transmission oil pan on
transmission 722.901
added
Remove
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not grasp hot or
burns during starting rotating parts.
procedure or when
working near engine

Risk of death caused by Align vehicle between the AS00.00-Z-0010-01A
vehicle slipping or columns of the lifting
toppling off of the liftingplatform and position the
platform. four support plates at the
lifting platform support
points specified by the
1 Raise vehicle with lifting The vehicle must be
platform situated on the lifting
platform so that it is level
in both the longitudinal
and transverse axes.
2.1 Check transmission oil Transmission 722.901
pan (3) The transmission oil
pan (3) and the overflow
pipe (31) have been
redesigned to optimize the
oil feed of the
transmission. The old
transmission oil pan (3)
without chamfers and
with a black overflow
pipe (31) after removal is
to be replaced by the
with chamfers and with a
white overflow pipe (31).
Oil pan and overflow tube BT27.10-P-0006-01W
modified
3 Remove oil drain screw Collect transmission
from the transmission oil oil which runs out in a
pan (3) suitable container.
4 Pay overflow pipe (31) Collect transmission
off base using a drift oil which runs out in a
(arrow) suitable container.
Drift Fig. 3
5 Remove transmission oil To do this, remove
pan (3) bolts (3b) and remove
sprag (3a).
6 Remove transmission oil
filter (34)
7 Remove overflow pipe
(31) from the
Clean
8 Clean seal (33) A seal (33) which is
not damaged can be used
again.
9 Clean magnet (32) Check magnet (32) for
damage and replace if
necessary.
10 Clean the transmission oil
pan (3)
Install
11 Install new transmission
oil filter (34)
12 Install new overflow pipe Press new overflow
(31) pipe (31) firmly onto the
base (arrow) in the
transmission oil pan (3).
The overflow pipe (31)
must latch noticeably.
13 Install transmission oil The sprags (3a) are
pan (3) only authorized for
transmission 722.9 and
may not be mixed up with
other sprags (3a)
otherwise contact
corrosion can occur.
Replace bolts (3b).
*BA27.10-P-1002-03A
Adding transmission oil
14 Mount adapter in the bore The adapter can be
of the oil drain screw and obtained from two
connect oil dispenser manufacturers.
Adapter NAG 2, Deutsche *WE58.40-Z-1003-17A
Teclamit 2000
Adapter NAG 2, Flaco *WE58.40-Z-1003-17A
Gerate
Oil dispenser, mobile with *WE58.40-Z-1001-17A
calibrated meter
meter not capable of
calibration
15 Fill with transmission oil With the oil dispenser
pump approx. 1 l more
transmission oil into the
transmission than was
drained.
Filling capacity *BF27.00-P-1001-01C
calibrated meter
meter not capable of
calibration
16 Call up the transmission On transmissions with
fluid temperature using chamfered transmission
STAR DIAGNOSIS oil pan (3) and white
overflow pipe (31) the
transmission oil
temperature must be 40°
C.
On transmissions
without chamfered
and with black overflow
pipe (31) the transmission
oil temperature must be
30°C
STAR DIAGNOSIS *WH58.30-Z-1048-13A
diagnosis system
17 Start engine and allow to
run in selector lever
position "P"
18 Shift through "P-R-N-D"
several times with the
vehicle stationary and the
engine idling
19 Allow engine to idle in
selector lever position "P"
20 Call up the transmission The transmission oil
fluid temperature using temperature must not
STAR DIAGNOSIS exceed the specified value
in each case as the
overflow pipe (31) in the
transmission oil pan (3) is
designed for the
respective transmission oil
temperature.
On transmissions with
chamfered transmission
oil pan (3) and white
transmission oil

C.
On transmissions
without chamfered
30°C
diagnosis system
21 Detach adapter
22 Allow the surplus oil It is essential that the
quantity to drain out at engine be running at idle,
the specified transmission and that the temperature
oil temperature until a of the transmission fluid
small quantity still drainsnot exceed the specified
out level. If the operation is
carried out with the fluid
at a higher temperature,
too much fluid will be
drained.
On transmissions with
chamfered transmission
oil pan (3) and white
transmission oil
C.
On transmissions
without chamfered
30°C
23 Screw oil drain screw into Replace sealing ring.
the transmission oil pan
(3)
*BA27.10-P-1001-03A
24 Turn off engine
25 Lower vehicle
OIL PAN, AUTOMATIC TRANSMISSION

Number Designation Transmission 722.9
BA27.10-P-1001-03A Oil drain plug to oil pan Nm 22

BA27.10-P-1002-03A Bolt, oil pan to Nm 4
transmission housing Angle ° 180
AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9 Transmission Transmission
except 722.960/961/962/963/964 722.901 with
722.960/961/962/963/964, code A25
except 722.901 with code
A25
For new
filling
BF27.00- Filling Initial charge Liters 9 9,6 6.7
P-1001- capacity Oil change Liters - - -
01C Specifications Sheet BB00.40-P-0236-12A BB00.40-P-0236-12A BB00.40-P-
for Operating 0236-12A
Fluids Sheet - - -
Fig. 2: Identifying Drift (722 589 03 15 00)


Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
system, Compact Passenger Car
WORKSHOP EQUIPMENT
WE58.40-Z-1001-17A Oil dispenser, mobile with calibrated counter
WE58.40-Z-1002-17A Mobile oil dispenser, with counter (cannot be
calibrated)
WE58.40-Z-1003-17A Adapter for NAG [New Automatic Transmission] 2

MODIFICATION NOTES
4.8.06 Disconnect ground line discontinued
2006-2008 TRANSMISSION Automatic Transmission - Testing & Repair - 164 Chassis
2006-2008 TRANSMISSION
Automatic Transmission - Testing & Repair - 164 Chassis
TESTING & REPAIR

CHECK OIL LEVEL IN AUTOMATIC TRANSMISSION AND CORRECT IF NECESSARY. -
AR27.00-P-0100W
TRANSMISSION 722.9 /9
Shown on transmission oil pan without sloped surface
Fig. 1: Checking Oil Level In Automatic Transmission - Shown On Transmission Oil Pan Without Sloped
Surface
Fig. 2: Draining Transmission Oil

MODIFICATION NOTES
25.7.06 Test temperature of the
transmission oil modified
and documentation
adapted to new repair

method
Removing
Risk of injury to skin Depressurize the hydraulic system AS00.00-Z-0013-
or eyes caused by completely before starting any work on 01A
hydraulic fluid the system. Wear protective clothing and
spraying out under safety glasses.
high pressure. Risk of
poisoning caused by
swallowing hydraulic
fluid.
Risk of accident Secure vehicle to prevent it from moving AS00.00-Z-0005-
caused by vehicle by itself. 01A
starting off by itself Wear closed and snug-fitting work
when engine is clothes.
running. Risk of Do not touch hot or rotating parts.
injury caused by
contusions and burns
during starting
procedure or when
working near the
Risk of injury to skin Wear safety gloves, protective clothing AS00.00-Z-0002-
and eyes caused by and safety glasses, if necessary. 01A
handling hot or
glowing objects.
Risk of death caused Align vehicle between columns of vehicle AS00.00-Z-0010-
by vehicle slipping or lift and position four support plates at 01A
toppling off of the vehicle lift support points specified by
lifting platform. vehicle manufacturer.
General information Note different transmission fluid
temperatures when checking and
correcting the level of the transmission
fluid.
1 Remove rear section
from engine
compartment
paneling or lower
soundproofing
Checking
2 Inspecting Vehicles with transmission 722.901
transmission oil pan
The transmission oil pan and the
overflow pipe (1) have been redesigned
to optimize the oil supply of the

transmission. When checking and
correcting the fluid level, always note the
fluid temperatures associated with the
specific individual oil pan versions: ?
Transmission oil pan and overflow pipe BT27.10-P-0006-
modified 01W
Check transmission
fluid level
3 Start the engine, then
allow it to idle and
maintain pressure on
the brake pedal while
shifting the
transmission through
the ranges "PR- N-D"
4 Call up the On transmissions with chamfered
transmission fluid transmission oil pan (white overflow
temperature using pipe), the transmission oil temperature
STAR DIAGNOSIS must be 45°C .
On transmissions without
chamfered transmission oil pan (black
overflow pipe), the transmission oil
temperature must be 35°C .
5 Allow the engine to The engine must run at idle speed and
run in selector lever each specified transmission oil
position "P" temperature must be adhered to. A lower
transmission oil temperature causes
measuring errors
On transmissions with chamfered
transmission oil pan (white overflow
pipe), the transmission oil temperature
must be 45°C .
6 Carefully unscrew the With an oil flow of thickness
oil drain screw (3) (arrow a) or thickness (arrow b) the
from the transmission oil level is OK and does not
transmission's oil pan have to be corrected. With an oil flow of
and observe the fluid thickness (arrow c) the transmission oil
as it emerges, then level must be corrected and in addition
screw the oil drain must be checked again.
screw (3) back in
immediately
*BA27.10-P-1001-
03A
7 Turn off engine
Correct
transmission oil level
(after check)
8 Start engine and
allow to run at idle
speed in selector lever
position "P"
9 Call up the Because the overflow tube (1)
transmission fluid within the oil pan is designed for
temperature using operation at the specified fluid
STAR DIAGNOSIS temperature, this temperature should
never exceed the level indicated.
must be 45°C .
10 Mount adapter (2) Adapter and transmission oil filler (NAT
and connect 2), see GOTIS
transmission oil filler
http://gotis.aftersales.daimlerchrysler.com
11 Shift through the
drive positions "P-R-
N-D" several times
when the brake is
actuated and the
engine is at idle speed
12 Pump 1 l transmission Always observe work procedure and
oil using filling pump Specifications for Operating Fluids,
into transmission otherwise transmission will be damaged.
*BF27.00-P-1001-
01C
13 Remove the adapter
(2)
14 Allow the excess The engine must run at idle speed and
fluid for the indicated the specified transmission oil temperature
fluid temperature to must be reached in each case, too much
drain, continuing until transmission oil is drained at a higher
only a small flow transmission oil temperature.
(arrow B) emerges
must be 45°C .
15 Replace sealing ring *BA27.10-P-1001-
and screw in oil drain 03A
screw (3)
16 Turn off engine
Install
17 Install rear section of
engine compartment
paneling or lower
soundproofing

BA27.10-P-1001-03A Drain plug on Nm 22
Automatic transmission
Number Designation Transmission 722.9 Transmission Transmission
except 722.901 with 722.960/961/
722.960/961/962 /963/964, code A25 962/963/964
A25
For new filling
BF27.00- Filling Initial charge Liters 9 6,7 9,6
P-1001- capacity during oil Liters - - -
01C change
Specifications Sheet BB00.40-P-0236-12A BB00.40-P- BB00.40-P-
for Operating 0236-12A 0236-12A
Fluids Sheet - - -
FILLING AUTOMATIC TRANSMISSION WITH FLUID - AR27.00-P-0270W
TRANSMISSION 722.9 /9 (except 722.960 /961 /962 /963 /964)
The illustration shows the transmission oil pan without the sloped surface
Fig. 3: Filling Automatic Transmission With Fluid - Transmission Oil Pan Without Sloped Surface
Fig. 4: Draining Transmission Oil

MODIFICATION NOTES
3.2.04 Notice on modified Step 2
transmission oil pan added
Adding
transmission oil
Risk of accident Secure vehicle to prevent it from moving AS00.00-Z-0005-
caused by vehicle by itself. 01A
starting off by itself Wear closed and snug-fitting work
when engine is clothes.
running. Risk of Do not touch hot or rotating parts.
injury caused by
contusions and burns
during starting
procedure or when
working near the
engine as it is
running
The transmission
must be filled with
transmission oil
before starting the
engine
Risk of death caused Align vehicle between columns of vehicle AS00.00-Z-0010-
by vehicle slipping or lift and position four support plates at 01A
toppling off of the vehicle lift support points specified by
lifting platform. vehicle manufacturer.
1 Raise vehicle The vehicle must be situated on
the lifting platform so that it is level in
both the longitudinal and transverse axes.
2 Inspecting To improve fluid supply to the
transmission oil pan transmission, the transmission oil pan and
the overflow tube have been redesigned.
When checking and correcting the fluid
level, always note the fluid temperatures
associated with the specific individual oil
pan versions: ?
Only category P with transmission BT27.10-P-0006-
722.901 01W
Transmission oil pan and overflow pipe
modified
3 Unscrew oil drain The adapter (2) and oil dispenser
screw (3) and mount can be obtained from two manufacturers.
adapter (2) and Adapter NAG 2, Flaco Gerate, refer to
connect oil dispenser GOTIS Oil dispenser, mobile
(calibrated), refer to GOTIS
4 Pump 6 liters of In order to avoid damage to the
transmission oil using transmission, always consult the
oil dispenser into Specifications for Operating Fluids.
transmission
On transmissions which have
been repaired the quantity of transmission
oil drained +0.5 liters should be poured
in.
*BF27.00-P-1001-
01C
5 Call up the
transmission fluid
temperature using
STAR DIAGNOSIS
On
transmissions with
chamfered
and white overflow
pipe, the transmission
oil temperature must
be 40°C.
chamfered transmission oil pan and with
white overflow pipe, the transmission oil
temperature must be 30°C.
STAR DIAGNOSIS Compact diagnosis
system for passenger cars, order number
6511 1801 00
6 Start engine and
allow to run in
selector lever position
"P"
7 Pump transmission After replacing the transmission
oil using oil dispenser and torque converter:
into transmission Pour in approx. 4 liters.
If the torque converter has not
been emptied:
Pour in approx. 2 liters.
*BF27.00-P-1001-
01C
Correct
transmission fluid
level
8 Shift through "P-R-
N-D" several times
with the vehicle
stationary and the
engine idling
9 Allow engine to idle
in selector lever
position "P"
10 Call up the Because the overflow tube (1)
transmission fluid within the oil pan is designed for
temperature using operation at the specified fluid
STAR DIAGNOSIS temperature, this temperature should
never exceed the level indicated.
Connect STAR AD00.00-P-2000-
DIAGNOSIS and 04A
read out fault
memory

transmission oil pan and white overflow
pipe, the transmission oil temperature
must be 40°C.
chamfered transmission oil pan and with
white overflow pipe, the transmission oil
11 Remove the adapter
(2)
12 Allow the excess It is essential that the engine be
fluid (arrow a) for the running at idle speed, and that the
indicated fluid temperature of the transmission fluid not
temperature to drain, exceed the specified level. If the
continuing until only operation is carried out with the fluid at a
a small flow (arrow higher temperature, too much fluid will
B) emerges be drained.
For transmissions with
chamfered transmission oil pan and white
overflow pipe the transmission oil
For transmissions with
chamfered transmission oil pan and black
overflow pipe the transmission oil
13 Replace sealing ring *BA27.10-P-1001-
and screw in oil drain 03A
screw (3)
14 Turn off engine
15 Lower vehicle

BA27.10-P-1001-03A Drain plug on Nm 22
AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9 Transmission
except 722.901 with
722.960/961/962 /963/964, code A25
A25
Initial charge
BF27.00-P- Filling Initial charge Liters 9 6.7
1001-01C capacity during oil Liters - -

change
Specifications Sheet BB00.40-P-0236-12A BB00.40-P-
Fluids Sheet - -
TESTING AND REPAIR WORK: PASSENGER CARS: AUTOMATIC TRANSMISSION - AR27.00-Z-

9722AC
TRANSMISSION 722
Checking oil level in TRANSMISSION 722.3/4/5 AR27.00-P-

automatic 0100A
transmission and
correcting, if
necessary
Check oil level in Transmission 722.8 in MODELS 169.0 /3, 245.2 AR27.00-P-
automatic 0100AK
transmission and
correct if necessary.
Check oil level in TRANSMISSION 722.9 /9 AR27.00-
automatic P-0100W
transmission and
correct if necessary.
Inspect ATF level in TRANSMISSION 722... AR27.00-P-
automatic 0101A
transmission, add
ATF if necessary
Checking oil level in TRANSMISSION 722... AR27.00-P-
automatic 0101GC
transmission and
adding oil
Inspect ATF level in TRANSMISSIONS 722.6 in MODELS 203, 209.3 /4 AR27.00-P-
automatic 0101P
transmission, add
ATF if necessary
Inspect ATF level in TRANSMISSION 722.6 in MODEL 199 with ENGINE 155 AR27.00-P-
automatic 0101SLR
transmission, add
ATF if necessary
Inspect ATF level in TRANSMISSION 722.6 in MODEL 221.1, 216.3 AR27.00-P-
automatic 0101SZ
transmission, add
ATF if necessary
Inspect ATF level in TRANSMISSION 722.6 in MODEL 204.0 /2, 219.3 AR27.00-P-
automatic 0101TZ
transmission, add
ATF if necessary
Inspect ATF level in TRANSMISSIONS 722.695 in MODEL 171.442 AR27.00-P-
automatic 0101V
transmission, add
ATF if necessary
Filling automatic Transmission 722.8 in MODELS 169.0 /3, 245.2 AR27.00-P-
transmission with 0270AK
fluid
Filling automatic TRANSMISSION 722.960 /961 /962 /963 /964 AR27.00-P-
transmission with 0270SYZ
fluid
Filling automatic TRANSMISSION 722.9 /9 (except AR27.00-
transmission with 722.960 /961 /962 /963 /964) P-0270W
fluid
Adjusting control TRANSMISSION 722.5 AR27.10-P-
pressure cable on 0120A
throttle linkage
Checking upshift TRANSMISSION 722.5 Vehicles with switching point rise by AR27.10-P-
delay push pull cable actuators 0140A
Measuring and TRANSMISSION 722.5 AR27.10-P-
adjusting pressure 0180A
values
Removal and TRANSMISSION 722.5 AR27.10-P-
installation of control 0200A
pressure cable with
vacuum actuator
Basic adjustment of TRANSMISSION 722.5 AR27.10-P-
control pressure cable 0220A
(after replacing)
installation of starter 0240A
lock-out switch
installation of vacuum 0260A
unit
installation of 0280A
centrifugal governor
Removal and TRANSMISSION 722.5## # to 3652931 AR27.10-P-
installation, 0300A
dismantling and
assembling secondary
pump
Remove/install oil TRANSMISSION 722.6 AR27.10-P-

pump 0400A
Remove/install oil TRANSMISSION 722.8 Transmission removed AR27.10-P-
pump 0400AK
transmission with
torque converter
Remove/install Transmission 722.8 in MODELS AR27.10-P-
transmission with 169.006 /007 /008 /306 /307 /308, 245.20 0500AK
torque converter
Remove/install Transmission 722.801 in MODELS 169.0 /3, 245.2 with AR27.10-P-
transmission with ENGINES 266.920 /940 /960 0500AL
torque converter
Remove/install Transmission 722.6 in MODELS 129, 140, 170, 202, 208, 210 AR27.10-P-
transmission with 0500B
torque converter
Remove/install Transmission 722.8 in MODEL 169.0 /3, 245.2 with ENGINE AR27.10-P-
transmission with 266.980 0500BK
torque converter
Remove/install TRANSMISSION 722.9 in MODEL 204.0 /2 AR27.10-P-
transmission with 0500CV
torque converter
transmission with 0500CW
torque converter
Remove/install TRANSMISSION 722... AR27.10-P-
transmission with 0500GC
torque converter
Removing and TRANSMISSION 722... AR27.10-P-
installing 0500GD
transmission with
torque converter
Remove/install Transmission 722.6 in MODEL 163 AR27.10-P-
transmission with 0500GH
torque converter
Remove/install TRANSMISSION 722... AR27.10-
transmission with P-0500GZ
torque converter
Remove/install TRANSMISSION 722.906 in MODEL 164.186 AR27.10-
transmission with TRANSMISSION 722.904 in MODEL 164.871 /886 P-
torque converter 0500GZA
Remove/install TRANSMISSION 722.907 in MODEL 164.177, 251.077 /177 AR27.10-
transmission with P-
torque converter 0500GZS

transmission with 0500H
torque converter
transmission with 0500I
torque converter
Remove/install Transmission 722.901 in MODEL 215.375, AR27.10-P-
transmission with 220.070 /075 /170 /175 0500IA
torque converter
Remove/install Transmission 722.6 in MODEL AR27.10-P-
transmission with 220.083 /084 /087 /183 /184 /187 0500IW
torque converter
transmission with 0500P
torque converter
Remove/install Transmission 722.9 in MODEL 203, 209 with ENGINE 642 AR27.10-P-
transmission with 0500PI
torque converter
transmission with 203.081 /084 /087 /092 /281 /284 /287 /292 0500PW
torque converter
transmission with TRANSMISSION 722.907 in MODEL 209.377 /477 0500Q
torque converter
Remove/install Transmission 722.643 /633 in MODEL 230 AR27.10-P-
transmission with 0500R
torque converter
Remove/install Transmission 722.901 in MODEL 230.475 AR27.10-P-
transmission with 0500RA
torque converter
transmission with 0500RC
torque converter
transmission with 0500RTA
torque converter
Remove/install Transmission 722.9 in MODEL 230 with ENGINE 272, 273 AR27.10-P-
transmission with 0500RX
torque converter
transmission with 0500SLR
torque converter
Remove/install TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 (except AR27.10-P-
transmission with 221.08 /18) 0500SX
torque converter

transmission with 0500SYZ
torque converter
Remove/install TRANSMISSION 722.6 in MODEL 221.1, 216.3 AR27.10-P-
transmission with 0500SZ
torque converter
transmission with 0500T
torque converter
transmission with TRANSMISSION 722.907 in MODEL 211.077 /277 0500TA
torque converter
Remove/install Transmission 722.9 in MODEL 211.020 /022 /220 /222 /620 AR27.10-P-
transmission with with ENGINE 642 0500TI
torque converter
Remove/install Transmission 722.9 in MODEL 211 with ENGINE 629 AR27.10-P-
transmission with 0500TJ
torque converter
Remove/install TRANSMISSION 722.689 in MODEL 211.084 /089 /284 /289 AR27.10-P-
transmission with 0500TK
torque converter
Remove/install Transmission 722.9 in MODEL 219.322 with ENGINE 642 AR27.10-P-
transmission with 0500TQ
torque converter
Remove/install TRANSMISSION 722.9 in MODEL AR27.10-P-
transmission with 211.052 /054 /056 /072 /254 /256 /272 0500TS
torque converter
transmission with 211.080 /082 /083 /087 /090 /092 /280 /282 /283 /287 /290 /292 0500TW
torque converter
Remove/install Transmission 722.9 in MODEL 219.3 (except 219.322) AR27.10-P-
transmission with Transmission 722.6 in MODEL 219.3 0500TX
torque converter
transmission with 0500V
torque converter
transmission with 0500VA
torque converter
Remove/install oil TRANSMISSION 722... AR27.10-P-
filler pipe for 7010AK
automatic
transmission
filler pipe for 7010AL
automatic
transmission
Remove/install oil Transmission 722.6 in MODEL 230, 240 AR27.10-P-
filler pipe for 7010H
automatic
transmission
Remove, install oil TRANSMISSION 722.639 in MODELS 220.028 /128 AR27.10-P-
filler tube for 7010M
automatic
transmission
Remove/install oil TRANSMISSION 722.6 in MODEL 216.3, 221.1 AR27.10-P-
filler pipe for 7010SZ
automatic
transmission
Remove/install oil Transmission 722.6 in MODELS 211.08 /09 /28 /29 AR27.10-P-
filler pipe for 7010TJ
automatic
transmission
automatic 7030AK
Remove/install TRANSMISSIONS 722.8 Transmission removed AR27.10-P-
automatic 7030AL
Remove/install TRANSMISSION 722.9 /9 AR27.10-
automatic P-7030W
electrohydraulic 0200A
controller unit
(transmission
installed)
electrohydraulic 0200CW
controller unit
(transmission
installed)
electrohydraulic 0200GC
control module
(transmission
installed)
Remove/install TRANSMISSION 722.6 in MODEL 230, 240 AR27.19-P-
electrohydraulic 0200H
controller unit
(transmission
installed)
electrohydraulic 0200P
controller unit
(transmission
installed)
Remove/install TRANSMISSION 722.6 in MODEL 171 AR27.19-P-
electrohydraulic 0200V
controller unit
(transmission
installed)
Remove/install TRANSMISSION 722.9 AR27.19-
electrohydraulic P-0200W
controller unit
(transmission
installed)
Remove/install CVT TRANSMISSION 722... AR27.19-P-
electric control unit 0201AK
Remove/install CVT TRANSMISSIONS 722.8 Transmission removed AR27.19-P-
electric control unit 0201AL
Disassemble and TRANSMISSION 722... AR27.19-P-
assemble 0220A
electrohydraulic
control unit
Disassemble and Transmission 722.6 in MODEL 203, 209.3 /4 AR27.19-P-
assemble 0220P
electrohydraulic
control unit
Replace pilot bushing TRANSMISSIONS 722.6 AR27.19-P-
in the electrohydraulic 0230A
control unit
Remove/install TRANSMISSION 722.9 in MODEL 164.1 /8 AR27.19-
intelligent servo P-
module 0550GZA
Remove/install TRANSMISSION 722.9 in MODEL AR27.19-P-
intelligent servo 251.020 /022 /065 /075 /077 /122 /165 /175 /177 0550RT
module
Remove/install TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 AR27.19-P-
intelligent servo 0550SX
module
Remove/install TRANSMISSION 722.6 in MODEL 221.1, 216.3 AR27.19-P-
intelligent servo 0550SZ
module
installing electronic 1719GH
transmission control
(ETC) control module
electronic 1719H
electronic 1719I
electronic 1719Q
(ETC) control unit
electronic 1719R
unit (EGS)
electronic 1719SLR
(ETC) control unit
Removing and TRANSMISSION 722.6 in MODEL 211.0 /2 AR27.19-P-
installing electronic 1719T
(ETC) control unit
Remove/install TRANSMISSIONS 722.9 in MODEL 171.4 AR27.19-P-
electronic 1719V
(ETC) control unit
Remove/install front TRANSMISSION 722.5 AR27.30-P-
transmission cover 0640A
with primary pump
Remove/install and TRANSMISSION 722... AR27.30-P-
disassemble/assemble 0650GC
oil pump
Dismantling and TRANSMISSION 722.5 AR27.30-P-
assembling front 0660A
transmission cover
with primary pump
Remove/install rear TRANSMISSION 722.5 AR27.30-P-
transmission cover 0680A
Remove/install rear TRANSMISSION 722... AR27.30-P-
transmission cover 0680AK
Remove/install rear TRANSMISSIONS 722.8 Transmission removed AR27.30-P-
transmission cover 0680AL

assembling rear 0700A
transmission cover
Remove/install radial TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.30-P-
shaft sealing ring on 4970CW
front transmission
cover
Remove/install radial TRANSMISSION 722.9 in MODEL 164.1 /8 AR27.30-
shaft sealing ring on P-4970GZ
front transmission
cover
Remove/install radial TRANSMISSION 722.9 in MODEL 203, 209 with ENGINE AR27.30-P-
shaft sealing ring on 642 4970PI
front transmission
cover
Remove/install radial TRANSMISSION 722.9 in MODEL 203, 209 AR27.30-P-
shaft sealing ring on 4970QB
front transmission
cover
Remove/install radial TRANSMISSION 722... AR27.30-P-
shaft sealing ring on 4970RT
front transmission
cover
Remove/install radial Transmission 722.9 in MODEL 211 AR27.30-P-
shaft sealing ring on 4970TI
front transmission
cover
Remove/install radial TRANSMISSION 722.9 in MODEL 219.322 AR27.30-P-
shaft sealing ring on 4970TQ
front transmission
cover
Remove/install valve TRANSMISSION 722.5 AR27.35-P-
body assembly 0320A
assembling shift valve 0340A
housing
Dismantle and TRANSMISSION 722... AR27.35-P-
assemble shift plate 0350A
installation of bottom 0360A
cover with
intermediate plate
Detaching and TRANSMISSION 722.5 AR27.35-P-
attaching bottom 0380A
cover at large
intermediate plate
assembling bottom 0400A
cover
Remove/install radial TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.40-P-
shaft sealing ring at 0205CW
output flange
Remove/install radial TRANSMISSION 722.9 in MODEL 164.1 /8 AR27.40-
shaft sealing ring at P-0205GZ
output flange
Remove/install radial TRANSMISSIONS 722.649 in MODEL 240 AR27.40-P-
shaft sealing ring at 0205H
output flange
Remove/install radial Transmission 722.901 in MODEL 215.375, AR27.40-P-
shaft sealing ring at 220.070 /075 /170 /175 0205I
output flange
Remove/install radial TRANSMISSION 722.9 in MODEL 203, 209 with ENGINE AR27.40-P-
shaft sealing ring at 642 0205PI
output flange
shaft sealing ring at 0205QB
output flange
Remove/install radial Transmission 722.6 in MODEL 211, 230 AR27.40-P-
shaft sealing ring at 0205R
output flange
shaft sealing ring at 0205RA
output flange
Remove/install radial TRANSMISSION 722.9 in MODEL AR27.40-P-
shaft sealing ring on 251.020 /022 /065 /075 /077 /122 /165 /175 /177 0205RT
output flange
shaft sealing ring at 0205SX
output flange
shaft sealing ring at 0205T
output flange
Remove/install radial TRANSMISSION 722.9 in MODEL 219.322 AR27.40-P-
shaft sealing ring at 0205TQ
output flange
Remove/install radial Transmission 722.9 in MODEL 219.3 (except 219.322) AR27.40-P-
shaft sealing ring at Transmission 722.6 in MODEL 219.3 0205TX
output flange
shaft sealing ring at 0205VA

output flange
Remove/install axle TRANSMISSION 722... AR27.40-P-
shaft radial shaft seals 0210AK
installing radial shaft 0210GC
seals for axle shafts
Remove/install shift TRANSMISSION 722.9 Transmission with intelligent servo AR27.40-
shaft radial shaft module ISM P-0220A
sealing ring
Remove/install shift TRANSMISSION 722... AR27.40-
shaft radial shaft P-0220B
sealing ring
Remove/install shift TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.40-P-
shaft radial shaft 0220CW
sealing ring
Remove/install oil TRANSMISSION 722.6 /9 /9 Torque converter developed AR27.40-
pump radial shaft P-0300A
sealing ring
Removing and TRANSMISSIONS 722.8 Transmission removed AR27.40-P-
installing radial shaft 0310AK
seal for torque
converter housing
installing radial shaft 0310GC
seal for torque
converter housing
shaft seal, shift lock 0320GC
and range selector
lever
installing expansion 0330GC
reservoir in torque
converter housing
installing expansion 0340GC
reservoir in
transmission housing
pipe in torque 0501AK
converter housing
Remove/install stator Transmission 722.8 Transmission removed AR27.40-P-
shaft flange 0502AK
Remove/install stator TRANSMISSIONS 722.8 Transmission removed AR27.40-P-
shaft flange bearing 0503AK

Remove/install anti- TRANSMISSION 722... AR27.40-P-
friction bearing in 0550GC
location for output 0570AK
gear in torque
converter housing
Remove/install the TRANSMISSION 722.8 Transmission removed AR27.50-P-
intermediate shaft and 0515AK
bearing
Disassemble/assemble TRANSMISSION 722... AR27.50-P-
input shaft 0550GC
Disassemble/assemble TRANSMISSIONS 722.8 Transmission removed AR27.50-P-
output shaft 0560AK
Disassemble/assemble TRANSMISSION 722... AR27.50-P-
output shaft 0560GC
Disassemble and TRANSMISSION 722... AR27.50-P-
assemble countershaft 0570GC
assembling 0600A
transmission (section
1)
Detach/attach TRANSMISSION 722.6 AR27.50-P-
transmission housing 0601A
on torque converter
housing.
Detaching, attaching TRANSMISSION 722... AR27.50-P-
transmission housing 0601GC
to torque converter
housing.
Detach/attach TRANSMISSION 722.9 Transmission removed AR27.50-
transmission housing P-0601W
on torque converter
housing.
Remove/install main TRANSMISSION 722.9 AR27.50-
components of the P-0610W
transmission
Remove/install K3, TRANSMISSION 722.9 AR27.50-
rear hollow shaft, rear P-0611W
planet carrier and
output shaft
Removing/installing TRANSMISSION 722.9 AR27.50-
drive shaft with K2, P-0612W
front planet carrier,
internal plate carrier

with K1 and B3
Remove/install output TRANSMISSIONS 722.8 Transmission removed AR27.50-P-
shaft 0613AK
Detach/install torque TRANSMISSION 722.8 Transmission removed AR27.50-P-
converter housing at 0615AK
assembling 0620A
2)
Removing and TRANSMISSION 722.6 AR27.50-P-
installing multiple- 0621A
disc clutches K1, K2
and K3
assembling 0720A
3)
Remove/install multi- TRANSMISSION 722.6 AR27.50-P-
disk brake B1 and oil 0721A
pump
Remove/install multi- TRANSMISSION 722.9 AR27.50-
disk brake B1 and oil P-0721W
pump
Remove brake of TRANSMISSION 722.5 AR27.50-P-
overdrive (BS) and 0740A
clutch (KS), install
Remove/install gear TRANSMISSION 722... AR27.50-P-
sets 0760GC
Remove / install TRANSMISSION 722... AR27.50-P-
differential 0770GC
differential and 0771AK
bearing
assembling 0780A
4)
Removing and TRANSMISSION 722.6 AR27.50-P-
installing multi-disk 0781A
brake B2, disk pack
B3 and park pawl
gear
Remove/install BPC TRANSMISSION 722.9 AR27.50-
clutch pack, multi- P-0782W

disk brake B2 and
park pawl gear
assembling output 0810A
shaft with center and
rear gear set
assembling gear set 0840A
Disassembling and TRANSMISSION 722.6 AR27.50-P-
assembling rear 0850A
hollow shaft with rear
freewheel
Dismantle and TRANSMISSION 722.9 AR27.50-
assemble rear tubular P-0851W
shaft
assembling freewheel 0860A
F2
assembling multi-disk 0870A
brake B1
Disassemble/assemble Transmission 722.9 AR27.50-
multi-disk brake B1 P-0870W
assembling multiple- 0880A
disc brake B2
Disassemble/assemble TRANSMISSION 722.9 AR27.50-
Disassemble/assemble Transmission 722.9 AR27.50-
assembling overdrive 0760A
clutch
assembling clutch K1 0800A
Disassemble/assemble TRANSMISSIONS 722.6 AR27.51-P-
clutch K1 0800B
Dismantling and TRANSMISSION 722.9 AR27.51-
assembling clutch K1 P-0800W
assembling clutch K2 0820A
K2 clutch P-0820W
assembling drive shaft 0825A

with clutch K2 and
front gear set
Disassemble and TRANSMISSION 722.6 AR27.51-P-
assemble clutch K3. 0830A
clutch K3 P-0830W
Remove/install brake TRANSMISSIONS 722.8 Transmission removed AR27.51-P-
pressure controller 4867AK
multidisk brake
Measure and adjust TRANSMISSION 722.9 Multiple-plate brake B1, B2, B3 and AR27.51-
clearance Multiple disk clutch K1, K2, K3 P-7229W
Remove/install pulley TRANSMISSION 722.8 Transmission removed AR27.52-P-
sets with thrust link 0100AK
belt
Flush out oil cooler TRANSMISSION 722.6 /7 AR27.55-P-
lines and oil cooler 0001A
Flushing out oil Transmission 722.8 in MODEL 169.0 /3, 245.2 AR27.55-P-
cooler lines and oil 0001AK
cooler
Flushing out oil TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.55-P-
cooler lines and oil 0001CW
cooler
Flushing out oil Transmission 722.9 in MODEL 164.1 /8 AR27.55-
cooler lines and oil P-0001GZ
cooler
Flushing out oil TRANSMISSIONS 722.9 in MODEL 203, 209 AR27.55-P-
cooler lines and oil 0001PI
cooler
Flushing out oil Transmission 722.9 in MODEL 211, 215, 220, 230 with AR27.55-P-
cooler lines and oil ENGINE 113 0001R
cooler
Flushing out oil TRANSMISSION 722.9 in MODEL AR27.55-P-
cooler lines and oil 251.022 /022 /065 /075 /077 /122 /165 /175 /177 0001RT
cooler
Flushing out oil TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 (except AR27.55-P-
cooler lines and oil 221.08 /18) 0001SX
cooler
Flushing out oil TRANSMISSION 722.9 in MODEL 221.08 /18 AR27.55-P-
cooler lines and oil 0001SYZ
cooler
Flushing out oil Transmission 722.9 in MODEL 211 with ENGINE 642, 629 AR27.55-P-
cooler lines and oil 0001TI
cooler
Flushing out oil TRANSMISSION 722.902 in MODEL 219.322 with ENGINE AR27.55-P-
cooler lines and oil 642.920 0001TQ

cooler
Flushing out oil Transmission 722.9 in MODEL 211 with ENGINE 156, 272, AR27.55-P-
cooler lines and oil 273 0001TS
cooler
Flushing out oil Transmission 722.9 in MODEL 219.3 (except 219.322) AR27.55-P-
cooler lines and oil 0001TX
cooler
Flushing out oil TRANSMISSION 722... AR27.55-P-
cooler lines and oil 0001V
cooler
Flush out automatic TRANSMISSION 722.6 AR27.55-P-
transmission and 0100A
converter
Flush out automatic TRANSMISSION 722.9 in MODEL 204.0 /2 AR27.55-P-
transmission and 0100CV
converter
Flush out automatic TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 (except AR27.55-P-
transmission and 221.08 /18) 0100SX
converter
Remove/install oil Transmission 722.8 in MODEL 169.0 /3, 245.2 feed AR27.55-P-
lines of oil cooling for 0600AK
automatic
transmission
Remove/install oil Transmission 722.8 in MODEL 169.0 /3, 245.2 return flow AR27.55-P-
lines of oil cooling for 0600AL
automatic
transmission
Remove/install oil TRANSMISSION 722.9 in MODEL 204.0 /2 AR27.55-P-
lines of oil cooling for 0600CV
automatic
transmission
lines of oil cooling for 0600CW
automatic
transmission
lines of oil cooling for 0600P
automatic
transmission
Remove/install oil Transmission 722.9 in MODEL 230 with ENGINE 272, 273 AR27.55-P-
lines of oil cooling for 0600RX
automatic
transmission
lines of oil cooling for 0600SX

automatic
transmission
lines of oil cooling for 0600SYZ
automatic
transmission
Remove/install oil Transmission 722.903 in MODEL 211.029 with ENGINE AR27.55-P-
lines of oil cooling for 629.910 0600TJ
automatic
transmission
lines of oil cooling for 0600TS
automatic
transmission
lines of oil cooling for 0600TX
automatic
transmission
lines of oil cooling for 0600TY
automatic
transmission
Remove/install oil Transmission 722.999 in MODEL 171.454 AR27.55-P-
lines of oil cooling for Transmission 722.906 in MODEL 171.456 0600V
automatic
transmission
Remove/install oil TRANSMISSION 722.907 in MODEL 171.473 AR27.55-P-
lines of oil cooling for 0600VT
automatic
transmission
installing automatic 1000A
transmission oil
cooler
Removing and TRANSMISSION 722.8 in MODEL 169.0 /3, 245.2 AR27.55-P-
installing automatic 1000AK
transmission oil
cooler
thermostat for 7380AK
automatic
transmission
installing ignition 0110GC
lock shift lock cable

installing ignition 0110GH
switch shift lock cable
installing brake pedal 0115GC
shift lock cable
installing brake pedal 0115GH
shift lock cable
Adjust shift lock TRANSMISSION 722... AR27.60-P-
cables 0120GC
cables 0120GH
ignition lock control 0122AK
cable
Removing and TRANSMISSION 722.6 in MODEL 202 as of 1.7.99 AR27.60-P-
installing ignition 0122E
lock control cable
installing ignition 0122F
lock control cable
installing ignition 0122G
lock control cable
Removing and TRANSMISSION 722.6 in MODEL 163.### #A as of 145273, AR27.60-P-
installing ignition 163.### #X as of 708319 0122GH
switch control cable
Remove/install TRANSMISSION 722.6 /9 in MODEL 215, 220 AR27.60-P-
ignition lock control 0122I
cable
installing ignition 0122K
lock control cable
ignition lock control 0122P
cable
Remove/install TRANSMISSION 722.9 in MODEL 203, 209 with ENGINE AR27.60-P-
ignition lock control 642 0122PI
cable
Remove/install TRANSMISSION 722.6 /9 in MODEL 209.3 /4 AR27.60-P-
ignition lock control 0122Q
cable
Remove/install Transmission 722.6 /9 in MODEL 230 AR27.60-P-
ignition lock control 0122R
cable
Remove/install TRANSMISSIONS 722.6 in MODEL 211.0 /2 AR27.60-P-
ignition lock control TRANSMISSIONS 722.9 in MODEL 211.0 /2 0122T
cable
ignition lock control 0122TX
cable
ignition lock control 0122VA
cable
Remove/install Transmission 722.8 in MODELS 169.0 /3, 245.20 AR27.60-P-
automatic 0125AK
transmission range
selector cable
installing automatic 0125GC
transmission range
selector cable
Adjust range selection TRANSMISSION 722... AR27.60-P-
cable 0130AK
Adjusting range TRANSMISSION 722... AR27.60-P-
selector cable 0130GC
installation of center 0900A
shift
Remove/install floor TRANSMISSION 722... AR27.60-P-
selector 0900B
installing floor shift 0900GC
Remove/install floor TRANSMISSION 722... AR27.60-P-
shift 0900I
electronic selector 0901AK
lever module (ESM)
Removing and TRANSMISSION 722.643 in MODEL 215.374, 220.074 /174 AR27.60-P-
installing electronic 0901AM
selector lever module
(ESM)
Removing and TRANSMISSION 722.6 in MODEL 163 as of 1.9.99, 170 as of AR27.60-P-
installing electronic 1.12.99, 202, 208, 210 as of 1.7.99 0901B
(ESM)
electronic selector 0901CW
lever module (ESM)
Removing and TRANSMISSION 722.649 in MODEL 240 AR27.60-P-

installing electronic 0901H
(ESM)
electronic selector 0901P
lever module (ESM)
electronic selector 642 0901PI
lever module (ESM)
electronic selector 0901R
lever module (ESM)
electronic selector 0901RA
lever module (ESM)
Removing and TRANSMISSION 722.901 in MODEL 215.375, AR27.60-P-
installing electronic 220.070 /075 /170 /175 0901RB
(ESM)
electronic selector 0901SLR
lever module (ESM)
electronic selector TRANSMISSION 722.9 in MODEL 211.0 /2 0901T
lever module (ESM)
electronic selector 0901TX
lever module (ESM)
electronic selector 0901VA
lever module (ESM)
selector lever handle 0905AK
with cover
selector lever handle 0905CW
with covering
Remove/install TRANSMISSION 722.6 in MODEL 203, 209.3 up to 30.4.02 AR27.60-P-
selector lever handle 0905P
with covering
Remove/install TRANSMISSION 722.6 in MODEL 203, 209 as of 1.5.02 AR27.60-P-
selector lever handle TRANSMISSION 722.9 in MODEL 203, 209 0905PA
with covering
selector lever handle 642 0905PI

with covering
Remove/install Transmission 722.6 in MODELS 211.0 /2, 230 AR27.60-P-
selector lever handle Transmission 722.9 in MODELS 211.0 /2, 230 0905R
with covering
selector lever handle 0905SLR
with covering
selector lever handle 0905TX
with covering
Remove/install TRANSMISSION 722.6 /9 in MODEL 171.4 AR27.60-P-
selector lever handle 0905VA
with cover
0910A
assembling center 0920A
shift
Disassembling and TRANSMISSION 722... AR27.60-P-
assembling floor shift 0920B
Disassembling and TRANSMISSION 722... AR27.60-P-
assembling floor shift 0920GC
Remove/install TRANSMISSION 722.6 up to 1.5.96 AR27.60-P-
selector lever 0930A
Remove/install Transmission 722.9 in MODEL 164 AR27.60-
DIRECT SELECT P-0931GZ
selector lever
DIRECT SELECT 0931RT
selector lever
Remove/install range TRANSMISSION 722... AR27.60-P-
selector lever 0934AK
Remove/install shift TRANSMISSION 722... AR27.60-P-
lock and range 0935GC
selector lever shaft
Remove/install shift TRANSMISSION 722... AR27.60-P-
lock lever shafts 0936GC
operating lever with
wire cable for parking
lock interlock
Remove/install park TRANSMISSION 722.6 AR27.60-P-
pawl mechanism 0950A
Remove, install park TRANSMISSION 722.8 Transmission removed AR27.60-P-

pawl mechanism 0950AK
Remove/install park TRANSMISSION 722... AR27.60-P-
pawl mechanism 0950GC
Remove, install park TRANSMISSION 722.9 Transmission removed AR27.60-
pawl mechanism P-0950W
Adjusting parking TRANSMISSION 722.5 AR27.60-P-
lock interlock 0960A
Adjusting wire cables TRANSMISSION 722.620 ## up to 1680, 722.621 ## up to AR27.60-P-
for parking lock 1976, 722.622 0965A
interlock
Adjusting wire cables TRANSMISSION 722... AR27.60-P-
for parking lock 0965B
interlock
selector lever position 0970SLR
indicator
Adjusting shift rod TRANSMISSION 722.5 in MODEL 124, 129, 140 AR27.60-P-
TRANSMISSION 722.3 in MODEL 461, 463 0980A
Adjusting shift rod TRANSMISSION 722... AR27.60-P-
0980B
Adjusting shift rod TRANSMISSION 722.5 in MODEL 210 AR27.60-P-
0980C
Adjusting shift rod TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.60-P-
0980CW
Adjusting shift rod TRANSMISSION 722.6 in MODEL 203, 209 AR27.60-P-
TRANSMISSION 722.9 in MODEL 203, 209 0980P
Adjusting shift rod TRANSMISSION 722.9 in MODEL 203, 209 with ENGINE AR27.60-P-
642 0980PI
Remove/install shift TRANSMISSION 722.6 /9 in MODEL 204.0 /2 AR27.60-P-
rod 0985CW
Remove, install shift TRANSMISSION 722.9 in MODEL 203, 209 with ENGINE AR27.60-P-
rod 642 0985PI
Remove/install shift TRANSMISSION 722.6 in MODEL 203, 209 AR27.60-P-
rod TRANSMISSION 722.9 in MODEL 203, 209 0985Q
Remove/install and TRANSMISSION 722.6 in MODEL 215, 220, 240 AR27.60-P-
set shift rod TRANSMISSION 722.9 in MODEL 215, 220 0990I
Remove/install and Transmission 722.6 /9 in MODEL 230 AR27.60-P-
set shift rod 0990R
Remove/install and TRANSMISSION 722.6 in MODEL 199 AR27.60-P-
set shift rod 0990SLR
Remove/install and TRANSMISSION 722.6 in MODEL 211.0 /2 AR27.60-P-
set shift rod TRANSMISSION 722.9 in MODEL 211.0 /2 0990T
Remove/install and Transmission 722.6 /9 in MODEL 219.3 AR27.60-P-
set shift rod 0990TX

Remove/install and TRANSMISSION 722... AR27.60-P-
set shift rod 0990VA
Removing and TRANSMISSION 722.620 # up to 0001680, 722.621 # up to AR27.60-P-
installing wire cable 0001976, 722.622 1000A
for parking lock
interlock
installing wire cable 1000B
for parking lock
interlock
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500
Remove/install transmission with torque converter - AR27.10-P-0500GZ
TRANSMISSION 722.9 in MODEL 164 with ENGINE 113, 642, 629
Shown on model 164.175 with offroad package code 430
Fig. 5: Identifying Transmission With Torque Converter Components - Shown On Model 164.175

MODIFICATION NOTES
25.6.07 Observe tightening procedure when assembling propeller shaft, added Operation step 7, 20.1
Remove/install
Information on preventing damage to AH54.00-

AH00.00-
Notes on bolted connections with
P-0007-
self tapping screws
01SF
AH00.00-
Notes on self-locking nuts and bolts N-0001-
01A
Before starting work the area
surrounding the oil cooling lines
(14a, 14b) must be thoroughly
cleaned in the area of the separation
points of the transmission (15). Even
the smallest dirt particles in the
hydraulic components can lead to
malfunctions and a total failure of
the transmission (15)
Move DIRECT SELECT gear
1
selector switch to position "N"
2 Release parking brake
AR54.10-
P-0003GZ
AH54.10-
Notes on battery P-0001-
01A
Secure vehicle on the lifting platform AR00.60-
4
and raise P-0100GZ
AR49.10-
5 Remove complete exhaust system Engine 113
P-7000GZ
AR49.10-
Engine 629, 642 P-
7100GZB
Unscrew bolts (1) and nuts (2),
6 remove shields of rear propeller shaft Remove all three shields completely.
(3)
Detach rear propeller shaft (3) from Mark rear propeller shaft (3) relative to
7
transfer case (5) propeller shaft flange.
AR41.10-
Installation: Observe tightening P-0050-
procedure for rear propeller shaft (3) to transfer 17GZ
case (5).
Fig. 9
*BA41.10-
P-1001-
01F
8 Remove heat shield (6) Vehicles with Offroad package code 430
Disconnect electrical connectors (6a) Vehicles with Offroad package code 430
9
at transfer case (5) Three connectors.
Detach automatic
transmission/intelligent servo
10 module connector (X22/6) on
intelligent servo module for DIRECT
SELECT (A80)
11 Remove exhaust bracket (29) On engine 113
AR27.40-
Remove shield (8) at transmission
12 P-0700-
(15).
01GZ
*BA27.40-
P-1003-
01E
Installation: Fix wiring harness to
Unplug transmission connector (9) at transmission housing using cable strap. The
13
electric controller unit wiring harness must not be allowed to come into
contact with the exhaust system.
For unscrewing and screwing in the bolts, do
not use any impact wrench/driver or compressed
Remove cover (7) and remove torque
14 air tool, otherwise the threaded unions in the
converter (24) from driven plate
torque converter (24) or in the driven plate will be
damaged.
AR27.20-
Engine 113 P-0100-
01GZ
AR27.20-
Engine 629, 642 P-0100-
01A
Fig. 12
Fig. 13
*BA27.20-
P-1002-
01C
*BA27.55-
Remove oil cooler line bolt (10) at
15 P-1003-
oil pan bracket (11).
01D
Remove double hose clamp bolt (12) *BA27.55-

at alternator bracket (13). P-1004-

16
01D
Do not bend or kink oil cooler lines (14a,
Detach oil cooler line (14a) and oil 14b).
cooler line (14b) from transmission Seal the connections at the transmission
17
(15) and engine oil pan and place to (15) and oil cooler lines (14a, 14b) immediately
one side using stop plugs.
Installation: Replace O-rings.
*BA27.55-
P-1002-
01D
Fig. 8
Lower transmission (15) slightly and
fasten to transmission platform using tensioning
Support transmission (15) with strap.
18 Transmission platform, refer to GOTIS
transmission jack and plate
Transmission jack, refer to GOTIS
Remove bolts (17, 18) and take off The rear engine mount remains on the
19 transmission (15). The bolts (18) must be
engine crossmember (16).
replaced: ?
AR22.10-
Engine 113 P-
1170GZA
Engine 629, 642 AR22.10-
Check rear engine mount for wear and damage P-
and replace if required. 1180GZD
Engine 629, 642
Mark front propeller shaft (20) relative to
Remove front propeller shaft (20) on
20.1 propeller shaft flange (20a).
transfer case (5)
Hook front propeller shaft (20) to one
side using cable ties.
AR41.10-
procedure for front propeller shaft (20).
03GZ
Fig. 9
*BA41.10-
P-1003-
01F
AR41.10-
20.2 Remove the front prop shaft (20) On engine 113
P-0070GZ
Place starter to the side with lines
21 Detach starter from transmission (15)
connected and secure to prevent it falling down.
*BA15.30-
Engine 113 P-1003-
01A
*BA15.30-
Engine 642 P-1003-
01N
*BA15.30-
Engine 629 P-1003-
01C
Remove transmission (15) from
First remove the bolt at the vent line
22 crankcase and engine oil pan by
bracket (22) and remove the vent line (23).
removing bolts (21)
*BA27.40-
P-1001-
01E
*BA27.40-
P-1002-
01E
Support front of engine at the engine
23 On engine 629, 642
oil pan
Secure torque converter (24) to prevent it
from falling out.
24 Installation: Align the bores of the
below
torque converter (24) with the bores in the driven
plate.
AR27.20-
25 Remove torque converter (24) If necessary P-0500-
01W
*BE27.20-
Installed height of torque converter P-1001-
01E
Fig. 10
Fig. 11
Checking
If the threaded unions are damaged or
Check threaded unions in the torque
26
converter (24) or in the driven plate loose the torque converter (24) or driven plate
must be replaced.
When replacing the transmission (15) or
if transmission oil is drained off.
Fill transmission (15) with AR27.00-
28 Adhere exactly to the specified work procedure P-0270W
transmission oil
and observe Specifications for Operating Fluids,
otherwise the transmission (15) will be damaged.
Check transmission oil level; correct Adhere exactly to the specified work procedure AR27.00-
if necessary and observe Specifications for Operating Fluids, P-0100W

29
Read out fault memory and erase if
30 STAR DIAGNOSIS diagnosis system
necessary
A transmission adaptation must be
31 Perform transmission adaptation carried out after exchanging or repairing the
transmission (15).
Secure vehicle to prevent it from moving by itself. AS00.00-
running. Risk of injury caused by
Wear closed and snug-fitting work clothes. Z-0005-
contusions and burns during starting
Do not touch hot or rotating parts. 01A
Test run engine and check
32 transmission (15) for leaktightness
and proper operation
TEST VALUES FOR TORQUE CONVERTER

Number Designation Transmission
722.9
helical screwed
mm 9,5
BE27.20-P- Installed height of Distance to flange for connection
1001-01E torque converter transmission housing axial screwed
mm 19,5
connection
PROPELLER SHAFT
164.1/8
Stage
Nm 40
BA41.10-P-1001- Self-locking screw, front propeller shaft to transfer case 1
01F (rear axle side) Stage
Angle° 90
2
Stage
Nm 40
BA41.10-P-1003- Self-locking bolt, propeller shaft to transfer case (to front 1
01F axle) Stage
Angle° 90
2
TRANSMISSION OIL COOLING SYSTEM

722.9
Stage
Nm 5
BA27.55-P-1002- Bolt, transmission oil line to Banjo 1
01D transmission housing bolt Stage
Angle° 90
2
Hexalobular bolt Nm 12
BA27.55-P-1003-
Bolt, oil cooler line to engine oil pan Nm 12
01D
BA27.55-P-1004-
Bolt, dual clamp to oil line Nm 8
01D
HOUSING
Number Designation Transmission 722.9 in model
164
BA27.40-P-1001-
Bolt, automatic transmission to crankcase Nm 39
01E
BA27.40-P-1002- Bolt, automatic transmission to engine oil
Nm 39
01E pan
BA27.40-P-1003-
Bolt, heat shield to transmission housing Nm 8
01E
STARTER
BA15.30-P-1003-01N Bolt, starter to cylinder crankcase Nm 40
TORQUE CONVERTER
722.9
Straight threaded
Nm 42
connection
BA27.20-P-1002- Bolt, torque converter to drive Stage 1 Nm 4
01C plate
Helical cut Stage 2 Nm 30
Stage 3 Angle° 90
STARTER
Number Designation Engine 113.964 in model 164
BA15.30-P-1003-01A Bolt connecting starter to crankcase Nm 40
STARTER
Number Designation Engine 601, 602, 604, 605, 606, 611, 628, 629
BA15.30-P-1003-01C Bolt for starter Nm 42

Fig. 9: Identifying Retainer Wrench (164 589 02 07 00)

Fig. 10: Identifying Grab Handle (168 589 00 62 00)

Fig. 11: Identifying Parallel Support (126 589 04 31 00)

Fig. 12: Identifying Wrench Socket (001 589 65 09 00)


Remove/install transmission with torque converter - AR27.10-P-0500GZA
TRANSMISSION 722.9 in MODEL 164 with ENGINE 272, 273

Fig. 14: Identifying Transmission With Torque Converter Components (1 Of 3)



MODIFICATION NOTES
25.6.07 Observe tightening procedure when assembling propeller shaft, added Operation step 14, 15
Remove/install

AH00.00-
Notes on bolted connections with self
P-0007-
tapping screws
01SF
AH00.00-
01A
surrounding the oil cooling lines (14a,
14b) must be thoroughly cleaned in the
area of the separation points of the
transmission (15). Even the smallest
dirt particles in the hydraulic
components can lead to malfunctions
and a total failure of the transmission
(15)
Move DIRECT SELECT gear selector
1
switch to position "N"

AR54.10-
P-0003GZ
AH54.10-
01A
4
and raise P-0100GZ
Unclip connectors (G3/3x1 up to
G3/6x1) of O2 sensors and electrical
5
lines of O2 sensors from the lower and
side brackets on transmission (15)
AR07.52-
Disconnect connectors (G3/3x1 up to
6 P-
G3/6x1) of O2 sensors
5303GZP
7 Remove bracket for O2 sensors (3) Below transmission (15).
AR49.10-
8 Remove complete exhaust system P-
7100GZA
AR27.40-
Detach right shield (8) at transmission
9 P-0700-
(15)
01GZ
*BA27.40-
P-1003-
01E
Unlock connector for the automatic
Unclip automatic
transmission/intelligent servo module
transmission/intelligent servo module connector
10 (X22/6) and detach from the intelligent
(X22/6) at transmission (15).
servo module for DIRECT SELECT
(A80) Installation: Install new cable ties.
Detach bleed line (23) from bleed valve
11
of front axle gear (4)
Seal oil cooler lines (14a, 14b) and
Detach oil cooler lines (14a, 14b) on
12 openings on transmission (15) immediately with
transmission (15)
stop plugs.
*BA27.55-
P-1002-
01D
Fig. 8
Loosen bolt of double clamp (12) at the *BA27.55-
13 side and place oil cooler lines (14a, P-1004-
14b) to one side 01D
Detach front propeller shaft (20) from Fix front propeller shaft (20) to left
14
front axle differential (4) exhaust bracket using cable tie.
AR41.10-
procedure for front propeller shaft (20). 03GZ
Fig. 9
*BA41.10-
P-1004-
01F
Detach rear propeller shaft from The rear propeller shaft can be put to
15
transfer case one side after lowering the transmission (15).
Installation: Observe tightening AR41.10-
procedure for rear propeller shaft to transfer P-0050-
case. 17GZ
Fig. 9
*BA41.10-
P-1001-
01F
Support transmission (15) using Transmission platform, refer to GOTIS
transmission jack and transmission http://gotis.aftersales.daimlerchrysler.com
16
platform and secure to prevent it from Transmission jack, refer to GOTIS
falling down http://gotis.aftersales.daimlerchrysler.com
AR22.10-
Remove bolts (17, 18) and take off The rear engine mount remains on the
17 P-
engine crossmember (16). transmission (15). Bolts (18) must be replaced. 1180GZD
Secure propeller shaft to prevent it from
18 guide rear propeller shaft out of flange
falling.
and place aside
To unscrew or screw in do not use an impact AR27.20-
Remove cover (5) and detach torque wrench or compressed-air tool, otherwise the
19 P-0100-
converter (24) from driven plate threaded unions in the driven plate will be 01A
damaged.
*BA27.20-
P-1002-
01C
Fig. 12
Fig. 13
*BA15.30-
P-1003-01J
Remove the bolt (21) from the bracket
Detach transmission (15) from
21 of the bleed line (22) first and remove bleed line
crankcase by removing bolts (21)
(23).
*BA27.40-
P-1001-
01E
*BA27.40-
P-1002-
01E
Secure torque converter (24) to prevent
it from falling out.
22 Remove transmission (15) from below Installation: Align bolt holes on torque
converter (24) with the threaded unions in the
driven plate.
AR27.20-
01W
*BE27.20-
01E
Fig. 10
Fig. 11
Checking
Check threaded unions in the driven A new driven plate must be installed if
24
plate the threaded unions are damaged and loose.
Only when replacing the transmission
(15) or if the transmission oil has been drained.
Fill transmission (15) with transmission Adhere to the specified work procedure AR27.00-
26
oil exactly and observe the Specifications for P-0270W
Operating Fluids, otherwise the transmission
(15) will be damaged.
Adhere exactly to the specified work
Check transmission oil level; correct if procedure and observe Specifications for AR27.00-
27
necessary Operating Fluids, otherwise the transmission P-0100W
Read out fault memory with STAR
DIAGNOSIS and erase if necessary
A transmission adaptation must be carried out
29 Perform transmission adaptation after exchanging or repairing the transmission
(15).
AS00.00-
running. Risk of injury caused by itself.
Z-0005-
contusions and burns during starting Wear closed and snug-fitting work clothes.
01A
procedure or when working near the Do not touch hot or rotating parts.
30 Test run engine and check transmission

(15) for leaktightness and proper
operation

722.9
helical screwed
mm 9,5
mm 19,5
connection
HOUSING
164
BA27.40-P-1001-
01E
Nm 39
01E pan
BA27.40-P-1003-
01E

722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
BA27.55-P-1004-
01D
STARTER
Number Designation Engine 272, 273
BA15.30-P-1003-01J Bolt connecting starter to crankcase Nm 40
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2
Stage
1 Nm 40
BA41.10-P-1004-
Self-locking bolt, propeller shaft to front axle gear Stage
01F Angle° 90
2
TORQUE CONVERTER
722.9
Straight threaded
Nm 42
connection
01C plate
Stage 3 Angle° 90






Remove/install transmission with torque converter - AR27.10-P-0500GZS
TRANSMISSION 722.9 in MODEL 164, 251 with ENGINE 156




MODIFICATION NOTES
Special tool for counterholding the propeller shaft modified
AR41.10-P-0070-
25.6.07 Observe tightening procedure when assembling propeller shaft, Step 03GZ
added 8
Remove/install

AH00.00-
Notes on bolted connections with self
P-0007-
tapping screws
01SF
AH00.00-
01A
surrounding the oil cooling lines (14a,
14b) must be thoroughly cleaned in
the area of the separation points of the
transmission (15). Even the smallest
dirt particles in the hydraulic
components can lead to malfunctions
and a total failure of the transmission
(15)

1
AR54.10-
3 Disconnect battery ground cable Model 164
P-0003GZ
AR54.10-
Model 251
P-0003RT
AH54.10-
01A
4 Model 164
and raise P-0100GZ
AR00.60-
Model 251
P-0100RT
AR49.10-
Remove exhaust system up to rear
5 Model 164 P-
flange connection
7000GZS
AR49.10-
Model 251
P-7000RT
Remove bolts from the stiffening
6 Model 251 only
bridge under the propeller shaft
*BA61.10-
P-1005-
01F
Unscrew the bolts (1) and nuts (2) and
7 Remove all three shields complete
remove shields of propeller shafts
Detach rear propeller shaft from Mark the rear propeller shaft relative to
8
transfer case (5) the propeller shaft flange.
procedure for rear propeller shaft to transfer case P-0050-
(5). 17GZ
Fig. 9
*BA41.10-
Model 164 P-1001-
01F
*BA41.10-
Model 251 P-1001-
01G
Disconnect automatic
9 connector (X22/6) from intelligent
servo module for DIRECT SELECT
(A80)
10 Remove exhaust bracket (29)
AR27.40-
Remove shield (8) at transmission
11 P-0700-
(15).
01GZ
*BA27.40-
P-1003-
01E
Disconnect connector (9) at electric
12
controller unit
For unscrewing and screwing in the bolts, do
not use any impact wrench/driver or compressed AR27.20-
Remove cover (7) and detach torque
13 air tool, otherwise the threaded unions in the P-0100-
converter (24) from drive plate.
torque converter (24) or in the driven plate will be 01A
damaged.
*BA27.20-
P-1002-
01C
Fig. 13
Fig. 12
*BA27.55-
Remove oil cooler line bolt (10) at oil
14 P-1003-
pan bracket (11).
01D
*BA27.55-
Remove double hose clamp bolt (12)
15 P-1004-
at alternator bracket (13).
01D
Do not bend or kink oil cooler lines (14a,
14b).
Detach oil cooler lines (14a, 14b)
Seal the connections on the transmission
16 from transmission (15) and engine oil
pan and place to one side (15) and oil cooler lines (14a, 14b) immediately
with stop plugs.
Installation: replace O-rings.
*BA27.55-
P-1002-
01D
Fig. 8
secure on the transmission platform with
tensioning strap to prevent it from falling down.
Support transmission (15) with
17 Transmission platform, see GOTIS
transmission jack and plate
Transmission jack, see GOTIS
The rear engine mount remains on the
AR22.10-
Remove bolts (17, 18) and take off transmission (15). Bolts (18) must be replaced.
18 P-
engine crossmember (16). Check rear engine mount for wear and replace 1170GZS
if necessary.

Remove front propeller shaft (20) on propeller shaft flange (20a).
19
transfer case (5) Hook front propeller shaft (20) to one side
using cable ties.
AR41.10-
procedure for front propeller shaft (20). 03GZ
Fig. 9
*BA41.10-
Model 164 P-1003-
01F
*BA41.10-
Model 251 P-1003-
01G
*BA15.30-
P-1003-
01O
First unscrew bolt (21) on the bracket of
21 crankcase and engine oil pan by
removing bolts (21). vent line (22) and remove vent line (23).
*BA27.40-
P-1001-
01E
*BA27.40-
P-1002-
01E
Secure torque converter (24) to prevent it
from falling out.
22 Installation: Align threaded holes in the
below
torque converter (24) with the holes in the drive
plate.
AR27.20-
01W
*BE27.20-
01E
Fig. 11
Fig. 10
Checking
Check thread for damage, replace torque
24 Check thread in torque converter (24)
converter (24) if damaged.

Only when replacing the transmission
(15) or if the transmission oil has been drained.
Fill transmission (15) with AR27.00-
26 Adhere exactly to the specified work procedure
transmission oil P-0270W
and observe Specifications for Operating Fluids,
Adhere exactly to the specified work procedure
Check transmission oil level; correct AR27.00-
27 and observe Specifications for Operating Fluids,
if necessary P-0100W
necessary
A transmission adaptation must be carried
29 Perform transmission adaptation out after exchanging or repairing the transmission
(15).
Test run engine and check
30 transmission (15) for leaktightness
and proper operation

722.9
helical screwed
mm 9,5
mm 19,5
connection
FRAME FLOOR ASSEMBLY

BA61.10-P-1005-01F Bolt, stiffening bridge to frame floor assembly Nm 20
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2
Stage
1 Nm 40
BA41.10-P-1003- Self-locking bolt, propeller shaft to transfer case (to front
01F axle) Stage
Angle° 90
2
PROPELLER SHAFT
251
Stage
Nm 40
BA41.10-P-1001- Self-locking bolt, propeller shaft to transfer case (to rear 1
01G axle) Stage
Angle° 90
2
Stage
Nm 40
01G axle) Stage
Angle° 90
2
HOUSING
Number Designation Transmission 722.9 in model 164
Transmission 722.9 in model 251
BA27.40-P- Bolt, automatic transmission to
Nm 39 39
1001-01E crankcase
BA27.40-P- Bolt, automatic transmission to
Nm 39 39
1002-01E engine oil pan
BA27.40-P- Bolt, heat shield to transmission
Nm 8 8
1003-01E housing
TORQUE CONVERTER
722.9
Straight threaded
Nm 42
connection
01C plate
Stage 3 Angle° 90

722.9
Stage
Nm 5
Banjo 1
2
BA27.55-P-1003-
01D
BA27.55-P-1004-
01D
STARTER
BA15.30-P-1003-01O Bolt connecting starter to crankcase Nm 40






SEPARATE/CONNECT TRANSMISSION OIL LINE - AR27.10-P-0501-03RT


Remove retaining clamp on connector
The area surrounding the separation point should be cleaned thoroughly before opening the hydraulic
system. Even minute particles of dirt in the hydraulic components can result in malfunctions and total failure of
the hydraulic system.
1. Detach dust cap (3) and push back along the transmission oil line (1) until the connector (2) is accessible.
2. Using a suitable tool attach at one end of the safety clip (2a), detach this from the connector (2) and pull
transmission oil line (1) out of the connector (2).
Seal off line connections using plugs.
3. Detach dust cap (3) from transmission oil line (1).
Fig. 33: Identifying Retaining Clamp On Connector

Attach retaining clamp to connector
The safety clamp (2a) must be replaced after every disconnection of a transmission oil line (1).
4. Insert safety clip (2a) in a recess (2b) of the connector (2), then push in the direction of the arrow until the
safety clip (2a) latches fully in the connector (2).
Fig. 34: Attaching Retaining Clamp To Connector

The safety clip (2a) must not be pushed straight over the connector (2) otherwise this will be
overstretched and correct sealing of the line connector is no longer guaranteed.
Fig. 35: Caution For Attaching Retaining Clamp To Connector

Attach transmission oil line to connector
5. Push dust cap (3) onto transmission oil line (1).

6. Introduce transmission oil line (1) straight into the connector (2) until it audibly and noticeably latches.
7. Push dust cap (3) onto the connector (2).
If the dust cap (3) cannot be pushed over the connecting point then the transmission oil line (1) is
not fully latched in the connector (2) or the safety clamp (2a) is overstretched.
FASTEN TRANSMISSION ON ASSEMBLY STAND - AR27.10-P-0600-01W
Transmission 722.9
Fig. 36: Identifying Assembly Stand (116 589 06 59 00)

Fig. 37: Identifying Support Plate (140 589 34 63 00)

1. Bolt support plate (H) to assembly stand (B) at threaded holes (B1, B2, B3).
2. Align holes (G1, G2, G3) of torque converter housing (1w) with threaded holes (H1, H2, H3) of support
plate (H).
After positioning, secure the transmission to prevent it from tilting and slipping off.
3. Bolt torque converter housing (1w) to support plate (H) at threaded holes (H1, H2, H3).
Fig. 38: Identifying Transmission Fastened On Assembly Stand

REMOVE/INSTALL AUTOMATIC TRANSMISSION OIL PAN - AR27.10-P-7030W
TRANSMISSION 722.9 /9
Fig. 39: Identifying Automatic Transmission Oil Pan Components - Transmission 722.9 /9
Illustration shows transmission oil pan without sloped surface and with black overflow tube
MODIFICATION NOTES
3.2.04 Notice on modified Step 1
transmission oil pan added
Remove/install
vehicle slipping or columns of vehicle lift and
toppling off of the lifting position four support
platform. plates at vehicle lift
support points specified by
General notes Pay attention to
cleanliness during all
operations. No fluffy
cleaning cloths may be
used. Chamois leathers are
the most suitable.
1 Check transmission oil The transmission
pan (3) oil pan (3) and the
overflow pipe (31) have
been redesigned to
optimize the oil feed of the
transmission. After
removal, replace the old
without chamfer with
black overflow pipe (31)
by the transmission oil pan
(3) with chamfer and with
white overflow pipe
(31): ? Transmission
722.901
Redesigned oil pan and BT27.10-P-0006-01W
overflow tube
pan (3) and its
surroundings thoroughly
3 Drain the transmission oil Unscrew drain
and collect for plug and pry overflow
determining the quantity pipe (31) off base (arrow)
of transmission using drift. The
remaining transmission oil
drains out immediately
after prying off.
Installation:
Replace sealing ring.
*BA27.10-P-1001-03A
Fig. 40
4 Detach the transmission Installation: The
oil pan (3) from the clamping bodies (3a) are
transmission housing (1) only permissible for the
transmission 722.9 and
must not be mixed up with
other clamping bodies, as
otherwise contact
corrosion occurs. Replace
bolts (3b).
*BA27.10-P-1002-03A
5 Remove overflow pipe Installation:
(31) from the transmission Replace overflow pipe
oil pan (3) (31) and press firmly onto
the base (arrow).
The distance from
the upper edge of the
overflow pipe (31) to the
base of the transmission

oil pan (3) determines the
filling capacity of the
transmission.
Clean
6 Remove and clean the Check the magnet
magnet (32) from the (32) for damage and
transmission oil pan (3) replace if necessary
7 Remove and clean seal A seal (33) which
(33) is not damaged can be
used again.
pan (3)
9 Replace oil filter (34)
11 Fill transmission with Transmission 722.9 AR27.00-P-0270W
transmission fluid (except 722.960/961/962/
963/964)
To prevent damage to
the transmission, it is
essential to observe the
work procedure and
Specifications for
Operating Fluids.
by vehicle starting off by it from moving by itself.
caused by contusions and Do not touch hot or
procedure or when
working near the engine
as it is running
12 Perform engine test run
and check transmission
for leaktightness and
proper operation

BA27.10-P-1001-03A Oil drain screw to Nm 22
BA27.10-P-1002-03A Bolt, oil pan to Nm 4
transmission housing Angle ° 180

REMOVE/INSTALL ELECTROHYDRAULIC CONTROLLER UNIT (TRANSMISSION

INSTALLED) - AR27.19-P-0200W
TRANSMISSION 722.9
Fig. 41: Identifying Electrohydraulic Controller Unit Components - Transmission 722.9

MODIFICATION NOTES
10.5.05 Carry out transmission Step 10.1
adaptation inserted
Remove/install
vehicle slipping or columns of vehicle lift

toppling off of the lifting and position four support
1 Switch off ignition, On vehicles with
remove ignition key or code 889 Keyless-Go:
transmitter key Press the start and stop
button repeatedly until the
ignition is switched off.
Remove the Keyless Go
transmitter card or
transmitter key from the
vehicle and store beyond
the reach of the
transmitter (at least 2 m).
2 Remove oil pan (3) AR27.10-P-7030W
3 Remove oil filter (34)
4 Remove heat shield above
the transmission connector
(4e)
5 Unplug 5-pin connector at Clean the
transmission connector transmission connector
(4e) (4e) and connector on the
electric controller unit
(VGS) and fully
integrated transmission
control controller unit
(Y3/8).
6 Unscrew bolts (4s) and Installation:
remove electric controller Replace bolts (4s). Before
unit (VGS) and fully installing the Electric
integrated transmission controller unit (VGS) or
control controller unit fully integrated
(Y3/8) transmission control
controller unit (Y3/8) plug
the supply pipe into the
transmission housing (1).
When inserting the
electric controller unit
(VGS) or fully integrated
controller unit (Y3/8)
insert the selector valve
(4w) into the drive plate
of the detent plate (82).
See: ?
Insert selector valve with AR27.19-P-0200-01A
driver into detent plate
*BA27.19-P-1001-01A
8 Check oil level and correct AR27.00-P-0100W
if necessary
9 Read out fault memory STAR
and erase DIAGNOSIS Stored
faults which can result
from cables being
disconnected or from
simulation during removal
and installation or test
work, have to be
processed and erased in
the fault memories after
completing the work
Connect STAR AD00.00-P-2000-04A
DIAGNOSIS and read out
fault memory
10 Perform transmission After replacing or
adaptation repairing transmission,
perform transmission
adaptation.
procedure or when
working near the engine as
it is running
11 Perform engine test run
and check transmission for
leaktightness and proper
operation
ELECTROHYDRAULIC CONTROLLER UNIT

BA27.19-P-1001- Bolt, electrohydraulic Stage 1 Nm 4
01A controller unit to
transmission housing Stage 2 Angle ° 90
Insert selector valve into driver of detent plate - AR27.19-P-0200-01A
1. When inserting electrohydraulic control unit into transmission housing, plastic part of selector valve (10)
must engage in driver of detent plate (11).
Fig. 42: Identifying Plastic Part Of Selector Valve, Driver Of Detent Plate
REMOVE/INSTALL INTELLIGENT SERVO MODULE - AR27.19-P-0550GZA
TRANSMISSION 722.9 in MODEL 164

Fig. 43: Identifying Intelligent Servo Module Components

Fig. 44: Locating Gear Selector Switch To Position D

MODIFICATION NOTES
25.6.07 Observe tightening procedure when assembling propeller shaft, added Step 9
Remove/install
Align vehicle between columns of vehicle lift

and position four support plates at vehicle lift AS00.00-Z-
support points specified by vehicle 0010-01A
platform.
manufacturer.
AH54.00-P-
0001-01A
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
1 Remove Keyless Go button Vehicles with Keyless Go Code 889
2 Turn ignition key to position 2.
Move DIRECT SELECT gear selector
3
switch to position "D"
4 Turn ignition key to position 2. The ignition key must not be removed.
Insulate clamping device of the ground line AR54.10-P-
6 Disconnect ground line from battery in order to prevent inadvertent contact with the 0003GZ
ground point of the battery.
AH54.10-P-
Notes on battery
0001-01A
AR00.60-P-
1000GZ
*BA62.30-
8 Remove bolts (1) and remove struts (2)
P-1001-01E
*BA62.30-
P-1002-01E
*BA62.30-
P-1003-01E
*BA62.30-
P-1004-01E
Mark front propeller shaft (5) relative
Detach front propeller shaft (5) from
9 to propeller shaft flange using colored pencil
transfer case (7).
or chalk.
Installation: Observe tightening AR41.10-P-
procedure for front propeller shaft (5). 0070-03GZ
Fig. 9
*BA41.10-
P-1003-01F
Remove cable ties (6) from bleed hose Installation: replace cable ties (6).
10
(8) at transmission housing Special cable ties (6) must be used.
Do not destroy the clip otherwise the
Open clip of bleed hose (8) at
11 correct control of the vent hose (8) is no longer
transmission housing.
guaranteed.
Detach automatic
12
connector (X22/6) on intelligent servo
module for DIRECT SELECT (A80)
13 Support transmission
The rear engine mount (19) remains
Remove bolts (17, 18) and remove
14 on the transmission. Bolts (18) must be
engine crossmember (16)
replaced.
AR22.10-P-
Vehicles with engine 113
1170GZA
AR22.10-P-
Vehicles with engine 272, 273, 642, 629
1180GZD
AR22.10-P-
Vehicles with engine 156
1170GZS
Checking
15 Check rear engine mount (19) for wear Replace if necessary.
Installation: Replace all bolts. Fit
Remove bolts at protective cover (9) bolts at protective cover (9). First tighten
16
and take off protective cover (9). special bolts (10) with attached centering
sleeve.
*BA27.40-
P-1004-01E
*BA27.40-
P-1005-01E
Remove special bolts (10) at intelligent
servo module for DIRECT SELECT Installation: Replace special bolts

17
(A80). (10).
Do not detach vent hose otherwise the
leaktightness at the connection can no longer
be guaranteed and this can lead to water entry
at the intelligent servo module (A80).
The vent hose (8) should also be
replaced when replacing the intelligent servo
module (A80).
Remove intelligent servo module for
18 DIRECT SELECT (A80) with bleed Installation: The intelligent servo
hose (8). module (A80) can only be assembled on the
transmission in one position. If necessary the
range selector shaft (3) on the transmission
must be turned clockwise using an assembly
tool.
The condition as delivered of the
intelligent servo module (A80) ensues in
position "D" (arrow).
Fig. 45
necessary
Using STAR DIAGNOSIS carry out
After installing new intelligent servo module
21 initial startup of the intelligent servo
(A80)
module for DIRECT SELECT (A80)
CROSSMEMBER AND FRONT REINFORCEMENT

BA62.30-P-1001-01E Bolt, right bracket to engine crossmember M10 Nm 45
BA62.30-P-1002-01E Bolt, right bracket to transmission tunnel M10 Nm 45
BA62.30-P-1003-01E Bolt, left bracket to engine crossmember M10 Nm 45
BA62.30-P-1004-01E Bolt, left bracket to transmission tunnel M10 Nm 45
HOUSING
Number Designation Transmission 722.9 in
model 164
BA27.40-P-1004- Bolt, shield to hexagon special bolt for shift module
Nm 7
01E (ISM)
BA27.40-P-1005- Hexagon special bolt, shift module (ISM) to
Nm 7
01E transmission housing
PROPELLER SHAFT
164.1/8
Stage
Nm 40
BA41.10-P-1003- Self-locking bolt, propeller shaft to transfer case (to 1
01F front axle) Stage
Angle° 90
2
Fig. 45: Identifying Assembly Tool (722 589 03 09 00)


DETACH/ATTACH TORQUE CONVERTER ON DRIVER - AR27.20-P-0100
Detach/attach torque converter on driver - AR27.20-P-0100-01A
TORQUE CONVERTER
722.9
BA27.20-P- Oil drain screw M8 Nm 10
1001-01C to torque
converter M10 Nm 15
BA27.20-P- Bolt, torque Straight threaded Nm 42
1002-01C converter to connection
drive plate Angled threaded Stage 1 Nm 4
connection Stage 2 Nm 30
Stage 3 Angle ° 90


Detaching
To unscrew and screw in do not use an impact wrench or compressed-air tool, otherwise the threaded unions
in the driven plate will be damaged.
1. Remove cover (8).

2. Unscrew bolts (1 to 6) of the torque converter from the driven plate (7).
Continue turning the engine in the direction of engine rotation using socket on the crankshaft
center bolt. If the center bolt is not accessible, continue turning the torque converter using a wide
screwdriver.
Fig. 49: Identifying Torque Converter Bolts At Driven Plate

Checking
3. Check driven plate (7) for damage.
If the threaded unions (7a) are damaged or loose, the driven plate (7) must be replaced.
Fig. 50: Identifying Driven Plate Threaded Unions

Attaching
4. Mount torque converter (9) on driven plate (7).
Replace bolts (1 to 6)
Observe tightening sequence and tightening torque otherwise the torque converter (9) or driven plate
Fig. 51: Identifying Tightening Sequence Of Torque Converter Bolts

TIGHTENING SEQUENCE
Tightening sequence Bolt stage
1 Press the torque converter (9)
against the driven plate (7)using a
long wedge
2 Attach the bolts (1 to 6) and
position by hand
3 Tighten bolts (1, 2) and while Stage 1
tightening press the torque
converter (9) against the driven
plate (7) with a long wedge
4 Tighten bolts (3 to 6) Stage 1
Detach/attach torque converter on driver - AR27.20-P-0100-01GZ
MODIFICATION NOTES
13.1.06 Bolt, torque converter to drive plate Transmission 722.9 *BA27.20-P-1002-01C
TORQUE CONVERTER
722.9
Straight threaded connection Nm 42
Stage
Nm 4
1
BA27.20-P-1002- Bolt, torque converter to
01C drive plate Stage

Nm 30
Angled threaded 2
connection Stage
Angle° 90
3

1. Remove cover (1) on crankcase.
Installation: Pay attention to correct seat of cover (1).
2. Turn engine by respectively approx. 120° at the crankshaft center bolt using socket in the direction of
engine rotation and unscrew the torque converter bolts.
The torque converter is attached to the drive plate with six bolts.
Installation: Before installing the transmission, align the tapped holes of the torque converter
and holes in the drive plate.
3. Install in the reverse order.

Fig. 53: Identifying Cover On Crankcase

REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500-01W
MODIFICATION NOTES
7.6.06 Installed height of torque Type 722.9 transmissions, *BE27.20-P-1001-01B
converter with exception of
Type 722.906
Installed height of torque Transmission 722.906 *BE27.20-P-1001-01B
converter
22.5.06 Measurement for Step 6
determining installed
height of torque converter
changed

Number Designation Type 722.9 Transmission
transmissions, 722.906
with exception of
Type 722.906
BE27.20-P- Installed height Distance from mm 39.5 (-2) 29.5 (-2)
1001-01B of torque transmission
converter housing


REPAIR MATERIALS
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Remove torque converter
1. Position transmission vertically.

2. Fit grab handles (065) to torque converter.
3. Remove torque converter from transmission housing.
4.1 If there are metal shavings in the transmission oil pan:
Drain transmission oil from torque converter through a clean cloth.
If there are metal chips in the cloth, replace torque converter.
In case of doubt flush out the torque converter with transmission oil.
Remaining metal chips can cause transmission damage!
4.2 If transmission oil is burnt or interspersed with abrasive particles: Flush oil cooler lines and oil cooler.
Fig. 56: Identifying Grab Handles On Torque Converter

Install torque converter
5 Grease the crankshaft journals with multi-purpose paste and insert torque converter into transmission
housing.
Do not use force, otherwise the axial stop of the torque converter will be destroyed.
Move torque converter back and forth so that the teeth on the torque converter and the
transmission primary pump engage in one another.
Fig. 57: Inserting Torque Converter Into Transmission Housing

Measure installed height of torque converter in transmission housing
6 Measure installed height dimension between parallel support (2) and converter mount using depth
gauge.
If the torque converter is seated incorrectly in the transmission housing, the torque converter and the
primary pump can be damaged.
Depth gauge, refer to GOTIS.
Fig. 58: Measuring Installed Height Dimension Between Parallel Support And Converter Mount
REMOVE/INSTALL RADIAL SHAFT SEALING RING ON FRONT TRANSMISSION COVER -

AR27.30-P-4970GZ
TRANSMISSION 722.9 in MODEL 164.1 /8
Fig. 59: Identifying Radial Shaft Seal On Front Transmission Cover

MODIFICATION NOTES
Model 722.9 transmissions, with
7.6.06 Installed height of torque converter exception of model 722.906
Installed height of torque converter Transmission 722.906

Measurement for determining installed AR27.20-P-
13.6.06 Step 7
height of torque converter changed 0500-01W
Removing
Risk of death caused by
Align vehicle between the columns of the lifting platform
vehicle slipping or AS00.00-Z-
and position the four support plates at the lifting platform
toppling off of the lifting 0010-01A
support points specified by the vehicle manufacturer.
platform.
Secure vehicle on the AR00.60-P-
1
lifting platform 1000GZ
Remove transmission with AR27.10-P-
2 Model 164.120/122/128/175/822/828
torque converter 0500GZ
Model 164.186/871/886 AR27.10-P-
Model 164.177 0500GZA
Fasten transmission on AR27.10-P-
3
assembly stand 0600-01W
AR27.20-P-
4 Remove torque converter
0500-01W
Pry off radial shaft sealing ring (1) using a suitable
Remove radial shaft
5 tool, in doing so do not damage the seat of the radial shaft
sealing ring (1).
sealing ring (1).
Install
Drive in radial shaft seal Pack the radial shaft sealing ring (1) between the
6
(1) flush using drift. lips (arrow) with grease.
Fig. 60
AR27.20-P-
7 Insert torque converter.
0500-01W
Install transmission with AR27.10-P-
8 Model 164.120/122/128/175/822/828
torque converter 0500GZ
Model 164.186/871/886 AR27.10-P-
Model 164.177 0500GZA

REMOVE/INSTALL RADIAL SHAFT SEALING RING AT OUTPUT FLANGE - AR27.40-P-0205GZ
Fig. 61: Identifying Radial Shaft Sealing Ring Components (1 Of 2)

Fig. 62: Identifying Radial Shaft Sealing Ring Components (2 Of 2)

MODIFICATION NOTES
25.6.07 Operation sequence adapted to the change in repair method
Remove/install

Risk of death caused by vehicle slipping lift and position four support plates at AS00.00-Z-
or toppling off of the lifting platform. vehicle lift support points specified by 0010-01A
AH00.00-N-
0001-01A
Installation: Grease toothing of AR28.10-P-
1 Remove transfer case
transfer case input shaft lightly. 0100GZ
*BR00.45-Z-
MB long-life grease
1001-06A
2 Remove intermediate housing (28) Installation: Install new bolts (6).
*BA27.40-P-
1020-01A
Unscrew collar nut (1) at connecting *BA27.50-P-
3
flange (2). 1001-01A
Fig. 64
Detach connecting flange (2) from output
4
shaft (3).
Use a screwdriver to lever radial shaft Do not damage seat of radial shaft sealing
5 sealing ring (4) out of transmission ring (4) as this can lead to oil loss or
housing. transmission damage.
Installation: Press in radial shaft
Press in new radial shaft sealing ring (4)
6 sealing ring (4) until drift (9) touches
using drift (9)
transmission housing.
Fig. 63
Secure vehicle to prevent it from moving by
Risk of accident due to vehicle starting itself. AS00.00-Z-
off when engine is running Wear closed and snug-fitting work clothes. 0005-01A
Risk of injury caused by contusions and
burns during starting procedure or when
working near the engine as it is running
8
Perform engine test run and check
transmission for leaks with engine
running
GEAR ASSEMBLY
Number Designation Transmission 722.6 722.9
BA27.50-P-1001-01A Collar nut, output flange to output shaft Nm 200

722.9
Stage
Nm 10
BA27.40-P-1020- Bolt, intermediate housing to transmission 1
01A housing Stage
Angle° 90
2



BR00.45-Z-1001-06A MB long-life grease 000 989 63 51
REMOVE/INSTALL SHIFT SHAFT RADIAL SHAFT SEALING RING - AR27.40-P-0220
Remove/install shift shaft radial shaft sealing ring - AR27.40-P-0220A
TRANSMISSION 722.9
Transmission with intelligent servo module ISM

Fig. 65: Identifying Shift Shaft Radial Shaft Sealing Ring Components - Transmission 722.9
Removing
1 Remove intelligent servo Model 164 AR27.19-P-0550GZA
module (ISM)
Model 221 AR27.19-P-0550SX
Model 251 AR27.19-P-0550RT
2 Remove heat shield (3) of
left catalytic converter
and bracket (2) of lower
engine compartment
paneling
Clean
3 Clean transmission LU cleaner *BR00.45-Z-1028-04A
housing (1) around shift
shaft (40) and radial shaft
sealing ring (20)
4 Remove transmission oil AR27.10-P-7030W
pan
5 Unscrew bolt (16a) and
detach spring element
(16)
6 Remove clamp bolt (82a) Pull out at the
and pull out shift shaft side without using tools.
(40)
7 Pry out radial shaft Make sure that the
sealing ring (20) using a contact surface in the
suitable tool transmission housing (1)
is not damaged, otherwise

leakage will occur.
Checking
8 Check shift shaft (40) for
galling and damage;
install a new shift shaft if
necessary
Install
9 Drive radial shaft sealing Check that the radial
ring (20) all the way into shaft sealing ring (20) is
transmission housing (1) seated correctly in the
using drift (01) transmission housing (1),
otherwise leakage will
occur.
Fig. 66
10 Insert shift shaft (40) and Make sure that
screw in clamp bolt (82a) the shift shaft (40) is
positioned correctly in the
detent plate (82).
*BA27.19-P-1004-01A
11 Mount spring element *BA27.19-P-1005-01A
(16) and screw in bolt
(16a)
12 Install transmission oil AR27.10-P-7030W
pan
13 Install intelligent servo Model 164 AR27.19-P-0550GZA
module (ISM)
Model 221 AR27.19-P-0550SX
Model 251 AR27.19-P-0550RT
14 Fill transmission with Transmission 722.9 AR27.00-P-0270W
gear oil except 722.960/ 961/ 962/
963/ 964
Transmissions 722.960/ AR27.00-P-0270SYZ
961/ 962/ 963/ 964
procedure or when
as it is running
15 Perform engine test run;
check transmission
housing (1) at separation
points and at radial shaft
sealing ring (20) for leaks
and check that
transmission is
functioning correctly

BA27.19-P-1004-01A Shift shaft clamp bolt to Nm 8
detent plate
BA27.19-P-1005-01A Detent plate spring Nm 9
element bolt to
electrohydraulic controller
unit

REPAIR MATERIALS
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
Remove/install shift shaft radial shaft sealing ring - AR27.40-P-0220B
TRANSMISSION 722.9
Transmission with range selector lever, with propeller shaft detached and rear engine crossmember
removed
Fig. 67: Identifying Shift Shaft Radial Shaft Sealing Ring Components - Transmission 722.9
Removing
1 Detach safety clip and
pull shift rod out of the
range selector lever (2)
2 Remove heat shield of the
left catalytic converter
and left bracket of the
lower engine
compartment paneling
Clean
3 Clean transmission LU cleaner *BR00.45-Z-1028-04A
housing (1) in the area of
the range selector lever
(2) and the radial shaft
sealing ring (20)
4 Remove transmission oil AR27.10-P-7030W
pan
5 Unscrew bolt (16a) and
detach spring element
(16)
6 Unscrew clamp screw Pull out at the
(82a) and remove range side without using tools.
selector lever (2) Check rubber
mount (5) of shift rod at
range selector lever (2)
and replace if necessary.
7 Pry out radial shaft Make sure that the
sealing ring (20) using a contact surface in the

suitable tool transmission housing (1)
is not damaged, otherwise
leakage will occur.
Checking
8 Check range selector
lever (2) for galling and
damage, replace if
necessary
Install
9 Drive radial shaft sealing Fig. 66
ring (20) all the way into
transmission housing (1)
using drift (01)
10 Insert range selector lever Pay attention to
(2) and screw in clamp the correct position of the
screw (82a) range selector lever (2) in
the detent plate (82).
*BA27.19-P-1004-01A
11 Mount spring element *BA27.19-P-1005-01A
(16) and screw in bolt
(16a)
12 Install transmission oil AR27.10-P-7030W
pan
13 Insert shift rod at range Replace safety
selector lever (2) and clip of shift rod at range
mount safety clip selector lever (2).
14 Fill transmission with AR27.00-P-0270W
gear oil
procedure or when
as it is running
15 Perform engine test run;
check transmission
housing (1) at separation
points and at radial shaft
sealing ring (20) for leaks
and check that
transmission is

BA27.19-P-1004-01A Shift shaft clamp bolt to Nm 8
detent plate
BA27.19-P-1005-01A Detent plate spring Nm 9
element bolt to
electrohydraulic controller
unit

REPAIR MATERIALS
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
REMOVE/INSTALL OIL PUMP RADIAL SHAFT SEALING RING - AR27.40-P-0300A
TRANSMISSION 722.6 /9 /9
Torque converter developed

Fig. 69: Identifying Oil Pump Radial Shaft Sealing Ring Components
Remove
Lever radial shaft sealing ring Do not damage seat of radial shaft sealing ring (1)
1 (1) out of oil pump housing to prevent oil loss and therefore damage to the
(2). transmission (3).
Install
Install new radial shaft sealing ring (1).
Install radial shaft sealing ring
2 Coat radial shaft sealing ring (1) between lips
(1) flush using drift (01).
with multi-purpose paste.
Drift Fig. 70
*BR00.45-Z-
Multi-purpose paste
1009-06A

REPAIR MATERIALS

BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
REMOVE/INSTALL SHIELD AT TRANSMISSION - AR27.40-P-0700-01GZ
HOUSING
BA27.40-P-1014-01A Bolt, heat shield to transmission housing Nm 9
1. Unscrew bolt (1) and remove shield (2) downwards.

2. Press cable holder (4) out of shield (2) and remove shield (2).
Installation: The shield (2) must be positioned under the leaf spring (3).
The leaf spring (3) must be modified if a new transmission is installed.
3. Install in the reverse order.
Shown on transmission 722.906
Fig. 71: Identifying Bolt, Shield, Leaf Spring And Cable Holder
REMOVE/INSTALL GROOVED BALL BEARING - AR27.50-P-0600
Install grooved ball bearing in rear transmission housing - AR27.50-P-0600-05A
1. Press grooved ball bearing (67) into transmission housing using a suitable drift.
Closed side of plastic cage must face towards park pawl gear.
2. Fit circlip (68) in groove.

3. Use feeler gage to determine play between grooved ball bearing (67) and circlip (68).
No play should exist between circlip (68) and grooved ball bearing (67). If circlip cannot be
fitted, a thinner one must be used. If play exists between circlip and grooved ball bearing, a thicker circlip
must be used.
Circlips (68) are available in thicknesses 2.0, 2.1 and 2.2 mm.
Fig. 72: Identifying Grooved Ball Bearing In Rear Transmission Housing

Measure end play between park pawl gear and grooved ball bearing - AR27.50-P-0600-06A
Test values for gear set

Number Designation Transmission 722.6 Transmission 722.9
BE27.50-P-1004- End play between mm 0.3...0.5 0.20...0.40
01A park pawl gear and
grooved ball
bearing

Determine measurement "a"

1. Fit parallel support (029) on transmission housing. Using the depth gauge measure from the parallel
support (029) to the park pawl gear (15).
Fig. 74: Identifying Transmission Housing, Parallel Support & Park Pawl Gear
Determine measurement "b"
2. Using the depth gauge measure from the parallel support (029) to the contact surface of the grooved ball
bearing (67) in the transmission housing.
Fig. 75: Identifying Parallel Support Transmission Housing, Grooved Ball Bearing
3. Adjust the axial play "E" by means of shim as per the calculation example.
Example calculation:
Dimension "a" 49.9 mm
Dimension "b" 49.0 mm
Difference 0.9 mm
Axial play "E" - 0.4 mm

Shim 0.5 mm
4. Install the corresponding shim.
Shims are available in thicknesses of 0.2 to 0.5 mm. The graduation is 0.1 mm.
DETACH/ATTACH TRANSMISSION HOUSING ON TORQUE CONVERTER HOUSING. - AR27.50-

P-0601W
TRANSMISSION 722.9
Transmission removed
Fig. 76: Identifying Transmission Housing And Torque Converter Housing Components - Transmission
722.9
Disassemble/assemble
General information Pay attention to cleanliness
during all operations. No
fluffy cleaning cloths may
be used. Chamois leathers
are the most suitable.
1 Fasten transmission on AR27.10-P-0600-01W
assembly stand
Assembly stand Fig. 36
Support plate Fig. 37
2 Drain transmission oil and AR27.10-P-7030W
detach oil pan (3)
3 Remove oil filter (34) Installation:
Replace sealing ring.
4 Remove electrohydraulic AR27.19-P-0200W
controller unit (4)
5 Detach output flange (20) Installation: AR27.50-P-0620-02W
Replace the collar nut.
Socket Fig. 64
Pin wrench Fig. 80
Puller Fig. 81
*BA27.50-P-1001-01A
6 Remove radial sealing ring Installation: Use
(1r) drift.
Drift Fig. 63
7 Remove grooved ball AR27.50-P-0601-01A
bearing (1l)
Puller Fig. 88
Clamping pliers Fig. 89
Installation: AR27.50-P-0600-05A
Check the play and insert
the circlip.
8 Remove shim between Installation:
grooved ball bearing (1l) Measure and adjust the
and park pawl gear axial play between the park
pawl gear and grooved ball
bearing (1l):?
Measure end play between
park pawl gear and grooved
ball bearing
Transmission 722.9 except AR27.50-P-0600-06A
722.960/961/962/963/964
Parallel support Fig. 11
End play between park pawl *BE27.50-P-1004-01A
gear and grooved ball
bearing
9 Detach rear engine mount Installation: Install
bearing bracket (1h) new bolts.
*BA27.40-P-1018-01A
10 Attach support plate (P1)
and valve lifter (H) to pry Position the

off transmission housing transmission so that it is
(1) vertical with the torque
converter housing (1w)
facing downward.
Valve lifter Fig. 87
11 Remove internal Torx bolts Position the transmission
(11w, 12w) so that it is vertical with the
torque converter housing
(1w) facing downward. The
will otherwise fall down
when the last internal Torx
bolt is removed.
Installation:
Replace the internal Torx
bolts (11w, 12w).
*BA27.40-P-1015-01A
12 Detach transmission Installation: Carefully
housing (1) from torque mount the transmission
converter housing (1w) housing (1). The disks of
using lever (H) the BPC clutch pack (5) and
multidisk brakes B2 (6)
break off easily.
Installation: The
must lie completely flush
(without gaps) against the
seal (1d) on the torque
(arrow). Never tighten the
against the torque converter
housing (1w) using the
internal Torx bolts (11w,
12w).
The disks of the BPC clutch
pack (5) and multidisk
brakes B2 (6) will otherwise
break off.
Installation: Align
the disks in the transmission
housing (1). Push the output
flange (20) onto the output
shaft (24). Quickly turn the
output shaft (24) and

simultaneously lift the
transmission housing (1) so
that the transmission
housing (1) gradually slips
at the seal (1d) of the torque
converter housing (1w).
13 Assemble in the reverse
order
TEST VALUES FOR GEAR SET

BE27.50-P-1004-01A End play between park mm 0.20 to 0.40
pawl gear and grooved
ball bearing
GEAR ASSEMBLY
BA27.50-P-1001-01A Collar nut, output flange Nm 200
to output shaft
HOUSING
BA27.40-P-1015- Bolt, transmission Stage 1 Nm 10
01A housing to converter
housing Stage 2 Angle ° 90
BA27.40-P-1018- Bolt, bracket for rear Stage 1 Nm 10
01A engine mount to
transmission Stage 2 Angle ° 90



Fig. 80: Identifying Pin Wrench (129 589 01 07 00)

Fig. 81: Identifying Two-Armed Puller (000 589 88 33 00)

Fig. 82: Identifying Clamping Pliers (140 589 06 34 00)

Fig. 83: Identifying Puller (001 589 50 33 00)




Fig. 87: Identifying Valve Lifter (442 589 00 31 00)

Remove grooved ball bearing in rear of transmission housing - AR27.50-P-0601-01A

Fig. 89: Identifying Clamping Pliers ((140 589 06 34 00)

1. Screw in clamping pliers in puller and tighten.

2. Position puller above bearing inner race.
3. Turning top part of puller counterclockwise (arrow) tightens clamping pliers (figure A).
4. Use puller to pull grooved ball bearing out of transmission housing (figure B).
Fig. 90: Turning Top Part Of Puller Counterclockwise

Fig. 91: Pulling Grooved Ball Bearing Out Of Transmission Housing

REMOVE/INSTALL MAIN COMPONENTS OF THE TRANSMISSION - AR27.50-P-0610W
TRANSMISSION 722.9
Fig. 92: Identifying Transmission Main Components - Transmission 722.9

MODIFICATION NOTES
1.7.03 Reference to Step 1
"disassembling
electrohydraulic control
unit" changed to
"removing".
Remove/Install
General note Pay attention to
cleanliness during all the
work Fluffy cleaning
cloths must not be used.
Leather cloths are
particularly suitable.
control unit (4)
2 Detach transmission AR27.50-P-0601W
housing (1) from torque
converter housing (1w).
3 Remove housing The housing AR27.50-P-0782W
components (55) components are BR
clutch pack, multi-disk
brake B2 and park pawl
gear.
4 Remove output unit (44) The output unit AR27.50-P-0611W

consists of multi-disk
clutch K3, rear hollow
shaft, rear planet carrier,
output shaft and rear
internally-geared wheel.
5 Remove drive unit (33) The drive unit AR27.50-P-0612W
consists of drive shaft,
multi-disk clutch K2,
internal plate carrier,
multi-disk clutch K1 and
multidisk brake B3.
6 Remove multi-disk brake AR27.50-P-0721W
B1 (16) and oil pump
REMOVE/INSTALL K3, REAR HOLLOW SHAFT, REAR PLANET CARRIER AND OUTPUT
SHAFT - AR27.50-P-0611W
TRANSMISSION 722.9
Fig. 93: Identifying K3, Rear Hollow Shaft, Rear Planet Carrier And Output Shaft Components -
Transmission 722.9 (1 Of 2)
Fig. 94: Identifying K3, Rear Hollow Shaft, Rear Planet Carrier And Output Shaft Components -
Transmission 722.9 (2 Of 2)
Remove/install
General information Apply oil to the
transmission components
before installation in order
to prevent damage during
the starting phase.
1 Detach transmission AR27.50-P-0601W
housing from torque
2 Detach Torlon rings (2a) Installation:
from output shaft (24) Replace the Torlon rings
(2a).
Fig. 95
3 Remove circlip (2b), shim Installation:
(2c), axial needle roller Check the axial play
bearing (2d) and thrust between the shim (2c) and
plate (2e) from output circlip (2b):?
shaft (24)
Check/adjust axial play AR27.50-P-0810-01A
between shim and circlip
4 Remove multidisk clutch According to condition: ?
K3 (21)
Disassemble/assemble AR27.51-P-0830W
multidisk clutch K3 (21).
5 Remove rear hollow shaft According to condition: ?
(22) from output shaft
Disassemble/assemble rear AR27.50-P-0851W
hollow shaft (22).
6 Remove output shaft (24)
7 Detach remaining Torlon Installation:
rings from output shaft Replace the Torlon rings.

(24)
Fig. 95
8 Remove circlip and
detach rear ring gear (25)
Fig. 95: Identifying Sleeve (722 589 00 14 00)

REMOVING/INSTALLING DRIVE SHAFT WITH K2, FRONT PLANET CARRIER, INTERNAL

PLATE CARRIER WITH K1 AND B3 - AR27.50-P-0612W
TRANSMISSION 722.9
Fig. 96: Identifying Drive Shaft With K2, Front Planet Carrier, Internal Plate Carrier With K1 And B3
Components - Transmission 722.9
Remove/Install
General note Lubricate transmission
components before
installing in order to
prevent damage during
starting phase.
1 Remove output unit Output unit AR27.50-P-0611W
consists of multi-disk
clutch K3, rear hollow
shaft, rear planet carrier,
output shaft and rear ring
gear.
2 Remove drive shaft (11) According to findings ?
Disassemble and AR27.51-P-0820W
assemble multi-disk
clutch K2
3 Detach Torlon rings (1a) Installation:
from drive shaft (11) Install new Torlon rings
(1a)
Fig. 97
4 Remove cylinder flange
together with front planet
carrier (12)
5 Remove internal plate
carrier (13)
6 Remove multi-disk brake Installation:
B3 (15) Align holes (arrows) of
multi- disk brake B3 (15)
precisely with multi-disk
brake B1 (16)
According to findings ?
B3 Disassemble and AR27.50-P-0890W
assemble multi-disk brake
(15)
7 Remove multi-disk clutch According to findings ?
K1 (14)
assemble multi-disk
clutch K1 (14)

OUTPUT FLANGE REMOVAL AND INSTALLATION - AR27.50-P-0620-02W
GEAR ASSEMBLY
BA27.50-P-1001-01A Collar nut, output flange Nm 200
to output shaft
Fig. 98: Identifying Socket Wrench Bit (126 589 02 09 00)

Fig. 99: Identifying Pin Wrench (129 589 01 07 00)

Fig. 100: Identifying Two-Legged Puller (000 589 88 33 00)

Remove output flange
1. Counter-hold output flange (1) with pin wrench (07).

2. Unscrew twelve-point nut (2) from output shaft (3) using socket wrench bit (3).
Fig. 101: Identifying Twelve-Point Nut And Output Shaft

3. Remove output flange (1).
If output flange (1) is firmly attached use two-arm puller (08).
Install output flange

5. Counterhold output flange (1) using pin wrench (07) and tighten twelve-point nut (2) using socket
wrench bit.
Fig. 102: Counterholding Output Flange

Replace twelve-point nut (2).
6. Secure twelve-point nut (2) in duplicate; to do this, hammer collar into the two grooves (arrow) of the
output shaft (3) using a drift punch.
Fig. 103: Identifying Twelve-Point Nut And Output Shaft

REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721W
TRANSMISSION 722.9
Fig. 104: Identifying Multi-Disk Brake B1 And Oil Pump Components - Transmission 722.9 (1 Of 2)
Fig. 105: Identifying Multi-Disk Brake B1 And Oil Pump Components - Transmission 722.9 (2 Of 2)
Removal
General note Lubricate transmission
components before
installing in order to
prevent damage during
starting phase.
1 Remove drive unit Drive unit AR27.50-P-0612W

consists of drive shaft,
multi-disk clutch K2,
internal plate carrier,
multi-disk clutch K1 and
multi-disk brake B3
2 Unscrew bolts (17a) and Screw two
remove oil pump (17) opposing bolts into
housing (17g) and release
oil pump (17) by tapping
softly with a plastic
mallet.
Impellers (17r,
17z) lie loose in housing
(17g)
3 Unscrew bolts (16a) and Release multi-
remove multi-disk brake disk brake (16) by tapping
(16) softly with a plastic
mallet.
According to findings ?
assemble multi-disk brake
(16)
4 Remove gasket (1d)
Install
5 Place gasket (1d) on Generally it is
torque converter housing possible to use gasket (1d)
(1w) and align several times. Gasket (1d)
must not have any
scratches and must not be
coated with sealing
compound.
6 Attach multi-disk brake Installation
(16) to torque converter position is determined by
housing (1w) a dowel pin on multi-disk
brake (16)
*BA27.40-P-1004-01A
7 Attach oil pump (17) Install new radial
sealing ring and O-ring
(17 o)
Fit impeller (17r)
such that chamfer (arrow)
faces housing (17g)
*BA27.40-P-1003-01A
8 Install drive unit AR27.50-P-0612W
HOUSING
BA27.40-P-1003-01A Bolt, oil pump with NM 20
multi-disk brake B1 to
torque converter housing
BA27.40-P-1004-01A Bolt, multi-disk brake B1 NM 11
to converter housing
REMOVE/INSTALL BPC CLUTCH PACK, MULTI-DISK BRAKE B2 AND PARK PAWL GEAR -
AR27.50-P-0782W
TRANSMISSION 722.9
Fig. 106: Identifying BPC Clutch Pack, Multi-Disk Brake B2 And Park Pawl Gear Components -
Transmission 722.9
Remove/install
1 Dismount transmission AR27.50-P-0601W
housing from torque
converter housing
2 Remove circlip (5s), for The thickness of
this step press together the circlip (5s) determines
BPC clutch pack (5) the clearance.
Installation: AR27.51-P-7229-01W
Measure clearance of BPC
multi-disk brake and adjust.
Clearance of BPC multi- *BE27.50-P-1004-02B
disk brake
3 Remove BPC clutch pack Check multiple-discs
(5) for scorch marks and wear.
Installation:
Observe lamella
sequence: ?
Survey of multiple-disc GF27.51-P-5200W
components, production
details
4 Take out disk spring (5t) Installation: Fit in disk
spring (5t) so that the arch
of the inside circumference
points in direction of the
multi-disk brake B2 (6).
5 Remove multi-disk brake Installation: The
B2 (6), for this step external plate carrier of the
unscrew screws (6s) multi-disk brake B2 (6) is
simultaneously the piston
of the BPC clutch pack (5)
and must not be tilted.
Before tightening the
screws (6s) press the
external plate carrier from
inside against the park pawl
gear (7).
Installation:
Replace screws (6s).
*BA27.40-P-1005-01A
According to findings: ?
Disassemble/assemble AR27.50-P-0880W
multi-disk brake B2.
6 Measure clearance of AR27.51-P-7229W
multi-disk brake B2 (6)
and adjust
7 Remove park pawl gear
(7)
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH

BE27.50-P-1004-02B Clearance of BPC mm 1.00...1.40

multidisk brake
HOUSING
BA27.40-P-1005- Bolt of multiple-disc 1st stage Nm 10
01A brake B2 to
converter housing 2nd stage Angle ° 90
CHECKING AND ADJUSTING END PLAY BETWEEN SHIM AND CIRCLIP - AR27.50-P-0810-01A
Test values for gear set

Number Designation Transmission 722.6 Transmission 722.9
BE27.50-P-1005- Axial play between mm 0.15...0.6 0.15...0.60
01A shim and circlip
1. Using a feeler gage, check axial play "S" between shim (42e) and circlip (42f).
Push multi-disk clutch K3 (44) hard by hand in direction of arrow.
2. Remove shim (42e) and measure thickness.

3. Adjust play with shim (42e).
Shims (42e) are available in thicknesses 3.1 to 3.7 mm. They are available in graduations of 0.3
mm.
Fig. 107: Identifying Multi-Disk Clutch K3

DISMANTLE AND ASSEMBLE REAR TUBULAR SHAFT - AR27.50-P-0851W
TRANSMISSION 722.9
Fig. 108: Identifying Rear Tubular Shaft Components - Transmission 722.9

1 Remove circlip (22c), shim Installation: The
(22b) and axial needle roller needles of the axial
bearing (22a) needle roller bearing
(22a) must point towards
the shim (22b). Check
circlip (22c) for correct
seating.
2 Detach sun gear (22s) from Installation:
hollow shaft (22w) Replace O-rings (22d).
3 Remove bearing (22l)
4 Assemble in reverse order
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B1 - AR27.50-P-0870W
TRANSMISSION 722.9
Fig. 109: Identifying Multi-Disk Brake B1 Components - Transmission 722.9 (1 Of 3)



Disassemble
1 Remove bearing (16l) Only on
transmissions up to year
of construction 12/04 as
the bearing on
transmissions as of year of
construction 01/05 is
permanently seated on the
inside diameter of the
Ravigneaux set and was
removed when the
planetary gear set was
removed.
Check the contact
surface and bearing (16l)
for swirl marks. Replace
the bearing (16l) if
necessary.
2 Remove thrust bearing Check the contact
(161) surface and thrust bearing
(161) for swirl marks.
Replace the thrust bearing
(161) if necessary.
3 Remove bearing (162) Check the contact
surface on the bearing
(162) and sealing rings
(see arrow in picture 1)
for swirl marks and
damage. Replace the
bearing (162) if necessary.

4 Remove circlip (105s)
and end disk (105)
5 Remove disk pack (5) and Check disks for scorch
disk spring (5t) marks and wear.
Replace if necessary.
6 Place multidisk brake in
lever press
7 Place clamping device on Position the
disk spring (16t) clamping device precisely
(see arrow in picture 2) to
enable later removal of
the circlip (16s).
Fig. 113
Fig. 112
8 Operate lever press until Stop lever press stoke
circlip (16s) is exposed as soon as accessibility to
groove is sufficient.
Excessive clamping forces
will damage the plate
supports.
from groove
10 Move back lever press
11 Take clamping device and
multidisk brake out of
lever press
13 Remove disk spring (16t)
14 Remove piston (16k) Check the vulcanized-
from external plate carrier on seal.
(16a)
Checking
15 Check external plate If an external
carrier (16a) plate carrier (16a) without
inner phase (1a) is fitted
(see picture 3), a circlip
(16s) with the following
replacement part number
must be used when
installing:
220 994 03 40
If an external
plate carrier (16a) with
inner phase (2a) is fitted

must be used when
installing:
001 994 18 40
Assemble
16 Install piston (16k)
17 Install disk spring (16t) Insert the disk
spring (16t) in such a way
that the camber of the
inner circumference faces
the piston (16k).
18 Position circlip (16s) Final installation
only after actuation of the
lever press.
lever press
enable installation of the
circlip (16s).
Fig. 113
Fig. 112
groove of circlip (16s) is as soon as accessibility to
exposed groove is sufficient.
supports.
22 Install circlip (16s) Observe the
installation position of the
circlip (16s). If installed
incorrectly, the disk
spring (5t) will jam.
lever press
25 Install disk spring (5t) and Insert the disk
disk pack (5) in external spring (5t) in such a way
plate carrier (16a) that the camber of the

the piston (16k).
Observe disk
sequence:
See Overview of GF27.51-P-5200W
multidisk components, as-
built configuration
26 Install end disk (105) and
circlip (105s)
27 Measure and adjust AR27.51-P-7229W
clearance
28 Install bearing (162)
29 Install thrust bearing
(161)
30 Insert bearing (16l)
Fig. 112: Identifying Drift Set (722 589 04 15 00)

Fig. 113: Identifying Clamping Device (722 589 01 31 00)

TRANSMISSION 722.9


Disassemble

and end disk (105)
2 Remove disk pack (5), Check disks for scorch
externally toothed plate marks and wear.
(105a) and spring washer
(5t)
3 Place assembly device Assembly device Fig. 116
on spring washer (61t)
and tension until the
circlip (61s) is exposed.
5 Remove assembly
device.
6 Remove spring plate (61f)
and spring washer (61t)
7 Remove guide ring (61r) Blow
and piston (61k) by compressed air in
blowing compressed air carefully.
into bore (B) of piston
guide (61b)
8 Detach piston guide (61b) Blow
from external plate carrier compressed air in
(61a) by blowing carefully.
compressed air into bore The external
(A) plate carrier (61a) is also
the piston for multi-disk
brake B3
Assemble
9 Assemble piston guide Install new AR27.50-P-0880-01W
(61b) and external plate sealing rings (161a, 161b,
carrier (61a) 161i). In the case of the
sealing rings (161a,
161b), the rounded edges
must point outwards.
10 Install piston (61k) Install new
sealing ring (161k).
The rounded off edges
11 Insert guide ring (61r) Install new
sealing ring (161r)
The rounded off edges
12 Insert spring washer (61t) Insert spring
and spring plate (61f). washer (61t) with the
curvature towards the

spring plate (61f)
13 Place assembly device Assembly device Fig. 116
on spring washer (61t)
and tension until the
groove for the circlip
(61s) is exposed.
14 Install circlip (61s)
15 Remove assembly
device.
16 Install spring washer (5t), Insert spring
externally toothed plate washer (5t) such that the
(105a) and disk pack (5). inward curvature is
towards the piston (61k)
Observe disk
sequence: ?
Survey of multi-disk GF27.51-P-5200W
details
circlip (105s)
clearance
Fig. 116: Identifying Assembly Device (140 589 13 43 00)

Assembling piston guide and external plate carrier of multi-disk brake B2 - AR27.50-P-0880-01W
1. Install piston guide (61b) in transmission housing (1) and secure with bolts (6s).
Push piston guide axially into housing to prevent canting while being secured with bolts.
2. Push external plate carrier (61a) into piston guide (61b) as far as it will go.
Recess in gearing and opening in external plate carrier (61a) must face downwards (arrow).
3. Remove preassembled multi-disk brake from transmission housing (1) again B2 to allow further assembly
operations to be performed.
Fig. 117: Identifying Piston Guide And External Plate Carrier Of Multi-Disk Brake B2
TRANSMISSION 722.9



Disassemble
and end disk (105)
lever press
disk spring (15t) in clamping device precisely
external plate carrier (see arrow in picture 2) to
(15a) enable later removal of
the circlip (15s).
Fig. 113
Fig. 112
circlip (15s) is exposed as soon as accessibility to
supports.
from groove
lever press
11 Remove piston (15k) Check the vulcanized-
from external plate carrier on seal.
(15a)
Checking
12 Check external plate If an external
carrier (15a) plate carrier (15a) without
outer phase (1) is fitted
must be used when
installing:
220 994 03 40
If an external
plate carrier (15a) with
outer phase (2) is fitted
must be used when
installing:
001 994 18 40
Assemble
14 Install disk spring (15t) Insert the disk
that the camber of the
the piston (15k).
15 Position circlip (15s) Final installation
only after actuation of the
lever press.
lever press
enable installation of the
circlip (15s).
Fig. 113
Fig. 112

groove of circlip (15s) is as soon as accessibility to
exposed groove is sufficient.
supports.
19 Install circlip (15s) Observe the
installation position of the
incorrectly, the disk
spring (5t) will jam.
lever press
disk pack (5) in external spring (5t) in such a way
plate carrier (15a) that the camber of the
the piston (15k).
Observe disk
sequence:
See Overview of GF27.51-P-5200W
multidisk components, as-
built configuration
circlip (105s)
clearance


DISMANTLING AND ASSEMBLING CLUTCH K1 - AR27.51-P-0800W
TRANSMISSION 722.9
Fig. 123: Identifying Clutch K1 Components - Transmission 722.9 (1 Of 2)


Dismantle
and end disk (105)
2 Remove clutch pack (5) Check multiple-discs
and disk spring (5t) for scorch marks and
wear.
3 Place multi-disk clutch in
lever press
4 Mount pressure device on Position pressure
piston cover (14b) device accurately in order
to permit subsequent
removal of the circlip
(14s).
Fig. 125
5 Operate the lever press Stop the lever press
until the circlip (14s) is stroke as soon as
free. accessibility is adequate.
Excessive contact forces
lead to damage.
from the groove
7 Reset lever press
8 Remove pressure device
and multi-disk clutch
from lever press
9 Remove circlip (14s) and
piston cover (14b)
10 Remove spring support
(14f)
11 Remove piston (14k) Check vulcanized
gasket.
Assembling
13 Insert spring support (14f)
14 Insert piston cover (14b)
15 Put on circlip (14s) The final
installation is only
possible when the lever
press is operated.
16 Place multi-disk clutch in
lever press
17 Mount pressure device on Position pressure
piston cover (14b) device accurately in order
to permit subsequent
removal of the circlip
(14s).
Fig. 125
18 Operate lever press until Stop the lever press
the groove (arrow) is free stroke as soon as
and install circlip (14s) accessibility is adequate.
Excessive contact forces
lead to damage.
Check
installation position of
circlip (14s).
19 Reset lever press
20 Remove pressure device
and multi-disk clutch
from lever press
21 Install disk spring (5t) Insert disk spring
and clutch pack (5) in (5t) so that the curvature
external plate carrier of the inner circumference
(14a) points towards the piston
(14k).
Observe lamella-
sequence: ?
components
circlip (105s)
clearance
Fig. 125: Identifying Thrust Device (208 589 00 21 00)

DISASSEMBLE/ASSEMBLE K2 CLUTCH - AR27.51-P-0820W
TRANSMISSION 722.9
Fig. 126: Identifying K2 Clutch Components - Transmission 722.9 (1 Of 2)

Fig. 127: Identifying K2 Clutch Components - Transmission 722.9 (2 Of 2)

Disassemble
1 Remove bearing (11l) Check the contact
surface and bearing (11l)
for swirl marks and
damage. Replace the
bearing (11l) if necessary.
2 Remove Torlon rings (1a)

3 Remove thrust bearing Check the contact
(2d) surface and radial bearing
(arrow) in the output shaft
guide for swirl marks and
damage. Replace the
thrust bearing (2d) and
radial bearing if
necessary.
and end disk (105)
5 Remove clutch pack (5) Check disks for scorch
and disk spring (5t) marks and wear.
6 Place multidisk clutch
(11) in lever press
7 Fit assembly device (076) Fig. 116
on spring cup (11f)
8 Operate lever press and Stop lever press stoke
expose circlip groove as soon as accessibility to
(104) groove is sufficient.
Excess force can cause
damage.
11 Remove assembly device
(076) and multidisk
clutch (11) from lever
press
12 Remove spring cup (11f)
14 Remove piston (11k)
Assemble
15 Install piston (11k) Replace sealing
ring. The rounded edge of
the sealing ring must face
outwards.
16 Insert disk spring (11t) Insert the disk
that the curvature of the
inner circumference
points toward the spring
cup (11f).
17 Position spring cup (11f) Replace sealing
ring. The rounded edge of
the sealing ring must face

outwards.
18 Place multidisk clutch
(11) in lever press
19 Fit assembly device (076) Fig. 116
on spring cup (11f)
20 Operate lever press and Position the spring cup
expose circlip groove (11f) precisely in order to
(104) prevent it from canting.
Stop lever press stoke
as soon as accessibility to
Excess force can cause
damage.
21 Install circlip (11s)
(076) and multidisk
clutch (11) from lever
press
clutch pack (5) spring (5t) in such a way
that the curvature of the
inner circumference
points toward the piston
(11k).
Observe disk
sequence: ?
components
circlip (105s)
clearance
27 Insert thrust bearing (2d)
28 Install Torlon rings (1a) Replace the
Torlon rings (1a).
Fig. 97
29 Install bearing (11l)

Fig. 129: Identifying Assembly Tool (140 589 13 43 00)

DISASSEMBLE/ASSEMBLE CLUTCH K3 - AR27.51-P-0830W
TRANSMISSION 722.9


Dismantling
and end disk (105)
3 Place assembly device on Assembly device Fig. 116
disk spring (21t) and
tension until circlip (21s)
is exposed
6 Remove disk spring (21t) Check sealing ring
and piston (21k) from (arrow) and stop faces for
external disk carrier (21a) damage and swirl marks.
Assembling
7 Install piston (21k) in
external plate carrier
(21a)
8 Insert spring plate (21) Install disk spring
(21t) such that curvature
of inner circumference
faces piston (21k)
9 Place assembly device on Assembly device Fig. 116
disk spring (21t) and
tension until circlip (21s)
is exposed
10 Install circlip (21s) Pay attention to
installation position of
incorrectly, disk spring

(5t) will become jammed.
12 Install disk spring (5t) and Install disk spring
disk pack (5) (5t) such that curvature of
piston (21k)
Make sure that
disks are installed in
correct sequence: ?
details
13 Installed end disk (105)
and circlip (105s)
clearance
Fig. 132: Identifying Assembly Device (140 589 13 43 00)

MEASURE AND ADJUST CLEARANCE - AR27.51-P-7229W
TRANSMISSION 722.9
Multiple Plate Brake B1, B2, B3 and Multiple Disk Clutch K1, K2, K3
Fig. 133: Identifying Distance Between Upper Edge Of Parallel Support And End Disk (1 Of 2)
Fig. 134: Identifying Distance Between Upper Edge Of Parallel Support And End Disk (2 Of 2)
Measuring
General note Disks must be laid in ATF
oil at least one hour prior
to measuring clearance so
that friction lining can
soak.
1 Place multi-disk brake /
multi-disk clutch in lever
press
2 Place drifts of thrust Position drifts on end
device on end disk (105) disk (105) such that they
cannot slip off during
pressing procedure.
Thrust device Fig. 113

Drift set Fig. 112
3 Actuate lever press Markings (M1) to
(M4) indicate required
pressure force. If pressure
force is exceeded, disks
and disk carrier will be
damaged.
Multi-disk brake B1:
(M1)
(M3)
(M1)
Multi-disk clutch K1:
(M2)
(M4)
(M1)
4 Position parallel support Fig. 11
5 Using depth gage (T), Measure distance
measure distance between at two points on
upper edge of parallel circumference of end disk
support and end disk (105) and note down
(105) mean value as value "a"
6 Return lever press to
original position
7 Push end disk (105) Carefully insert tool
against circlip (105s) (e.g. screwdriver) between
end disk (105) and first
friction disk (arrow). Do
not turn tool, otherwise
disks will be deformed
and friction lining will be
damaged.
8 Using depth gage (T), Measure distance
measure distance between at two points on
upper edge of parallel circumference of end disk
support and end disk (105) and note down
(105) mean value as value "b"
Difference
between values "a" and
"b" gives clearance value.
Adjust clearance

and determine its
thickness
10 Adjust clearance; to do Circlips (105s)
so, install circlip (105s) are available in
of appropriate thickness graduations of 0.3 mm.
Multi-disk brake B1 *BE27.50-P-1001-02B
Multi-disk clutch K1 *BE27.51-P-1001-01B
Assignment of
number of disks to
respective transmission
type: ?
details

722.9
BE27.50-P-1001- Play in multi- Number of disks 2 mm -
02B disk brake B1 3 mm 2.00...2.40
4 mm 2.20...2.60
BE27.50-P-1002- Play in multi- Number of disks 4 mm 1.70...2.1
02B disk brake B2 5 mm 1.80...2.20
6 mm 1.80...2.20
BE27.50-P-1003- Play in multi- mm -
02B disk brake B3 Number of disks 3 mm 2.20...2.60
4 mm 2.00...2.40

722.9
01B disk clutch K1 4 mm 2.20...2.60
5 mm 2.40...2.80
6 mm -
5 mm 2.10...2.50
6 mm 2.20...2.60
BE27.51-P-1003- Play in multi- Number of disks 3 mm -
5 mm 2.40...2.80
Fig. 135: Identifying Thrust Device (722 589 01 31 00)



Measure and adjust clearance of BR multi-disk brake - AR27.51-P-7229-01W

BE27.50-P-1004-02B Clearance of BR multi- mm 1.00...1.40
disk brake
Disks must be laid in ATF oil at least one hour prior to measuring clearance so that friction lining can
soak.
1. Using a feeler gage, determine clearance at three points between circlip (133a) and externally toothed
plate (133c).
During measuring procedure, circlip (133a) must lie against upper contact surface of groove in
external plate carrier.
2. Remove circlip (133a) and determine its thickness.

3. Adjust clearance; to do so, install circlip (133a) of appropriate thickness.
Replacement circlips (133a) are available in thicknesses 3.2 to 4.7 mm. They are available in
graduations of 0.3 mm.
Fig. 138: Identifying Clearance Between Circlip (133a) And Externally Toothed Plate (133c)
FLUSHING OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001GZ

Fig. 139: Identifying Flushing Components Of Cooler Lines And Oil Cooler (1 Of 2)
Fig. 140: Identifying Flushing Components Of Cooler Lines And Oil Cooler (2 Of 2)
MODIFICATION NOTES
Kerosene cleaning agent replaced by 7-speed automatic transmission fluids (ATF, Step
30.5.07
specification 236.12) for the flushing process. 5
Remove/install
Risk of death caused by vehicle slipping or Align vehicle between columns AS00.00-Z-
toppling off of the lifting platform. of vehicle lift and position four 0010-01A
support plates at vehicle lift

AH00.00-N-
0001-01A
Before opening the hydraulic system, thoroughly
clean the area surrounding the separation point.
Even the smallest dirt particles, introduced into
the hydraulic components, can lead to
malfunctions and a total failure of the hydraulic
system
Unscrew drain plug from the transmission oil *BA27.10-
1
pan and drain transmission oil P-1001-03A
*BA27.55-
2 Remove bolts (5, 6) from oil cooling lines (7, 8)
P-1002-01D
Detach retaining clamps of oil cooling lines (7, *BA27.55-
3
8) on the engine oil pan P-1004-01D
Do not kink or bend oil
cooling lines (7, 8) otherwise
damage will occur.
Collect transmission oil
4 Detach oil cooling lines (7, 8) from transmission
which flows out in a container.
Installation: Fit new O-
rings on the oil cooling lines (7,
8).
Flushing
Fill reservoir (3) of hand pump (2) with
5 Fig. 141
transmission oil
7-gear automatic transmission fluids (ATF, BB00.40-P-
specification 236.12) 0236-12A
Connect hand pump (2) with pressure fitting to
6
reservoir (3)
Connect plastic hose to connection fitting (1) Secure plastic hose to
7 and connect corresponding connector (4) to left connection fitting (1) using hose
oil cooling line (7) clamp if necessary.
8 Connect plastic hose to right oil cooling line (8)
In the event of severe
contamination, change the
transmission oil several times.
Operate hand pump (2) and flush out oil cooling
9 Collect transmission oil
lines (7, 8) and oil cooler with transmission oil
which flows out in a container.
Ensure that the transmission oil
flows freely.
10 Remove hand pump (2)
It is essential to adhere to the

work procedure and AR27.00-P-
12 Fill transmission with gear oil Specifications for Operating 0270W
Fluids, otherwise the
transmission will be damaged.
AR27.00-P-
13 Check transmission oil level; correct if necessary
0100W
AR00.19-P-
0200GZ
15 Read out fault memory and erase if necessary
system
Risk of accident caused by vehicle starting off
moving by itself.
by itself when engine is running. Risk of injury
Wear closed and snug-fitting AS00.00-Z-
caused by contusions and burns during starting
work clothes. 0005-01A
procedure or when working near the engine as it
Do not touch hot or rotating
is running
parts.
Perform engine test run and check transmission
16
for leaks with engine running
TRANSMISSION OIL COOLING

722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to transmission bolt
Stage
01D housing Angle° 90
2
hex. head screw Nm 12
BA27.55-P-1004-
01D

BA27.10-P-1001-03A Oil drain screw to oil pan Nm 22
Fig. 141: Identifying Hand Pump (210 589 00 71 00)

REMOVE/INSTALL DIRECT SELECT SELECTOR LEVER - AR27.60-P-0931GZ
TRANSMISSION 722.9 in MODEL 164
Shown on vehicle with electrically adjustable steering column, code 441
Fig. 142: Identifying Direct Select Selector Lever Components - Shown On Vehicle With Electrically
Adjustable Steering Column
MODIFICATION NOTES
Remove/install

100°C. When working on these units, disconnect 0001-01A
the power supply.
AR91.60-P-
1 Remove driver airbag unit (1)
0660GZ
AR46.10-P-
2 Remove steering wheel (2)
0100GZ
AR54.25-P-
3 Removing jacket tube module (N80)
2802GZ
AR46.10-P-
4 Remove clock spring contact (3)
0200GZ
AR46.10-P-
5 Remove steering angle sensor (4)
0300GZ
The number of bolts (7) is dependent on
6 Remove bolts (7)
the equipment.
Only on vehicles with electrically
Detach steering column adjustment
7 adjustable steering column, code 441.
switch (6)
Do not damage electrical connector.
8 Remove combination switch (5). Do not damage electrical connector.
DIRECT SELECT selector lever (8) and
9 Install in the reverse order cruise control pushbutton switch (9) form a unit
which cannot be disassembled.
AR00.19-P-
0200GZ
REMOVE, INSTALL PARK PAWL MECHANISM - AR27.60-P-0950W
TRANSMISSION 722.9
Transmission removed
Fig. 143: Identifying Park Pawl Mechanism Components - Transmission 722.9

Remove/install
General information Pay attention to
cleanliness during all
operations. No fluffy
cleaning cloths may be

used. Chamois leathers
are the most suitable.
1 Fasten transmission on AR27.10-P-0600-01W
assembly stand
Assembly stand Fig. 36
2 Drain transmission oil and AR27.10-P-7030W
detach oil pan
3 Remove oil filter Installation:
Replace O-ring.
controller unit
5 Detach rear engine mount Installation:
bearing bracket Install new bolts.
*BA27.40-P-1018-01A
6 Remove range selector Check the sealing ring
lever (81); to do so, (81d) and replace if
unscrew bolt (82s) necessary.
*BA27.40-P-1006-01A
7 Remove detent plate (82)
with tapered rod
8 Remove bearing pin (85); Pull out the
to do so, unscrew screw bearing pin (85) using a
plug (85s) bar magnet.
*BA27.40-P-1017-01A
9 Remove pilot bushing Press the park
(84); to do so, unscrew detent (83) as far as
screw plug (84s) possible against the
spring (83f) and pull out
the pilot bushing (84)
using a bar magnet.
*BA27.40-P-1016-01A
10 Remove park detent (83) Installation:
together with spring (83f) Push the spring (83f) onto
the stud (arrow) of the
park detent (83) and
insert both components
together into the
transmission housing (1).
HOUSING

BA27.40-P-1006- Bolt, detent plate to Nm 8
01A range selector lever
BA27.40-P-1016- Screw plug, pilot Nm 70
01A bushing of park pawl
mechanism
BA27.40-P-1017- Screw plug, bearing Nm 22
01A bolt of park detent
BA27.40-P-1018- Bolt, bracket for rear Stage 1 Nm 10
01A engine mount to
transmission Stage 2 Angle ° 90


2006-2008 ACCESSORIES & BODY, CAB Electrical System - General Information - Body - 164 Chassis
Electrical System - General Information - Body - 164 Chassis
GENERAL INFORMATION
ADJUSTING HEADLAMPS WHEN DRIVING ABROAD - AH82.10-P-0001-01A
Model 164, 169, 171, 203, 204.0/2, 209, 211, 215, 216, 219, 220, 221, 230, 245, 251 headlamp with
projection system (with Halogen or xenon headlamps)
For model 164, 169, 171, 203, 204.0/2 with halogen headlamps, 209, 211, 215, 219, 220, 221, 230, 245, 251
the headlamps are mechanically converted.
Pressing a lever changes the position of a movable covering. The movable covering then conceals the part of the
light beam which - through corresponding projection - is responsible for illuminating the edge of the roadway.
The lever for this purpose is located next to the bulb and can be accessed after removing the corresponding
cover on the headlamp housing.
The lever's location, version and actuation are dependent on the manufacturer of the headlamp and the model.
Observe the safety regulations pertaining to handling high-voltage parts on xenon and bi-xenon headlamps.
On model 204.0/2 with xenon headlamps, on model 211 with xenon headlamps as of 1.6.06 and on model 216
the conversion process for the headlamp is conducted electronically using STAR DIAGNOSIS.
The setting must be checked after any adjustment using a headlamp aimer.
Change to light beam following adjustment of movable covering (2) (viewed from rear through lamp aperture
(3)).
The overview shows the status for right-hand traffic.
Fig. 1: Identifying Headlamps Adjusting

Model 164 with halogen headlamps
Fig. 2: Identifying Left, Right Front Headlamp Unit And Lever - Model 164 With Halogen Headlamps
Model 164 with xenon headlamps
Fig. 3: Identifying Left, Right Front Headlamp Unit And Lever - Model 164 With Xenon Headlamps

Model 204.0/2 with halogen headlamps

Fig. 9: Identifying Left, Right Front Headlamp Unit And Lever - Model 204.0/2 With Halogen
Headlamps
Model 204.0/2 with xenon headlamps
On model 204.0/2 with xenon headlamps, headlamp adjustment is not mechanical. The headlamps are adjusted
using STAR DIAGNOSIS.
Procedure:
 "Control units" menu item

 "Body" menu item
 "Left xenon headlamp control unit" menu item
 Menu item "Control unit adaptations"
Model 209 with bi-xenon headlamps
Fig. 10: Identifying Left, Right Front Headlamp Unit And Lever - Model 209 With Bi-Xenon Headlamps
Model 209 with bi-xenon headlamps with integrated curve illumination

Fig. 11: Identifying Left, Right Front Headlamp Unit And Lever - Model 209 With Bi-Xenon Headlamps
Only one of the two levers (7) must be adjusted. The other lever (7) moves automatically in parallel.
Model 211 with xenon headlamps up to 31.5.06

Model 211 with xenon headlamps as of 1.6.06 and model 216
For model 211 with xenon headlamps as of 1.6.06 and model 216, headlamp adjustment is not mechanical. The
headlamps are adjusted using STAR DIAGNOSIS.
Procedure:
 "Control units" menu item

 "Body" menu item
 "Left xenon headlamp control unit" menu item
 Menu item "Control unit adaptations"

Model 215 with xenon headlamp (top picture)
Model 220 with xenon headlamp (bottom picture)

Fig. 16: Identifying Lever - Model 215 And 215 With Xenon Headlamp
Model 230
Fig. 20: Identifying Left, Right Front Headlamp Unit And Lever - Model 230


NOTES ON WIPER ARM ADJUSTMENT - AH82.30-P-0001
Notes on wiper arm adjustment - AH82.30-P-0001-01A
Model 171.4, 203, 204.0/2, 209, 211, 215, 220, 230, 240
By checking the angle of incidence of the wiper arms in parked position and reverse position it can be assessed
whether the wiper arm or the wiper system is to be adjusted.
 Adjusting wiper arm
In the event that the test values deviate from the tolerance range in reverse position or in parked position
and reverse position:
The angles of incidence are changed by "twisting" the wiper arms with the aid of the adjuster levers. The
angle of incidence of the wiper arm always has to be adjusted in parked position.
In doing so the angle of incidence in parked position and reversing position changes by the same amount.
The angle of incidence of the wiper arm to be adjusted is changed by at least the value of the tolerance
deviation in reversing position. To ensure that both adjustment values lie within the tolerance range, the
angle of incidence has to be checked again when in parked position and corrected if necessary.
 Adjusting wiper system
In the event that the test values of both wiper arms deviate from the tolerance range in parked position.
Notes on wiper arm adjustment - AH82.30-P-0001-01GZ
Models 164, 251
By checking the angle of incidence of the wiper arms in parked position and reverse position, it can be assessed
whether one wiper arm, both wiper arms or the wiper system are to be adjusted.
 Adjusting wiper arm
In the event that the check values deviate from the tolerance range in reverse position only or both in
parked position and in reverse position.
The angles of incidence are changed by "twisting" (distorting) the wiper arms with the aid of the adjuster
levers. The angle of incidence of the wiper arm always has to be adjusted in parked position.
In doing so the angle of incidence in parked position and reverse position changes by the same amount.
The angle of incidence of the wiper arm to be adjusted is changed by at least the value of the tolerance
deviation in reverse position. To make sure that both adjustment values lie within the tolerance range, the
angles of incidence have to be checked again and corrected if necessary.
 Adjusting wiper system
In the event that the check values of both wiper arms deviate from the tolerance range in parked position
only.
NOTES ON AVOIDING DAMAGE TO FIBER OPTIC CABLES DURING REPAIR WORK - AH82.60-
P-0001-05AK
Model 164, 169.0/3, 204, 211.0/2/6, 216.3, 221.0/1 245.2, 251, 454 with Media Oriented System Transport
(MOST)
For all repair work requiring that fiber optic cable couplings be separated, the following handling notes must
be observed, otherwise the damping of the light pulses transferred will compromise the data transfer quality.
 For repair work, the protective covers of the fiber optic cables at the device connection or at the connector
of the optical wiring harness must not be prematurely detached.
 Separated fiber optic cable connectors must be immediately covered.
 Do not kink fiber optic cable, route over sharp edges or in radii smaller than 25 mm.
 The fiber optic cable must not be exposed to temperatures greater than 85°C or lower than minus 40°C.
The protective covers of the fiber optic cables at the device connection or at the connector of the optical
wiring harness cannot be separately acquired. The protective covers of the installed replacement parts or clean
rags can be used.
2006-2008 ACCESSORIES & BODY, CAB Electrical System - Testing & Repair - Body - 164 Chassis
Electrical System - Testing & Repair - Body - 164 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM BODY - AR82.00-Z-
9164AA
MODEL 164
AR82.10-P-
Remove/install front axle level sensors MODEL 164
0004GZ
AR82.10-P-
Remove/install rear axle level sensor MODEL 164
0005GZ
AR82.10-P-
Remove/install bulbs of headlamp unit MODEL 164 ...
1201GZ
AR82.10-P-
Remove/install fog lamp bulb MODEL 164
1825GZ
Remove/install power module of
AR82.10-P-
headlamp range adjustment (HRA MODEL 164 ...
4013GZ
[LWR])
Remove/install headlight beam AR82.10-P-
MODEL 164
adjustment control unit 4081GZ
Remove/install xenon headlamp control AR82.10-P-
MODEL 164 ...
unit 4632GZ
Remove/install xenon bulb ignition AR82.10-P-
MODEL 164 ...
module 4633GZ
AR82.10-P-
Remove/install lamp unit MODEL 164
4730GZ
MODEL 164, 169, 171, 203, 209, 211, 215, 216, AR82.10-P-
Adjust headlamps
219, 220, 221, 230, 245, 251 ... 4735A
AR82.10-P-
Removing and installing taillamp MODEL 164
4905GZ
AR82.10-P-
Remove/install fog lamp MODEL 164.8
5103GY
AR82.10-P-
Remove/install fog lamp MODEL 164.1
5103GZ
AR82.10-P-
Remove/install license plate lamps MODEL 164
5161GZ
Remove/install center high-mounted AR82.10-P-
MODEL 164
stop lamp 5375GZ
Remove/install telescoping nozzle for MODEL 164 with CODE (600) Headlamp AR82.15-P-
headlamp cleaning system cleaning system 6100GZ
Remove/install washer fluid hose of MODEL 164 with CODE (600) Headlamp AR82.15-P-
headlamp cleaning system cleaning system 6201GZ
AR82.20-P-
Remove/install rear dome lamp MODEL 164
0113GZ
Remove/install front overhead control AR82.20-P-
MODEL 164
panel 1100GZ
AR82.20-P-
Remove/install lamp for vanity mirror MODEL 164 ...
5582GZ
Remove/install additional turn signal AR82.25-P-
MODEL 164
lamp 4726GZ
AR82.30-P-
Check wiper arms and adjust MODEL 164
6000GZ
AR82.30-P-
Remove and install wiper arm MODEL 164
6100GZ
AR82.30-P-
Removing and installing wiper system MODEL 164
6400GZ
AR82.30-P-
Remove/install wiper motor MODEL 164
6800GZ
Remove/install rear window wiper AR82.30-P-
MODEL 164
motor 6900GZ
AR82.30-P-
Remove/install tailgate wiper arm MODEL 164
6910GZ
Removing and installing rain/light MODEL 164.1 with CODE (345) Rain sensor AR82.30-P-
sensor MODEL 164.8 7800GZ
MODEL 164.1 with CODE (600) Headlamp
AR82.35-P-
Removing and installing washer fluid reservoir of windshield washer system cleaning
6000GZ
system
Remove/install windshield washer AR82.35-P-
MODEL 164
system pump 6002GZ
Remove/install headlamp cleaning MODEL 164 with CODE (600) Headlamp AR82.35-P-
system pump cleaning system 6003GZ
Remove/install fluid level sensor for the AR82.35-P-
MODEL 164
windshield washer system 6005GZ
AR82.35-P-
Remove/install tailgate spray nozzle MODEL 164
6920GZ
Remove/install windshield washer AR82.35-P-
MODEL 164
nozzle 6970GZ
AR82.35-P-
Remove/install windshield washer hose MODEL 164
6980GZ
AR82.60-P-
Remove/install radio MODEL 164
7502GZ
MODEL 164 with CODE (864) Rear AR82.60-P-
Remove/install DVD player
Remove/install satellite radio control AR82.60-P-
unit MODEL 164 ... 7545GZ

MODEL 164, 251 with CODE (864) Rear AR82.60-P-
Remove/install display in rear
Remove/install CD drive in the Audio AR82.61-P-
MODEL 164, 169, 203, 209, 245, 251 ...
50 APS 0100AB
AR82.62-P-
Check microphone for sound amplifier MODEL 164 with CODE (810) Sound system
1110GZ
AR82.62-P-
Removing and installing microphone MODEL 164 with CODE (810) Sound system
7700GZ
Remove/install loudspeaker amplifier MODEL 164 with CODE (810) Sound unit AR82.62-P-
control system 7720GZ
Removing and installing loudspeaker in AR82.62-P-
MODEL 164 with CODE (810) Sound system
instrument panel 7833GZ
AR82.62-P-
Remove/install bass module speaker MODEL 164 with CODE (810) Sound system
7839GZ
Remove/install loudspeakers in front AR82.62-P-
MODEL 164
doors 7845GZ
Remove/install front door speakers in AR82.62-P-
MODEL 164
mirror triangle 7850GZ
Remove/install loudspeakers in rear AR82.62-P-
MODEL 164
doors 7874GZ
Remove/install the speakers in the AR82.62-P-
headliner 7876GZ
Removing and installing keyless go AR82.62-P-
MODEL 164 with CODE (889) Keyless Go.
antenna 8000GZ
Remove/install antenna amplifier AR82.62-P-
MODEL 164 roof antenna module
module 8300GZ
AR82.62-P-
Remove/install radio antenna amplifier MODEL 164
8301GZ
MODEL 164, 251 with CODE (863) AR82.62-P-
Remove/install TV antenna amplifier
Digital/analog TV tuner 8302GZ
AR82.62-P-
Remove/install roof antenna module MODEL 164
8979GZ
AR82.64-P-
Remove/install CD player with changer MODEL 164.1
7507GZ
AR82.64-P-
Removing and installing CD changer MODEL 164
7508GZ
Remove/install voice control system MODEL 164.1 with CODE (813) Voice control AR82.70-P-
control unit system (VCS [SBS]) 0003GZ
Remove/install compensator control MODEL 164.1 with CODE (388) "Portable AR82.70-P-
unit CTEL" UPCI telephone system 0030GZ
Remove and install bracket for portable AR82.70-P-
MODEL 164 ...
CTEL telephone 8918GZ
Remove/install vehicle interface MODEL 164 with CODE (388) Telephone AR82.70-P-
(portable CTEL) "Handy", UPCI system 8920GZ

Remove/install stowage tray for AR82.70-P-
MODEL 164
portable CTEL (telephone) 8921GZ
AR82.70-P-
Remove/install antenna splitter MODEL 164 ...
8953GZ
MODEL 164.8 with CODE (863) Digital/analog AR82.85-P-
Remove/install TV tuner
TV tuner 7366GY
MODEL 164.1 with CODE (863) Digital/analog AR82.85-P-
Remove/install TV tuner
TV tuner 7366GZ
MODEL 164 Only vehicles without navigation AR82.85-P-
Remove/install electronic compass
system 7371GZ
AR82.85-P-
Remove/install navigation processor MODEL 164 with CODE (494) USA version
7373GZ
Remove/install the pushbutton switch AR82.95-P-
MODEL 164 ...
for the Tele-Aid emergency call system 0002GZ
Removing and installing backup MODEL 164 with CODE (359) TELE AID
AR82.95-P-
antenna for Tele Aid emergency call emergency call system with CODE (494) USA
0004GZ
system version
Remove/install control unit for TELE MODEL 164 with CODE (359) TELE AID AR82.95-P-
AID emergency call system emergency call system 0005GZ
Remove/install MB-Info and AR82.95-P-
MODEL 164 ...
telediagnosis button group 3212GZ
REMOVE/INSTALL FRONT AXLE LEVEL SENSORS - AR82.10-P-0004GZ
MODEL 164
Fig. 1: Identifying Front Level Sensor, Electrical Connector, Connecting Arm, Bracket And Nut
Remove/install
Align vehicle between the columns of the
Risk of death caused by vehicle lifting platform and position the four support AS00.00-Z-
slipping or toppling off of the plates at the lifting platform support points 0010-01A
lifting platform. specified by the vehicle manufacturer.
AR00.60-P-
1 Raise vehicle with lifting platform
1000GZ
On vehicles with Keyless Go, code
Turn key in ignition switch to
2 889: Press keyless go start/stop button
position "0".
Remove connecting arm (2) from
4 left front level sensor (B22/8) or
right front level sensor (B22/9)
5 Unscrew nuts (3) for bracket (4) Installation: Replace self-locking
nuts (3).
BA82.10-P-
1001-01B
Notes on self-locking nuts and AH00.00-N-
All models
bolts 0001-01A
Remove left front level sensor
6 (B22/8) or right front level sensor
(B22/9) with bracket (4)
Remove screws from bracket (4)
and remove left front level sensor *BA82.10-P-
7
(B22/8) or right front level sensor 1002-01B
(B22/9)
Checking
Adjust the zero position of the
9
xenon headlamps
*WH58.30-Z-
1048-13A
FRONT AXLE LEVEL SENSOR

164.1/8
BA82.10-P-1001- Nut for sensor with bracket to "console for upper transverse
Nm 8
01B control arm"
BA82.10-P-1002-
Bolt/nut of level sensor to retaining plate Nm 4
01B

Number Designation
REMOVE/INSTALL REAR AXLE LEVEL SENSOR - AR82.10-P-0005GZ
MODEL 164
Fig. 2: Identifying Rear Level Sensor, Electrical Connector, Connecting Arm And Bolts
Remove/install
lifting platform and position the four support AS00.00-Z-
slipping or toppling off of the
plates at the lifting platform support points 0010-01A
lifting platform.
specified by the vehicle manufacturer.
AR00.60-P-
1 Place vehicle on lifting platform
1000GZ
position "0".
3
(1)
Remove connecting arm (2) from
4 left rear level sensor (B22/7) or
right rear level sensor (B22/10)
*BA82.10-P-
5 Remove bolts (3)
1001-02C
Remove left rear level sensor
6 (B22/7) or right rear level sensor
(B22/10)
Checking
Adjust the zero position of the
8
xenon headlamps
*WH58.30-Z-
1048-13A
REAR AXLE LEVEL SENSOR

BA82.10-P-1001-02C Bolt, level sensor to retaining plate Nm 4

Number Designation
REMOVE/INSTALL BULBS OF HEADLAMP UNIT - AR82.10-P-1201GZ
MODEL 164 with CODE (615) Bi-xenon headlamp unit with integrated curve illumination with CODE
(616) Bi-xenon headlamp unit with integrated asymmetric curve illumination
Fig. 3: Identifying Headlamp Components

Removing
Risk of death caused by high
voltage levels present at xenon
headlamps.
Do not come into contact with parts that are under high
Risk of explosion/risk of fire
voltage. Persons with active electronic implants (e.g.
due to highly flammable
heart pacemakers) must never work on xenon headlamps. AS82.10-
materials in the area of
Switch off entire lighting system. Wear insulating safety Z-0001-
damaged xenon bulbs
shoes, safety glasses and protective gloves. Remove highly 01A
Risk of injury from UV light,
inflammable materials from the hazard area. Ensure the
hot components at xenon
work area is adequately ventilated.
headlamps and glass splinters
when xenon bulbs crack
Risk of poisoning from
inhaling mercury vapors and

from swallowing/skin contact
with poisonous salts and
mercury compounds
remove the transmitter key Keyless Go start/stop button repeatedly until the ignition is
unit store it in a location beyond its transmission range (at least
2 m).
Remove cover (1) from left
Observe rotation direction information on the cover
2 front lamp unit (E1) and right
(1).
front lamp unit (E2)
Carefully remove xenon headlamp ignition module
(E1n2, E2n2), otherwise the catch lugs can break off.
Release xenon headlamp
3 ignition module (E1n2, E2n2) Observe rotation direction information on the rear
by twisting it and remove of the xenon headlamp ignition module (E1n2, E2n2).
The electrical connector (2) is disconnected
automatically during removal.
Release retaining springs
4
(arrows)
Do not touch the left low beam (E1e2) or right low
Remove left low beam (E1e2)
5 beam (E2e2) with the fingers during removal. Handle the
or right low beam (E2e2)
glass bulb only with a soft, clean cloth.
Check power supply contact
6 If required, replace corroded parts.
points for corrosion
Install
Do not touch the left low beam (E1e2) or right low
Insert and hold left low beam beam (E2e2) with the fingers during installation. Handle
7 (E1e2) or right low beam the glass bulb only with a soft, clean cloth.
(E2e2) Ensure that they are installed in the correct position
(notch).
Lock retaining springs
8
(arrows)
Fit xenon headlamp ignition Observe installation position and rotation direction
9 module (E1n2, E2n2) and lock information on the rear of the xenon headlamp ignition
by twisting module (E1n2, E2n2).
Connect electrical connector
10
(2)
Check seal in cover (1) for signs of damage and
Install cover (1) at left front
wear; replace the seal if necessary.
11 lamp unit (E1) or right front
lamp unit (E2) Observe rotation direction information on the cover
(1).
REMOVE/INSTALL FOG LAMP BULB - AR82.10-P-1825GZ

MODEL 164
Fig. 4: Identifying Fog Lamp Bulb

Remove/install
Remove left front fog lamp

AR82.10-P-
1 (E5/1) or right front fog lamp Model 164.1
5103GZ
(E5/2)
AR82.10-P-
Model 164.8
5103GY
Do not hold the bulb (1) with your fingers directly, as
fingerprints can bake and leave behind opaqueness on
2 Remove bulb (1) the bulb. Use a soft, lint-free cloth.
To unlock, rotate counterclockwise.
Bulb and electrical connector form a single unit.
REMOVE/INSTALL POWER MODULE OF HEADLAMP RANGE ADJUSTMENT (HRA [LWR]) -

AR82.10-P-4013GZ
Fig. 5: Identifying HRA [LWR] Power Module And Front Lamp Unit
Remove/install
high voltage levels present
at xenon headlamps.
Risk of explosion/fire
hazard through highly
flammable material in the Do not come into contact with parts that are under
area of damaged xenon high voltage. Persons with active electronic
bulbs. implants (e.g. heart pacemakers) must never work on
Risk of injury through UV xenon headlamps. Switch off complete lighting AS82.10-Z-
light, hot components on system. Wear insulating safety shoes, safety glasses 0001-01A
xenon headlamps and glass and protective gloves. Remove highly inflammable
splinters when xenon bulbs materials from the hazard area. Ensure that the
burst. workplace is sufficiently ventilated.
Risk of poisoning through
inhalation of mercury vapor
and swallowing of or skin
contact with toxic salts and
mercury compounds.
Remove left front lamp unit
AR82.10-P-
1 (E1) or right front lamp unit
4730GZ
(E2)
2 Remove bolts (1)
Pry up HRA [LWR] power Installation: Ensure that the rubber seal is
3
module (E1n3, E2n3) built-in tightly.
Checking
Adjust the zero position of *WH58.30-
the xenon headlamps Z-1048-13A
Connect STAR
DIAGNOSIS and read out AD00.00-P-

Check the setting of the
6 xenon headlamps and adjust
if necessary
Check and correct headlamp AP82.10-P-
adjustment 8260GZ

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS Compact diagnosis system for passenger cars 6511 1801 00
REMOVE/INSTALL HEADLIGHT BEAM ADJUSTMENT CONTROL UNIT - AR82.10-P-4081GZ
MODEL 164
Fig. 6: Identifying Headlight Beam Components (1 Of 2)

Fig. 7: Identifying Headlight Beam Components (2 Of 2)

Remove/install

oxyhydrogen gas. Risk of poisoning and No fire, sparks, open flames or
caustic burns caused by swallowing smoking. Wear acid-resistant gloves,
AS54.10-Z-
battery acid. Risk of injury caused by clothing and safety glasses. Only pour
0001-01A
burns to skin and eyes from battery acid battery acid into suitable and
or when handling damaged lead-acid appropriately marked containers.
batteries
AH54.10-P-
Notes on battery All models
0001-01A
AH54.00-P-
0001-01A
discharge
AH54.10-P-
Notes on AGM battery
0002-01A
Read out data of headlamp range Only when replacing the
1.1 adjustment control unit (N71) and store headlamp range adjustment control unit
temporarily (N71) and if it can still be read out.
*WH58.30-
Z-1048-13A
Otherwise, the sun visor can be
Move head restraint of front passenger
2 damaged when tilting the seat backrest
seat (1) all the way down
forward.
Move front passenger seat (1) forward
3 and upward as far as possible, tilt seat
backrest forward
4 Remove cover (2).
Separate floor covering (3) at both If it has not yet been separated
5.1
depicted positions (arrows) earlier.
Move front passenger seat (1) all the way
6
back
Fold floor covering (3) forward and move
Make sure that the floor
front passenger seat (1) as far forward as
7 covering (3) does not tear at the
possible until the battery compartment is
breakover.
accessible
code 889: Press Keyless Go start/stop
Switch off ignition and remove the button repeatedly until the ignition is
8 transmitter key from the EIS [EZS] switched off. Remove transmitter key
control unit from vehicle and store it in a location
beyond its transmission range (at least 2
m).
Remove spreader clip (5) and detach air Installation: Replace spreader
9
outlet (4) clip (5) if necessary.
10 Remove battery cover (12)

Put down headlamp range
11 Unscrew nut (9) on left and right adjustment control unit (N71) on the
battery (G1).
12 Release plug (10) and disconnect.
Remove headlamp range adjustment
13
control unit (N71)
Only when replacing the
Transmit stored data into the headlamp
15.1 headlamp range adjustment control unit
range adjustment control unit (N71)
(N71).
*WH58.30-
Z-1048-13A
Check headlamp adjustment, correct if Only when replacing the
16.1 headlamp range adjustment control unit
necessary
(N71).
AP82.10-P-
Check and correct headlamp adjustment
8260GZ

Number Designation
REMOVE/INSTALL XENON HEADLAMP CONTROL UNIT - AR82.10-P-4632GZ
Fig. 8: Identifying Xenon Headlamp Control Unit Components Location

Remove/install
at xenon headlamps.
flammable material in the Do not come into contact with parts that are under
area of damaged xenon high voltage. Persons with active electronic
bulbs. implants (e.g. heart pacemakers) must never work on
Risk of injury through UV xenon headlamps. Switch off complete lighting AS82.10-Z-
light, hot components on system. Wear insulating safety shoes, safety glasses 0001-01A
xenon headlamps and glass and protective gloves. Remove highly inflammable
splinters when xenon bulbs materials from the hazard area. Ensure that the
burst. workplace is sufficiently ventilated.
mercury compounds.
AR82.10-P-
1 (E1) or right front lamp unit
4730GZ
(E2)
2 Remove bolts (1)
Pry off xenon headlamp
Installation: Ensure that the rubber seal (2) is
3 supply module (E1n4,
built-in tightly.
E2n4)
Checking
Connect STAR
AD00.00-P-
2000-04A
fault memory
if necessary
Check and correct headlamp AP82.10-P-
adjustment 8260GZ

Number Designation
REMOVE/INSTALL XENON BULB IGNITION MODULE - AR82.10-P-4633GZ

Fig. 9: Identifying Xenon headlamp Ignition Module And Cover

Remove/install

high voltage levels present at
xenon headlamps.
flammable material in the
Do not come into contact with parts that are under high
area of damaged xenon
voltage. Persons with active electronic implants (e.g. heart
bulbs.
pacemakers) must never work on xenon headlamps. Switch AS82.10-
Risk of injury through UV
off complete lighting system. Wear insulating safety shoes, Z-0001-
light, hot components on
safety glasses and protective gloves. Remove highly 01A
xenon headlamps and glass
inflammable materials from the hazard area. Ensure that the
splinters when xenon bulbs
workplace is sufficiently ventilated.
burst.
mercury compounds.
Keyless Go start/stop button repeatedly until the ignition is
1 remove transmitter key from
switched off. Remove transmitter key from vehicle and store
EIS control unit
it in a location beyond its transmission range (at least 2 m).
Rotate counterclockwise to unlock.
2 Remove cover (1)
Installation: Ensure correct seating of the cover (1).
Rotate counterclockwise to unlock. The electrical

connector is disconnected automatically during removal.
Remove xenon headlamp
3 Installation: The electrical connector cannot be
control unit (E1n2, E2n2)
connected until the xenon headlamp ignition module (E1n2,
E2n2) is correctly installed again.
REMOVE/INSTALL LAMP UNIT - AR82.10-P-4730GZ
MODEL 164
Fig. 10: Identifying Front Lamp Unit, Electrical Connector And Bolts
Remove/install

at xenon headlamps.
hazard through highly Do not come into contact with parts that are under
flammable material in the high voltage. Persons with active electronic
area of damaged xenon implants (e.g. heart pacemakers) must never work on
bulbs. xenon headlamps. Switch off complete lighting AS82.10-Z-
Risk of injury through UV system. Wear insulating safety shoes, safety glasses 0001-01A
light, hot components on and protective gloves. Remove highly inflammable
xenon headlamps and glass materials from the hazard area. Ensure that the
splinters when xenon bulbs workplace is sufficiently ventilated.
burst.
mercury compounds.
On vehicles with Keyless Go, code 889
Switch off ignition and Press Keyless Go start/stop button repeatedly until
1 remove transmitter key ignition is switched off. Remove transmitter key from
from EIS control unit vehicle and store it in a location beyond its
transmission range (at least 2 m).
AR88.20-P-
2 Remove front bumper
2000GZ
3 Remove bolts (1)
(E1) or right front lamp unit
4
(E2) and disconnect
electrical connector (2)
Checking
6 TAR DIAGNOSIS diagnosis system
Connect STAR
AD00.00-P-
2000-04A
fault memory
if necessary

Number Designation
ADJUST HEADLAMPS - AR82.10-P-4735A
MODEL 164, 169, 171, 203, 209, 211, 215, 216, 219, 220, 221, 230, 245, 251
Headlamps with projection system (for halogen or xenon headlamps)
MODIFICATION NOTES
29.8.06 Headlamp adjustment
changed from manual to
automatic for model 216.
Risk of death caused by Do not come into contact AS82.10-Z-0001-01A

high voltage levels present with parts that are under
at xenon headlamps. high voltage. Persons
Risk of explosion/fire due with active electronic
to highly flammable implants (e.g. heart
materials in the area of pacemakers) must never

damaged xenon bulbs work on xenon
Risk of injury caused by headlamps. Switch off
UV light, hot components entire lighting system.
on xenon headlamps and Wear insulating safety
glass splinters when xenon shoes, safety glasses, and
bulbs are bursting protective gloves.
Risk of poisoning due to Remove highly
inhaling mercury vapors and inflammable materials
when swallowing/coming in from the hazard area.
contact with toxic salts and Ensure that the working
mercury compounds area is sufficiently
ventilated.
1 Switch off the ignition and On vehicles with
remove the transmitter key code (889) Keyless Go,
from the EIS control unit press Keyless Go
start/stop button
repeatedly until ignition
is switched off.
Remove Keyless Go
transmitter card or
transmitter key from
vehicle and store beyond
reach of transmitter (min.
2 m).
2 Open engine hood
3 Adjust headlamps
Adjusting headlamps when AH82.10-P-0001-01A
driving abroad
4 Close engine hood
5 Check headlamp adjustment
Check and correct headlamp
adjustment
Model 164 AP82.10-P-8260GZ
Model 169, 245 AP82.10-P-8260AK
Model 171.4 AP82.10-P-8260V
Model 203, 209 AP82.10-P-8260P
Model 211 AP82.10-P-8260T
Model 215, 220 AP82.10-P-8260M
Model 219.3 AP82.10-P-8260TX
Model 216, 221 AP82.10-P-8260SX
Model 230 AP82.10-P-8260R
Model 251 AP82.10-P-8260RT
REMOVING AND INSTALLING TAILLAMP - AR82.10-P-4905GZ

MODEL 164
Fig. 11: Identifying Taillamp, Trim, Electrical Connector And Nut

Remove/install

1 Press Keyless Go start/stop button repeatedly until ignition is
transmitter key from EIS control
switched off. Remove transmitter key from vehicle and store it in a
unit
Remove panel (1) in load
2 For model 164.8 remove left stowage compartment.
compartment
3
(2)
For model 164.1 undo four nuts (3).
4 Unscrew nuts (3).
For model 164.8 undo three nuts (3).
Remove left taillamp (E3) or Installation: Ensure that the rubber seal is secured
5
right taillamp (E4) to the rear properly.
REMOVE/INSTALL FOG LAMP - AR82.10-P-5103
Remove/install fog lamp - AR82.10-P-5103GY
MODEL 164.8
Fig. 12: Identifying Foglamp Components Location

Remove/install
Press Keyless Go start/stop button repeatedly
until ignition is switched off. Remove
transmitter key from vehicle and store it in a
1 transmitter key from EIS control
location beyond its transmission range (at least 2
unit
m).
Ensure that the light is switched off. The light
switch must be in the "0" position.
2 Remove cover (1) Long wedge Fig. 13
3 Unscrew bolt (2)
Remove left front fog lamp (E5/1)
4 or right front fog lamp (E5/2) and
disconnect electrical connector (3)
Check front fog lamp settings,
6
adjust if necessary
AP82.10-P-
Set or inspect fog lamps
8260-04GZ

Remove/install fog lamp - AR82.10-P-5103GZ
MODEL 164.1
Fig. 14: Identifying Foglamp Components Location

Remove/install
On vehicles with keyless go, Code 889:

Press keyless go start/stop button repeatedly until the
1 ignition is switched off. Remove transmitter key from
transmitter key from EIS control unit
vehicle and store outside transmitter range (at least 2
m).
Fig.
2 Remove cover (1) Long wedge 13
3 Unscrew bolts (2)
Take out left front fog lamp (E5/1) or
4 right front fog lamp (E5/2) and
Fig. 15: Identifying Longitudinal Wedge (115 589 03 59 00)

REMOVE/INSTALL LICENSE PLATE LAMPS - AR82.10-P-5161GZ
MODEL 164
Fig. 16: Identifying Seal And Bolts Of License Plate Lamps

Remove/install
1 Remove bolts (1)

Pry out license plate lamp, left rear-end door (E19/3) Installation: Check condition of
2 or license plate lamp, right rear-end door (E19/4) license plate lamp's gasket (2) and gasket
using suitable tool seating.
Fig.
Long wedge 13

REMOVE/INSTALL CENTER HIGH-MOUNTED STOP LAMP - AR82.10-P-5375GZ

MODEL 164
Fig. 18: Identifying Center High-Mounted Stop Lamp

Fig. 19: Identifying Center High-Mounted Stop Lamp, Electrical Connector, Clamps And Bolts
Fig. 20: Identifying Clamps

Removing
AR72.20-P-
1 Remove liner on tailgate Only top door lining panel. 3520GZ
Avoid paint damage!
2 Remove bolts (1) Unscrew screws (1) through the holes
(arrows A). Do not allow screws (1) to drop into
rear-end door.
3 Pull off clamps (2) Do not allow to drop in rear-end door.
4 Close rear-end door
Pull out center high-mounted stop
5 lamp (E21) until electrical connector Avoid paint damage!
(3) is visible
6 from center high-mounted stop lamp
(E21)
Install
Only when reusing the center high-stop
mounted stop lamp (E21).
Install clamps (2) in center high-
7.1 Ensure that the clamps (2) are seated
mounted lamp (E21)
correctly. Install with longer side (arrow B) of
clamps (2) facing upward.
8.1 Screw in bolts (1). Only when reusing the center high-
mounted stop lamp (E21).
9 Connect electrical connector (3).
Insert center high-mounted stop lamp Center high-mounted stop lamp (E21)
10
(E21) must latch in position audibly.
AR72.20-P-
11 Install door liner on rear door Only top door lining panel. 3520GZ

REMOVE/INSTALL TELESCOPING NOZZLE FOR HEADLAMP CLEANING SYSTEM - AR82.15-

P-6100GZ
MODEL 164 with CODE (600) Headlamp cleaning system
Fig. 22: Identifying Telescopic Nozzle, Hose And Nuts

Remove/install
AR88.20-P-
2000GZ
2 Detach hose (1) from telescopic nozzle (2)
3 Loosen nuts (3)
4 Remove telescopic nozzle (2)
Correct if
6 Check the fluid level in the windshield washer system
necessary
Check windshield washer system fluid level and AP82.35-P-
correct if necessary 8210GZ
REMOVE/INSTALL WASHER FLUID HOSE OF HEADLAMP CLEANING SYSTEM - AR82.15-P-

6201GZ

Fig. 23: Identifying Washer Fluid Hose, Crossmember, Telescopic Nozzles, HCS [SRA] Pump And
Connector
Remove/install
Align vehicle between the columns of the lifting
platform and position the four support plates at the AS00.00-Z-
vehicle slipping or toppling off
lifting platform support points specified by the 0010-01A
of the lifting platform.
AR00.60-P-
1 Lift/jack up vehicle
1000GZ
Remove front section of fender AR88.10-P-
2 On both sides of vehicle.
liner in front fender 1310GZ
Detach washer fluid hose (1)
3 from both telescopic nozzles Collect washer fluid which flows out.
(2)
Disconnect washer fluid hose
4 (1) from connector (3) of HCS
[SRA] pump (M5/2)
Pull washer fluid hose (1) out
5
of crossmember (4)
7 Fill washer fluid reservoir
Check windshield washer
AP82.35-P-
system fluid level and correct if
8210GZ
necessary
Check headlamp cleaning
8
system for proper function
REMOVE/INSTALL REAR DOME LAMP - AR82.20-P-0113GZ
MODEL 164
Shown on model 164.1, with Parktronic system (PTS), code 220

Fig. 24: Identifying Rear PTS Warning Indicator Dome Lamp

Remove/install

Switch off ignition and remove the Press Keyless Go start/stop button repeatedly until
1 transmitter key from the EIS [EZS] ignition is switched off. Remove transmitter key
control unit from vehicle and store it in a location beyond its
Unclip rear dome lamp PTS warning Only for vehicles with Parktronic system (PTS), code
indicator (A44/3) by moving to right
2.1 220.
(arrow A) and then remove by lowering
Treat ribbon cable carefully to prevent damage.
(arrow B)
Disconnect electrical connector (1) of the
Only for vehicles with Parktronic system (PTS), code
3.1 rear dome lamp PTS warning indicator
220.
(A44/3)
Carefully unclip left dome lamp, 3rd seat
4 Treat ribbon cable carefully to prevent damage.
row (E15/3) at the clips (2) and remove
Fig.
Long wedge 13
Disconnect electrical connector (3) of the
5
left dome lamp, 3rd seat row (E15/3)

REMOVE/INSTALL FRONT OVERHEAD CONTROL PANEL - AR82.20-P-1100GZ
MODEL 164
Fig. 26: Identifying Front Overhead Control Panel Components Location

Remove/install

AH54.00-P-
electronic components due to All models
0001-01A
Switch off ignition and remove the
1 transmitter key from the EIS [EZS] until ignition is switched off. Remove
control unit
location beyond its transmission range (at least
2 m).
Unclip front section, covering,
2 Carefully unclip tabs (5).
rain/light sensor (1) toward the front
Unclip rear section, covering, rain/light Carefully detach rear section of
3
sensor (2) downward rain/light sensor covering from line.
First unclip overhead control panel
control unit (N70) at the front clips (3), Treat ribbon cable (4) carefully to prevent
4
then at the rear clips (3) and carefully damage.
remove downward
Disconnect electrical connectors from
5 overhead control panel control unit
(N70)

REMOVE/INSTALL LAMP FOR VANITY MIRROR - AR82.20-P-5582GZ
MODEL 164 with CODE (543) Sun visors with illuminated mirror
Changing light bulb lamp for cosmetic mirror
Fig. 28: Identifying Lamp For Left And Right Vanity Mirror And Bulb
Remove/Install
For removal, insert a long wedge into the side

of the cutout (arrow).
Carefully pry off lamp for left vanity
1 mirror (1) or lamp for right vanity mirror The lamp for the left vanity mirror and the
(2) from the headliner lamp for the right vanity mirror cannot be
individually exchanged. Only the bulbs can be
replaced.
Fig.
Long wedge 13
2 Remove bulb (3)

REMOVE/INSTALL ADDITIONAL TURN SIGNAL LAMP - AR82.25-P-4726GZ
MODEL 164
Illustrated on left outside rearview mirror
Fig. 30: Identifying Additional Turn Signal Lamp Components Location

Remove/Install
AR88.70-P-
1 Remove trim panel of outside mirror (1)
9040GZ
2 Remove bolt (2).
3 Remove ambient lamp (3) from the outside mirror paneling (1)
Remove the left outside mirror turn signal lamp (E6/5) or the right outside mirror
4
turn signal lamp (E6/6) from the outside rearview mirror cover (1)
CHECK WIPER ARMS AND ADJUST - AR82.30-P-6000
Check wiper arms and adjust - AR82.30-P-6000GZ
MODEL 164
Shown using model 251 as an example
Fig. 31: Identifying Distance From Outer/Inner Marking To A-Pillar

Shown using model 251 as an example
Fig. 32: Identifying Distance Between Upper End Of Driver Side Wiper Blade And Driver Side A-Pillar
MODIFICATION NOTES
16.5.06 Special tool 211 589 05 21 00 added Operation steps 6, 7.1, 7.2,
Check
moving parts that can pinch, Always remove ignition key when working on AS82.30-Z-
crush or, in extreme cases even windshield wiper mechanism. 0001-01A
sever extremities.
Make sure when working on
lifted wiper arms that they do not

fall onto the windshield.
Otherwise the windshield will be
damaged
Switch off ignition and remove Press Keyless Go start/stop button repeatedly
1 the transmitter key from the EIS
[EZS] control unit transmitter key from vehicle and store it in a
m).
Check wiper blades, replace if
2 For wear and damage.
necessary
The wiper blade ends must lie on the
markings (arrow C) and may not be offset by
more than 10 mm upwards or downwards.
The distance from the outer marking to
Check position of wiper arms in the A-pillar (A) is approx. 60 mm, the distance
parked position on the basis of from the inner marking to the A-pillar (B) is
3
the markings (arrow C) in the approx. 510 mm.
windshield Excessive deviations may be caused by a
damaged wiper linkage, incorrect positioning of
the wiper arms on the linkage pins, or bent
wiper arms. Replace damaged components,
see: ?
AR82.30-P-
Remove/install wiper system
6400GZ
AR82.30-P-
Remove and install wiper arm
6100GZ
Switch on ignition and windshield
wipers. If the wiper arms are close to the upper
reversing position, switch off ignition and
windshield wipers.
Move wiper system from parked On vehicles with Keyless Go, code 889:
4
position Press Keyless Go start/stop button repeatedly
m).
Upper reversing position:

Manually move driver-side wiper
arm (1) and passenger-side wiper  The distance from the upper end of the
5 driver-side wiper blade to the driver-side
arm (2) into upper reversing
position. A-pillar (D) is approx. 30 mm,
 The distance from the upper end of the
passenger-side wiper blade to the driver-
side A-pillar (D) is approx. 460 mm,

Measure
Check angle of incidence of Select a suitable adjustment method on AR82.30-P-
6
wiper arms to windshield the basis of the result of the check. 6000-01GZ
AH82.30-P-
0001-01GZ
*BE82.30-P-
1001-01J
*BE82.30-P-
Notes on wiper arm adjustment
1002-01J
*BE82.30-P-
1003-01J
*BE82.30-P-
1004-01J
Adjustment tool set Fig. 35
Adapter Fig. 36
Adjust
In the event of impermissible deviations only
Adjust angle of incidence of AR82.30-P-
7.1 in reversing position or both in reverse and in
wiper arms in parked position 6100-01GZ
parked position.
AH82.30-P-
0001-01GZ
*BE82.30-P-
1001-01J
*BE82.30-P-
1002-01J
*BE82.30-P-
1003-01J
*BE82.30-P-
1004-01J
Adapter Fig. 36
In the event of impermissible deviations of AR82.30-P-
7.2 Adjusting wiper system
both wiper arms only in parked position. 6400-01GZ
AH82.30-P-
0001-01GZ
*BE82.30-P-
1003-01J
Adapter Fig. 36
Check
Windshield wipers, windshield AP82.30-P-

washer system and headlamp 8252GZ
cleaning system - function check
WIPER ARM TEST AND ADJUSTMENT VALUES

Number Designation Model 164.1/8, left- Model 164.1/8, right-
hand drive vehicle hand drive vehicle
BE82.30-P- Angle of incidence of wiper arm on
Angle° -4.0° (± 2.0°) +4.0° (± 2.0°)
1001-01J driver-side in reversing position
Angle of incidence of wiper arm on
BE82.30-P-
front passenger side in reversing Angle° -6.0° (± 2.0°) +6.0° (± 2.0°)
1002-01J
position
Angle° +4.0° (± 2.0°) -4.0° (± 2.0°)
1003-01J driver-side in parked position
BE82.30-P-
front passenger side in parked Angle° +6.0° (± 2.0°) -6.0° (± 2.0°)
1004-01J
position
Fig. 33: Identifying Adjustment Tool Set (211 589 02 21 00)

Fig. 34: Identifying Adapter (211 589 05 21 00)

Check wiper arms - AR82.30-P-6000-01GZ
Model 164, 251
MODIFICATION NOTES
15.6.06 Special tool 211 589 05 21 00 added Adapter "E" in steps 2, 4, 7

Angle° -4.0° (± 2.0°) +4.0° (± 2.0°)
BE82.30-P-
1002-01J
position
Angle° +4.0° (± 2.0°) -4.0° (± 2.0°)
BE82.30-P-
1004-01J
position

Number Designation Model 251, left- Model 251, right-
hand steering hand steering
Angle° -2.0 to -6.0 +2.0 to +6.0
1001-01K driver-side in reversing position
BE82.30-P- Angle of incidence of wiper arm on front
Angle° -4.0 to -8.0 +4.0 to +8.0
1002-01K passenger side in reversing position
Angle° +2.0 to +6.0 -2.0 to -6.0
1003-01K driver-side in parked position
Angle° +4.0 to +8.0 -4.0 to -8.0
1004-01K passenger side in parked position


Illustrated on model 251
Fig. 37: Identifying Distance Between Upper End Of Driver Side Wiper Blade And Driver Side A-Pillar
Shown on model 251 on driver-side wiper arm (1) in parked position
Fig. 38: Identifying Driver-Side Wiper Arm And Blade, Angle Gauge And Knurled Screw
1.1 If the wiper arms are not in the reversing position:
Switch on ignition, set wiper switch to position "2". When the wiper arms are close to the reversing
position, switch ignition off again, set wiper switch to position "0". Remove ignition key from EIS [EZS]
control unit.
On vehicles with Keyless Go, code 889: Press start/stop button repeatedly until the ignition is
switched off. Remove transmitter key from vehicle and store it in a location beyond its transmission range
(at least 2 m).
1.2 If the wiper arms are not precisely in the reversing position:
Manually move driver-side wiper arm (1) and passenger-side wiper arm (2) into the reversing position.
The wiper arms are in the upper reversing position, if
 the distance between the upper end of the driver-side wiper blade (3) and the rubber seal of the
driver-side A-pillar (dimension D) is approx. 30 mm,
 the distance between the upper end of the passenger-side wiper blade (4) and the rubber seal of the
driver-side A-pillar (dimension E) is approx. 460 mm,
2. Insert adapter "E" into the guide of the angle gauge (5) and fasten with knurled bolt (6a) to
angle gauge (5).
3. Fold up driver-side wiper arm (1), remove driver-side wiper blade (3).
4. Slide adapter "E" together with the angle gauge (5) onto the wiper blade mount of the driver-side
wiper arm (1) and clamp tight with the knurled bolt (6b).
5. Carefully lower driver-side wiper arm (1) onto windshield. All three contact points at the foot of
angle gauge (5) must touch the windshield.
6. Read off angle of incidence of driver-side wiper arm (1) in the reversing position on the scale of the
angle gauge (5), record and compare to the corresponding specified value.
7. Lift driver-side wiper arm (1), loosen knurled screw (6b), remove adapter "E" together with the
angle gauge (5) from driver-side wiper arm (1).
8. Attach driver-side wiper blade (3), carefully fold driver-side wiper arm (1) onto windshield.
9. Repeat test procedures 3 to 8 on passenger-side wiper arm (2) in reversing position.
10. Switch on ignition, turn wiper switch to position "0". When the wiper arms are in parked position,
switch off ignition again and remove transmitter key from EIS [EZS] control unit.
On vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until
ignition is switched off. Remove transmitter key from vehicle and store it in a location beyond its
11. Repeat test procedures 3 to 8 on driver-side wiper arm (1) and on passenger-side wiper arm (2) in
parked position.
Check wiper arms and adjust - AR82.30-P-6000T
MODELS 211, 215, 220, 230, 240

Shown on model 211, wiper system in reverse position
Fig. 39: Checking Wiper System In Reverse Position

Check
Risk of injury in the Always remove ignition AS82.30-Z-0001-01A
form of trapping or key when working on
crushing, or even windshield wiper
severing of limbs, if mechanism.
caught in windshield
wiper mechanism
When working on raised
driver-side wiper arm (1)
or front passenger side
wiper arm (2) it has to be
observed that they do not
fall onto the windshield
to prevent it from being
damaged.
1 Move wiper system from To do this, turn on
parked position ignition (circuit 15 or
circuit 15R) and turn
wiper switch to position
"Two". After the wiper
system has left the parked
position, turn off ignition
and turn back wiper
switch to position "Zero".
2 Manually position wiper Distance between
system into reverse driver-side wiper blade
position and A-pillar (A):
Models 211, 215, 220,
230 approx. 50 mm,
Model 240 approx. 70

mm
Distance between front
passenger side wiper
blade and A-pillar (B):
for model 211 approx.
350 mm,
for models 215, 220, 230,
240, the distance between
the front passenger side
wiper blade and the A-
pillar (B) results from the
distance between the
driver-side wiper blade to
the A-pillar (A).
For left-hand drive
vehicles, measured from
the upper wiper blade end
of the driver-side wiper
blade (1) and the front
blade (2) to the inside of
the left A-pillar.
For right-hand drive
vehicles, measured from
the upper wiper blade end
of the driver-side wiper
blade (1) and the front
blade (2) to the inside of
the right A-pillar.
3 Remove wiper blades See Operating
Instructions
4 Measure angle of When changing from AR82.30-P-6000-01T
incidence of driver-side reverse position to parked
wiper blade (1) and front position it has to be
passenger side wiper observed that the driver-
blade (2) to windshield side wiper arm (1) and
and record the front passenger side
wiper arm (2) do not have
any direct contact to the
windshield to prevent it
from being scratched.
Cover driver-side
wiper arm (1) and front
passenger side wiper arm
(2) with appropriate
means.
Fig. 35
5 Compare test values with The specified
adjustment values and adjustment values are
select correct adjustment only valid for left-hand
measure drive vehicles. For right-
hand drive vehicles, the
particular sign has to be
changed.
Angle of incidence of *BE82.30-P-1001-01E
wiper arm on driver-side
(1) in reverse position
wiper arm on front
passenger side (2) in
reverse position
(1) in parked position
wiper arm on front-
parked position
Notes on wiper arm AH82.30-P-0001-01A
adjustment
6.1 Adjust angle of incidence In the event that the test AR82.30-P-6100-01T
of driver-side wiper arm values deviate from the
(1) or front passenger tolerance range in reverse
side wiper arm (2) in position or in parked
parked position position and reverse
position:
Distort driver-side
wiper arm (1) or front
(2) by at least the value of
the tolerance deviation in
reverse position.
The specified adjustment
values are only valid for
left-hand drive vehicles.
For right-hand drive
vehicles, the particular
sign has to be changed.

wiper arm on front-
parked position
Fig. 35
6.2 Adjusting wiper system In the event that the test
values of the driver-side
wiper arm (1) and front
(2) deviate from the
tolerance range in parked
position.
The specified
adjustment values are
only valid for left-hand
drive vehicles. For right-
hand drive vehicles, the
particular sign has to be
changed.
Model 211 AR82.30-P-6400-01T
*BA82.30-P-1007-01A
Fig. 21
Fig. 41
Fig. 35
Model 215, 220 AR82.30-P-6400-01M
*BA82.30-P-1005-01A
Fig. 35
Model 230 AR82.30-P-6400-01R
*BA82.30-P-1005-01A
Fig. 35
Model 240 AR82.30-P-6400-01H
*BA82.30-P-1007-01A
Fig. 21
Fig. 35
7 Cover the wiper arm on When moving the
the driver-side (1) and wiper system out of the
wiper arm on the front parked position, make
passenger side (2) using sure that the driver-side
suitable aids and move wiper arm (1) and the
the wiper system out of front passenger side
the parked position wiper arm (2) do not have
any direct contact to the
windshield to prevent it
from being scratched.
To do this, turn on
ignition (circuit 15 or
circuit 15R) and turn
wiper switch to position
"Two". After the wiper
system has left the parked
position, turn off ignition
and turn back wiper
switch to position "Zero".
8 Install wiper blades See Operating
Instructions
9 Perform wiper system
function check

Number Designation Model 211 Model 215 Model 220
BE82.30-P- Angle of Angle ° -0.5...-3.5 -1.0...-6.0 -1.0...-6.0
1001-01E incidence of
wiper arm on
driver-side in
reverse position
BE82.30-P- Angle of Angle ° -0.5...-3.5 -0.5...-4.0 -0.5...-4.0
wiper arm on
front passenger
side in reverse
position
BE82.30-P- Angle of Angle ° 2.5...6.5 2.0...6.0 2.0...6.0
wiper arm on
driver-side in
parked position
BE82.30-P- Angle of Angle ° 2.5...6.5 2.0...6.0 2.0...6.0
wiper arm on
front passenger
side in parked
position

Number Designation Model 230 Model 240
BE82.30-P-1001- Angle of incidence Angle ° -1.0...-6.0 -1.0...-4.0
01E of wiper arm on
driver-side in
reverse position
BE82.30-P-1002- Angle of incidence Angle ° -0.5...-4.0 0.0...-3.0
01E of wiper arm on
front passenger side
in reverse position
BE82.30-P-1003- Angle of incidence Angle ° 2.0...6.0 3.0...5.0
01E of wiper arm on
driver-side in
parked position
BE82.30-P-1004- Angle of incidence Angle ° 2.0...6.0 3.0...5.0
01E of wiper arm on
front passenger side
in parked position
WINDSHIELD WIPER
BA82.30-P- Nut, wiper Nm 20 20 10
1005-01A system
WINDSHIELD WIPER
Number Designation Model 211.0 Model 211.2 Type 211.6 Model 240
BA82.30-P- Nut/screw, wiper Nm 11 11 11 10
1007-01A system to
partition wall



Check wiper arms - AR82.30-P-6000-01T
Model 211, 215, 220, 230, 240

1. Remove adapter (B) and choke angle gauge (A) from the adjustment tool set.
2. Insert adapter (B) into the guide (arrow) of the choke angle gauge (A) and fasten with knurled bolt
to choke angle gauge (A).
Fig. 44: Inserting Adapter Into Guide

Shown on model 211, driver-side wiper arm (1) in reverse position
3. Slide adapter (B) with the choke angle gauge (A) onto the wiper blade mount of the driver-side
wiper arm (1).
4. Lower driver-side wiper arm (1) until all three jacking points of the choke angle gauge foot (A) touch
the windshield.
5. Read angle of incidence of driver-side wiper arm (1) on the dial of the choke angle gauge (A) and
record.
6. Lift driver-side wiper arm (1) and remove choke angle gauge (A).
7. Repeat testing procedure for front passenger side wiper arm.
Fig. 45: Identifying Wiper Arm And Angle Gauge

8. Lift wiper arms, cover with appropriate aids and set down on windshield.
When changing from reverse position to parked position it has to be observed, that the wiper arms do
not have any direct contact to the windshield, otherwise it will be scratched.
9. Turn on ignition (circuit 15 or circuit 15R), let wiper system run in parked position, turn ignition off again
and remove aid (scratch protection) from the wiper arms.
Shown on model 211, driver-side wiper arm (1) in parked position
10. Side choke angle gauge (A) onto the wiper blade mount of the driver-side wiper arm (1).
11. Lower driver-side wiper arm (1) until all three jacking points of the choke angle gauge foot (A) touch
the windshield.
12. Read angle of incidence of driver-side wiper arm (1) on the dial of the choke angle gauge (A) and
record.
13. Remove choke angle gauge (A) from driver-side wiper arm (1).
14. Repeat testing procedure for front passenger side wiper arm.
Fig. 46: Checking Driver-Side Wiper Arm In Parked Position

REMOVE AND INSTALL WIPER ARM - AR82.30-P-6100GZ
MODEL 164
Shown on model 164.1 with engine 113

Fig. 47: Identifying Passenger/Driver's Side Wiper Arm And Nuts

Remove
Risk of injury in the form of
trapping or crushing, or even Always remove ignition key when working on AS82.30-Z-
severing of limbs, if caught in windshield wiper mechanism. 0001-01A
windshield wiper mechanism
Switch on ignition, move the wiper
1
arm into the park position
unit
2 m).
3
Unscrew nut (3) on the driver-side
4
wiper arm (1)
Remove driver-side wiper arm (1)
5
with wiper blade
Unscrew nuts (4) on passenger
6
side wiper arm (2)
Remove passenger side wiper arm
7
(2) with wiper blade
Install
Install passenger side wiper arm
8
(2) with wiper blade
Tighten nuts (4) on passenger side *BA82.30-P-
9
wiper arm (2) 1002-01J
Install driver-side wiper arm (1)
10
with wiper blade
Tighten nut (3) on driver-side *BA82.30-P-
11
wiper arm (1) 1002-01J
AR88.40-P-
1000GZ
AR82.30-P-
13 Check wiper arms and adjust
6000GZ
Windshield wipers, windshield
AP82.30-P-
washer system and headlamp
8252GZ
cleaning system function check
WINDSHIELD WIPER
BA82.30-P-1002-01J Nut on wiper motor shaft Nm 32
Adjust wiper arms - AR82.30-P-6100-01GZ
Model 164, 251
MODIFICATION NOTES

Angle° -4.0° (± 2.0°) +4.0° (± 2.0°)
BE82.30-P-
1002-01J
position
Angle° +4.0° (± 2.0°) -4.0° (± 2.0°)
BE82.30-P-
1004-01J
position

Number Designation Model 251, left- Model 251, right-
hand steering hand steering
Angle° -2.0 to -6.0 +2.0 to +6.0
1001-01K driver-side in reversing position
Angle° -4.0 to -8.0 +4.0 to +8.0
1002-01K passenger side in reversing position
Angle° +2.0 to +6.0 -2.0 to -6.0
1003-01K driver-side in parked position
Angle° +4.0 to +8.0 -4.0 to -8.0
1004-01K passenger side in parked position


Fig. 50: Identifying Wiper Arm Components Location

The angle of incidence of the wiper arms
 is always adjusted in parked position,

 if the check values deviate from the tolerance range only in reversing position,
 if the check values deviate from the tolerance range both in reversing position and parked position.
The adjuster levers (7) are attached with the side into which the marking "Z4" is imprinted to the
driver-side wiper arm (1) or the passenger-side wiper arm. The wiper arm is twisted with the aid of one
adjuster lever (7), which was positioned close to the angle gauge (5). The second adjuster lever (7) is
used as a counterholder.
1. If the wiper arms are not in parked position:
Switch on ignition, switch off windshield wipers. When the wiper arms are in parked position, switch off
ignition again, remove ignition key.
ignition is switched off. Remove transmitter key from vehicle and store it in a location beyond its
2. Insert adapter "E" into the guide of the angle gauge (5) and fasten with knurled bolt (6a) to
angle gauge (5).
4. Slide adapter "E" together with the angle gauge (5) onto the wiper blade mount of the driver-side
wiper arm (1) and clamp tight with the knurled bolt (6b).
5. Carefully lower driver-side wiper arm (1) onto windshield. All three contact points at the foot of angle
gauge (5) must touch the windshield.
6. Attach adjuster levers (7) onto driver-side wiper arm (1).
Attach the adjuster levers (7) as far from each other as possible onto the driver-side wiper arm
(1).
7. Press adjuster lever (7) into the required direction (arrow F) until the specified value is reached.
8. Remove adjuster levers (7) from wiper arm, check angle of incidence again.
The angle of incidence can change slightly when removing the adjuster levers (7), since the
wiper arm is slightly twisted due to the dead weight of the adjuster levers (7).
9. Lift driver-side wiper arm (1), loosen knurled screw (6b), remove adapter "E" together with the
angle gauge (5) from driver-side wiper arm (1).
11. Repeat adjustment procedure 3 to 6 on passenger-side wiper arm.
Adjust wiper arms - AR82.30-P-6100-01T

BE82.30-P-1003- Angle of Angle ° -3.0...-7.0 2.0...6.0 2.0...6.0
01E incidence of
wiper arm on
driver-side in
parked position
BE82.30-P-1004- Angle of Angle ° -3.0...-7.0 2.0...6.0 4.0...8.0
01E incidence of
wiper arm on
front passenger
side in parked
position

BE82.30-P-1003- Angle of Angle ° 1.5...5.5 2.5...6.5 2.0...6.0
01E incidence of
wiper arm on
driver-side in
parked position
BE82.30-P-1004- Angle of Angle ° 2.5...6.5 2.5...6.5 2.0...6.0
01E incidence of
wiper arm on
front passenger
side in parked
position

BE82.30-P-1003- Angle of Angle ° 2,0...6,0 2,0...6,0 3,0...5,0
01E incidence of
wiper arm on
driver-side in
parked position
BE82.30-P-1004- Angle of Angle ° 2,0...6,0 2,0...6,0 3,0...5,0
01E incidence of
wiper arm on
front passenger
side in parked
position

The angle of incidence of the driver-side wiper arm and the passenger-side wiper arm is always adjusted
in the parked position and is only carried out if the test values are out of the tolerance range in the reverse or
parked position. The driver-side wiper arm or the passenger-side wiper arm is distorted by at least the value of
the tolerance deviation in reverse position during this procedure.
Use adjuster lever (Z4) from adjustment tool set.
Change relevant sign of test and adjustment values for right-hand drive vehicles.
Fig. 52: Identifying Adjuster Lever

Shown on model 203, driver-side wiper arm in parked position
1. Fit angle measuring device (A) with adapter to wiper arm to be adjusted.
2. Lower wiper arm until all three contact points of the angle measuring device (A) foot are lying against
the windshield.
3. Put adjuster lever (Z4) as far apart as possible on this wiper arm.
The wiper arm is distorted with the aid of the adjuster lever (Z4) which was positioned
close to the angle measuring device. The second adjuster lever (Z4) is used as a counterholder.
4. Press the adjuster lever (Z4) into the required direction until the wiper arm is at least distorted by the
value of the tolerance deviation in reverse position.
5. Remove adjuster lever (Z4) from wiper arm.
Fig. 53: Identifying Driver-Side Wiper Arm In Parked Position - Shown On Model 203
Shown on model 203, driver-side wiper arm in parked position
6. Read off angle of incidence of adjusted wiper arm from scale of angle measuring device (A), note
down and compare with test and adjustment values.
7. Remove angle measuring device (A) with adapter from adjusted wiper arm.
Fig. 54: Identifying Measuring Angle Device

REMOVING AND INSTALLING WIPER SYSTEM - AR82.30-P-6400GZ
MODEL 164
Fig. 55: Identifying Wiper Motor, Wiper System Bracket, Electrical Connector, Wiper System And Bolts
Remove/install
Risk of injury in the form of

trapping or crushing, or even Always remove ignition key when working on AS82.30-Z-
severing of limbs, if caught in windshield wiper mechanism. 0001-01A
windshield wiper mechanism
Remove water repellent over wiper AR83.25-P-
1
system 1406GZ
Do not change installation position of wiper
system bracket (3) at partition wall, since this
2 Remove screw (1)
would change the contact pressure of the wiper
arms and therefore the wipe pattern.
*BA82.30-P-
3 Unscrew bolt (2)
1003-01J
Lift wiper system (4) and disconnect
4 electrical connector from wiper motor
(M6/1)
5 Remove wiper system (4)
7 Perform function test of wiper system
WINDSHIELD WIPER
BA82.30-P-1003-01J Bolt for window wiper frame to body Nm 20
Adjusting wiper system - AR82.30-P-6400-01GZ
MODIFICATION NOTES

BE82.30-P- Angle of incidence of wiper arm
Angle° +4.0° (± 2.0°) -4.0° (± 2.0°)
1003-01J on driver-side in parked position


Fig. 58: Identifying Wiper System Component Location

Exemplified on model 251 with engine 272

1. Switch on ignition, set wiper switch to position "0". When the wiper arms are in the parked position,
switch off ignition again, remove ignition key from EIS [EZS] control unit.
Remove transmitter key from vehicle and store it in a location beyond its transmission range (at least 2
m).
If the wiper arms are not in the park position.
2. Insert adapter "E" into the guide (arrow) of the angle gauge (5) and fasten with knurled screw to
angle gauge (5).
4. Slide adapter "E" together with the angle gauge (5) onto the wiper blade mounting of the driver-
side wiper arm (1) and clamp in place using the knurled screw.
5. Carefully lower driver-side wiper arm (1) onto windshield. All three contact points at the foot of angle
gauge (5) must touch the windshield.
6. Open engine hood, remove the rubber seal (8) at the driver side approx. up to the vehicle center.
7. Remove bolts (9) and remove partition wall (10).
8. Loosen bolt (11), enlarge the angle of incidence of the driver side wiper arm (1) by lifting (arrow G) the
wiper system (12) or reduce it by lowering (arrow H) the wiper system (12). Tighten bolt (11) if the angle
of incidence is correct.
9. Install partition wall (10), screw in bolts (9).
10. Mount rubber seal, close engine hood.
11. Lift driver-side wiper arm (1), loosen knurled screw, remove adapter "E" together with the angle
gauge (5) from driver-side wiper arm (1).
REMOVE/INSTALL WIPER MOTOR - AR82.30-P-6800GZ
MODEL 164
Fig. 59: Identifying Wiper Motor, Wiper Linkage And Bolts

Remove
Risk of injury in the form of trapping or Always remove ignition key when
AS82.30-Z-
crushing, or even severing of limbs, if caught in working on windshield wiper
0001-01A
windshield wiper mechanism mechanism.
AR82.30-P-
1 Remove wiper system
6400GZ
2 Pry wiper linkage (1) off wiper motor (M6/1) Long wedge Fig. 13
*BA82.30-P-
3 Remove bolts (2)
1001-01J
4 Remove wiper motor (M6/1)
Install
AR82.30-P-
5 Move wiper motor to parking position
6800-01GZ
6 Install wiper motor (M6/1)
*BA82.30-P-
7 Tighten bolts (2)
1001-01J
8 Mount wiper linkage (1) on wiper motor (M6/1)
AR82.30-P-
9 Install wiper system
6400GZ
WINDSHIELD WIPER
BA82.30-P-1001-01J Bolt on wiper motor Nm 10

Move wiper motor to parking position - AR82.30-P-6800-01GZ
1. Plug the electrical connector (1) into the wiper motor (M6/1).
2. Fix wiper system (2) in position with the nuts (3).
3. Switch on the ignition, turn the combination switch to position 2 and turn it back to position 0. Switch off
the ignition as soon as the wiper motor (M6/1) stops in park position.
Fig. 61: Identifying Wiper Motor, Electrical Connector, Wiper System And Nuts
REMOVE/INSTALL REAR WINDOW WIPER MOTOR - AR82.30-P-6900GZ
MODEL 164

Fig. 62: Identifying Rear Window Wiper Motor Components Location

Remove/install
Injury Hazard! Windshield wiper

Always remove ignition key when AS82.30-Z-
mechanism can pinch, crush or, in extreme
working on windshield wiper mechanism. 0001-01A
cases even sever extremities.
AR82.30-P-
1 Move wiper motor to parking position
6800-01GZ
AR72.20-P-
2 Remove liner on tailgate
3520GZ
AR82.30-P-
3 Remove wiper arm of rear-end door
6910GZ
5 Remove bolts (2) of tailgate wiper motor
Installation: Remove rubber
6 Remove tailgate wiper motor (M6/4) passage for rear window (3) if required.
Note the installation position!
REMOVE/INSTALL TAILGATE WIPER ARM - AR82.30-P-6910GZ
MODEL 164

Fig. 63: Identifying Tailgate Wiper Arm Components Location

Remove/install
Risk of injury in the form of trapping or Always remove ignition key

AS82.30-Z-
crushing, or even severing of limbs, if caught in when working on windshield
0001-01A
windshield wiper mechanism wiper mechanism.
1 Open the cover (1)
*BA82.30-P-
2 Unscrew nut on wiper arm (2)
1004-01J
Fold wiper arm back and
3 Remove wiper arm in parking position (3)
remove, use puller if necessary.
Puller Fig. 64
Mount wiper arm such
4 Install in the reverse order that the wiper arm faces to the
right
WINDSHIELD WIPER
BA82.30-P-1004-01J Nut for rear window wiper arm to wiper motor Nm 12

REMOVING AND INSTALLING RAIN/LIGHT SENSOR - AR82.30-P-7800GZ
MODEL 164.1 with CODE (345) Rain sensor
MODEL 164.8
Fig. 65: Identifying Rain/Light Sensor Components Location

Remove/install
Information on preventing damage
AH54.00-P-
to electronic components due to All models
0001-01A
889:
1 the transmitter key from the EIS until ignition is switched off. Remove
2 m).
2 rain/light sensor (1) toward the
front (arrow)
3
(2)
Push interlocks (3) on both sides
of the rain/light sensor (B38/2) The lens of the rain/light sensor (B38/2) is
4 bonded to the windshield and must not be
down and remove the rain/light
sensor (B38/2) removed as this will damage the lens.
Code adaptation of the rain sensor
and the light sensor amplification *WH58.30-Z-
factor and select type of 1048-13A
windshield


Number Designation
REMOVING AND INSTALLING WASHER FLUID RESERVOIR OF WINDSHIELD WASHER

SYSTEM - AR82.35-P-6000GZ
MODEL 164.1 with CODE (600) Headlamp cleaning system
Fig. 66: Identifying Windshield Washer Fluid Pump And Windshield Washer Fluid Level Indicator
Switch
Remove/install
AR88.20-P-
2000GZ
Pump washer fluid out of the washer
2
fluid reservoir (2)
Unclip washer fluid hoses (1) from
3
the washer fluid reservoir (2)
Remove windshield washer fluid
4
level indicator switch (S42)
Remove windshield washer fluid
pump (M5/1) and main headlamps-
5
washer fluid pump (3) from washer
fluid reservoir (2)
*BA82.35-P-
6 Remove bolts (4)
1001-01B
7 Remove filler neck (5) upwards
8 Remove washer fluid reservoir (2)
downwards
10 Fill up washer fluid reservoir (2)
Windshield washer system - inspect AP82.35-P-
fluid level, adjust to correct level 8210GZ
Switch on ignition and check the
Check windshield washer system for function of the pumps by operating the
11 combination switch. A sufficient quantity of
proper function
washer fluid must spray out of the spray
nozzles.
WINDSHIELD WASHER SYSTEM

BA82.35-P-1001-01B Bolt, washer fluid reservoir to front end assembly Nm 10
REMOVE/INSTALL WINDSHIELD WASHER SYSTEM PUMP - AR82.35-P-6002GZ
MODEL 164
Fig. 67: Identifying Windshield Washer System Pump Components Location

Remove/Install
Remove front part section of AR88.10-
1
fender liner in front fender P-1310GZ
Remove windshield washer
fluid pump (M5/1) up out of the
2 Collect washer fluid which flows out.
washer fluid reservoir (1) and
seal off
Set of plugs Fig. 68
Detach washer fluid hoses (3) at
Installation: Check gasket (4), replace if
3 windshield washer fluid pump
necessary.
(M5/1)

4
(2)
Top up washer fluid reservoir
6
(1)
Inspect fluid level of windshield
AP82.35-P-
washer system, adjust to correct
8210GZ
level
Switch on ignition and check the function
Carry out function check of the of the window washer fluid pump (M5/1) by
7 windshield wipers and the pressing the combination switch. A sufficient
windshield washer system quantity of washer fluid must spray out of the
spray nozzles.

REMOVE/INSTALL HEADLAMP CLEANING SYSTEM PUMP - AR82.35-P-6003GZ
Fig. 69: Identifying Washer Fluid Hose, Washing Water Reservoir, Electrical Connector And Seal
Remove/install
Remove front section of AR88.10-P-

1
fender liner in front fender 1310GZ
Detach washer fluid hose (1)
2 from main headlamp washer Collect washer fluid which flows out.
fluid pump (3)
connector (2) from main
3
headlamp washer fluid pump
(3)
Pull main headlamp washer
4 fluid pump (3) out from Installation: Use new gasket!
washer fluid reservoir (5)
Top up washer fluid reservoir
6
(5)
Windshield washer system -
AP82.35-P-
inspect fluid level, adjust to
8210GZ
correct level
Switch on ignition and check the function of the
Check windshield washer pump for the headlamp cleaning system by actuating
7
system for proper function the combination switch. A sufficient quantity of
washer fluid must spray out of the spray nozzles.
Fig. 70: Identifying Set Of Plugs (129 589 00 91 00)

REMOVE/INSTALL FLUID LEVEL SENSOR FOR THE WINDSHIELD WASHER SYSTEM -

AR82.35-P-6005GZ
MODEL 164
Shown on vehicle with headlamp cleaning system

Fig. 71: Identifying Windshield Washer Fluid Level Indicator Switch, Washing Water Reservoir And
Gasket
Remove/Install
Remove front part section of fender AR88.10-P-
1
liner in front fender 1310GZ
2 Disconnect electrical connector (1).
Collect escaping water.
Pry windshield washer fluid level Installation: Install a new gasket for
3 indicator switch (S42) out of washer the fluid level sensor for the windshield
fluid reservoir (2) and close washer system (S42) in the windshield washer
fluid reservoir (2).
Long wedge Fig. 13
5 Fill washer fluid reservoir (2)
Inspect fluid level of windshield
AP82.35-P-
washer system, adjust to correct
8210GZ
level


REMOVE/INSTALL TAILGATE SPRAY NOZZLE - AR82.35-P-6920GZ
MODEL 164
Fig. 74: Identifying Spray Nozzle, Rear-End Door And Washer Fluid Hose
Remove/install
1 Unclip spray nozzle (1) from rear-end door Long wedge (2) Long wedge Fig. 13
2 Detach spray nozzle (1) from washer fluid hose (3)

REMOVE/INSTALL WINDSHIELD WASHER NOZZLE - AR82.35-P-6970GZ
MODEL 164
Fig. 76: Identifying Windshield Washer Nozzle Components Location

Remove/install
AR83.25-P-
1 Remove air inlet duct under the hood
1407GZ
Unclip windshield washer nozzles (2) from air inlet grille
2
(3)
3 Remove windshield washer nozzles (2)
4 Unclip windshield washer nozzle (4) (arrows) Avoid
damaging paint.
5
Detach washer fluid hoses (1) from windshield washer
nozzles (2) and windshield washer nozzle (4)

7 Fill up washer fluid reservoir
Windshield washer system - inspect fluid level, adjust to AP82.35-P-
correct level 8210GZ
REMOVE/INSTALL WINDSHIELD WASHER HOSE - AR82.35-P-6980GZ
MODEL 164
Fig. 77: Identifying Windshield Washer Hose Components Location

Remove/Install
1
position 1000GZ
AR83.25-P-
2 Remove air inlet duct under hood
1407GZ
Detach washer fluid hose (6) from the
3
windshield washer nozzles (1)
Detach rubber seal (2) in the area of the
4
left partition wall section (4)
5 Remove bolt (3)
Unclip left partition wall section (4) and
6
remove
Unclip washer fluid hose (6) out of clips
7
(5)
Remove front part section of fender liner Remove front part section of AR88.10-P-
8
in front fender fender liner in left front fender. 1310GZ
Collect any escaping window
9 Detach washer fluid hose (6) and seal
washer fluid in a suitable container.
10 Expose washer fluid hose (6) and remove
12 Perform function check
Check windshield washer system fluid

13
level and correct if necessary
Inspect fluid level of windshield washer AP82.35-P-
system, adjust to correct level 8210GZ

REMOVE/INSTALL RADIO - AR82.60-P-7502GZ
MODEL 164
Shown on model 164.1, with USA version, code 494
Fig. 79: Identifying Radio Components Location

MODIFICATION NOTES
26.7.06
removed 8
Remove/install
Only when replacing radio
1 Read out coding of radio (1) and if it can still be read out using
STAR DIAGNOSIS.
STAR DIAGNOSIS diagnosis *WH58.30-Z-
system 1048-13A
Unlatch instrument panel center part (2) at Protect trim parts of the
2 bottom edge (arrows A) and pull forward instrument panel and center console
out of the instrument panel from scratches.
Unscrew bolts (3) and slide latches (6) on
3
both sides downwards (arrow B)
Pull radio (1) out of installation opening and Protect instrument panel,
4 detach electrical connector (4) along with center console trim parts and the
antenna cable connectors (5) radio from scratches.
Only after installing a new
6 Code radio (1)
radio.
system 1048-13A

Number Designation
REMOVE/INSTALL DVD PLAYER - AR82.60-P-7505GZ
MODEL 164 with CODE (864) Rear entertainment system

Fig. 80: Identifying DVD Player, Electrical Connector, Covers And Bolts
MODIFICATION NOTES
Remove/install
Unscrew two
1 Remove front cover at bottom of rear seat
bolts, remove cover.
2 Remove bolts (1)
3 Remove covers (2)
4 Fold floor covering to rear
Press left and right locking hooks (arrows) on DVD player (A40/4) Fig.
6 Removal fixture
upward and pull DVD player (A40/4) out from front 81
Fig. 81: Identifying Removal Assembly (000 589 88 63 00)

REMOVE/INSTALL DISPLAY IN REAR - AR82.60-P-7720GZ
MODEL 164, 251 with CODE (864) Rear entertainment system
Fig. 82: Identifying Rear Display

Fig. 83: Identifying Rear Display Components Location (1 Of 2)

Fig. 84: Identifying Rear Display Components Location (2 Of 2)

Remove/install

code 889:
1 Turn key in ignition switch to position "0". Press keyless go start/stop button
repeatedly until ignition is switched
off
Model 164 with electrically AR91.16-P-
adjustable head restraint. 0040GZ
Model 164 with mechanically AR91.16-P-
adjustable head restraint. 0040GZA
AR91.16-P-
Model 251. 0040RT
Unclip at bottom left and right
3 Unclip cover (2)
(arrows A).
4 Detach clamping plates (3)
Unclip at bottom left and right
6 Unclip cover (5)
(arrows B).
7 Loosen bolts (7) Do not remove completely.
8 Pull monitor frame unit (6) out upwards
Pay attention to electrical lines, risk
of breakage!
9 Unclip clips (8)
10 Remove bolts (9)
12 Pull out pin (11)
13 Remove locking pin (12)
Remove left rear display (A40/5) or right rear
14
display (A40/6) from monitor frame (1)
CHECK MICROPHONE FOR SOUND AMPLIFIER - AR82.62-P-1110GZ
Check
Connect STAR *WH58.30-Z-
DIAGNOSIS 1048-13A
Connect STAR
AD00.00-P-
2000-04A
fault memory
Select Actual values in
2 menu SOUND - Sound
system
Select Microphone test: Follow the instructions on the screen for
3 B25/6 (sound amplifier every test in order to determine the source of fault.
microphone) Carry out repair against a separate order.

Number Designation
REMOVING AND INSTALLING MICROPHONE - AR82.62-P-7700GZ

Fig. 85: Identifying Microphone Components Location

Remove/install
Information on preventing
AH54.00-P-
damage to electronic components All models
0001-01A
due to electrostatic discharge
Switch off ignition and remove Press Keyless Go start/stop button repeatedly until
1 the transmitter key from the EIS ignition is switched off. Remove transmitter key from
[EZS] control unit vehicle and store it in a location beyond its
2 rain/light sensor (1) toward the
front (arrow A)
Unclip rear section, covering,
3 rain/light sensor (2) downward
(arrow B)
Disconnect sound amplifier
4
microphone connector (B25/6x1)
Remove sound amplifier
microphone (B25/6) from Carefully press both tabs (3) away from each
5
rain/light sensor covering rear other to remove sound amplifier microphone.
section
Check sound amplifier AR82.62-P-

7
microphone 1110GZ
REMOVE/INSTALL LOUDSPEAKER AMPLIFIER CONTROL UNIT - AR82.62-P-7720GZ
Fig. 86: Identifying Sound System Amplifier

Fig. 87: Identifying Loudspeaker Amplifier Control Unit Components Location

Fig. 88: Identifying Sound System Amplifier, Bracket And Bolts

MODIFICATION NOTES
26.7.06
removed 18
Remove/install
AH54.00-P-
0001-01A
Only when replacing amplifier for sound
Read out coding of amplifier for
1 system (N40/3) and when it can still be
sound system (N40/3)
read out with STAR DIAGNOSIS.
*WH58.30-Z-
1048-13A
AR91.10-P-
2 Remove left front seat
1000GZ
AR68.30-P-
3 Remove left front door sill molding
4100GZ
AR68.30-P-
4 Remove left rear door sill molding
4100GZ
Remove B-pillar paneling at bottom AR68.30-P-
5
left 4700GZ
6 Remove cover (2).
7 Remove anchoring lug cover (3)
Remove bolt (4) and remove Installation: Insert anchoring lug
8
anchoring lug (5) with its positioning tab properly aligned.
*BA68.50-P-
1001-03F
9 Fold over left rear floor covering (1)
Remove clip (6) and remove air duct

10
(7)
Remove nuts (8) and remove left
11
intermediate bottom (9)
Disconnect electrical connectors
Cover fiber optic cable using
12 from amplifier for sound system
suitable means.
(N40/3)
Remove nuts (10) and remove
13 amplifier for sound system (N40/3)
together with bracket
Remove bolts (11) and remove
14 bracket (12) from amplifier for
sound system (N40/3)
Code amplifier for sound system Only when installing new amplifier for
16
(N40/3) sound system (N40/3).
*WH58.30-Z-
1048-13A
CARGO RETAINERS

Number Designation
REMOVING AND INSTALLING LOUDSPEAKER IN INSTRUMENT PANEL - AR82.62-P-7833GZ
Shown on vehicles with Parktronic system (PTS), code 220

Fig. 89: Identifying Instrument Panel Loudspeaker Components Location

Remove/install

1 transmitter key from the EIS [EZS] ignition is switched off. Remove transmitter key from
control unit vehicle and store it in a location beyond its
Protect instrument panel from being
Carefully unlatch center cockpit speaker
scratched.
(centerfill) cover (1) at rear edge (arrow)
2 Installation: Insert center cockpit speaker
and pull upward out of installation
opening (centerfill) cover with the two front lugs first, then
latch in at the rear at the clamp.
Fig.
Long wedge 13
Undo screws (3) and remove center
4
cockpit speaker (centerfill) (H4/27)

REMOVE/INSTALL BASS MODULE SPEAKER - AR82.62-P-7839GZ
Fig. 91: Identifying Subwoofer, Electrical Connector, Plastic Nuts And Cover (Model 164.1)

Fig. 92: Identifying Subwoofer, Electrical Connector, Plastic Nuts And Cover (Model 164.8)
Remove/install
1 Remove cover (1) Model 164.1. Left-hand side.

Remove side paneling AR68.30-P-
2 Model 164.8. right side.
in trunk 4800RT
Unscrew plastic nuts
3
(2).
Installation: In model 164.1 do not damage wiring
Remove subwoofer
4 harness! For vehicles with power glass tilting/sliding roof, code
(H4/29)
414, do not damage water drain hose!
5
connector (3)
6
order
REMOVE/INSTALL LOUDSPEAKERS IN FRONT DOORS - AR82.62-P-7845GZ
MODEL 164

Fig. 93: Identifying Front Door Loudspeaker, Electrical Connector And Rivets
Remove/install
Switch off radio
Remove door lining from left or right AR72.10-P-
1
front door 1000GZ
2 the left front door speaker (H4/5) or from
right front door speaker (H4/6)
Remaining rivet material must be
completely removed, otherwise this
Drill out rivets (1) with a dia. 4.8 mm drill
3 can cause corrosion damage.
bit
Use aluminum/steel hollow
rivets, dia. 4.8 x 15 mm
*WH58.30-Z-
*WH58.30-Z-
Cordless drill/driver
1007-20A
*WE58.40-Z-
1005-03A
Remove left front door speaker (H4/5) or
4 right front door speaker (H4/6) from door
module

Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL FRONT DOOR SPEAKERS IN MIRROR TRIANGLE - AR82.62-P-7850GZ
MODEL 164
Fig. 94: Identifying Front Door Tweeter, Electrical Connector And Cover
Remove/install
1 Unclip cover (1) Unclip cover (1) at top first.

Fig.
Mounting wedge 21
Unclip left front door tweeter (H4/33) or right Installation: The catch lug on the
3
front door tweeter (H4/34) from cover (1) speaker determines the installation position.

REMOVE/INSTALL LOUDSPEAKERS IN REAR DOORS - AR82.62-P-7874GZ
MODEL 164
Fig. 96: Identifying Rear Door Speaker, Electrical Connector, Door Module And Rivets
Remove/install
Switch off radio
Remove door lining from left or right AR72.12-P-
1
rear door 1010GZ
Detach electrical connector (2) from left
2 rear door speaker (H4/3) or right rear
door speaker (H4/4)
Remaining rivet material must be
completely removed, otherwise this can
Drill out rivets (3) with a dia. 4.8 mm
3 cause corrosion damage.
drill bit
Use aluminum/steel hollow
rivets, dia. 4.8 x 15 mm
*WH58.30-Z-
*WH58.30-Z-
Cordless drill/driver
1007-20A
*WE58.40-Z-
1005-03A
Remove left rear door speaker (H4/3) or
4 right rear door speaker (H4/4) from
door module (1)

Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL THE SPEAKERS IN THE HEADLINER - AR82.62-P-7876GZ
Fig. 97: Identifying Left And Right Headliner Speaker And Bolts
Remove/install
Covering for speaker is AR68.30-P-

1 Remove headliner
bolted to headliner from inside. 4300GZ
Unscrew bolts (3) from left headliner speaker (2) or
2
from right headliner speaker (1)
Disconnect electrical connector (4) from left
3 headliner speaker (2) or from right headliner speaker
(1)
REMOVING AND INSTALLING KEYLESS GO ANTENNA - AR82.62-P-8000GZ

Fig. 98: Identifying Keyless Go Antenna Components Location (1 Of 5)





Remove/install
Press Keyless Go start and stop button
Switch off ignition and remove repeatedly until the ignition is switched off.
1 transmitter key from EIS control Remove keyless go transmitter card or
unit transmitter key from vehicle and store outside
of transmission range (min. 2 m)
Unlatch the instrument panel Only for removal of the cockpit Keyless
center part (3) at the bottom edge Go antenna (A2/60).
2.1
(arrows) and pull forward out of Protect trim parts of the instrument
the instrument panel panel and center console from scratches.
Only for removal of left rear door
Remove door lining from rear AR72.12-P-
2.2 Keyless Go antenna (A2/39) or right rear door 1010GZ
door
Keyless Go antenna (A2/41).
Only for removal of interior Keyless Go
2.3 Remove covering under the seats
antenna (A2/61).
Only for removal of luggage AR72.20-P-

2.4 Remove liner on tailgate
compartment Keyless Go antenna (A2/35). 3520GZ
3 Remove bolts (1)
4
(2)
Stored faults which may be caused by
disconnecting cables or by simulation during
6 Read out fault memory
test operations, must be erased in the fault
memory after completing the work.
*WH58.30-
Z-1048-13A

Number Designation
REMOVE/INSTALL ANTENNA AMPLIFIER MODULE - AR82.62-P-8300GZ
MODEL 164
roof antenna module
Fig. 103: Identifying Roof Antenna Module, Antenna Amplifier And Screws
Remove/install
Notes on avoiding damage to electronic components AH54.00-P-

due to electrostatic discharge 0001-01A
AR68.30-P-
1 Remove headliner
4300GZ
AR82.62-P-
2 Remove roof antenna module (A2/93)
8979GZ
3 Remove bolts (1)
Do not damage or
Release antenna amplifier module (A2/93a2) toward
4 contaminate printed circuit
side (arrow A) and remove upward (arrow B).
board.
REMOVE/INSTALL RADIO ANTENNA AMPLIFIER - AR82.62-P-8301GZ
MODEL 164
Fig. 104: Identifying FM Rear Window Antenna Amplifier, Electrical Connectors And Nut
Remove/install
damage to electronic AH54.00-P-
components due to 0001-01A

Switch off ignition and Keyless Go start/stop button repeatedly until ignition is
remove transmitter key from switched off. Remove transmitter key from vehicle and
1 EIS control unit store it in a location beyond its transmission range (at
least 2 m).
AR72.20-P-
2 Remove liner on tailgate
3520GZ
Separate electrical connectors
3
(1)
4 Unscrew nut (2)
Remove FM rear window
5
antenna amplifier (A2/19)
REMOVE/INSTALL TV ANTENNA AMPLIFIER - AR82.62-P-8302GZ
MODEL 164, 251 with CODE (863) Digital/analog TV tuner
Fig. 105: Identifying TV Antenna Amplifier Components Location (Shown On Model 164.1)
Shown on model 251

Fig. 106: Identifying TV Antenna Amplifier Components Location (Shown On Model 251)
Remove/install

AH54.00-P-
0001-01A
Switch off ignition and remove Press Keyless Go start/stop button repeatedly until the
1 transmitter key from EIS ignition is switched off. Remove transmitter key from
control unit vehicle and store it in a location beyond its
Only when removing left antenna amplifier
Remove moldings from C- AR68.30-P-
2.1 module (A2/64) or right antenna amplifier module
pillar 4490GZ
(A2/65) on model 164.
Only when removing left antenna amplifier AR68.30-P-
2.2 Remove side paneling in trunk module (A2/64) or right antenna amplifier module
4800RT
(A2/65) on model 251.
Only when removing TV rear window antenna
amplifier (A2/92).
2.3 Remove liner on tailgate Installation: Ensure that guide on TV rear
window antenna amplifier (A2/92) is seated correctly
in corresponding opening in rear-end door.
AR72.20-P-
Model 164
3520GZ
AR72.20-P-
Model 251
3520RT
3
connectors (1).
4 Unscrew nut (2) On model 251: Unscrew bolt (3).
REMOVE/INSTALL ROOF ANTENNA MODULE - AR82.62-P-8979GZ
MODEL 164
Fig. 107: Identifying Roof Antenna Module Components Location

Remove/install
Information on preventing damage to electronic AH54.00-P-

All models
AR68.30-P-
1 Remove headliner
4300GZ
Unclip cable
2 Disconnect electrical connector (1, 2, 3)
tie if present.
Unclip cable
3 Disconnect antenna cable (4) connectors
tie if present.
4 Unscrew nuts (5).
Release roof antenna module (A2/93) at the two tabs
(arrow) and remove

REMOVE/INSTALL CD PLAYER WITH CHANGER - AR82.64-P-7507GZ
MODEL 164.1
Fig. 109: Identifying CD Changer, Glove Compartment, Bracket And Bolts

Removal/installation
On vehicles with keyless go, code 889:

Switch off ignition and remove Press keyless go start/stop button repeatedly until the
1 transmitter key from the EIS ignition is switched off. Remove the transmitter key
control unit from the vehicle and store it in a location beyond its
AR68.10-P-
2 Remove glove compartment (1)
1400GZ
3 (arrow) Two electrical connectors.

Support CD changer (A2/6) to prevent it from
4 Remove screws (2)
dropping.
Remove CD changer (A2/6) with
5
bracket (3)
Place CD changer (A2/6) on
6
workbench
7 Remove bolts (4).
Pull CD changer (A2/6) forward
8
out of bracket (3)
REMOVING AND INSTALLING CD CHANGER - AR82.64-P-7508GZ
MODEL 164
Fig. 110: Identifying CD Changer, Glove Compartment, Bracket And Bolts

Remove/install

Switch off radio and ignition, Press Keyless Go start/stop button repeatedly until
1 and remove transmitter key ignition is switched off. Remove transmitter key from
from EIS control unit vehicle and store it in a location beyond its transmission
range (at least 2 m).
AR68.10-P-
2 Remove glove compartment (1)
1400GZ
Detach electrical connectors
3 Two electrical connectors.
(arrow)
Prop up CD changer (A2/6) to prevent it from
4 Unscrew bolt (2)
falling out.
Remove CD changer (A2/6)
5
with bracket (3)
Place CD changer (A2/6) onto
6
workbench
7 Remove screws (4)
Remove CD changer (A2/6)
8 from bracket (3) towards the
front
REMOVE/INSTALL VOICE CONTROL SYSTEM CONTROL UNIT - AR82.70-P-0003GZ
MODEL 164.1 with CODE (813) Voice control system (VCS [SBS])
Fig. 111: Identifying Voice Control System Control Unit Components Location
MODIFICATION NOTES
27.6.06 Torque added Step 5
Remove/install

AH54.00-P-
0001-01A
When replacing the voice control system (VCS
Temporarily store basic data of [SBS]) control unit (N41/3).
voice control system (VCS
1 Installation: Copy temporarily stored
[SBS]) control unit (N41/3) in
basic data to the new voice control system (VCS
STAR DIAGNOSIS
[SBS]) control unit (N41/3).
*WH58.30-
Z-1048-13A
until the ignition is switched off. Remove
2 transmitter key from EIS
control unit
m).
Set 60% rear seat cushion of
3
rear seat in vertical position
4 Remove cover (1)
*BA91.40-P-
5 Remove bolt (2)
1003-01H
Unscrew bolt (3) and remove On vehicles with electrically heated left
6 cross strut (4) or place to one and right rear seats, code 872: Do not damage
side wiring harness.
*BA61.10-P-
1006-01F
Separate electrical connector
7
(5)
Unscrew bolts (6) and remove
8 voice control system (VCS
[SBS]) control unit (N41/3)

BA61.10-P-1006-01F Bolt, rear console to vehicle floor Nm 25


Number Designation
REMOVE/INSTALL COMPENSATOR CONTROL UNIT - AR82.70-P-0030GZ
MODEL 164.1 with CODE (388) "Portable CTEL" UPCI telephone system
Fig. 112: Identifying Compensator Control Unit Components Location

Remove/Install

AH54.00-P-
0001-01A
1 transmitter key from the EIS control
unit
Remove paneling (2) at side in load AR68.30-P-
2
compartment 4800GZ
3 Unclip cover (4)
Undo 3 bolts (arrows) and carefully
4 Detach trim (3) from C-pillar detach trim from clips. Place trim to one side,
but do not completely remove.
Detach antenna cable connectors (5,
5
8) and electrical connector (7)
Undo four screws (6) and remove

6
compensator control unit (1)

REMOVE AND INSTALL BRACKET FOR PORTABLE CTEL TELEPHONE - AR82.70-P-8918GZ
MODEL 164 with CODE (386) Preinstallation for "portable CTEL" UPCI telephone system with CODE
(388) "Portable CTEL" UPCI telephone system
Shown on vehicle with telephone "portable CTEL" UPCI system, code 388 and USA version, code 494
Fig. 114: Identifying Portable CTEL Telephone Remove/Install Components

Shown on vehicle with telephone "portable CTEL" UPCI system, code 388 and USA version, code 494
Fig. 115: Identifying Portable CTEL Telephone Components Location

Remove/Install
1 Open upper stowage box in center console

Press and hold release button of portable
2 Remove portable CTEL adapter (1) CTEL adapter (arrow A) and slide portable CTEL
adapter backwards to remove (arrow B).
3 Open lower stowage box in center console
4 Unscrew bolts (5)
Do not damage wiring harness.
Release stowage tray (2), lift up slightly and
5 Installation: Insert stowage tray with its guide
turn over
tab first.
6 Disconnect electrical connectors (3, 6)
7 Disconnect antenna cable connector (4)
8 Remove clamp (7) Carefully remove clamp!
Detach wiring harness from stowage tray (2)
9
(arrow C) and remove stowage tray
Remove UPCI portable CTEL holder Carefully unclip UPCI portable CTEL holder
10 (Universal Portable CTEL Interface) (Universal Portable CTEL Interface) at the three
(A34/15) from stowage tray (2) locking tabs (8).
REMOVE/INSTALL VEHICLE INTERFACE (PORTABLE CTEL) - AR82.70-P-8920GZ
MODEL 164 with CODE (388) Telephone "Handy", UPCI system
P82.70-5377-09
Fig. 116: Identifying Vehicle Interface (Portable CTEL) Components Location

MODIFICATION NOTES
26.7.06
removed 9
Remove/install
Buffer basic data of Universal Portable Only when replacing Universal

CTEL Interface (UPCI [UHI]) control Portable CTEL Interface (UPCI
1 [UHI]) control unit (N123/1).
unit (N123/1) in STAR DIAGNOSIS
diagnosis system Installation: Transfer buffered
basic data to new Universal Portable
CTEL Interface (UPCI [UHI]) control

unit (N123/1).
*WH58.30-Z-
1048-13A
2 Release rear seat (1) and fold forward
3 Raise cover (2)
Disconnect and cover fiber optic cable
4
coupling (3)
Model 164, 169.0/3, 211.0/2/6, 221.0/1
Notes on avoiding damage to fiber optic AH82.60-P-
245.2, 251 with Media Oriented
cables during repair work 0001-05AK
System Transport (MOST)
Remove four nuts (arrows) and remove
6 Universal Portable CTEL Interface
(UPCI [UHI]) control unit (N123/1)

Number Designation
REMOVE/INSTALL STOWAGE TRAY FOR PORTABLE CTEL (TELEPHONE) - AR82.70-P-

8921GZ
MODEL 164
Fig. 117: Identifying Portable CTEL Stowage Tray, Armrest Cover, Plug Connections And Guide Lug
Remove/install
1 Unlock armrest cover (1) and set upright

2 Remove bolts (2)
3 Unlock stowage tray and set upright
Lift portable CTEL stowage tray (3) (arrow A) Installation: Pay attention to installation
4
and pull forward position of guide tab (7).
5 Turn over portable CTEL stowage tray (3)
7 Unclip connectors (5)
8 Remove clamp (6)
REMOVE/INSTALL ANTENNA SPLITTER - AR82.70-P-8953GZ
MODEL 164 with CODE (359) TELE AID emergency call system
Only in combination with a navigation system
Shown on model 164.1 with USA version, code 494
Fig. 118: Identifying Antenna Splitter Components Location

Remove/install

AH54.00-P-
0001-01A
1 Release rear seat (1) and fold forward
2 Raise cover (2)
Press together locking tabs of antenna
cable connector in lower section (arrows A) and
Disconnect antenna cable connector detach antenna cable connector from GPS
3
(3) from GPS antenna splitter (A2/5) antenna splitter (A2/5).
Installation: Pay attention to correct
latching of the locking tabs.
Detach GPS antenna splitter (A2/5)
4 Do not damage clip (4).
upwards from bracket
Long wedge Fig. 13
Press together locking tabs of antenna
Disconnect antenna cable connector cable connectors in upper section (arrows B and
(5, 6) from GPS antenna splitter C) and detach antenna cable connectors from
5
(A2/5) and remove GPS antenna GPS antenna splitter (A2/5).
splitter (A2/5) Installation: Pay attention to correct
latching of the locking tabs.

REMOVE/INSTALL TV TUNER - AR82.85-P-7366
Remove/install TV tuner - AR82.85-P-7366GY
MODEL 164.8 with CODE (863) Digital/analog TV tuner

Fig. 120: Identifying TV Combination Tuner (Analog/Digital) And Nuts

Read out data

AH54.00-P-
0001-01A
Read out coding of TV combination
tuner (analog/digital) (A91/1) and Only if a new TV combination tuner
1 (analog/digital) (A91/1) is to be installed and
temporarily store in STAR
DIAGNOSIS diagnostic unit the old device can still be read out.
*WH58.30-
Z-1048-13A
Remove/install
Switch off radio and entertainment
2 system, turn key in ignition switch 889:
Press keyless go start/stop button repeatedly
to position "0"
AR68.30-P-
3.1 Remove spare tire well panel On vehicles with spare wheel. 4620GZ
Remove stowage compartment
3.2 On vehicles with TIREFIT.
under the load compartment floor
Remove left styrofoam insert from
4
spare tire well
5 Unscrew nuts (1)
Mark antenna plugs and jacks to This is to ensure that they are not
6
match each other by color mixed up during installation.
Detach all connectors on the TV The number of connectors varies
7 combination tuner (analog/digital) depending on the equipment and connected
(A91/1) peripherals.
Remove TV combination tuner
(analog/digital) (A91/1) with Remove bracket if necessary.
bracket
Install in the reverse order

Code and test the TV
combination tuner
If a new TV combination tuner
(analog/digital) (A91/1) was installed and the
old device could still be read out:
Transfer the coding temporarily stored in the
STAR DIAGNOSIS diagnostic unit to the
Code the TV combination tuner
new device, read out fault memory.
(analog/digital) (A91/1)
If a new TV combination tuner (analog/
digital) (A91/1) was installed, but the old
device could not be read out anymore: Code
the TV combination tuner (analog/digital)
(A91/1).
*WH58.30-
Z-1048-13A
Test the TV combination tuner

Number Designation
Remove/install TV tuner - AR82.85-P-7366GZ
MODEL 164.1 with CODE (863) Digital/analog TV tuner
Fig. 121: Identifying Stowage Compartment And Cover

Fig. 122: Identifying TV Tuner Components Location

Remove/install
AH54.00-P-
0001-01A
When replacing TV combination
Temporarily store basic data from TV tuner (analog/digital) (A90/1).
1 combination tuner (analog/digital) Installation: Copy temporarily
(A90/1) in STAR DIAGNOSIS stored basic data to new TV combination
tuner (analog/digital) (A90/1).
*WH58.30-Z-
1048-13A
889: Press Keyless Go start/stop button
repeatedly until the ignition is switched
2
transmitter key from EIS control unit off.
Remove transmitter key from vehicle and
store it in a location beyond its
Only vehicles with stowage
compartment
3 Remove cover (1)
Unlock both rotary catches (arrows
A) to open and remove cover
Only vehicles with stowage
compartment
Release both rotary catches
4 Remove storage compartment (2) (arrows B) to loosen and remove stowage
compartment.
Installation: First position
stowage compartment at bottom of stay on
paneling at side.
Remove multicontour seat pneumatic Do not kink pneumatic lines.

5 pump (M40) from bracket (3) and lay Only on vehicles with left/right
down to side. multicontour seat, code 404/405.
Unscrew nut (4), unscrew bolts (5) Only on vehicles with left/right
6
and remove bracket (3). multicontour seat, code 404/405.
7 Unscrew nut (6)
8 Unscrew bolt (7) and lift bracket (8).
Remove TV combination tuner
9
10 Disconnect electrical connectors (9).
Model 164, 169.0/3, 211.0/2/6, 221.0/1
Notes on avoiding damage to fiber AH82.60-P-
245.2, 251 with Media Oriented System
optic cables during repair work 0001-05AK
Transport (MOST)

Number Designation
REMOVE/INSTALL ELECTRONIC COMPASS - AR82.85-P-7371GZ
MODEL 164
Only vehicles without navigation system
Fig. 123: Identifying Electronic Compass, Instrument Cluster And Bracket

Fig. 124: Identifying Electronic Compass, Electrical Connector And Bolts

MODIFICATION NOTES
26.7.06
removed 9
Remove/install
AH54.00-P-
0001-01A
Read out data from electronic
1 compass (B26) using STAR Only if the electronic compass
(B26) is replaced.
DIAGNOSIS diagnosis system
*WH58.30-Z-
1048-13A
Do not separate the instrument
cluster (A1) electrically
2 Remove instrument cluster (A1) Protect the instrument cluster (A1), AR54.30-P-
instrument panel and steering wheel from 6015GZ
damage. Do not damage electric wiring
harness on instrument cluster (A1).
Remove bolts (2) and disengage and Do not damage the electric wiring
3 pull out bracket (1) until electrical harness.
connector (3) is accessible Installation: Ensure correct
positioning of bracket on journal (arrow A)
and in the interlock (arrow B).

Separate electrical connector (3) and
4 remove the bracket (1) together with
the electronic compass (B26)
Three tabs (arrows C).
Remove electronic compass (B26) Installation: The electronic
5
from the bracket (1) compass (B26) must audibly engage in the
three catch tabs (arrows C).
Transfer the data read out previously
using the STAR DIAGNOSIS Only if the electronic compass (B26) is
7
diagnosis system to the electronic replaced.
compass (B26).
*WH58.30-Z-
1048-13A

Number Designation
REMOVE/INSTALL NAVIGATION PROCESSOR - AR82.85-P-7373GZ

Fig. 125: Identifying Navigation Processor, Radio And Bolts

MODIFICATION NOTES
26.7.06
removed 5
Remove/install

AH54.00-P-
0001-01A
Protect center console instrument panel AR82.60-P-
1 Remove radio (2)
against scratches. 7502GZ
The navigation processor must not be from
pulled upwards. This would damage the
electrical connectors.
Remove screws (3) and detach
2 navigation processor (1) by pressing The electrical connectors are integrated
in the radio or in the navigation processor, they
back (arrows) the radio (2)
are separated as they are pushed back (arrow).
Installation: Align electrical connectors
with each other before pushing together.
REMOVE/INSTALL THE PUSHBUTTON SWITCH FOR THE TELE-AID EMERGENCY CALL

MODEL 164 with CODE (359) TELE AID emergency call system with CODE (494) USA version
In overhead control panel
Fig. 126: Identifying SOS Pushbutton Switch, Overhead Control Panel Control And Electrical Connector
Remove/install
Treat ribbon cable carefully to prevent

damage.
Detach overhead control panel control AR82.20-P-
1 Overhead control panel control unit
unit (N70) 1100GZ
(N70) does not have to be disconnected
electrically!
Push SOS pushbutton switch (S93/3) out Installation: Insert SOS pushbutton
of overhead control panel control unit switch (S93/3) into overhead control panel
3
(N70) in downward direction and control unit (N70) so that the guide bars
remove (arrows) engage properly.
REMOVING AND INSTALLING BACKUP ANTENNA FOR TELE AID EMERGENCY CALL
MODEL 164 with CODE (359) TELE AID emergency call system with CODE (494) USA version

Fig. 127: Identifying Antenna Cable Connector, Substitute Antenna And Nuts
Fig. 128: Identifying D-Pillar Paneling, Antenna Cable Connector And Nuts
Remove/install
1.1 Remove headliner Model 164.1 AR68.30-P-4300GZ
1.2 Remove D-pillar trim (4) Model 164.8 AR68.30-P-4495GZ
2 Disconnect antenna cable connector (3)
3 Unscrew nuts (2) and remove backup antenna (1)
REMOVE/INSTALL CONTROL UNIT FOR TELE AID EMERGENCY CALL SYSTEM - AR82.95-P-
0005GZ
MODEL 164 with CODE (359) TELE AID emergency call system

Fig. 129: Identifying Emergency Call System Control Unit Components Location
MODIFICATION NOTES
26.7.06
removed 9
Remove/install

AH54.00-P-
0001-01A
discharge
1 Fold 60 % rear seat (1) forward
On model 164.8 the covers of the
2 Lift up cover (2)
rear seat bolts must be removed.
Loosen 3 nuts and swivel around
Remove emergency call system control
3 emergency call system control unit
unit (N123/4) with bracket
(N123/4) with bracket.
5 Unscrew nuts (4)
Remove emergency call system control
6
unit (N123/4)
REMOVE/INSTALL MB-INFO AND TELEDIAGNOSIS BUTTON GROUP - AR82.95-P-3212GZ
MODEL 164 with CODE (386) Preinstallation for telephone "Handy", UPCI system with CODE (388)
Telephone "Handy", UPCI system
Illustrated on vehicle with telephone "Handy" UPCI system, code 388 and USA version, code 494
Fig. 130: Identifying MB-Info And Telediagnosis Button Group, Stowage Tray And Bolts
Remove/install
Open upper and lower stowage box in

1
center console
2 Remove bolts (1)
Do not damage wiring harness.
Detach stowage shell (2), pull up
3 Installation: Insert stowage shell (2) with its guide
slightly and turn around
lug first.
Separate electrical plug connection
4
(3)
Push the two catch lugs (arrows B) together and push
the MB-Info and telediagnosis button group (S93/6) out of
Remove MB-Info and telediagnosis
the stowage shell (2) (arrow A).
5 button group (S93/6) from stowage
shell (2) Installation: Pay attention to the correct installation
position of the MB-Info and telediagnosis button group
(S93/6).
2006-2008 GENERAL INFORMATION Body - General - 164 Chassis
2006-2008 GENERAL INFORMATION
Body - General - 164 Chassis
GENERAL INFORMATION
GENERAL INFORMATION ON REPAIRS TO BODY - AH60.00-N-0001-01A
All models
General information on repair instructions
The repair instructions form the basis for proper and competent maintenance and repair.
The content of the work procedures described is based on the training level of a fully qualified auto mechanic
with extensive product expertise. This level of knowledge is essential for carrying out the described work.
Basic prerequisites for properly performing body repairs include:
 Use of genuine Mercedes-Benz parts.

 Strict observance of the Mercedes-Benz guidelines for bodywork.
 Workshop equipped with suitable special tools and workshop equipment.
Notes on repair method
Repair of damaged body panels is one of the most economical and time-saving measures and is preferable to
replacing assemblies.
A precise check should always be made to determine which repair procedure is most economical. Repair should
always be considered to be the "first choice", because this has the least effect on the strength, dimensional
accuracy and corrosion resistance, etc. achieved at the factory
Work protection and safety information
In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to
prevent damage to the vehicle as a result of work improperly carried out, these instructions are to be read
carefully and complied with in full. Consequently, it is not possible for DaimlerChrysler AG to evaluate in the
last consequence every situation which might present a risk of injury for the operative. It is therefore urgent that
everyone who carries out repair operations on MB passenger cars applies their professional knowledge to
ensure that their own safety is not at risk and that the vehicle will not be adversely affected (in particular with
regards to safety) as a result of the repair procedure chosen It is therefore expressly pointed out that all work of
the operations described shall be carried out only by complying with valid directives and instructions of the
local, competent authorities and those relating to health and safety at work, and environmental protection.
Sectional repairs
We recommend the following procedure for repairing body sections or sectional repairs:
Inert gas welds which are not in the immediately visible area or which are concealed by installed parts when the
vehicle is completed should not be ground down smooth or filled for reasons of economy and operating
stability..
Labor protection equipment
In addition to personal occupational clothing to include cap and safety shoes, working gloves, safety glasses, ear
protection, dust protection mask, etc. must be worn as required when working.
Battery
Before performing any type of welding work or other work causing sparks in the area of the vehicle battery,
always remove the battery and store in a protected location.
Components.
During repair work following accidents, visually check electronic components, steering and seat belts.
Air conditioning
Do not weld or perform similar types of work on components in the closed air conditioning system or in its
immediate vicinity.
Drill, saw
Before drilling or sawing, remove electric leads and pipes installed in cavities as well as reservoirs located in
concealed locations (e.g. battery) and electronic components from hazard area
Helicoil-compatible thread
Defective metric threads (>= M8) are helicoil-compatible in coordination with the DC development department
Vehicles
Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as fire
hazard from flying sparks using dividing walls or cover with fire-resistant tarpaulin
Lifting platform
The vehicle can fall from the lifting platform due to weight transfer caused by removed parts (e.g. engine,
shafts, etc.). Secure vehicle or add sand bags to compensate the weight.
Corrosion protection
After painting, treat areas affected by repair with appropriate corrosion protection measures (e.g. wax, cavity
sealing agent, underbody protection, if present).
Metal shavings
Do not use compressed air to blow away metal shavings produced by machining work on the body; remove with
vacuum cleaner instead.
Engine and auxiliary equipment
Before performing any type of machining work on the body (e.g. with spherical cutter), cover engine including
all auxiliary assemblies (e.g. alternator, solenoids, etc.) to prevent damage from metal shavings.
Straightening work
When performing straightening work never stand in a direct line in front of the pull chains when introducing
straightening forces to in front of the pull chains when introducing straightening forces to the frame or body.
Secure pull chains with catch cables or chains to prevent it from snapping away.
Observe notes on straightening and verify position of check bores. If necessary, detach body from straightening
bench and realign.
Welding vapors
Evacuate health enhazarding gases, vapors, dust and welding smoke in the area where it occurs.
Welding and related work
During all welding work, observe accident prevention regulations for welding, cutting and related types of work
In addition, before performing arc welding work, observe safety precautions for electronic control units.
Moreover, remove easily combustible and flammable materials and liquids from the hazard area. Use shields to
protect against flying sparks and heat radiation and protect electric leads and tubes laid in hollow cavities.
When spot welding, maintain a spot weld interval of approx. 20 mm Clean, smooth electrode tips are required.
Set the current time or power according to the sheet metal thickness (new part) on the spot welder.
Standard bonded load-bearing sections
For standard bonded load-bearing sections that are not rebonded following accident repair, the number of spot
welds is indicated in the specific repair description.
Always observe these specifications to ensure operating stability
Welding procedures, connections and symbols
Resistance spot welding

Single-row spot weld:
Double-row spot weld:
Double-row spot weld offset:
Brazing:
MIG welding
Stitch weld:
Continuous weld:
Continuous weld interrupted:
Plug weld:
Fig. 1: Identifying Welding Procedures - Brazing

Assembly examples for spot welding fittings
PRODUCT LIABILITY AND VIN - AH60.00-P-0800
Product liability, trademark and traffic laws - AH60.00-P-0800-01Z
Model 163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 221, 230, 240, 245.2, 251,
414.700, 690.6, 638, 639, 901, 902, 903, 904, 905, Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3,
XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
For legal reasons (product liability, trademark and traffic laws) and to prevent negative effects to the Mercedes-
Benz corporation and employees of the specific Mercedes-Benz dealerships, we recommend that the vehicle
identification number and Mercedes stars at the end (trademark) only be marked on vehicles when the body or
vehicle has been replaced or repaired within the Mercedes-Benz service organization.
This recommendation is based on the following factors:
Some companies have specialized in rebuilding Mercedes-Benz vehicles with used or new bodies and often
finishing these vehicles with second-hand parts from various accident vehicles of the same model.
Cases are repeatedly reported where other companies have then asked service outlets or authorized workshops
to mark the vehicle with the vehicle identification number of the original (accident) vehicle
We request you to never perform such work, even when the other company assures that they have rebuilt the
vehicle for themselves or at the request of a customer.
Legal problems in context with the protection of our trademark could result from marking such vehicles with
the vehicle identification number with stars at the end (trademark) without reservations.
The new product liability laws consider the manufacturer to be the company who attaches its trademark to a
product, regardless of whether the product was actually produced by this manufacturer.
Moreover, Mercedes-Benz could, under certain circumstances, be considered to be the manufacturer and be
liable in the event of damage.
Assembly of used or new bodies with various parts is the equivalent of new production. If such assembly is
performed by another company, Mercedes-Benz does not consider itself to be the manufacturer.
For this reason it is necessary for the registration authorities to issue a new vehicle title, which is legally
possible, in which the assembling company is entered as the manufacturer and the serial number of the technical
testing point becomes the vehicle identification number.
Moreover, such rebuilt vehicles usually require an operating permit. According to Section 59, Paragraph 2 of
the German vehicle licensing regulations (StVZO), this requires notification of the responsible registration
authority.
On the other hand, if a dealership or authorized workshop marks the rebuilt vehicle with the vehicle
identification number of the original (accident) vehicle, the assembling company would be given the
opportunity of circumventing its liability according to Section 59, Paragraph 2 of the German vehicle licensing
regulations.
Companies requesting that rebuilt vehicles be marked with the vehicle identification number should be advised
accordingly and referred to the responsible registration authority.
Vehicle identification number - AH60.00-P-0800-02A

All EU vehicles
Fig. 2: Identifying Vehicle Identification Number Diagram

The vehicle identification number starts and ends with the "Mercedes star" (trademark) and has 19 punched
numbers with a total length of 106 +/-4 mm.
If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it is
necessary to punch it in at the same point.
This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic of
Germany immediately inform motor vehicle registration authorities in writing .
The vehicle holder is required to complete a certificate for the vehicle licensing authority which indicates that
the vehicle identification number has been re-stamped after completing body repairs.
As prove, the original vehicle identification number cut out of the old part, may also be enclosed.
A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched in
correctly in the spare field on the right crossmember, the right side of the drive shaft tunnel, the rear partition
wall or the firewall.
This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:
"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicle
identification number punched in the spare field."
Export countries must observe their relevant vehicle licensing provisions and legal regulations.
Vehicle identification number - AH60.00-P-0800-02B
All vehicles with USA version, code 491, 494

Fig. 3: Identifying Vehicle Identification Number

The vehicle identification number starts and ends with the "Mercedes star" trademark (1, 19) and has 19
punched numbers with a total length of 103 mm.
If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it is
necessary to punch in the vehicle identification number at the same point.
This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic of
Germany immediately inform the vehicle licensing authority in writing .
The vehicle owner is required to complete a certificate for the vehicle licensing authority which indicates that
the vehicle identification number has been re-stamped after completing body repairs.
As prove, the original vehicle identification number cut out of the old part, may also be enclosed.
A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched in
correctly in the spare field on the right crossmember, the right side of the drive shaft tunnel, the rear partition
wall or the firewall.
This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:
"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicle
identification number punched in the spare field."
Export countries must observe their relevant vehicle licensing provisions and legal regulations.
SAFETY PRECAUTIONS
RISK OF INJURY CAUSED BY IRRITATION OF THE SKIN, EYES AND RESPIRATORY SYSTEM
THROUGH CONTACT OR INHALATION OF SUBSTANCES CONTAINED IN THE MIRROR
LENS. - AS60.00-Z-0008-01R
Wear protective gloves and safety glasses.
Potential risks
Risk of injury
 The liquid electrolyte contained in the mirror lens may escape if the lens is broken.
 This liquid electrolyte is an irritant. It is therefore important that the liquid electrolyte does not come into
contact with unprotected skin, eyes or respiratory organs.
 For further information see the accident prevention regulations (UVV) or the trade association
regulations.
Safety precautions/instructions
 Wear protective gloves and safety glasses.
First aid measures
 Immediately rinse affected skin areas with plenty of clean water and dry or dress with sterile bandages.
 A medical service and/or physician should be consulted after first aid has been applied.
TESTING & REPAIR

GAP DIMENSIONS ON HOODS, DOORS AND LIDS - AR60.00-P-0700-01GZ
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Dimension
Front fender to A-pillar mm 4.5 (± 0.5) 3.5 (± 1.0)
"A"
Dimension
Fuel filler flap mm 3 (± 0.5) 3.0 (± 0.5)
"A1"
Dimension
Fender to engine hood mm 3.5 (± 0.5) 3.5 (± 1.0)
BE60.00-P- Gap "B"
1001-01P dimension Rear door to side roof Dimension
mm 4.5 (± 0.5) 4.5 (± 1.0)
frame "B1"
Front fender to front Dimension
mm 4.5 (± 0.5) 4.5 (± 1.0)
door "C"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
Rear bumper to fender mm - 0.0 (± 0.5)
"C1"
Dimension
Front door to rear door mm 5 (± 0.5) 5.0 (± 1.0)
"D"
Rear-end door to D- Dimension mm 5 (± 1) 5.0 (± 1.0)

pillar "D1"
Front door to rear door Dimension
mm 5 (± 0.5) 5.0 (± 1.0)
in area of B-pillar "E"
BE60.00-P- Gap
1002-01P dimension Door sill molding to Dimension
mm 6 (± 1) 6.0 (± 1.0)
rear door "F"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Door sill molding to Dimension"
mm 6 (± 1) 6.0 (± 1.0)
front door G"
Dimension
Rear door to rear fender mm 4.5 (± 0.5) 4.5 (± 1.0)
"H"
Dimension
Front door to A-pillar mm 4.5 (± 0.5) 4.5 (± 1.0)
BE60.00-P- Gap "I"
1003-01P dimension Fender to side Dimension
mm 4 (± 1) 4.0 (± 1.0)
headlamps "J"
Engine hood to front Dimension
mm 6 (± 1.5) 6.0 (± 1.0)
grill "K"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
Rear door to C-pillar mm 4.5 (± 0.5) 4.5 (± 1.0)
"L"
Engine hood to Dimension
mm 4 (± 1) 4.0 (± 1.0)
headlamp "M"
Dimension
Bumper to headlamps mm 4 (± 1) 4.0 (± 1.0)
BE60.00-P- Gap "N"
1004-01P dimension Dimension
Front grill to bumper mm 6 (± 1.5) -
"O"
Taillamp to rear-end Dimension
mm 5 (± 0.5) 5.0 (± 1.0)
door "P"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
Front bumper to fender mm - 0.0 (± 1.0)
"Q"
mm 5 (± 0.5) 5.0 (± 1.0)
door "R"
Dimension
Bumper to taillamp mm 3 (± 0.5) 3.0 (± 1.0)
BE60.00-P- Gap "S"
1005-01P dimension Taillamp to upper D- Dimension
mm 3 (± 0.5) 3.0 (± 1.0)
pillar "T"
Taillamp to lower D- Dimension
mm 5 (± 0.5) 3.0 (± 1.0)
pillar "T1"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Rear-end door to D- Dimension
pillar "D1" mm - 5.0 (± 1.0)

Dimension
for glass mm 5 (± 1) 5.0 (± 1.0)
"U"
Rear-end door to Dimension
mm 8 (± 1.5) 8.0 (± 1.5)
bumper "V"
BE60.00-P- Gap Antenna cover
on roof mm 5 (± 2) 6.0 (± 2.5)
"W"
Dimension
On rear-end door mm 8 (± 0.5) 6.0 (± 1.0)
"W"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Fig. 4: Identifying Feeler Gauge (129 589 03 21 00)

Adjust hoods, doors and lids as shown in drawing. The gap should not run wedgeshaped or be too narrow at
points. Deviations from parallel gap should be max. 0.5 mm over the entire length. If the inside clearance is too
large or too small, the movable body parts must be centered accordingly. The reference measurements apply
only for repair work on bodies damaged in accidents.

Fig. 5: Identifying Adjust Hoods, Doors And Lids Gap Or At Points (1 Of 3)




STAMP IN VEHICLE IDENTIFICATION NUMBER - AR60.00-P-0800GZ
MODEL 164
Fig. 8: Identifying Stamp In Vehicle Identification Number

AH60.00-P-0800-
Product liability, trademark and traffic laws
01Z
AH60.00-P-0800-
Vehicle identification number All EC vehicles
02A
All vehicles (Code 491) for AH60.00-P-0800-
Vehicle identification number
USA models 02B
AR60.00-P-0800-
1 Mount stamping guide
01GZ
Stamping guide Fig. 11
AR60.00-P-0800-
2 Punch in vehicle identification number
02GZ
Set of number stamps Fig. 13
Cross out vehicle identification number and punch AR60.00-P-0800-
3
into reserve field 05GZ
Set of number stamps Fig. 13
Fig. 9: Identifying Set Of Number Stamps (140 589 26 63 00)

Fig. 10: Identifying Stamping Guide (251 589 00 63 00)

Mount stamping guide - AR60.00-P-0800-01GZ

1. Mount stamping guide (1) onto crossmember below right rear seat (2).
2. Move stamping guide (1) completely toward rear (arrows A)
3. Clamp stamping guide (1) to crossmember below right rear seat (2).
Ensure that bolt (3) is located inside of opening in stamping guide (1).
Fig. 12: Locating Mount Stamping Guide And Move Stamping Guide
Stamping in vehicle identification number - AR60.00-P-0800-02GZ


1. Install window plate so that opening points toward rear (arrow B).
If required, unscrew bolts (4) and turn window plate around.
2. Start with "Mercedes star" number stamp at left in window plate (arrow).
The tip of the Mercedes star must point upward in the script.
Fig. 15: Identifying Stamping In Vehicle Identification Number

Move forward one increment mark on the scale in the window plate with each subsequent number
stamp until the complete vehicle identification number and final Mercedes star have been stamped in the
crossmember.
Spare field (broken border).
Crossing out vehicle identification number and restamp in spare field - AR60.00-P-0800-05GZ


1. Cross out erroneous vehicle identification number with letter stamp "X".
2. Reposition window plate on spare field (broken border) (arrow C)
3. Start with "Mercedes star" number stamp at left in window plate (arrow). The number stamp must be
positioned completely on the left at the window plate.
The tip of the Mercedes star must point upward in the script.
Fig. 18: Identifying Stamping In Vehicle Identification Number

Move forward one increment mark on the scale in the window plate with each subsequent number
stamp until the complete vehicle identification number and final Mercedes star have been stamped in the
crossmember.
TESTING AND REPAIR WORK: PASSENGER CARS: BODY - GENERAL - AR60.00-Z-9164AA
MODEL 164
Stamp in vehicle identification number MODEL 164 AR60.00-P-0800GZ

Set up Celette straightening bench MODEL 164 AR60.10-P-1060GZ
SET UP CELETTE STRAIGHTENING BENCH - AR60.10-P-1060GZ
MODEL 164
Fig. 19: Identifying Celette Straightening Bench

Installation, removal
lifting platform.
*WE58.40-Z-
1 Lift vehicle with two-post lift Two-post lift
1001-05A
Set-up Celette straightening *WE58.40-Z-
2 Celette straightening bench M8S
bench (1) 1001-01E
*WE58.40-Z-
NT 10 Celette straightening bench
1001-01E
*WE58.40-Z-
Celette straightening bench Sevenne
1001-01E
Setup of module members
(base frame)
AR60.10-P-
3 Install Celette module members Model 164.1
1060-01GZ
AR60.10-P-
Model 164.8
1060-01GY
Screwdriver insert 8 mm for hexagon socket head *WH58.30-Z-
screws 1026-06A
*WH58.30-Z-
Reversible ratchet 1007-06A
*WE58.40-Z-
Pneumatic ratchet 1/2" 1008-03A
*WH58.30-Z-
Double end box wrench, offset, 22 24 mm 1002-11A
*WE58.40-Z-
Celette straightening bench M8S
1001-01E
*WE58.40-Z-
NT 10 Celette straightening bench
1001-01E
*WE58.40-Z-
Celette straightening bench Sevenne
1001-01E
*WE58.40-Z-
Set of Celette module members 955.940
1007-01E
*WE58.40-Z-
Celette additional member 955.908
1008-01E
Setup of Celette straightening
tools and multi-Z elements (for
body work)
Install Celette straightening tool AR60.10-P-
4 Model 164.1
and multi-Z-elements 1060-02GZ
AR60.10-P-
Model 164.8
1060-02GY
*WH58.30-Z-
*WE58.40-Z-
*WH58.30-Z-
Remove stop plugs from jack
5
support points
Set vehicle onto straightening
6
bench
Align vehicle on straightening
7 Observe check bore!
bench
Fasten vehicle to straightening
8
bench
Setup of portal frame and of

welding devices (for operations
on A, B, C and D-pillars)
Install side portal with portal
9 Only when required for repair to vehicle.
straightening set
AR60.20-P-
Model 164.1
1550-01GZ
Portal frame Fig. 20
Inspection and welding devices Fig. 21
AR60.20-P-
Type 164.8
1550-01GY
Portal frame Fig. 20
Inspection and welding devices Fig. 21
Welding device Fig. 22
Model 164
Screwdriver insert 8 mm for hexagon socket head *WH58.30-Z-
screws 1026-06A
Socket wrench insert, SW 19 for hex. socket head *WH58.30-Z-
bolts 1010-06A
*WH58.30-Z-
*WE58.40-Z-
*WH58.30-Z-
*WH58.30-Z-
10 Detach in the reverse order
Fig. 20: Identifying Portal frame (129 589 03 23 00)

Fig. 21: Identifying Inspection And Welding Devices (164 589 00 23 00)
Fig. 22: Identifying Welding Device (164 589 03 23 00)


Number Designation
WH58.30-Z-1007-06A Reversible ratchet
WH58.30-Z-1010-06A Socket SW19 for hexagon head screws
WH58.30-Z-1026-06A Screwdriver bit, 8 mm for hexagon socket head screws
WH58.30-Z-1001-11A Double end box wrench, offset, 17 x 19 mm
WORKSHOP EQUIPMENT
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1008-03A Pneumatic ratchet
WE58.40-Z-1001-05A Two-post lifting platform
Install Celette module members - AR60.10-P-1060-01GY

Number Designation

WORKSHOP EQUIPMENT
Fig. 23: Identifying Celette Module Members

The figure shows the basic setup of the Celette straightening bench. If straightening and welding operations
are to be performed on A, B, C or D-pillars, additional modules must be installed on the Celette straightening
bench. Refer to the Celette setup plans and separate work instructions.
The modular longitudinal members (A1, B1), the module members (C), the auxiliary member module (D),
the rear extension plate (E) and the front extension plate (F) can be used on any Celette straightening bench
approved by Mercedes-Benz.
1. Place modular longitudinal members (A1, B1) onto basic carrier, align parallel to one another and install.
The modular longitudinal members (A1, B1) are aligned parallel to one another with the assembly
strips provided with the straightening bench.
2. Install module members (C) in index fields 14, 22, 24, 28, 32 and 38.
The basic carrier of the Celette straightening bench is subdivided into index fields in the longitudinal
direction. The index fields are marked with numbers at the side straightening bench flange.
3. Install auxiliary member module (D) in index field 43.
4. Install rear extension plate (E) and front extension plate (F) on Celette straightening bench.
Install Celette module members - AR60.10-P-1060-01GZ

Number Designation
WORKSHOP EQUIPMENT
Fig. 24: Identifying Celette Module Members

The figure shows the basic setup of the Celette straightening bench. If straightening and welding operations
are to be performed on A, B, C or D-pillars, additional modules must be installed on the Celette straightening
bench. Refer to the Celette setup plans and separate work instructions.
The modular longitudinal members (A1, B1), the module members (C) and the auxiliary member module
(D) can be used on any Celette straightening bench approved by Mercedes-Benz.
1. Place modular longitudinal members (A1, B1) onto basic carrier, align parallel to one another and install.
The modular longitudinal members (A1, B1) are aligned parallel to one another with the assembly
strips provided with the straightening bench.
2. Install module members (C) in index fields 14, 27, 30, 36 and 41.
3. Install auxiliary member module (D) in index field 24.
Install Celette straightening tools and MZ elements - AR60.10-P-1060-02GY

Number Designation
WORKSHOP EQUIPMENT
Set-up for straightening tool MZ elements (front)

Fig. 25: Identifying Celette Straightening Tools And MZ Elements

Set-up for straightening tool MZ elements (rear)

Fig. 26: Identifying Set-Up For Straightening Tool MZ Elements (Rear)

The figures show the setup of the Celette straightening bench for body work. If straightening and welding
operations are to be performed on A, B, C or D-pillars, additional modules must be installed on the Celette
straightening bench. Refer to the Celette setup plans and separate work instructions.
1. Install MZ elements and straightening bracket set.
Position and exact setup of the MZ elements and of the straightening tools are given in the relevant
Celette setup plan.
MZ elements
 When installing the MZ elements on the straightening bench, the direction of the arrow on the MZ
elements must be observed
 The part numbers for the MZ elements are cast onto the side
Straightening tool:
 Arrows for straightening tool always toward direction of travel

 In addition to the straightening tool number, the straightening tool for the left side have the letter "L" next
to the arrow
 The position number in combination with the 8-digit reference number (e.g.: 7169.7001), is also the order
number for replacement parts
Always setup the right side of the straightening bench analog to the left side.
Install Celette straightening tools and MZ elements - AR60.10-P-1060-02GZ

Number Designation
WORKSHOP EQUIPMENT
Setup for straightening tool MZ elements (front)

Fig. 27: Identifying Setup For Straightening Tool MZ Elements

Setup for straightening tool MZ elements (rear)
Fig. 28: Identifying Setup For Straightening Tool MZ Elements (Rear)

The figures show the setup of the Celette straightening bench for body work. If straightening and welding
operations are to be performed on A, B, C or D-pillars, additional modules must be installed on the Celette
straightening bench. Refer to the Celette setup plans and separate work instructions.
1. Install MZ elements and straightening bracket set.
Position and exact setup of the MZ elements and of the straightening tools are given in the relevant
Celette setup plan.
MZ elements
Straightening tool:
 Arrows for straightening tool always toward direction of travel

 In addition to the straightening tool number, the straightening tool for the left side have the letter "L" next
to the arrow
INSTALL SIDE PORTAL WITH PORTAL STRAIGHTENING SET - AR60.20-P-1550
Install side portal with portal straightening set - AR60.20-P-1550-01GY
Fig. 29: Identifying Portal Frame (129 589 03 23 00)

Fig. 30: Identifying Inspection and Welding Devices (164 589 00 23 00)
Fig. 31: Identifying Welding Device (164 589 03 23 00)


Number Designation
WORKSHOP EQUIPMENT
A and B-pillar portal setup
Fig. 32: Identifying A And B-Pillar Portal Setup

B, C and D-pillar portal setup

Fig. 33: Identifying B, C And D-Pillar Portal Setup

The figures show the setup for body work on the A, B, C and D-pillars.
1. Install MZ elements, portal frame, inspection and welding device and welding device.
Position and exact setup of the MZ elements are given in the relevant Celette setup plan.
MZ elements
Inspection and welding device and welding device:
 Direction of arrow of inspection and welding device or of welding device always in the direction of
travel
 The inspection and welding device and the welding device on the left side additionally have on "L"
next to the arrow
Install side portal with portal straightening set - AR60.20-P-1550-01GZ
Fig. 34: Identifying Portal Frame (129 589 03 23 00)

Fig. 35: Identifying Inspection and Welding Devices (164 589 00 23 00)

Number Designation
WORKSHOP EQUIPMENT
A and B-pillar portal setup

Fig. 36: Identifying A And B-Pillar Portal Setup

B and C-pillar portal setup
Fig. 37: Identifying B And C-Pillar Portal Setup

C and D-pillar portal set-up
Fig. 38: Identifying C And D-Pillar Portal Set-Up

The figures show the setup for body work on the A, B, C and D-pillars.
1. Install MZ elements, portal frame and inspection and welding device.
Position and exact setup of the MZ elements are given in the relevant Celette setup plan.
MZ elements
Inspection and welding device:
 Direction of arrow for inspection and welding device always in the direction of travel
 The inspection and welding device on the left side additionally has an "L" next to the arrow
2006-2008 BRAKES Brakes - Pneumatic System - 164 Chassis
2006-2008 BRAKES
Brakes - Pneumatic System - 164 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND
AUXILIARY BRAKES - AR43.00-Z-9164AA
MODEL 164
Remove/install vacuum pump MODEL 164, 251 with ENGINE 642 AR43.05-P-1320GZ
Remove/install vacuum pump MODEL 164 with ENGINE 629 AR43.05-P-1320GZD
Check the check valve MODEL 164 AR43.10-P-0023GZ
Checking brake booster MODEL 164 AR43.10-P-0325GZ
Remove/install brake booster MODEL 164 AR43.10-P-0350GZ
CHECK THE CHECK VALVE - AR43.10-P-0023GZ
MODEL 164
Fig. 1: Identifying Check Valve Components


Check
AR88.40-P-
1 Open engine hood
1000GZ
Observe manufacturer's operating
instructions to avoid erroneous
Connect vacuum tester (1) to brake booster measurements and incorrect operation. AR43.10-P-
2
(3). Reduce vacuum of brake pedal 0024-01GZ
beforehand by pressing pedal several
times.
Test connection Fig. 2
Vacuum tester Fig. 3
Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving.
off by itself when engine is running. Risk of Wear closed and snug-fitting work AS00.00-Z-
injury caused by contusions and burns when clothes. 0005-01A
working in engine during starting procedure. Do not grasp hot or rotating parts.
Start engine and create a vacuum of 0.75 to If vacuum is > 0.8 bar, reduce
3 0.80 bar by accelerating and then suddenly vacuum to 0.75 to 0.80 bar by pressing
releasing the accelerator pedal. pedal.
Vacuum must not drop by more
than 0.2 bar within 30 seconds. If the
Switch off engine and observe measured
vacuum drop is > 0.2 bar, install new
4 value for vacuum at pressure gauge of
vacuum line with check valve.
vacuum tester.
With notes on defective brake
booster: ?
AR43.10-P-
Check brake booster
0325GZ
Disconnect vacuum tester (1) from brake AR43.10-P-
5
booster (3). 0024-01GZ
AR88.40-P-
6 Close engine hood
1000GZ
Fig. 2: Identifying Test Connection (168 589 08 63 00)

Fig. 3: Identifying Vacuum Tester (201 589 13 21 00)

CONNECT/DISCONNECT TESTER AT BRAKE BOOSTER - AR43.10-P-0024-01GZ
Fig. 4: Identifying Test connection (168 589 08 63 00)

Fig. 5: Identifying Vacuum tester (201 589 13 21 00)

Fig. 6: Identifying Brake Booster Tester

Attaching
Observe manufacturer's operating instructions to avoid erroneous measurements and incorrect operation.
Reduce any vacuum in the brake booster (3) by pressing the brake pedal several times.
1. Carefully detach vacuum line with check valve (2) from brake booster (3).
2. Connect test connection (4) for testing the vacuum line with check valve (2) or the brake booster
(3) between the brake booster (3) and the vacuum line with check valve (2).
3. Connect vacuum tester (1) to test connection (4).
Disconnecting
4. Disconnect in reverse order.
CHECKING BRAKE BOOSTER - AR43.10-P-0325GZ
MODEL 164
Fig. 7: Checking Brake Booster

Checking
Risk of poisoning caused by
swallowing brake fluid. Risk Only pour brake fluid into suitable and appropriately
AS42.50-Z-
of injury caused by brake marked containers. Wear protective clothing and eye
0001-01A
fluid coming into contact with protection when handling brake fluid.
skin and eyes.
AH42.50-
Brake fluid notes P-0001-
01A
AH42.00-
Notes on repairs to brake
P-0003-
system
01A
Risk of death caused by Align vehicle between columns of vehicle lift and position
AS00.00-Z-
vehicle slipping or toppling four support plates at vehicle lift support points specified
0010-01A
off of the lifting platform. by vehicle manufacturer.
Open engine hood and raise AR88.40-
1
to vertical position P-1000GZ
Connect vacuum tester (1) to Observe manufacturer's operating instructions in order AR43.10-
2 to prevent erroneous measurement or faulty operation! P-0024-
brake booster (3).
01GZ
Reduce vacuum of brake pedal beforehand by
pressing pedal several times.

Observe manufacturer's operating instructions!
Connect brake fluid
3 Brake fluid changer, see GOTIS
replacement unit
Only lift vehicle until wheels have sufficient
Raise vehicle using two-post ground clearance. AR00.60-
4
lift Two-post lift, see GOTIS P-1000GZ
5 Take off left front wheel
Remove/install wheels, rotate AP40.10-P-
if necessary 4050Z
Pressure testers for hydraulic oil systems should not be
used for systems with brake fluid otherwise the brake fluid
will be mixed with mineral oil which can then lead to
Remove bleed screw from brake failure.
6 floating brake caliper (7) and Observe manufacturer's operating instructions in order
connect pressure tester (6). to prevent erroneous measurement or faulty operation!
Collect escaping brake fluid.
Pressure tester, see GOTIS
Observe manufacturer's operating instructions in order
to prevent erroneous measurement or faulty operation!
Bleed pressure tester (6) Pressure tester, see GOTIS
7
using brake fluid changer http://gotis.aftersales.daimlerchrysler.com
Brake fluid changer, see GOTIS
Switch off brake fluid Brake fluid changer, see GOTIS
8
changer and release pressure http://gotis.aftersales.daimlerchrysler.com
Install pedal force meter sensor (4) at brake pedal
9 Install pedal force meter and set up pedal force meter display unit (5) so that it can
be seen.
Pedal force meter, see GOTIS
Risk of accident caused by
vehicle starting off by itself
when engine is running. Risk
Secure vehicle to prevent it from moving by itself.
of injury caused by AS00.00-Z-
Wear closed and snug-fitting work clothes.
contusions and burns during 0005-01A
starting procedure or when
working near the engine as it
is running
Start engine and create a If only a substantially lower vacuum is attained or

vacuum of 0.75 to 0.80 bar by if the vacuum immediately falls away, the O-ring between
10 accelerating and then the brake booster and the tandem master brake cylinder
suddenly releasing the may be damaged or the vacuum line with check valve (2)
accelerator pedal. may be defective: ?
AR43.10-
Checking check valve
P-0023GZ
Remove/install stepped tandem brake master cylinder, AR42.10-
install new O-ring. P-0310GZ
Read off and note the relevant measured values of
the brake line pressure on the low pressure gauge or on the
Apply five specified brake *BE43.10-
high pressure gauge of the pressure tester (6).
11 pedal forces to brake pedal in P-1002-
succession Measured values must be within specified ranges. 01E
With each measurement, ensure that a vacuum of 0.75 to
0.80 bar is maintained.
Vacuum tester
http://gotis.aftersales.daimlerchrysler.com Fig. 3
Pressure tester, see GOTIS
12 Turn off engine
13 Remove pedal force meter
Detach pressure tester (6) and
screw bleed screw into
14 Pressure tester, see GOTIS
floating brake caliper (7)
again http://gotis.aftersales.daimlerchrysler.com
After the test only bleed the floating brake caliper
AR42.10-
15 Bleed brake system (7) to which the pressure tester (6) was connected.
P-0010GZ
Bleed screw to brake caliper *BA42.10-
Brake fluid changer, see GOTIS P-1001-
http://gotis.aftersales.daimlerchrysler.com 10L
16 Install left front wheel
Remove/install wheels, rotate AP40.10-P-
if necessary 4050Z
AR00.60-
17 Lower vehicle
P-1000GZ
Two-post lift, see GOTIS
Detach brake fluid Brake fluid changer, see GOTIS
18
replacement unit http://gotis.aftersales.daimlerchrysler.com
Disconnect vacuum tester (1) AR43.10-

from brake booster (3) P-0024-

19
01GZ
AR88.40-
P-1000GZ
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS

164.1/8
Intake manifold
50 N bar 26.5...32
vacuum
100
bar 50...57
N
BE43.10-P-1002- Brake pipe line Force on brake 150
bar 72...82
01E pressure pedal N
0.75...0.8 bar
200
bar 95...107
N
250
bar 118...124
N
FRONT AXLE BRAKE CALIPER

Number Designation Model 164 except 164.177 Model 164.177
BA42.10-P-1001-10L Bleed screw to brake caliper Nm 18 18
Fig. 8: Identifying Test Connection (168 589 08 63 00)

Fig. 9: Identifying Vacuum Tester (201 589 13 21 00)

REMOVE/INSTALL BRAKE BOOSTER - AR43.10-P-0350GZ
MODEL 164
Fig. 10: Identifying Brake Booster Components (1 Of 4)




Remove/install
Pour brake fluid only into suitable

Risk of poisoning caused by swallowing and appropriately marked
AS42.50-Z-
brake fluid. Risk of injury caused by brake containers. Wear protective
0001-01A
fluid coming into contact with skin and eyes. clothing and eye protection when
handling brake fluid.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
Notes on repairs to brake system
0003-01A
AH42.10-P-
Notes on externally invisible brake fluid loss
9406-02GZ
1 Move wiper arms to end position
On vehicles with Keyless
Go, code 889: Press keyless go
2 Turn key in ignition switch to position "0".
Reduce vacuum by
Eliminate vacuum in BAS brake booster
3 depressing the brake pedal several
(A7/7)
times.
AR68.10-P-
4 Remove left cover below instrument panel
1500GZ
Remove securing clamp (1) and pull out pin
5
(2).
Unscrew nuts (3) of BAS brake booster *BA43.10-
6
(A7/7) P-1001-01G
7
position 1000GZ
8
section, left partition wall (7)
9 Remove screw (5)
Unclip left partition wall section (7) from
10
clips (6).
Risk of injury caused by moving parts that Always remove ignition key when
AS82.30-Z-
can pinch, crush or, in extreme cases even working on windshield wiper
0001-01A
sever extremities. mechanism.
AR82.30-P-
11 Remove wiper arms
6100GZ
AR83.25-P-
12 Remove water deflector over wiper system
1406GZ
13 Disconnect release switch connector (8).
Disconnect BAS diaphragm travel sensor
14
connector (9)
15 Remove wiper link rod (10).
Risk of confusion! Before
unscrewing, mark the brake line in
Unscrew union nuts of pressure circuit and relation to the appropriate
16 secondary brake circuit (11) from tandem connection.
master brake cylinder Plug connections with blind
plugs to prevent brake fluid
flowing out.
*BA42.10-
P-1003-04J
Box wrench bit Fig. 14
Set of stop plugs Fig. 15

Disconnect connector from brake fluid
17
reservoir (12).
Disconnect vacuum line (13) from BAS brake
18
booster (A7/7).
Disconnect EPS pressure sensor connector
19
(14).
Installation: Do not damage
boot when installing BAS brake
booster (A7/7) as this will cause
20 Take out BAS brake booster (A7/7)
leaks.
Installation: Install new
gasket
Check rear primary piston
of tandem brake master cylinder for
Remove nuts (17) from tandem brake master
21 leaks.
cylinder.
O-ring.
*BA42.10-
P-1001-05H
AR42.10-P-
23 Bleed brake system
0010GZ
Checking
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
running engine Do not grasp hot or rotating parts.
AR42.10-P-
24 Check brake system for leaks
0100-01GZ
Do not insert your hand into
rotating parts.
Risk of death caused by body parts being clothes.
AS00.00-Z-
pulled in by rotating vehicle wheels and roller Safeguard areas with rotating
0019-01A
dynamometer rollers vehicle parts and dynamometer
rollers against unauthorized access.
Safeguard roller dynamometer
from unauthorized access.
AP42.00-P-
Brake testing on test stand
4290GZ

BA43.10-P-1001-01G Nut, brake booster carrier to front end Nm 20
BRAKE LINES AND BRAKE HOSES

BA42.10-P-1003-04J Brake pipe to master brake cylinder Nm 18
MASTER BRAKE CYLINDER

BA42.10-P-1001-05H Nut, brake master cylinder to brake booster Nm 10
Fig. 14: Identifying Box Wrench Bit (140 589 00 03 00)


2006-2008 BRAKES Brakes - 164 Chassis
2006-2008 BRAKES
Brakes - 164 Chassis
GENERAL INFORMATION
NOTES ON REPAIRS TO BRAKE SYSTEM - AH42.00-P-0003-01A
All models
 During maintenance and repair work on the brake system ensure that no mineral oil, grease or similar
substances enter the brake system
 New brake fluid must be used as washing and cleaning medium for cylinders, lines and expansion
containers in the hydraulic braking system.
 If mineral oil is found in the brake system or mineral oil is suspected of being in the brake system, the
following procedure must be carried out:
1. Replace the tandem master brake cylinder or brake operating unit and expansion reservoir for brake
fluid.
2. Flush out entire brake system thoroughly with fresh brake fluid.
3. All brake parts with components made from rubber, such as brake calipers, brake hoses,
SBC/ABS/ETS/ASR or ESP hydraulic unit, pressure reservoir, charge plunger unit and charging
pump, which may have come into contact with mineral oil, must be replaced.
4. Bleed the braking system.
Handling SBC/ABS/ETS/ASR and ESP parts on vehicles involved in accidents:
If, due to the extent of the damage to the vehicle, or from the position and external appearance of the
hydraulic unit it can be recognized that the hydraulic unit has received a heavy blow, the hydraulic unit should
be replaced.
Indications of this are e.g.:
 Hydraulic lines kinked

 Connections on hydraulic unit leaking
 Cables or plug connections damaged
 The metal block of the hydraulic unit has signs of damage
 The hydraulic unit has sprung out of the bracket and cannot be inserted again without a lot of force.
If the above conditions do not apply, the system must nevertheless be subjected to a thorough function test
and the steps for testing the solenoid valves and pump must be carried out.
NOTES ON INSTALLING BRAKE PAD WEAR SENSOR CONTACT SENSORS - AH42.10-P-0003-

01GZ
Model 164
Fig. 1: Identifying Brake Pad Wear Sensor And Contact Sensors

 When replacing the brake pads the left front brake pad contact sensor (S10/1), the right front brake pad
contact sensor (S10/2) and the right rear brake pad contact sensor (S10/4) must also be replaced.
 The left front brake pad contact sensor (S10/1), the right front brake pad contact sensor (S10/2) and right
rear brake pad contact sensor (S10/4) may only be mounted on the inner brake pads.
 The electrical feed line of the contact sensors must be routed as shown in the picture.
 Check the correct latching of the left front brake pad contact sensor connector (S10/1x1), right front brake
pad contact sensor connector (S10/2x1) and right rear brake pad contact sensor connector (S10/4x1).
Engrossing moisture can result in the warning lamp lighting up.
NOTES ON BRAKE FLUID SYSTEM - AH42.10-P-9406
Notes on installing brake hoses - AH42.10-P-9406-01GZ
Only install brake hoses which are approved by Mercedes-Benz.
It must be ensured that all brake hoses are correctly seated in their brackets and that all brackets are closed,
correctly positioned and fastened.
When connecting the brake hose should be as free of twists as possible. The minimum distances must however
be adhered to (see below).
On the brake hose connection piece there are two elevated sections (arrow) which lock the brake hose in the
multi-point profile of the bracket.
Fig. 2: Identifying Brake Hose And Elevated Sections

Front axle: The minimum distance of the brake hose to the longitudinal member in assembly status (vehicle
on lifting platform, suspension strut at full rebound travel) must be at least 25 mm; the brake hose should be
mounted as parallel as possible to the longitudinal member.
A minimum distance of 15 mm from other axle components must be guaranteed in all driving situations.
Where applicable the brake hose may be slightly twisted within itself during the mounting process, to ensure
that the minimum distances are adhered with.
Rear axle: The minimum distance of the brake hose to the suspension strut in assembly status (vehicle on
lifting platform, suspension strut at full rebound travel) must be at least 30 mm. A minimum distance of 15 mm
from other axle components must be guaranteed in all driving situations.
Where applicable the brake hose may be slightly twisted within itself during the mounting process, to ensure
that the minimum distances are adhered with.
Notes on externally invisible brake fluid loss - AH42.10-P-9406-02GZ
Model 164
In the event of brake fluid loss which is not visible from outside, check whether there is brake fluid ingress into
the brake booster through a leaking secondary seal in the tandem master brake cylinder:
 Remove tandem master brake cylinder.

 Draw off any brake fluid which has entered and empty into a measuring beaker.
If there are more than 100 cm3 of brake fluid in the brake booster, the brake booster must be replaced.
The power diaphragm in the brake booster is resistant to brake fluid, but not the reaction disk and the plate
valve in the master control unit. Brake fluid must therefore only be suctioned off when the brake booster is
installed. Up to a quantity of 100 cm3 no brake fluid can reach the reaction disk or the poppet valve when the
brake booster is installed.
BRAKE FLUID NOTES - AH42.50-P-0001-01A
All models
 Do not allow brake fluid to come into contact with vehicle paintwork, as it contains ingredients that act as
solvents on the paint. Should brake fluid come into contact with the paint despite all precautions, the
moistened surface must be flushed immediately with a lot of water (do not rub off brake fluid).
 Brake fluid is highly hygroscopic, i.e. it absorbs humidity which reduces its boiling point. Brake fluid
must therefore only be stored in properly sealed reservoirs (original container) in order to avoid moisture
absorption via the air humidity. A boiling point which is reduced as a result can lead to problems up to
the total failure of the brake system at high operating temperatures.
 Used brake fluid must not be re-used.
 Brake fluid is colorless to yellow colored and is therefore easily confused with mineral oil products.
Therefore only remove brake fluids from original containers and store separately from mineral oils and
other fluids.
 For disposal notes for the location area Federal Republic of Germany see:
"Environmental Manual for Motor Vehicle Repair Operations" Publisher: Association of the German
Automotive Industry e.V.
(VDA)
60625 Frankfurt am Main, Westendstrabe 61
BASIC KNOWLEDGE
STOP LAMP SWITCH COMPONENT DESCRIPTION - GF42.10-P-2010BK
MODEL 219 with ENGINE 113.967
MODEL 164.1 with ENGINE 113.964
Shows model 219
Location
The brake light switch is installed at the brake pedal.

Fig. 3: Identifying Stop Lamp Switch Components - Model 219

Task
Record the actuation of the brake pedal to activate the brake lights and deactivate the cruise control, Distronic,
etc.
Function
Contact closure is recorded (e.g. on model 219 by the Driver-side SAM control unit with fuse and relay module)
and transferred on the CAN data bus.
BRAKING ASSISTANT (BAS) - OPERATION - GF42.31-P-0001GZ
MODEL 164
On model 164 the BAS function is integrated in the ESP control unit.
Studies with normal drivers in the driving simulator and on the test track have shown that in emergency braking
situations most drivers press the brake pedal quickly but not hard enough, above all in the initial phase of the
brake application.
Fig. 4: Brake Assistant Operation Graph

A distinction is made between:
 Hesitant brake application - in the initial phase the driver applies too little pedal force and increases it too
slowly
 Inadequate braking - the driver applies too little brake force throughout the entire brake application
To improve these situations, Brake Assist has been developed.
"Brake Assist" BAS is an active safety system. It becomes active when the driver brakes very quickly in an
emergency situation. The system detects whether an emergency braking situation exists on the basis of the
speed at which the brake pedal is depressed.
If this is the case, a solenoid valve opens in the brake servo and activates the full servo power. If the driver
releases the brake, this is detected and the solenoid valve closes again.
Advantages
 Reduces the accident risk in hazardous situations through optimal brake deceleration and thus assists the
driver considerably
 Supports the ABS by providing the greatest possible servo action.
 ABS retains the full steerability also during intervention by the BAS
 Reduces the brake distance considerably during hesitant or inadequate brake application
Fig. 5: Identifying BAS Brake Booster, BAS Diaphragm Travel Sensor, Release Switch And
Solenoid Valve
Function overview
The normal brake booster amplifies the force of the driver's foot proportionally. If the vehicle is not braked the
vacuum which is produced by the engine prevails in both chambers. A mechanical control valve in the brake
servo operated by the force of the driver's foot allows air at atmospheric pressure to flow into the rear chamber
when braking. The pressure difference existing between the two chambers and the amplification force created is
therefore proportional to the force applied by the driver's foot. Amplification of the force of the foot takes place
up to the point at which full atmospheric pressure exists in the rear chamber.
With the BAS brake booster BAS (A7/7) the basic version is expanded by the following parts:
 Diaphragm travel sensor BAS (A7/7b1) for measuring the brake pedal travel
 BAS solenoid valve (A7/7y1) for actively carrying out brake force assist
 BAS release switch (A7/7s1) for detecting the end of the brake application
 ESP (N47-5) for recording the values and for actuating the BAS brake intervention
A vehicle identification and self-check of the system takes place once the engine has started. The BAS is ready
to function if no fault is present and the vehicle has exceeded a speed of 8 km/h after driving off. Following
this, BAS can be activated down to a speed of 3 km/h.
The operating speed of the brake pedal and the vehicle speed is recorded in the ESP control unit.
If the pedal speed is greater than the threshold value specified for the respective vehicle speed, the BAS
solenoid valve in the brake booster is actuated and thus the full booster force is reached.
BAS is not used in the event of a defect (display by ESP warning lamp (A1e41) (in the instrument cluster). The
normal function of the brake booster is not affected by this.
BAS Braking Assistant - Operation GF42.31-P-2000GZ
BRAKE ASSIST (BAS), CONTENTS, FUNCTION DESCRIPTION - GF42.31-P-0999GZ
MODEL 164
Braking Assistant (BAS) - Operation GF42.31-P-0001GZ

BAS brake application, function GF42.31-P-2000GZ
Overview of system components, Brake Assist (BAS), component description GF42.31-P-9996GZ
BAS BRAKE APPLICATION, FUNCTION - GF42.31-P-2000GZ
MODEL 164
Fig. 6: BAS Brake Application Function Diagram

The functions of the BAS brake booster (A7/7) are controlled using the components of the electric/electronic
system.
The ESP control unit (N47-5) receives input signals from the following components:
 ME control unit (N3/10) (Controller Area Network bus class C) (engine compartment) (CAN-C)
 BAS diaphragm travel sensor (A7/7b1)
 BAS release switch (A7/7s1)
Normal operation
In this case, the brake application is not at the higher pedal speed (that requires activation of BAS). The BAS
solenoid valve (A7/7y1) in the BAS brake booster is de-energized in the basic position.
The system is ready for braking. Service brake and ABS function normally. This mode is also set if there is a
fault in the BAS.
The input signals are processed in the ESP control unit to form output signals for the following components:
 BAS solenoid valve

 ESP warning lamp (A1e41)(via CAN-C)
Based on input signals the ESP control unit decides which of the 3 modes
 BAS Normal mode,

 BAS pressure buildup,
 BAS pressure reduction
is to be activated.
Brake application in normal operation
The BAS brake booster is constantly supplied with the intake manifold vacuum via the vacuum line. If the
brake is not actuated, equal vacuum exists on both sides of the diaphragms. The compression spring holds the
vacuum piston in its starting position.
On brake application, atmospheric air is fed to the back of the diaphragms via a duct. A pressure difference that
increases with the braking is created between the front and rear chambers of the booster and the resulting force
acts in the direction of the master brake cylinder and supplements foot pressure.
Illustration shows partial braking
Fig. 7: Identifying BAS Brake Booster And BAS Release Switch - Illustration Shows Partial Braking
BAS pressure increase

The ESP control unit recognizes that the preconditions exist for activation of BAS from the speed of the brake
pedal and the vehicle speed.
The BAS solenoid valve is activated by the ESP control unit and the brake booster produces the maximum
brake assistance power.
BAS is activated when the following conditions exist
simultaneously:
 Speed > 8 km/h

 BAS release switch is operated
 no current fault is detected.
 the system is enabled (after self-test)
 The activation threshold of the pedal speed has been exceeded
Illustration shows pressure buildup
Fig. 8: Identifying BAS Brake Booster And BAS Release Switch - Illustration Shows Pressure Buildup
Brake application with BAS, pressure buildup
The activation conditions for a BAS brake application are fulfilled, the BAS solenoid valve is opened.
Atmospheric pressure is applied to the back of the power diaphragm. The pressure difference between the front
and back of the diaphragm provides maximum brake power assistance.
BAS pressure reduction

The ESP control unit receives information from the BAS release switch that the emergency brake application
has terminated. The BAS solenoid valve is no longer activated and the maximum braking assistance force is
switched off. The normal braking assistance force remains unchanged.
BAS is switched off when one of the following conditions exists:
 BAS release switch (A7/7s1) is not actuated

 Speed <3 km/h
 Duration of activation >20 s
 A fault is detected that causes the ESP warning lamp to be activated.
Illustration shows pressure release
Fig. 9: Identifying BAS Brake Booster And BAS Release Switch - Illustration Shows Pressure Release
Brake application with BAS, pressure release
The BAS release switch is switched passively. The solenoid valve is switched off and only creates sufficient
brake pressure to correspond to the position of the brake pedal.
BAS brake booster component description GF42.31-P-4004GZ

Description of components in ESP control unit GF42.45-P-5118GZ
BAS BRAKE BOOSTER, COMPONENT DESCRIPTION - GF42.31-P-4004GZ
MODEL 164
The BAS brake booster (A7/7) is installed in the left major assemblies compartment. Like a conventional brake
booster it assists the foot force of the driver when braking and carries out the BAS brake application.
Fig. 10: Identifying BAS Brake Booster Components

BAS brake servo
(section drawing)
Fig. 11: Sectional View Of BAS Brake Servo

An emergency brake application is determined by the ESP control unit through the diaphragm travel sensor
(A7/7b1). With a BAS brake application the BAS solenoid valve (A7/7y1) opens the valve (d) which introduces
atmospheric pressure from the vehicle interior via the air cleaner (g and f) to the backs of the rolling diaphragms
(c).
The full assistance pressure from the brake servo is transmitted to the master brake cylinder via the output rod
(h). If the brake application has ended, then the ESP control unit receives a signal from the BAS release switch
(A7/7s1) and the BAS solenoid valve is closed again. The BAS assistance is terminated.
OVERVIEW OF SYSTEM COMPONENTS, BRAKE ASSIST (BAS), COMPONENT DESCRIPTION -

GF42.31-P-9996GZ
MODEL 164
BAS brake booster Component description GF42.31-P-4004GZ

ESP control unit Component description GF42.45-P-5118GZ
ASR DRIVE TORQUE CONTROL CIRCUIT, FUNCTION - GF42.40-P-2100GZ
MODEL 164
Acceleration slip regulation (ASR)
In order to achieve optimum traction for a too large drive torque (spinning wheels), the drive torque must be
controlled. The drive torque reduction is controlled by the data exchange between the ESP control unit (N47-5)
and the ME control unit (N3/10) via the Controller Area Network bus class C (engine compartment) (CANC).
Through the ME control unit the throttle valve position is reduced by the throttle valve actuator (M16/6) relative
to the accelerator pedal position specified by the driver and the ignition timing is retarded. The ESP control unit
constantly checks whether the control functions can be canceled as a result of a sudden improvement in road
adhesion.
So the drive torque specified by the driver via the accelerator pedal can be permitted again in good time.
Engine braking regulation control (MSR)
If slip at the drive wheels is detected when the throttle is closed, then this is detected by the ESP control unit.
The signal of the throttle valve position is transmitted to the ME control unit via the CAN-C. Through the ME
control unit the calculated throttle valve opening is regulated by the throttle valve actuator.
With this information, the drive torque can be changed so that no slip occurs at the drive wheels. This improves
the lateral stability of the vehicle. This process occurs without the driver being informed via the ESP warning
lamp (A1e41).
Electronic stability program (ESP), function GF42.45-P-0001GZ

ESP braking moment control circuit, function GF42.45-P-2000GZ
Wheel rpm sensor, component description GF42.45-P-5134GZ
Steering angle sensor, component description GF42.45-P-5107GZ
Yaw rate and lateral acceleration sensor, component description GF42.45-P-5120GZ
ESP Off switch, component description GF42.45-P-5121GZ
Traction system hydraulic unit, component description GF42.50-P-4001GZ
ELECTRONIC STABILITY PROGRAM (ESP) FUNCTION - GF42.45-P-0001GZ

MODEL 164
Shown on model designation 164.1
Fig. 12: Electronic Stability Program (ESP) Function Diagram (1 Of 2)


Fig. 13: Electronic Stability Program (ESP) Function Diagram (2 Of 2)

Advantages of Electronic Stability Program (ESP)
 Improves the starting off and acceleration capacity by increased traction; particularly advantageous on a
road surface with different adhesion and in curves
 Increases the active driving dynamics safety as only a wheel which is not spinning makes possible
optimum traction without loss of lateral support
 Automatically adapts the engine torque to the respective transmission possibilities of the wheels to the
road, even if the driver accelerates too hard
 Reduces the danger of skidding under all driving and road conditions by automatic stabilization
 Improves the on-course stability significantly when cornering up to the critical limits
 Reduces the brake distance
 A flashing warning lamp in the instrument cluster signals antilock brake system (ABS) or ESP closed-
loop operation to the driver and informs him that he has got close to the physical limits with his vehicle
 Via the ESP Off switch (N72/1s1) an ESP and acceleration slip regulation (ASR) shutoff can take place
which is recognized by the warning lamp in the instrument cluster lighting up permanently. As a result
better traction can be achieved in deep snow or when snow chains are fitted
ESP
ESP is an active safety system for improving the vehicle stability under all driving situations. It monitors the
driving characteristics with the longitudinal and transverse dynamics.
The specified value requirements starting from the driver, such as steering requirements, brake pressure,
steering wheel position or drive torque are read in by the ESP control unit and processed further for vehicle
stabilization.
It operates by means of individual brake control cycles at one or several wheels of the front or rear axle.
The instructions on towing in the operator's manual must be observed.
Drive torque control
The ESP control unit communicates with the ME-SFI [ME] control unit to adjust the drive torque. The gear
stage is also evaluated by the Electric control unit (VGS) to calculate the ESP drive moment control.
Data is exchanged between the electric control unit (VGS), the MESFI [ME] control unit and the ESP control
unit via the Controller Area Network bus class C (engine compartment) (CAN-C).
The following system functions are integrated in the ESP control unit:
ABS antilock brake system prevents the wheels locking when braking and thus maintains the steerability and
directional stability and road adhesion when the vehicle decelerates.
ASR acceleration slip regulation prevents the drive wheels spinning by adapting the drive torque. It also
improves directional stability with better traction across the entire speed range.
BAS Brake Assist supports the driver during panic braking.
EBV Electronic brake force distribution prevents overbraking of the rear wheels by corresponding brake force
distribution between the front and rear axle.
ETS electronic traction system achieves a locking effect by specific brake application.
EBR engine braking regulation prevents brake slip of the drive wheels in overrun mode and take care of
directional stability and road adhesion.
PML speed-sensitive power steering varies the steering assistance corresponding to the vehicle speed.
RDW By comparing the wheel speeds (FL and RR as well as FR and RL) tire pressure loss warning detects the
pressure loss at a tire before flat tire damage can occur.
 Signal evaluation and monitoring of sensors

 Safety circuits with shutoff strategy
The ESP control unit is divided up functionally as follows:

 Signal conditioning
 Function logic component
 Safety circuit
 Additional functions
Signal conditioning
The following input signals are processed by the function logic component for calculations or as information:
 Computation of vehicle speed/slip

 Signals of the four rpm sensors at the wheels
 Calculation of lateral forces

 Steering angle sensor signal via CAN-C
 Micromechanical yaw rate sensor AY pickup signal
 BAS diaphragm travel sensor signal (A7/7b1)
 Calculation of longitudinal forces

 CAN C information on engine torque
 CAN C information on current gear
 ESP brake pressure sensor signal (B34)
 Information signals (operation)

 ESP brake pressure sensor signal
 Parking brake indicator switch signal via CAN-C
 ESP Off switch signal
 BAS release switch signal (A7/7s1)
 BAS diaphragm travel sensor signal
Function logic component
The conditioned input signals are processed in the logic section and converted into output signals. The
processed four wheel speed signals are constantly compared amongst each other and with specified slip
thresholds at the front and rear wheels, depending on the vehicle speed.
The following values and controlled variables are determined:
 Vehicle speed
 Acceleration/deceleration
 Wheel slip (ABS)
 Drive slip (ASR)
 Decel slip (MSR)
Steering angle sensor

The change in the direction of travel or cornering is detected via the signal from the steering angle sensor and
different wheel speeds of the front wheels.
The signal from the steering angle sensor in combination with the vehicle speed enable the ESP control unit to
record the driver's personal preferences.
Micromechanical yaw rate sensor AY pickup
From the sensor signal the ESP control unit determines the lateral forces when cornering and the rotational
speed about the vertical axis. The drive status regulator in the ESP control unit detects an oversteering or
understeering vehicle from the lateral acceleration signal, the yaw rate signal and the signal from the steering
angle sensor.
CAN C information on engine torque
Via CAN C the ESP control unit is informed by the ME-SFI [ME] control unit about the engine torque
delivered. In ESP control mode the function logic component requests the engine control unit to set a reduced
engine torque.
CAN C information on the current gear
Via CAN C the function logic section is constantly informed by the electric control unit (VGS) about the
current gear. The drive torques acting on the drive wheels are calculated via the current gear and the engine
torque signal from the ME-SFI [ME] control unit and are used for drive torque control.
ESP Off switch signal
If a signal from the switch is applied, then the drive moment control circuit is switched off and the ESP warning
lamp (A1e41) actuated continuously.
ESP brake pressure sensor signal
The brake pressure is recorded by the sensor and used by the function logic section for calculating the wheel
brake forces (longitudinal forces). Actuation of the brake is also registered by the driver.
If an ESP control is necessary, the existing wheel brake forces (longitudinal forces) are also included as well for
calculating the lateral stability (lateral forces).
Parking brake indicator switch signal
If there is a signal from this switch, no engine braking regulation is permitted.
BAS diaphragm travel sensor signal
Using this the brake pedal speed is calculated which is needed for the use of BAS.
Safety circuit
The safety circuit detects faulty signals from sensors, faults in the control unit and in the electric line system.
The actuation of the high pressure and return pump (A7/3m1) is monitored during the control process. The
solenoid valves are monitored permanently.
If a fault is detected, the system is switched off and this is displayed to the driver by the multifunction display
(A1p13). In addition, a fault code is stored in the control unit. The safety circuit also constantly monitors the
battery voltage. If the voltage drops below 10.5 V or rises above 17.5 V, the system is again shut down until the
voltage returns to the specified range.
Speed-sensitive power steering subfunction (SPS)
The control unit calculates the specified current for actuating the SPS [PML} solenoid valve from the internal
vehicle speed and the status signal (Y10).
Brake Assist (BAS) sub-function
The conditioned input signals are processed in the function logic section and a Brake Assist System brake
application is introduced if necessary.
Wheel speeds and speed status signal outputs
 Output of wheel rpm
For systems which need a wheel speed signal the ESP control unit supplies the current wheel speed from
each wheel.
 Output of rpm status signal
The ESP control unit supplies the rotational speed status signal for systems which need information on
the current vehicle condition (vehicle stationary, vehicle being driven, rpm sensor defective).
Indicator lamp actuation
The ESP control unit records the signals from the parking brake indicator switch and the signals from the brake
lining wear contacts. They are passed on via CAN C to the instrument cluster together with the signals for the
multifunction display, the ABS indicator lamp (A1e17) and ESP warning lamp (A1e41).
Function overview
All forces which act on a vehicle outside the center of gravity always want to turn the vehicle about this center
of gravity, irrespective of whether they are brake forces, driving forces or side forces acting on one side. The
ESP records the vehicle behavior and specifically introduces brake forces for correction at the individual
wheels.
Fig. 14: ESP Control Unit Function Diagram

Example A: Understeering vehicle (in left-hand curve)
The vehicle pushes outwards over the front wheels.
A precisely calculated braking action is performed on the left rear wheel .
Example B: Oversteering vehicle (in left-hand curve)
The tail of the vehicle breaks away.
A precisely calculated braking action is performed on the right front wheel .
For the ESP, displays with various symbols are located in the instrument cluster.
Fig. 15: Identifying Multifunction Display, Instrument Cluster, ABS Indicator Lamp And ESP Warning
Lamp
Turning on the ignition and starting the engine
When the ignition is switched on (ignition/starter switch in position 2) the warning lamps and indicator lamps
light up in the instrument cluster (bulb check) and go out when the engine is running and the systems are
operational.
Function of ABS indicator lamp
The ABS indicator lamp in the instrument cluster lights up when the key is turned into position "circuit 15 ON".
The ABS indicator lamp goes out once the engine has started. This indicates that the ABS is operational.
ABS indicator lamp lights up permanently
The ABS indicator lamp lights up permanently if the ABS/ESP/BAS is not available due to a fault, CAN
communication with the instrument cluster is faulty, or ESP is on the diagnosis test or exhaust emission test.
Function of ESP warning lamp
The ESP warning lamp in the instrument cluster lights up if the key is turned to position "circuit 15 ON". The
ESP warning lamp goes out once the engine has started. This indicates that the ESP is operational.
Function of ESP warning lamp in driving mode
Once the ESP warning lamp has gone out, it remains off, as long as the ESP closed-loop operation is not active
(no wheel has exceeded the adhesion limit).
ESP warning lamp flashes
The ESP warning lamp flashes whilst the ESP closed-loop operation is active (at least one wheel has exceeded
the adhesion limit). The ESP warning lamp flashes if one wheel has exceeded the adhesion limit during a
starting off process or during a brake application.
ESP warning lamp lights up permanently
The ESP warning lamp lights up permanently if the Electronic Stability Program [ESP] is not available. This is
the case if there is an ESP system fault (e.g. fault in the ESP control unit).
The brake system continues to function normally.
ASC drive torque control circuit, function GF42.40-P-2100GZ


TABLE OF CONTENTS: FUNCTIONAL DESCRIPTION, ELECTRONIC STABILITY PROGRAM

(ESP) - GF42.45-P-0999GZ
MODEL 164
Braking Assistant (BAS) - Operation GF42.31-P-0001GZ

ASC drive torque control circuit, function GF42.40-P-2100GZ
Electronic stability program (ESP) function GF42.45-P-0001GZ
Overview of system components for ESP, component description GF42.45-P-9996GZ
ESP BRAKING MOMENT CONTROL CIRCUIT, FUNCTION - GF42.45-P-2000GZ
MODEL 164
Fig. 16: ESP Braking Moment Control Circuit Function Diagram

The
Electronic Stability Program (ESP) regulates:
 when cornering (vehicle understeering or oversteering)

 when driving straight ahead (vehicle deviates off course due to uneven road conditions)
To be able to perform these control interventions, an expanded system of sensors is required compared with
acceleration slip regulation (ASR).
There are general distinctions between:

 Signals which communicate the wishes of the driver

 signal from the steering angle sensor (N49)
 signal from accelerator pedal sensor (B37)
 Signals which communicate actual vehicle handling characteristics

 Signals (yaw speed and lateral acceleration) from the micromechanical yaw rate sensor AY pickup
(B24/15)
 Signal (brake pressure) from the brake pressure sensor (B34)
 Signals (wheel speeds) from the left front rpm sensor (L6/1), right front rpm sensor (L6/2), left rear
rpm sensor (L6/3), right rear rpm sensor (L6/4)
 Signals (gear switch) from the electric control unit (VGS) (Y3/8)
In the ESP control unit (N47-5) the wheel speeds, steering angle, vehicle yaw speed, lateral acceleration and
brake pressure of the individual wheels are recorded and processed.
The ESP control unit is connected to the engine/transmission management control units via the Controller Area
Network bus class C (engine compartment) (CAN-C). This digital cable connection enables rapid data exchange
between the ESP control unit, ME control unit (N3/10) and the electric control unit (VGS).
The ESP control unit is constantly supplied with the current data on engine torque, accelerator pedal position
and transmission ratio. Via the micromechanical yaw rate sensor AY pickup the forces are detected which want
to turn the vehicle about the center of gravity.
The longitudinal and lateral forces acting on the wheels can be calculated by means of the data acquisition
described. If these values exceed certain control thresholds, the corresponding control valves are actuated by the
ESP control unit in order to selectively regulate the brake pressure applied at one or several wheels.
The commands transmitted via CAN-C to the ME control unit and the electric control unit (VGS) relating to the
torque requirement initiate a reduction in the drive torque and if necessary a downshift is prevented by the
electric control unit (VGS). The precise and accurately proportioned intervention is completed within a few
fractions of a second. Active brake intervention and drive torque reduction by the ESP ensure optimum vehicle
stability.
The following processes are performed:
Start-off assist
If the driver changes from the brake pedal to the accelerator pedal the vehicle can roll away against the engaged
gear if the vehicle is positioned on a steep enough gradient or slope. An integrated inclination sensor detects
when a defined slope or gradient is exceeded. A booster helps to maintain the brake pressure until the
accelerator pedal is pressed.
Antilock brake system (ABS)
If, for example, a wheel has a tendency to lock when braking, the brake pressure in this wheel brake is
regulated. The regulation in the traction system hydraulic unit (A7/3) takes place via the control valves through
the control phases of pressure buildup, pressure maintenance and pressure reduction.
Electronic traction system (ETS)
To brake the spinning wheel (slippery ground) brake pressure is applied to the brake caliper of the spinning
wheel (pressure buildup) through the pressure system of the traction system hydraulic unit. This allows the
other wheel to continue to transmit drive force (differential lock effect).
Via control valves in the traction system hydraulic unit the braking torque is regulated by pressure buildup,
pressure maintenance and pressure reduction.
Acceleration slip regulation (ASR)
To prevent the drive wheels from spinning as a result of a drive torque which is too great for the surface, the
ME control unit reduces the drive torque. The ESP control unit detects this occurrence by evaluating the wheel
sensor signals and transmits this to the engine control unit via CAN-C.
The ESP control unit constantly checks whether, for example, the control functions can be canceled due to a
sudden improvement in road grip, in order to once again permit the drive torque specified by the driver through
the accelerator pedal.
Engine braking regulation control (MSR)
If wheel slip caused by the engine braking torque occurs at the drive wheels when the throttle is released, this is
also detected in the ESP control unit. The signal is sent to the ME control unit via the CAN-C. On the basis of
this information, the wheel slip is reduced by increasing the drive torque, and the side stability of the vehicle is
thus increased. This process occurs without notifying the driver (ESP warning lamp (A1e41)).
Electronic Stability Program (ESP)
If oversteer or understeer is detected, a calculated braking action is performed at the front or rear axle via the
ESP control unit. This brake intervention counteracts the undesired driving behavior.
A signal sent to the ME control unit via the CAN-C triggers the required reduction in drive torque by decreasing
engine torque.
Electronic brake force distribution (EBV)
A dynamic movement of the center of gravity is caused by braking, the vehicle's center of gravity moves
forwards. The rear axle wheels are relieved of pressure and tend towards overbraking. The lack of side stability
at the rear wheels would result in unstable driving conditions. This situation is detected by the ESP control unit
through the wheel sensors. The ESP control unit then reduces the brake pressure in the rear wheels and prevents
the rear wheels from overbraking.
Offroad operation
Some control parameters of the ESP control unit are changed for offroad operation.
Offroad ABS
The offroad ABS function was developed for speeds under 30 km/h when the Low Range switch is pressed
(N72s31). It permits the wheels to block when the surface is poor to reduce brake travel by up to 50 %.
ASR control in offroad operation
ASR control detects road surfaces with low friction values. The ASR activation thresholds are developed
depending on the tire characteristics to improve traction quality.
Downhill Speed Regulation
This system can provide considerable safety benefits when driving downhill in offroad mode. This system can
be activated at speeds below 30 km/h by pressing the Downhill Speed Regulation switch (N72s30). The slow
driving speed specified by the driver (between 6 km/h and 18 km/h) is now maintained. This is achieved by
appropriate engine and transmission control and by automatic brake use.
Offroad package
The Offroad package is a special equipment package with the following additional components:
 two-stage transfer case with up to 100% interaxle differential lock

 strengthened rear axle differential with up to 100% interwheel differential lock
 Rear axle differential lock control unit
 Transfer case control unit
 Lower control panel control unit (N72/)
The two-stage transfer case included in the Offroad package allows the driver to choose between an on-road
ratio (1:1) and an off-road ratio (2.93:1).
The high drive torque that is made possible, combined with the locking differentials, considerably improves off-
road characteristics.
ESP traction control has been adjusted to take the special requirements into account.
If the differential locks are active, these are immediately opened when brakes are applied by ESP (speed-
dependent), or ABS control (speed < 15 km/h) or driver braking (speed > 15 km/h). The signal to open the locks
comes from the ESP control unit.
Electronic stability program (ESP), function GF42.45-P-0001GZ

ASR drive torque control circuit, function GF42.40-P-2100GZ

STEERING ANGLE SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5107GZ
MODEL 164
The steering angle sensor (N49) is located in the steering column module (N80). It is fastened to the steering
column module in connection with the clock spring contact/fanfare horns and airbag (A45).
The task of the steering angle sensor working on an optical basis is to record a steering angle specified by the
driver and to pass on to the connected systems.
Fig. 17: Identifying Steering Angle Sensor And Steering Column Module
The steering angle sensor consists of 2 microcomputers which together with a signal measuring ring form one
unit. The 9 light-emitting diodes are located at equal distances in the signal measuring ring They are located in a
light barrier channel which is passed through by 8 blades of different length. The light barriers are located in the
upper section of the clock spring contact/fanfare horns and airbag and only form the complete functional unit of
the steering angle sensor by assembling (clipping in) both components.
Fig. 18: Identifying Steering Angle Sensor And Fanfare Horns And Airbag Clock Spring Contact
Function of steering angle sensor
In the center position of the steering wheel the 8 blades assumes a defined position relative to the 9 light-
emitting diodes. This center position is recorded by the computer in the steering angle sensor.
When the steering wheel is turned, the position of the blades changes with respect to the light-emitting diodes
(light/dark). Because of the different lengths of the blades and the different intervals between them, a defined
signal pattern is produced for computing the current steering wheel position.
The signal patterns are used to calculate angle values which are converted into serial data for the connected
control units.
The signals are recorded by light-emitting diodes and light barriers in 2.5° steps. The signal recording is
designed for a steering angle ± of 720° (4 steering wheel rotations from stop to stop).
So that the steering angle is also recorded after "ignition OFF", voltage is supplied via circuit 30. The steering
angle sensor must be re-initialized after a voltage interruption (circuit 30). This is done by turning the steering
wheel from lock to lock.
DESCRIPTION OF COMPONENTS IN ESP CONTROL UNIT - GF42.45-P-5118GZ
MODEL 164
Fig. 19: Identifying ESP Control Unit

The ESP control unit (N47-5) is installed on the hydraulic unit (A7/3).
Carries out all brake control functions of Antilock Brake System (ABS), Acceleration Slip Regulation (ASR)
and Electronic Stability Program (ESP). Data exchange with the engine/transmission control units takes place
via the Controller Area Network bus class C (engine compartment) (CAN-C) for ASR and ESP.
 Influence the engine/transmission management in the case of an ESP control

 Contains the complete Brake Assist (BAS) control unit function
 Supplies other systems with the vehicle speed signal and wheel rpm signal (direct or via CAN-C).
 Supplies the instrument cluster (A1) with the signals for the ABS indicator lamp (A1e17), the ESP
warning lamp (A1e41) and the multifunction display (A1p13) via CAN-C
 On vehicles with CODE (213) Speed-sensitive power steering the ESP control unit also contains the
electronics and control logic necessary for this
 The ESP control unit contains the software for CODE (477) tire pressure loss warning. It recognizes
pressure loss by comparing the wheel speeds and displays this in the multifunction display (A1p13)
YAW RATE AND LATERAL ACCELERATION SENSOR, COMPONENT DESCRIPTION - GF42.45-

P-5120GZ
MODEL 164

Fig. 20: Identifying Micromechanical Yaw Rate Sensor AY Pickup

The micromechanical yaw rate sensor (micromechanical yaw rate sensor AY pickup) is located in the vehicle
interior. It records the rotational speed of the vehicle about the vertical axis and the force of the lateral
acceleration during cornering or skidding motions.
The pickup consists of one sensor to detect the rotational speed about the vertical axis and one sensor to detect
the lateral acceleration. These sensors are combined into one housing. This reduces installation space
considerably.
Function
The micromechanical sensor system converts the lateral acceleration and rotational speed about the vehicle's
vertical axis into electrically usable signals. The respective vehicle movements result in different displacements
of the various types of masses.
Signal changes are recorded electronically and passed on to the ESP control unit via a CAN bus (Dynamics
CAN) specially designed for the sensor to the ESP control unit (N47-5).
Fig. 21: Identifying Yaw Rate And Lateral Acceleration Sensor Components
Function of lateral acceleration
The measuring principle of the lateral acceleration sensor is based on a deflection/extension and mass system
with capacitive detector. The voltage is supplied via the ESP control unit. The lateral acceleration which occurs
during cornering causes the mass element to move against the flexible bar (that functions like a spring) from its
normal position to a position corresponding to the magnitude of the lateral acceleration.
Every change in position changes the electrical capacitance of the detector. An electronic analysis system
produces a voltage signal afterwards which depends on the capacitance and therefore on the lateral acceleration
of the vehicle. This voltage signal is evaluated by the ESP control unit.
Fig. 22: Identifying Micromechanical Silicon Ring Structure And Sensor Electronics
Function of rotational speed
A micromechanical silicon ring structure which is made vibratory via 8 bridges is used as a sensor element. The
oscillations are induced electromagnetically. Under the influence of a yaw rate, additional forces (Coriolis) act
on the vibration structure. These Coriolis forces change according to the rotational speed.
These Coriolis forces are also read out electromagnetically. After conditioning in a sensor-specific way, they
are supplied as an analog signal to the signal processor inside the instrument cluster. The sensor electronics
provide an output signal for the ESP control unit.
ESP OFF SWITCH, COMPONENT DESCRIPTION - GF42.45-P-5121GZ
MODEL 164
Fig. 23: Identifying ESP OFF Switch

The ESP Off switch (N72/1s1) is located in the upper control panel control unit (N72/1).
The acceleration slip regulation (ASR) and Electronic Stability Program (Electronic-Stability-Program) (ESP)
function can be switched passive by operating the ESP Off switch when the engine is running.
Through this passive circuit an ESP intervention is only carried with larger deviations between the actual value
and specified value than with ESP-ON. The ESP function cannot be switched off.
WHEEL RPM SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5134GZ
MODEL 164

Fig. 24: Identifying Front/Rear Wheel Rpm Sensor

The rpm sensors supply the current wheel speeds to the ESP control unit (N47-5). The ESP evaluates these
signals corresponding to the direction of rotation, the wheel speed and fault detection
The active sensors consist of a housing and a sensor element which is based on the magnetoresistive measuring
principle.
Fig. 25: Rpm Sensor Output Signals Graph

An active rpm sensor during an acceleration phase shows the curve of the current.
Function of the active wheel speed sensor
The strength and direction of an external magnetic field causes a change in the internal resistance inside the
sensor. A square wave signal is produced via an electronic analysis system accommodated in the sensor the
frequency of which depends on the rpm, the amplitude height remains constant.
This signal is read in and processed by the ESP control unit.
The external magnetic field is produced by a multipole ring. This consists of an elastomer plastic into which
metal particles have been incorporated. Using a special magnetization procedure the metal particles are aligned
so that magnets occur, the polarities of which change from North to South at the periphery.
OVERVIEW OF SYSTEM COMPONENTS FOR ESP, COMPONENT DESCRIPTION - GF42.45-P-

9996GZ
MODEL 164
BAS brake booster, component description GF42.31-P-4004GZ

Traction systems hydraulic unit, component description GF42.50-P-4001GZ
SPS [PML] solenoid valve, component description GF46.50-P-5140GZ
Table of contents: Functional description, Electronic Stability Program (ESP) GF42.45-P-0999GZ
TRACTION SYSTEM HYDRAULIC UNIT, COMPONENT DESCRIPTION - GF42.50-P-4001GZ
MODEL 164
Fig. 26: Identifying Traction System Hydraulic Unit

The traction system hydraulic unit is located in the left front of the engine compartment. It carries out the
closed-loop operation of the braking torque control circuit and controls intervention by the brake system for:
 Electronic Stability Program (ESP)

 Antilock brake system (ABS)
 Acceleration Slip Regulation (ASR)
 Engine braking regulation control (MSR)
 Electronic brake force distribution (EBV)
 ESP®-trailer stabilization (164.8 only)
 Distronic (DTR) (164.8 only)
Fig. 27: Identifying Traction System Hydraulic Unit Components

Function diagram
Fig. 28: Traction System Hydraulic Unit Function Diagram

Function
The switching components of the ABS, ASR and ESP are combined in the traction system hydraulic unit .
For control per wheel one 2/2 directional control valve each are used for the function of pressure
buildup/holding and pressure holding/depressurization.
High pressure and return pump
The self-priming high pressure and return pumps integrated in the traction system hydraulic circuit are used for
pressure buildup, depressurization during ASR-/ESP controls and for return delivery during ABS controls. A
damper is fitted to each brake circuit to damp the delivery noise.
The low-pressure reservoir takes up brake fluid in the ABS/ ASR/or ESP pressure reduction phase and passes
it on to the high pressure/return flow pump.
Switchover solenoid valves

During ABS, ASR and ESP controls, the switchover solenoid valves shut off the self-priming pumps for the
pressure circuit (DK1) (FL and RR) and the self-priming pumps for the pressure circuit (DK2) (FR und RL)
between the wheel brakes and the master brake cylinder. They are designed simultaneously as pressure limiting
valves and open at approx. 150 bar.
The brake fluid flowing away via the switchover solenoid valve is lead back to the master brake cylinder.
Solenoid valves, pressure holding/depressurization
For control per wheel, one directional control valve each is used for the pressure buildup/holding functions and
pressure holding/depressurization functions in ABS/ASR und ESP closed-loop operation:
 Left front solenoid valve (pressure hold)

 Left front solenoid valve (pressure release)
 Right front solenoid valve (pressure hold)
 Right front solenoid valve (pressure release)
 Left rear solenoid valve (pressure hold)
 Left rear solenoid valve (pressure release)
 Right rear solenoid valve (pressure hold)
 Right rear solenoid valve (pressure release)
Intake solenoid valves
The inlet solenoid valves are opened during the ASR/ESP pressure buildup phases when the calculated
pressures in the respective brake caliper are 60 bar and one of the
 Left front solenoid valve (pressure hold),

 Right front solenoid valve (pressure hold),
 Left rear axle solenoid valve (pressure hold) or
 Right rear solenoid valve (pressure hold)
is actuated.
If the calculated pressure are > 60 bar, the
 Pressure circuit 1 inlet solenoid valve and

 Pressure circuit 2 inlet solenoid valve
also remain open during the ASR-/ESP holding phases.
SAFETY PRECAUTIONS
RISK OF POISONING FROM SWALLOWING BRAKE FLUID. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH BRAKE FLUID - AS42.50-Z-0001-01A
Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and
eye protection when handling brake fluid.
Possible hazards
Risk of poisoning
Swallowing brake fluid can cause symptoms of poisoning such as headaches, dizziness, stomach pains,
vomiting, diarrhea, cramps and unconsciousness. A dose of more than 100 cm3 can have fatal consequences.
Risk of injury
Contact with brake fluid can cause serious skin damage to unprotected skin.
Procedural guidelines and safety precautions
 Ensure that brake fluid is only accessible to authorized personnel.

 Store brake fluid in original containers only.
 Only store brake fluid in suitable, appropriately marked containers. Never use beverage bottles such as
those for mineral water, beer etc.
 Wear safety glasses and protective clothing such as rubber gloves.
If rubber gloves cannot be worn, the following instructions must be observed:
 Allow brake fluid to act on the skin for as short a time as possible; wash affected skin with soap and
water.
 Change contaminated clothing as quickly as possible.
First aid measures
 Wash affected skin with soap and water.

 Change contaminated clothing as quickly as possible.
 If brake fluid enters the eyes, flush immediately with plenty of clean water and seek medical attention if
necessary.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND
MECHANICAL SYSTEMS - AR42.00-Z-9164AA
MODEL 164
MODEL AR42.10-P-
Bleed brake system
164 0010GZ
MODEL AR42.10-P-
Replace brake hoses
164 0013GZ
MODEL AR42.10-P-
Test brake system with pressure tester for leaks
164 0015GZ
MODEL AR42.10-P-
Remove/install front axle brake caliper
164 0070GZ
MODEL AR42.10-P-
Remove/install rear axle brake caliper
164 0080GZ
MODEL AR42.10-P-
Remove/install brake pad on floating brake caliper
164 0160GZ
MODEL AR42.10-P-
Remove/install brake disc
164 0220GZ
MODEL AR42.10-P-
Remove/install stepped tandem master brake cylinder
164 0310GZ
MODEL AR42.20-P-
Removing and installing parking brake indicator switch
164 0501GZ
MODEL AR42.20-P-
Remove/install parking brake pedal assembly
164 0510GZ
MODEL AR42.20-P-
Remove/install front brake control cable
164 0520GZ
MODEL AR42.20-P-
Remove/install rear brake control cable
164 0525GZ
MODEL AR42.20-P-
Remove/install brake shoes of parking brake
164 0530GZ
MODEL AR42.20-P-
Adjust parking brake
164 0540GZ
MODEL AR42.30-P-
Remove/install left front or right rpm sensor
164 0712GZ
MODEL AR42.31-P-
Remove/install BAS diaphragm travel sensor
164 6002GZ
MODEL AR42.40-P-
Remove/install left or right rear axle speed sensor
164 0820GZ
MODEL AR42.45-P-
Remove/install ESP brake pressure sensor
164 0816GZ
MODEL AR42.45-P-
Remove/install electronic stability program (ESP) hydraulic unit
164 0817GZ
MODEL AR42.45-P-
Remove/install electronic stability program (ESP) control unit
164 0820GZ
MODEL AR42.45-P-
Remove/install yaw rate and lateral acceleration sensor
164 0841GZ
Remove, install brake line from stepped tandem brake master cylinder MODEL AR42.50-P-
to hydraulic unit 164 0002GZ
BLEED BRAKE SYSTEM - AR42.10-P-0010GZ

MODEL 164
Shown on vehicle with AIRmatic (air suspension with level adjustment and adaptive damping system
(ADS)), code 489
Fig. 29: Identifying Bleed Brake System Components

Bleeding
Risk of poisoning caused
by swallowing brake fluid. Only pour brake fluid into suitable and appropriately
AS42.50-Z-
Risk of injury caused by marked containers. Wear protective clothing and eye
0001-01A
brake fluid coming into protection when handling brake fluid.
contact with skin and eyes.
AH42.50-
Brake fluid notes All models P-0001-
01A
AH42.00-
All models P-0003-
system
01A
AH42.10-
Notes on externally
P-9406-
invisible brake fluid loss
02GZ
Open engine hood and AR88.40-

1
raise to vertical position P-1000GZ
Remove cap (5) from
2
brake fluid reservoir (6).
Connect filling and Pay attention to manufacturer's operating instructions.
3
bleeding device Bleeding pressure must be 2 bar.
Brake fluid *BF42.10-
http://gotis.aftersales.daimlerchrysler.com 01G
Align vehicle between columns of vehicle lift and
vehicle slipping or AS00.00-Z-
position four support plates at vehicle lift support points
toppling off of the lifting 0010-01A
specified by vehicle manufacturer.
platform.
AR00.60-
P-1000GZ
Adjust bleeding pressure
5 on filling and bleeding unit
to 2.0 bar
6 Remove bleeder dust caps
Connect bleed bottle hose
7 to bleed screw on right
rear axle brake caliper (1)
Open bleed screw on right
rear axle brake caliper (1)
*BA42.10-
8 and allow approx. 80 cm3 P-1001-
of brake fluid to drain out 12L
free of bubbles and then
tighten to correct torque
Sequence when bleeding: Bleed screw on right rear
Repeat bleeding procedure axle brake caliper (1), bleed screw on left rear axle brake
9
at remaining brake calipers caliper (2), bleed screw on right front axle brake caliper
(3), bleed screw on left front axle brake caliper (4).
*BA42.10-
P-1001-
12L
*BA42.10-
P-1001-
10L
Detach filling/bleeding Brake fluid changer, see GOTIS
10
device http://gotis.aftersales.daimlerchrysler.com
Attach bleeder dust caps
11
and screw cap
Checking
Check the fluid level in the *BF42.10-

brake fluid reservoir (6) P-1001-

12 Brake fluid
and correct if necessary 01G
Brake system - inspect AP42.10-P-
fluid level 4210GZ
AR42.10-
Check brake system for
13 P-0100-
leaks
01GZ
REAR AXLE BRAKE CALIPER

BA42.10-P-1001-12L Bleed screw to brake caliper Nm 7

BRAKE FLUID
Filling capacity Liters approx. 0.8
BF42.10-P-1001-01G Brake fluid Sheet BB00.40-P-0330-01A
Specifications for Operating Fluids
Sheet BB00.40-P-0331-00A
REPLACE BRAKE HOSES - AR42.10-P-0013GZ
MODEL 164
Front axle brake hose
Overview of AIRmatic suspension, shown on model 164.1 with AIRmatic (air suspension with level
adjustment and adaptive damping system ADS), code 489
Fig. 30: Identifying Front Axle Brake Hose Components

Rear axle brake hose
Overview of AIRmatic suspension, shown on model 164.1 with AIRmatic (air suspension with level
adjustment and adaptive damping system ADS), code 489
Fig. 31: Identifying Rear Axle Brake Hose Components

MODIFICATION NOTES
12.6.06 Special tool added Step 6
Remove/install
Risk of poisoning caused by Pour brake fluid only into suitable and
swallowing brake fluid. Risk of injury appropriately marked containers. Wear AS42.50-Z-
caused by brake fluid coming into protective clothing and eye protection when 0001-01A
contact with skin and eyes. handling brake fluid.
Risk of death caused by vehicle lifting platform and position the four
AS00.00-Z-
slipping or toppling off of the lifting support plates at the lifting platform support
0010-01A
platform. points specified by the vehicle
manufacturer.
AH42.10-P-
Notes on installing brake hoses
9406-01GZ
AH42.50-P-
Brake fluid notes All models
0001-01A
AH42.00-P-
Notes on repairs to brake system All models
0003-01A
1 Lift/jack up vehicle AR00.60-P-
1000GZ
2 Remove wheels
Remove/install wheels, rotate if AP40.10-P-
necessary 4050Z
Clean
The area around the separation point
should be cleaned thoroughly before
Clean the area around the brake line (1) opening the brake system. Even the
3 and brake hose (2) in the area of the smallest particles of dirt, introduced into the
separation points hydraulic components, can lead to
malfunctions and a total failure of the SBC
brake system.
*BR00.45-
LU cleaner
Z-1028-04A
Seal brake line (1) immediately using
stop plug. The reservoir must not run empty
otherwise air gets into the system.
Detach brake line (1) from brake hose When loosening and tightening the
4
(2) brake line (1) at the brake hose (2) ensure
that the bracket (3) is not twisted. Therefore
counterhold at the two flats of the brake
hose (2) using a fork wrench.
*BA42.10-
P-1002-04J
Unscrew brake hose (2) from floating *BA42.10-
5
brake caliper (4) P-1001-04J
Box wrench Fig. 33
When removing a brake hose (2) from
the front axle.
Detach brake hose (2) from steering
6 Installation: Installation position must
knuckle bracket (5)
be observed.
Installation: Use new cable tie.
Pliers Fig. 35
Detach brake hose (2) from brake hose
7
clip (6)
Tighten all union nuts and bolts on the
brake hose by hand first. Ensure free of
8 Install in the reverse order tension assembly of brake line (1) and
brake hose (2), then tighten union nuts and
bolts.
Use water to rinse off any escaped
9
brake fluid.
AR42.10-P-
0010GZ
Checking
AR42.10-P-
0100-01GZ
Do not insert your hand into rotating parts.
Risk of death caused by body parts Safeguard areas with rotating vehicle parts
AS00.00-Z-
being pulled in by rotating vehicle and dynamometer rollers against
0019-01A
wheels and roller dynamometer rollers unauthorized access.
Safeguard roller dynamometer from
unauthorized access.
AP42.00-P-
4290GZ
BRAKE LINES, BRAKE HOSES

BA42.10-P-1001-04J Brake line to floating brake caliper Nm 22
BA42.10-P-1002-04J Brake pipe to brake hose Nm 15

Fig. 33: Identifying Ring Wrench (000 589 76 03 00)


Fig. 35: Identifying Pliers (164 589 01 37 00)

REPAIR MATERIALS
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
TEST BRAKE SYSTEM WITH PRESSURE TESTER FOR LEAKS - AR42.10-P-0015GZ
MODEL 164
Shown on model 164.1 on left front wheel brake
Fig. 36: Identifying Rotary Knob, Floating Caliper, Pressure Tester And Brake Pedal Winch
Fig. 37: Identifying Rotary Knob, Brake Pedal Winch, Brake Pedal And Driver Seat Frame
Connection diagram and accessories required for pressure test on rear wheel brake
Fig. 38: Identifying Pressure Tester Connection, Bleed Screw, Banjo Bolt And Seals
Checking
by swallowing brake
Only pour brake fluid into suitable and appropriately AS42.50-
fluid. Risk of injury
marked containers. Wear protective clothing and eye Z-0001-
caused by brake fluid
protection when handling brake fluid. 01A
coming into contact with
skin and eyes.
AH42.50-
Brake fluid notes All models P-0001-
01A
AH42.10-
Notes on externally
Model 164 P-9406-
invisible brake fluid loss
02GZ
AH42.00-
All models P-0003-
system
01A
Align vehicle between columns of vehicle lift and position AS00.00-
vehicle slipping or
four support plates at vehicle lift support points specified Z-0010-
toppling off of the lifting
by vehicle manufacturer. 01A
platform.
Open engine hood and AR88.40-
1
raise to vertical position P-1000GZ

Connect brake fluid
2 Brake fluid changer, see GOTIS
changing equipment
Half the height.
Raise vehicle using two- AR00.60-
3 Two-post lift, see GOTIS
post lift P-1000GZ
Remove left front wheel When testing the brake line pressure at the front wheel
4
or right front wheel brake.
Remove/install wheels, AP40.10-
rotate if necessary P-4050Z
Pressure testers for hydraulic oil systems must not be
used for systems with brake fluid otherwise brake fluid is
mixed with mineral oil which can cause the brakes to fail!
At the rear wheel brake a banjo union (11), a banjo
bolt (9) as well as three gaskets (10) are to be used for
adaptation. The banjo union (11) is to be mounted at the
pressure tester connection (12) with a gasket. Unscrew the
bleed screw (8) from the corresponding floating brake
Remove bleed screw on a caliper of the rear wheel brake. Attach the banjo union
(11) to the floating brake caliper together with the banjo
5 of the brake circuit to be bolt (9) and the two gaskets in place of the bleed screw
(8).
tested and connect
pressure tester (3) The banjo union (11) as well as the banjo bolt (9)
are to be obtained as accessories from the
manufacturer of the recommended pressure tester (see
the manufacturer information attached to the pressure
tester). A range of gaskets (10) is already supplied with
the pressure tester.
ATE part number of banjo bolt (9):
03.3520-0300.1
ATE part number of banjo union (11):
03.3521-0100.1
Pressure tester
Bleed pressure tester (3) Pressure tester, see GOTIS
6
using brake fluid changer http://gotis.aftersales.daimlerchrysler.com
Switch off brake fluid
7 changing unit and release
pressure
High-pressure check
Allow the engine to run at
moderate speed in neutral
and by jerkily releasing
8 the accelerator pedal,
produce as high a vacuum
as possible in the brake
booster.
Press down the brake to prevent erroneous measurement or faulty operation!
pedal as far as possible, Only use the brake pedal jack in combination with the
then insert the brake adapter for the brake pedal jack (6). Insert the brake pedal
pedal jack (4) and using jack so that its rubber mounting is propped up on the
the knob (1) tighten as far driver seat frame (7) as illustrated (arrow). If the brake
as possible. After a short pedal jack is inserted differently, there is a danger that
9
dwell time of a few components could be damaged and erroneous
seconds, read off and note measurements occur when testing the brake line pressure!
the measured value of the Duration of high pressure test: 5 min.
brake line pressure from Throughout the 5 min duration of the test, the brake
high pressure gauge of line pressure decrease must not amount to more than 5%
the pressure tester (3) of the measurement which was read off and noted down at
the beginning.
Brake pedal winch Fig. 39
Adapter for brake pedal winch
Pressure tester, see GOTIS Fig. 40
Low-pressure testing
Switch off the engine and
release the brake pedal
jack (4). Then press brake
10 Brake pedal winch Fig. 39
pedal several times until
vacuum in brake booster
is eliminated
Adapter for brake pedal winch Fig. 40
Press down the brake Observe manufacturer's operating instructions in order

pedal as far as possible to prevent erroneous measurement or faulty operation!
and insert the brake pedal Only use the brake pedal jack in combination with the
jack (4). Then turn back adapter for the brake pedal jack (6). Insert the brake pedal
at the knob (1) slowly jack so that its rubber mounting is propped up on the
11 driver seat frame (7) as illustrated (arrow). If the brake
until a brake line pressure
of approx. 3 bar is pedal jack is inserted differently, there is a danger that
displayed on the low components could be damaged and erroneous
pressure gauge of the measurements occur when testing the brake line pressure!
pressure tester (3) Duration of low pressure test: 2 min.
The previously set brake line pressure must not fall
throughout the 2 min duration of the test

Brake pedal winch Fig. 39
Adapter for brake pedal winch
Pressure tester, see GOTIS Fig. 40
Release and remove
12 Brake pedal winch Fig. 39
brake pedal jack (4)
Adapter for brake pedal winch Fig. 40
Detach pressure tester (3)
and screw the bleed screw Collect escaping brake fluid.
13 Pressure tester, see GOTIS
into the floating brake
caliper (2) again http://gotis.aftersales.daimlerchrysler.com
After the brake line pressure test only bleed the floating
brake caliper to which the pressure tester (3) was AR42.10-
connected. P-0010GZ
*BA42.10-
P-1001-
10L
*BA42.10-
http://gotis.aftersales.daimlerchrysler.com 12L
Mount left front wheel or If a brake line pressure test was carried out on the front
15
right front wheel wheel brake.
Remove/install wheels, AP40.10-
rotate if necessary P-4050Z
Lower vehicle using two- AR00.60-
16
post lift P-1000GZ
Two-post lift, see GOTIS
Detach brake fluid Brake fluid changer, see GOTIS
17
changer http://gotis.aftersales.daimlerchrysler.com
AR88.40-
P-1000GZ


Fig. 39: Identifying Brake Pedal Winch (000 589 18 31 00)

Fig. 40: Identifying Adapter For Brake Pedal Winch (211 589 00 31 00)
REMOVE/INSTALL FRONT AXLE BRAKE CALIPER - AR42.10-P-0070GZ
MODEL 164
Fig. 41: Identifying Front Axle Brake Caliper Components - Shown On Model 164.175
MODIFICATION NOTES
Guide pin to caliper support
18.1.06
Brake line to floating brake caliper *BA42.10-P-1001-04J
Remove/install
platform.
Risk of poisoning caused by Only pour brake fluid into suitable and
caused by brake fluid coming into protective clothing and eye protection 0001-01A
contact with skin and eyes. when handling brake fluid.
AH42.00-P-
0003-01A
AH42.10-P-
9406-01GZ
AR00.60-P-
1000GZ
2 Remove the front wheels
necessary 4050Z
Remove brake pads from floating brake AR42.10-P-
3
caliper (1) 0160GZ
Seal brake hose (3) immediately with
Detach brake hose (3) from floating stop plugs. The brake fluid expansion
4
brake caliper (1) reservoir must not run empty otherwise air
gets into the brake system.
*BA42.10-P-
1001-04J
Detach electrical feed line of front
5 brake pad contact sensor (2) from Installation: Replace bolt.
AH00.00-N-
Notes on self-locking nuts and bolts All models
0001-01A
Notes on installing brake pad wear AH42.10-P-
sensor contact sensors 0003-01GZ
6 Remove floating brake caliper (1)
Unscrew bolts (4) and remove floating
7 Installation: Install new bolts (4).
caliper carrier (5)
*BA42.10-P-
1003-10L
AR42.10-P-
0010GZ



Number Designation Model 164 except Model
164.177 164.177
Stage
Nm 80 80
BA42.10-P-1003- Self-locking bolt, caliper support to 1
10L steering knuckle Stage
Angle° 45 45
2

REMOVE/INSTALL REAR AXLE BRAKE CALIPER - AR42.10-P-0080GZ
MODEL 164
Shown on model 164.175 with airmatic (air suspension with level adjustment and adaptive damping
system ADS), code 489
Fig. 43: Identifying Rear Axle Brake Caliper Components - Shown On Model 164.175
MODIFICATION NOTES
Self-locking bolt of floating caliper to wheel carrier
18.1.06
Brake line to floating brake caliper *BA42.10-P-1001-04J
Remove/install
platform.
caused by brake fluid coming into protective clothing and eye protection 0001-01A
contact with skin and eyes. when handling brake fluid.
AH42.00-P-
0003-01A
AH42.10-P-
9406-01GZ
AR00.60-P-
1000GZ
2 Remove rear wheels.
necessary 4050Z
Remove brake pads from floating brake AR42.10-P-
3
caliper (1) 0160GZ
Seal brake hose (2) immediately with
Detach brake hose (2) from floating stop plugs. The brake fluid expansion
4
brake caliper (1) reservoir must not run empty otherwise air
gets into the brake system.
*BA42.10-P-
1001-04J
5 Remove floating brake caliper (1)
Unscrew bolts (3) and remove floating
6 Installation: Replace the bolts (3).
caliper carrier (4)
*BA42.10-P-
1002-12L
AR42.10-P-
0010GZ


BA42.10-P-1002-12L Self-locking bolt, brake caliper to steering knuckle Stage 1 Nm 60
Stage 2 Angle° 45

CHECK BRAKE SYSTEM FOR LEAKS - AR42.10-P-0100-01GZ
1. After bleeding the brake system, press the brake pedal firmly several times in order to bring the brake
pads into contact with the brake disks.
2. Start engine and operate brake pedal with approx. 200 N to 300 N.
3. Check brake system for leaks.
The pressure built up in the brake system must be held without it being possible to depress the brake
pedal further.
4. Check line and hose connections as well as all components of the brake system for leaks.
5. Check fluid level in brake fluid expansion reservoir and correct if necessary.
REMOVE/INSTALL BRAKE PAD ON FLOATING BRAKE CALIPER - AR42.10-P-0160GZ
MODEL 164
Front axle
Fig. 45: Identifying Brake Pad On Floating Brake Caliper Components (1 Of 2)

Rear axle
Fig. 46: Identifying Brake Pad On Floating Brake Caliper Components (2 Of 2)

MODIFICATION NOTES
21.7.06 Section on repeated application of brake pedal has been added Operation step 17
Remove/install
swallowing brake fluid. Risk of appropriately marked containers. Wear AS42.50-Z-
injury caused by brake fluid coming protective clothing and eye protection when 0001-01A
into contact with skin and eyes. handling brake fluid.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and AS00.00-Z-
caused by handling hot or glowing
safety glasses, if necessary. 0002-01A
objects.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
0003-01A
AH00.00-N-
0001-01A
In order to prevent the expansion
Lower brake fluid level in brake fluid
1 reservoir overflowing when pressing back
reservoir down to "MIN" mark
the brake pistons.
2 Remove wheels
necessary 4050Z
Disconnect electrical connector of the
3
brake pad contact sensor
4
Pry off spring steel sheet (1) and
remove
Remove protective caps (4) and
5 Installation: Install new bolts.
unscrew bolts of guide pins
*BA42.10-
P-1002-10L
*BA42.10-
P-1003-12L
Do not tension or kink brake hose. To
relieve the load on the brake hose attach the
Remove floating brake caliper (2)
6 floating brake caliper (2) to the vehicle
with brake pads (3)
unstressed, otherwise the brake hose will be
damaged.
Installation: Check the correct routing AH42.10-P-
of the brake hose. 9406-01GZ
Brake pads (3) are to be disposed of as
special waste. The local authorities can
provide information regarding whether
disposal is also permitted as industrial waste
Remove brake pads (3) from floating similar to domestic waste.
7
brake caliper (2)
Only brake pads approved by Mercedes-
Benz (3) may be fitted in sets.
Installation: Install brake pads (3)
without grease.
Checking
Check brake lining thickness and Replace brake pads (3) and brake disks
8
brake disks in complete sets if necessary.
AP42.10-P-
Check brake lining thickness
4253A
AP42.10-P-
Inspect condition of brake disks
4258GZ
Pull brake pad contact sensor out of
Check for damage, replace contact sensor
9 the pad backing plate of the brake pad
and check if necessary.
Notes on installing brake pad wear AH42.10-P-
sensor contact sensors 0003-01GZ
Check guide pins for sluggishness and
10 Check guide pins and boots damage. Check boots for damage and loose
seat. Replace damaged parts with new parts.
In the event of a leaky floating brake
11 Check floating brake caliper (2)
caliper (2) or damaged dust boot: ?
AR42.10-P-
Install new front axle brake caliper.
0070GZ
AR42.10-P-
Replace rear axle brake caliper.
0080GZ
Press back brake piston using If the brake piston is difficult to move:
12
pusher tool (5) ?
AR42.10-P-
Install new front axle brake caliper.
0070GZ
AR42.10-P-
Replace rear axle brake caliper.
0080GZ
Fig. 47
If the dust boot projects beyond the brake
13 Check fall of the dust boot
piston, position the dust boot correctly.
Clean
Installation: In the process do not
Clean the contact surfaces of brake damage the dust boot and boots. Do not use
14 pads (3) on floating brake caliper (2) any sharp-edged or pointed tools, otherwise
and floating caliper carrier with a rag the floating brake caliper (2) or floating
caliper carrier will be damaged.
*BR00.45-
LU cleaner
Z-1028-04A
Risk of accident when
commissioning the vehicle due to a Before starting engine, actuate brake pedal
AS42.50-Z-
lack of braking effect when the several times until the pressure is built up
0002-01A
service brake is operated for the first and maintained in the brake system.
time after repair work
Operate the brake pedal several times
Firm resistance should be noticeable at
16 until the brake pads (3) contact the
the brake pedal.
brake disks
Check brake fluid level, correct if
17
necessary
AP42.10-P-
Brake system - inspect fluid level
4210GZ

BA42.10-P-1002-10L Guide pin to caliper support Nm 55 30

BA42.10-P-1003-12L Guide pin to caliper support Nm 25
Fig. 47: Identifying Pusher Tool (000 589 52 43 00)


Tel. +49-7940-15-0
Fax +49-7940-15-1000
www.wuerth.de
REMOVE/INSTALL BRAKE DISC - AR42.10-P-0220GZ
MODEL 164
Fig. 48: Identifying Brake Disc Components

Remove/install
Notes on repairs to brake AH42.00-P-
system 0003-01A
Notes on self-locking AH00.00-N-
nuts and bolts 0001-01A
1 Release parking brake Only if removing brake disk (3) at the rear axle.
Detach floating caliper AR42.10-P-
carrier from upright or 0070GZ

2 Remove/install floating brake caliper of front axle.
wheel carrier
AR42.10-P-
Remove/install floating brake caliper of rear axle.
0080GZ
When removing the brake disk (3) on the rear axle:
Unscrew locking bolt (2)
with run in parking brake drums first turn back the
3 and remove brake disk
parking brake adjusting mechanism, otherwise the
(3)
parking brake shoes will be damaged:
See Adjust parking brake.
Installation: Always replace the brake disks (3) in
pairs. Grease the snug fit of the brake disk (3) lightly AR42.20-P-
with MB long-life grease. 0540GZ
Replace locking bolt (2).
After installing brake disk (3) on the rear axle: ?
AR42.20-P-
Adjusting parking brake.
0540GZ
*BA42.10-P-
1001-11A
*BA42.10-P-
1001-13B
*BR00.45-Z-
Long-life grease
1001-06A
Checking
4 Check brake disk (3)
Inspect condition of AP42.10-P-
brake disks 4258GZ
Check parking brake After removing the brake disk (3) from the rear axle.
5
shoes Check lining thickness and condition, if necessary: ?
AR42.20-P-
Replace parking brake shoe.
0530GZ
6
order
FRONT AXLE BRAKE DISKS

BA42.10-P-1001-11A Locking screw, brake disk to front axle Nm 10
REAR AXLE BRAKE DISCS

BA42.10-P-1001-13B Locking bolt for rear axle brake disk Nm 10
REPAIR MATERIALS
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51
REMOVE/INSTALL STEPPED TANDEM MASTER BRAKE CYLINDER - AR42.10-P-0310GZ
MODEL 164
Fig. 49: Identifying Stepped Tandem Master Brake Cylinder Components (1 Of 2)

Fig. 50: Identifying Stepped Tandem Master Brake Cylinder Components (2 Of 2)

Remove/install
Risk of poisoning caused by swallowing Pour brake fluid only into suitable and
brake fluid. Risk of injury caused by appropriately marked containers. Wear

AS42.50-Z-
brake fluid coming into contact with skin protective clothing and eye protection
0001-01A
and eyes. when handling brake fluid.
AH42.50-P-
0001-01A
AH42.00-P-
0003-01A
Notes on externally invisible brake fluid AH42.10-P-
All models
loss 9406-02GZ
To do this, press the brake pedal
1 Reduce vacuum in BAS brake booster several times with the engine switched
off.
2
position 1000GZ
3
4 Remove bolt (2)
Detach section, left partition wall (4)
5
from the clips (3)
Detach connector of the brake fluid
6
indicator switch (5)
Before unscrewing, mark the brake
Unscrew union nuts from pressure circuit line relative to the corresponding
brake line and unscrew secondary brake connection as here is a risk of mixing
7
circuit brake line (6) from stepped up!
tandem brake master cylinder (10) Plug connections with blind plugs to
prevent brake fluid flowing out.
*BA42.10-
P-1003-04J
Unscrew nuts (7) from stepped tandem Check stepped tandem brake master
8
brake master cylinder (10) cylinder for leaks at rear primary piston.
*BA42.10-
P-1001-05H
Do not tilt stepped tandem brake
Pull stepped tandem brake master master cylinder (10), but pull out from
the front otherwise the thrust rod no
9 cylinder (10) off threaded studs and turn
to the side longer makes axial contact and can break
free of the retaining lugs at the master
control unit.
Detach connector of ESP brake pressure
10
sensor (8)
Remove stepped tandem master brake
11 cylinder (10) Installation: Replace O-ring (16).

*BA42.10-
12 Remove screw (12)
P-1003-05H
Pull brake fluid reservoir (11) out of
13 stepped tandem brake master cylinder Installation: Check reservoir plugs
(15) and replace if necessary.
(10)
*BA42.10-
14 Remove bolts (13)
P-1002-05H
15 Remove impact deflection panel (14)
Unscrew ESP brake pressure sensor *BA42.45-
16
(B34) P-1001-01J
AR42.10-P-
0010GZ
*BF42.10-
Brake fluid P-1001-01G
Checking
by itself.
clothes.
running engine
AR42.10-P-
0100-01GZ
Do not insert your hand into rotating
parts.
Risk of death caused by body parts Wear closed and snug-fitting work
AS00.00-Z-
being pulled in by rotating vehicle wheels clothes.
0019-01A
and roller dynamometer rollers Safeguard areas with rotating vehicle
parts and dynamometer rollers against
Perform a function test Safeguard roller
20
dynamometer from unauthorized access.
AP42.00-P-
4290GZ


BA42.10-P-1002-05H Bolt, impact deflection panel to master brake cylinder Nm 14

BA42.10-P-1003-05H Bolt, brake fluid reservoir to master brake cylinder Nm 4
ELECTRONIC STABILITY PROGRAM (ESP)

BA42.45-P-1001-01J Brake pressure sensor to master brake cylinder Nm 35
BRAKE FLUID
BF42.10-P-1001-01G Brake fluid Sheet BB00.40-P-0330-01A
Sheet BB00.40-P-0331-00A


REMOVING AND INSTALLING PARKING BRAKE INDICATOR SWITCH - AR42.20-P-0501GZ
MODEL 164
Fig. 53: Identifying Electrical Connector And Parking Brake Indicator Switch
Remove/Install
AR68.30-P-
1 Remove paneling in footwell
4010GZ
Press parking brake indicator switch Installation: The parking brake
3
(S12) on both sides and remove indicator switch (S12) must latch audibly.
REMOVE/INSTALL PARKING BRAKE PEDAL ASSEMBLY - AR42.20-P-0510GZ
MODEL 164
Fig. 54: Identifying Parking Brake Pedal Assembly Components - Shown On Model 164.1 (1 Of 3)
Removing
AR68.30-P-
1 Remove footwell paneling (1)
4010GZ
2 Undo bolts (5) and bolt (7) and fold cover
under instrument panel (6) with air duct (9)
downwards
Release plug (11) and detach from data link
3 connector (X11/4) and then unplug electrical
connector (10)
Thread hood release (8) out of covering under
the instrument panel (6) and remove covering
4
under the instrument panel (6) together with
the air duct (9)
Pull out release (2) and remove both bolts
5
concealed behind it
Pull out internal component of release (4)
Make sure that the parking brake
6 together with release cable (3), until the
has been released.
cable's ball head is accessible
Unhook ball head on internal component of
7 release (4), remove release (2) and internal
has been released.
component of release (4)
Detach plug (13) on parking brake indicator
8 switch (S12) and unclip securing clip (18) Make sure that the parking brake
using suitable tool has been released.
Release notch (16) using suitable tool and
9 thread notched rail (17) towards rear and out
has been released.
of the parking brake pedal assembly (12)
Undo bolt (14, 15) and remove parking brake
10
pedal assembly (12) with release cable (3)
AH00.00-N-
0001-01A
Unhook release cable (3) on parking brake
11 pedal assembly (12), unclip plastic clip and Snap-release tool Fig. 58
remove release cable (3)
Install
Clip plastic clip on release cable (3) into
parking brake pedal assembly (12) and hook
12
release cable (3) onto parking brake pedal
assembly (12)
Position parking brake pedal assembly (12) *BA42.20-P-
13
and turn in bolt (14, 15) 1001-01I
AH00.00-N-
0001-01A
Thread notched rail (17) into parking brake
14 pedal assembly (12) and allow to latch into
first notch (16)
15 Clip securing clip (18) into place
Connect plug (13) onto parking brake
16
indicator switch (S12)
Route release cable (3) behind paneling

17 upwards and hook ball head of cable in
internal component of release (4)
Fasten internal component of release (4) with
18
pulled release (2) using the two bolts
Engaging and disengaging
Engage and disengage the parking brake several times enables the cable
19
several times in succession length to be automatically adjusted
using the cable slack adjuster.
Do not insert your hand into rotating
parts.
Risk of death caused by body parts being clothes.
AS00.00-Z-
pulled in by rotating vehicle wheels and roller Safeguard areas with rotating
0019-01A
dynamometer rollers vehicle parts and dynamometer
rollers against unauthorized access.
20 Test parking brake
AP42.00-P-
4290GZ
21 Mount footwell paneling (1)
Thread hood release (8) into covering under
22 the instrument panel (6) and fasten in place
using bolt (7)
Fit plug (11) onto data link connector (X11/4)
23
and join with connector (10)
Insert covering under instrument panel (6) at
rear into corresponding fixtures, fold the Make sure that the air duct (9) is
24 correctly positioned on the matching
covering under the instrument panel (6)
piece under the steering wheel.
upwards and fasten in place using bolts (5)
PARKING BRAKE
BA42.20-P-1001-01I Bolt for pedal assembly of parking brake to A-pillar Nm 20

Fig. 58: Identifying Snap-Release Tool (129 589 11 63 00)

REMOVE/INSTALL FRONT BRAKE CONTROL CABLE - AR42.20-P-0520GZ
MODEL 164
Shown removed for better illustration
Fig. 59: Identifying Front Brake Control Cable Components Shown On Model 164.1 (1 Of 5)

Remove/install
moving parts that can AS00.00-Z-
Keep body parts and limbs well clear of moving parts.
pinch, crush or , in extreme 0009-01A
cases even sever extremities.
vehicle slipping or toppling
lifting platform support points specified by the vehicle 0010-01A
off of the lifting platform.
manufacturer.
AR68.30-P-
1 Remove door sill molding Left front. 4100GZ
Remove cover below AR68.10-P-
2 instrument panel 1500GZ

Remove paneling in AR68.30-P-
3 Left.
footwell. 4010GZ
AR68.20-P-
4 Remove center console
2000GZ
AR68.20-P-
5 Remove front floor covering
2050GZ
6 Remove retaining clips (2) Installation: Replace retaining clips.
7 Separate tie strap (3) Installation: Install new tie straps.
Beforehand secure vehicle to prevent it rolling
away.
Remove securing clip (5)
When the parking brake is released the cable
and withdraw front brake
9 element (6) should be free to move and can easily be
cable (1) out of pedal
pulled out downwards from the pedal assembly.
assembly (4)
If the cable element (6) jams, once again ensure
that the parking brake is released. Should the cable
element (6) not be free to move despite the released
parking brake, then the drive plate (7) is to be pressed
away from the cable element (6) using a suitable
screwdriver in order to loosen the teeth.
Push sound deadening mat
10 (8) to one side and remove Installation: Replace retaining clip.
retaining clip (9)
Fold down the rear seats on
11.1 the left and right and remove Model 164.1.
the cover under the rear seats
Model 164.8.
Remove the rear seat on the Removal is necessary in order to loosen the fixing
of the front brake cable (1). AR91.12-P-
11.2 left and remove the cover
Installation: Pay attention to correct routing of the 1000GYA
under the rear seat
front brake cable (1) in the area under the rear seat on
the left.
Fold down the rear seat on
12 the right and place floor Model 164.8
covering to one side
13 Remove retaining clip (10) Installation: Replace retaining clip.
Cut a suitable cable with sufficient cross section to
Prepare the pull-in cable and
a length of approx. 3 m. Fasten the pull-in cable on the
14 connect to the front brake
cable element of the front brake cable and wrap using
cable (1)
insulation tape onto attachment point.
Raise vehicle using two-post AR00.60-P-
15 Raise the vehicle entirely off the ground.
lift 1000GZ
*WE58.40-
Two-post lift Z-1001-05A

Remove (unhook) clip (15)
from the connection piece
16 (16) and detach the outer
brake cable (17, 18) from the
front brake cable (1)
Remove guide tube of front
17 brake cable (13) from clip
over the rear axle carrier
AR00.60-P-
18 Lower vehicle Half the height. 1000GZ
*WE58.40-
Two-post lift
Z-1001-05A
Loosen rubber grommet (12) from the body and
pull out the front brake cable carefully to the rear.
When doing so have an assistant route the front brake
cable and pull-in cable along the transmission tunnel
through the duct (11) and through the rear seat
bracket. Do not damage the outer sleeve of the front
brake cable by pulling it over sharp-edged
components!
The end of the pull-in cable must remain in the
footwell on the driver-side!
Installation: Fasten the pull-in cable on the cable
element (6) of the front brake cable and wrap using
Remove front brake cable insulation tape onto attachment point. Have someone
19
(1) to rear and out of vehicle assist you to pull-in the front brake cable. Carefully
insert the front brake cable with the aid of the pull-in
cable. Do not damage the outer sleeve of the front
brake cable by pulling it over sharp-edged
components!
When pulling in the front brake cable proceed in two
steps:
Step one:
Pull-in the front brake cable in full length into the rear
footwell and then insert the rubber grommet (12).
Step two:
Route the front brake cable along the transmission
tunnel and then place into its final installation
position.
Checking
Engage and disengage
parking brake pedal several *BE42.20-
21
times, then check the pedal P-1001-01F
travel (number of notches)
of the parking brake pedal

If the pedal travel is not within the tolerance
range: ?
AR42.20-P-
Adjust parking brake
0540GZ
ADJUSTMENT VALUES FOR PARKING BRAKE

164
BE42.20-P- Number of notches at which the parking brake must be adjusted if up to that
7
1001-01F point there is insufficient braking effect
WORKSHOP EQUIPMENT
WE58.40-Z-1001-05A Two-post lifting platform
REMOVE/INSTALL REAR BRAKE CONTROL CABLE - AR42.20-P-0525GZ
MODEL 164
Fig. 64: Identifying Rear Brake Control Cable Components (1 Of 2)

Fig. 65: Identifying Rear Brake Control Cable Components (2 Of 2)

Remove/install
Risk of death caused by Align vehicle between the columns of the lifting
vehicle slipping or platform and position the four support plates at the AS00.00-Z-
toppling off of the lifting lifting platform support points specified by the vehicle 0010-01A
platform. manufacturer.
All models
system 0003-01A
Notes on self-locking nuts AH00.00-N-
All models
and bolts 0001-01A
AR00.60-P-
1000GZ
3 Remove rear wheels.
Remove/install wheels, AP40.10-P-
rotate if necessary 4050Z
Remove left brake disk or
AR42.10-P-
4 right brake disk from rear
0220GZ
axle
Unhook retracting spring
5 (3) using removal and Removal and installation tool Fig. 66
installation tool
To do so, open the expanding lock (1) and push out
Remove expanding lock of the rear brake cable (4).
6
(1) Installation: Grease slide surfaces on expanding
lock (1) lightly with MB long-life grease.
*BR00.45-
Long-life grease
Z-1001-06A
Unclip rear brake cable (4)
7 from wheel carrier
(arrows)
Unclip clip (6) from
8
connecting piece (7)
Unclip rear brake cable (4)
9
from connecting piece (7)
10 Unclip guide (8) To unclip, squeeze the lock tabs on the guide (8)
together.
Squeeze retaining ring (9)
together and unclip from
11
bracket together with cable
sheathing (5)
Installation: The distance from the plastic holder
Open plastic holder (10) (10) to the outer tie rod end must be 76 mm and the
and remove rear brake cable sheathing (5) must not rub against the plastic
12
cable (4) together with holder (10) when the brake is in its released state,
cable sheathing (5) otherwise the plastic holder (10) could open by itself
when the brake is applied or released.
AR42.20-P-
14 Adjust parking brake
0540GZ
Fig. 66: Identifying Removal And Installation Tool (116 589 01 62 00)
REPAIR MATERIALS
REMOVE/INSTALL BRAKE SHOES OF PARKING BRAKE - AR42.20-P-0530GZ
MODEL 164
Shown on model 164.1, left side
Fig. 67: Identifying Brake Shoes Of Parking Brake Components - Shown On Model 164.1
Remove/install
AH42.00-P-
0003-01A
Risk of death caused by vehicle Align vehicle between columns of vehicle lift
AS00.00-Z-
slipping or toppling off of the and position four support plates at vehicle lift
0010-01A
lifting platform. support points specified by vehicle manufacturer.
AR00.60-P-
1000GZ
3 Remove rear wheels
necessary 4050Z
AR42.10-P-
4 Remove brake disks on rear axle
0220GZ
Unhook retracting spring (6)
5 using removal and installation Removal and installation tool Fig. 66
tool
Compress retaining springs (7) and turn 90° to
6 Remove retaining springs (7).
the left or right.
If the brake shoes (1) are burnt or the brake
Remove brake shoes (1) with
disk surfaces are damaged, the brake shoes (1),
7 adjusting mechanism (5) and
retracting spring (2, 6), retaining springs (7) and
retracting spring (2)
brake disks should be replaced.
Installation: Grease thread of thrust piece (4)

and inner cylinder of adjusting mechanism (5)
lightly with MB-long-life grease. Turn back
Remove retracting spring (2) and adjusting mechanism (5) and mount thrust piece
8
adjusting mechanism (5) (4) as follows.
Left side: Left thrust piece to lower brake shoes.
Right side: Right thrust piece to upper brake
shoes.
*BR00.45-
Long-life grease
Z-1001-06A
For this purpose, fold down expansion lock
(8) and press out of the rear parking brake cable.
9 Remove expansion lock (8) Installation: Grease slide surfaces on
expansion lock (8) lightly with MB long-life
grease.
*BR00.45-
Long-life grease
Z-1001-06A
Checking
Check parking-brake brake Check for ease of movement and chafing
10
cables marks, replace if necessary.
AR42.20-P-
12 Adjust parking brake
0540GZ
13 Bed in the parking brake brakes
Bed in parking brake according AP42.20-P-
to instructions. 4290-01BA
Risk of death caused by body Wear closed and snug-fitting work clothes.
parts being pulled in by rotating Safeguard areas with rotating vehicle parts and AS00.00-Z-
vehicle wheels and roller dynamometer rollers against unauthorized access. 0019-01A
dynamometer rollers Safeguard roller dynamometer from unauthorized
access.
Carry out brake test on the test
14
stand
AP42.00-P-
4290GZ
Fig. 68: Identifying Removal And Installation Tool (116 589 01 62 00)
REPAIR MATERIALS
ADJUST PARKING BRAKE - AR42.20-P-0540GZ
MODEL 164
Fig. 69: Identifying Brake Disk, Rubber Insert, Thumbwheel And Brake Shoes
MODIFICATION NOTES
Number of notches at which the parking brake must be adjusted if up Model *BE42.20-P-
12.4.06
to that point there is insufficient braking effect 164 1001-01F
Removing
lifting platform.
manufacturer.
AH42.00-P-
0003-01A
AR00.60-P-
1000GZ
3 Remove rear wheels
necessary. 4050Z
Adjust
4 Remove rubber insert (2)
Turn the adjusting wheel (3) by means of a
screw driver until the brake shoes (4) contact
the brake drum and the brake disk (1) cannot
Bring brake shoes (4) into contact
5 be turned by hand anymore.
with parking brake drum
Positioning direction for applying the brake
shoes (4): Turn both adjustment wheels from
above downwards.
Loosen left and right adjustment wheel by
the same number of teeth. It must be possible
6 Detach adjustment wheel (3)
to rotate the rear wheel or brake disk (1)
completely freely by hand.
Checking
Operate the parking brake lever Number of notches by which the parking brake
*BE42.20-P-
7 several times and check the travel has to be adjusted, if until then there is no
1001-01F
of the parking brake lever adequate braking effect
Release parking brake and check
8 unobstructed movement of rear
wheels or brake disks
Install
9 Fit rear wheels
necessary 4050Z
Risk of death caused by body parts
Safeguard areas with rotating vehicle parts and
being pulled in by rotating vehicle AS00.00-Z-
dynamometer rollers against unauthorized
wheels and roller dynamometer 0019-01A
access.
rollers
Carry out brake test on the test
10
stand
AP42.00-P-
4290GZ
ADJUSTMENT VALUES FOR PARKING BRAKE

164
BE42.20-P- Number of notches at which the parking brake must be adjusted if up to that
7
1001-01F point there is insufficient braking effect
REMOVE/INSTALL LEFT FRONT OR RIGHT RPM SENSOR - AR42.30-P-0712GZ
MODEL 164
Shown on right side of vehicle.
Fig. 70: Identifying Left/Right Front RPM Sensor And Electrical Connectors
Remove/install
Information on preventing damage
AH54.00-P-
to electronic components due to All models
0001-01A
Turn steering to the side where the
1
repair is to be performed
Switch off ignition and remove the On vehicles with Keyless Go, code 889:
2 transmitter key from the EIS Press Keyless Go start/stop button repeatedly
[EZS] control unit until ignition is switched off.
store it in a location beyond its transmission

lifting platform.
AR00.60-P-
1000GZ
Remove front section of fender
liner in left front fender or front AR88.10-P-
4
section of fender liner in right 1310GZ
front fender
Remove bolt (1) and pull left front
rpm sensor (L6/1) or right front
5 Installation: Replace bolt (1).
rpm sensor (L6/2) out of steering
knuckle
*BA42.30-P-
1001-01G
6
(3) at body socket
7 Disconnect electrical connectors carefully.
(3) from each other (arrows B)
Remove rpm sensor line (2) on the Installation: Make sure that lines for rpm
8 left or right side of the vehicle sensors are routed correctly. Route rpm
from the brackets (arrows A) sensor lines without crossing over.
10 Read out fault memory and erase
*WH58.30-Z-
1048-13A
FRONT AXLE RPM SENSOR

BA42.30-P-1001-01G Self-locking bolt, front axle rpm sensor to steering knuckle Nm 8

Number Designation
REMOVE/INSTALL BAS DIAPHRAGM TRAVEL SENSOR - AR42.31-P-6002GZ
MODEL 164
Fig. 71: Identifying BAS Diaphragm Travel Sensor Components - Shown On Model 164.1
Remove/install
The sealing ring of the membrane travel
sensor can be drawn into the brake booster
under vacuum.
1 Reduce vacuum in brake booster If this is the case, new brake booster must
be fitted.
Reduce vacuum by depressing the brake
pedal several times.
2
Detach rubber seal (1) at left
3
partition wall section (4)
4 Remove bolt (2)
Unclip section of the left partition
5
wall (4) at the clips (3)
Unlock and disconnect diaphragm
6
travel sensor connector (5)
Use a suitable tool, e.g. angled scriber

(arrow A).
7 In order to prevent permanent set of
spring lock washer (7), lift spring lock
Raise lock washer (7) and pull BAS washer (7) by max. 10 mm.
diaphragm travel sensor (6) out of Installation: Apply liquid lubricant to
the brake booster (arrow B) front of BAS diaphragm travel sensor (6).
Installation: Install new O-ring (8).
Installation: Check to make sure that
spring lock washer (7) engages correctly in
groove of BAS diaphragm travel sensor (6)
and BAS brake booster.
*BR00.45-Z-
Lubricant
1002-06A
*WH58.30-Z-
9 Read out fault memory STAR DIAGNOSIS diagnosis system
1048-13A
Risk of death caused by body parts
Safeguard areas with rotating vehicle parts
being pulled in by rotating vehicle AS00.00-Z-
and dynamometer rollers against
wheels and roller dynamometer 0019-01A
rollers
AP42.00-P-
4290GZ

Number Designation
REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
REMOVE/INSTALL LEFT OR RIGHT REAR AXLE SPEED SENSOR - AR42.40-P-0820GZ
MODEL 164
Fig. 72: Identifying Left/Right Rear Axle Speed Sensor Components

Remove/install
AH54.00-P-
0001-01A
position "0".
lifting platform.
AR00.60-P-
2 Raise vehicle
1000GZ
Remove left rear wheel or right
3
rear wheel
necessary 4050Z
4 Remove bolt (3) Installation: Replace bolt (3).
*BA42.30-P-
1001-02G
Pull the left rear rpm sensor
5 (L6/3) or right rear rpm sensor
(L6/4) out of the wheel carrier
Unclip line from the left rear
rpm sensor or line from right Installation: Pay attention to correct routing
6
rear rpm sensor from the of the line.
brackets (1)
7
(2)

*WH58.30-Z-
9 Read out fault memory and erase STAR DIAGNOSIS diagnosis system
1048-13A
REAR AXLE RPM SENSOR

BA42.30-P-1001-02G Self-locking bolt of rear axle rpm sensor to wheel carrier Nm 8

Number Designation
REMOVE/INSTALL ESP BRAKE PRESSURE SENSOR - AR42.45-P-0816GZ
MODEL 164
Fig. 73: Identifying ESP Brake Pressure Sensor Components - Shown On Model 164.1
Remove/install
Pour brake fluid only into suitable
Risk of poisoning caused by swallowing and appropriately marked
AS42.50-Z-
brake fluid. Risk of injury caused by brake containers. Wear protective
0001-01A
fluid coming into contact with skin and eyes. clothing and eye protection when
handling brake fluid.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
0003-01A
1 Turn key in ignition switch to position "0". code 889: Press keyless go

2
position 1000GZ
3
4 Remove bolt (2)
Detach section, left partition wall (4) from the
5
clips (3)
Suction off brake fluid from brake fluid
6
reservoir (5)
Disconnect electrical connector (6) from ESP
7
brake pressure sensor (B34)
Collect brake fluid which runs
Detach ESP brake pressure sensor (B34) from
8 out with an absorbent rag or in a
tandem master brake cylinder (7)
suitably marked container.
*BA42.45-P-
1001-01J
AR42.10-P-
0010GZ
*BF42.10-P-
Brake fluid 1001-01G
Check the fluid level in the brake fluid
11
reservoir (5) and correct if necessary
AP42.10-P-
Brake system - inspect fluid level
4210GZ
12 Read out fault memory
system Z-1048-13A
Checking
AS00.00-Z-
0005-01A
AR42.10-P-
0100-01GZ

BRAKE FLUID

Sheet
BF42.10-P-1001-01G Brake fluid BB00.40-P-0330-01A
Sheet
BB00.40-P-0331-00A

Number Designation
REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP) HYDRAULIC UNIT - AR42.45-

P-0817GZ
MODEL 164
Fig. 74: Identifying Electronic Stability Program (ESP) Hydraulic Unit Components (1 Of 2)
Fig. 75: Identifying Electronic Stability Program (ESP) Hydraulic Unit Components (2 Of 2)
Remove/install
Risk of poisoning caused by Pour brake fluid only into suitable and
caused by brake fluid coming into protective clothing and eye protection when 0001-01A
contact with skin and eyes. handling brake fluid.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
0003-01A
"0".
2
position 1000GZ
3 Pull off intake air duct (1)
Before opening the brake system, clean
the area around the separation point
Clean ESP hydraulic unit (2) at line thoroughly. Even the smallest dirt particles,
4
connections introduced into the hydraulic components,
can lead to malfunctions and a total failure
of the hydraulic system
Before detaching, mark brake lines
relative to corresponding line connection;
Unscrew union nuts of pressure circuit when doing so, observe markings on ESP
and secondary brake circuit (3) and hydraulic unit (2). Trace line routing to the
5
union nuts of brake lines (4) from the corresponding wheel.
ESP hydraulic unit (2) Collect any brake fluid which runs out in
a fluff-free, absorbent cloth. Seal brake
lines and line connections on ESP hydraulic
unit (2) immediately with stop plugs in

order to prevent ingress of foreign bodies.
Installation: Do not mix up brake lines;
pay attention to markings.
*BA42.45-
P-1002-01J
Unlock ESP control unit connector (5)
6 and disconnect from ESP control unit
(N47-5)
Flush off brake fluid which runs out in
the area of the longitudinal frame member
Pull ESP hydraulic unit (2) with ESP
with water in order to avoid paint damage.
7 hydraulic unit bracket (6) out of rubber
supports (8) Installation: Coat rubber supports (8)
with liquid lubricant to allow easier
installation.
*BR00.45-
Lubricant
Z-1002-06A
Detach ESP hydraulic unit bracket (6)
*BA42.45-
8 from ESP hydraulic unit (2); to do so,
P-1003-01J
remove bolts (7)
Torx bit set Fig. 79
Detach ESP control unit (N47-5) from
9 ESP hydraulic unit (2); to do so, remove Torx bit set Fig. 79
bolts (9)
AR42.10-P-
0010GZ
Checking
starting off by itself when engine is Secure vehicle to prevent it from moving
running. Risk of injury caused by by itself. AS00.00-Z-
procedure or when working near the Do not grasp hot or rotating parts.
running engine
AR42.10-P-
0100-01GZ

BA42.45-P-1002-01J Union nut, brake line to ESP hydraulic unit Nm 18
BA42.45-P-1003-01J Bolt, ESP hydraulic unit to bracket Nm 8
REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricant A 000 989 01 60



Fig. 79: Identifying Torx Bit Set (000 589 01 10 00)

REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP) CONTROL UNIT - AR42.45-P-

0820GZ
MODEL 164
Fig. 80: Identifying ESP Control Unit, Electrical Connector And Bolts
MODIFICATION NOTES
Remove/install
Notes on avoiding damage to electronic components due to All AH54.00-P-0001-

electrostatic discharge models 01A
AR88.40-P-
1 Open engine hood
1000GZ
Unlock and disconnect electrical connector (1) from ESP control
2
unit (N47-5)
3 Unscrew bolt (2)
4 Pull ESP control unit (N47-5) forwards off hydraulic unit

REMOVE/INSTALL YAW RATE AND LATERAL ACCELERATION SENSOR - AR42.45-P-0841GZ
MODEL 164
Fig. 81: Identifying Yaw Rate And Lateral Acceleration Sensor Components (1 Of 2)
Fig. 82: Identifying Yaw Rate And Lateral Acceleration Sensor Components (2 Of 2)
MODIFICATION NOTES
7.8.06 Carry out road test as per STAR DIAGNOSIS Step 8
Remove/install
AH54.00-P-
0001-01A
Keyless Go start/stop button repeatedly until
1
from the EIS [EZS] control ignition is switched off. Remove transmitter key
from vehicle and store it in a location beyond its
unit
Remove right front floor AR68.20-P-
2
covering 2070GZ
3 Remove vapor barrier (1)
Unscrew nuts (2) and remove
4
right intermediate bottom (3)
5
connector (4)
Unscrew nuts (5) and remove
6 micromechanical yaw rate
sensor AY pickup (B24/15)
Carry out road test as per Only when the yaw rate, lateral and longitudinal
8
STAR DIAGNOSIS acceleration sensor (B24/15) has been replaced.
and read out fault memory 2000-04AK
*WH58.30-
Z-1048-13A

Number Designation
REMOVE, INSTALL BRAKE LINE FROM STEPPED TANDEM BRAKE MASTER CYLINDER TO
HYDRAULIC UNIT - AR42.50-P-0002GZ
MODEL 164
Fig. 83: Identifying Brake Line From Stepped Tandem Brake Master Cylinder To Hydraulic Unit
Components
Remove/install
Risk of poisoning caused by swallowing Pour brake fluid only into suitable and
brake fluid. Risk of injury caused by appropriately marked containers. Wear AS42.50-Z-
brake fluid coming into contact with skin protective clothing and eye protection 0001-01A
and eyes. when handling brake fluid.
AH42.50-P-
0001-01A
Notes on externally invisible brake fluid AH42.10-P-
Model 164
loss 9406-02GZ
AH42.00-P-
0003-01A
1
position 1000GZ
Unscrew union nuts from pressure circuit
brake line and secondary brake circuit
2 relation to the appropriate connection.
brake line (1) from tandem master brake
cylinder (2) Plug connections with blind plugs to
prevent brake fluid flowing out.
*BA42.10-P-
1003-04J
Unclip pressure circuit brake line and
3 Clips (3, 4).
secondary brake circuit brake line (7)

relation to the appropriate connection.
Unscrew union nuts from pressure circuit Plug brake line and connections with
4 brake line and secondary brake circuit blind plugs to prevent brake fluid flowing
brake line (5) from hydraulic unit (6) out.
Installation: When screwing on the
brake lines, observe markings applied.
Do not mix up brake lines.
*BA42.45-P-
1002-01J
Remove pressure circuit brake line and
5 Risk of confusion! Label brake lines.
secondary brake circuit brake line (7)
AR42.10-P-
0010GZ




MAINTENANCE
REPLACE BRAKE FLUID - AP42.00-P-4280GZ
MODEL 164.1 /8
Fig. 86: Identifying Brake Fluid Reservoir And Cap

Figure Work instructions

item,
etc.
Risk of death caused by Align vehicle between columns of vehicle lift and
AS00.00-Z-
vehicle slipping or toppling position four support plates at vehicle lift support
0010-01A
off of the lifting platform. points specified by vehicle manufacturer.
fingers being pinched or Keep body parts and limbs well clear of moving AS00.00-Z-
crushed when removing, parts. 0011-01A
installing or aligning hoods,
doors, trunk lids, tailgates

or sliding roof.
by swallowing brake fluid. Only pour brake fluid into suitable and appropriately
AS42.50-Z-
Risk of injury caused by marked containers. Wear protective clothing and eye
0001-01A
brake fluid coming into protection when handling brake fluid.
contact with skin and eyes.
AH42.50-P-
Brake fluid notes
0001-01A
system 0003-01A
Open engine hood and raise
1
to vertical position
Opening engine hood,
AR88.40-P-
moving to upright position
1000GZ
and closing
Unscrew cap (11) from
2
brake fluid reservoir (10)
Pump brake fluid out of the
3
Pour in new brake fluid up
*BF42.10-
4 to the "MAX" mark on the Brake fluid P-1001-01G
Follow the operating instructions for the brake
Connect brake fluid
5 fluid changing unit.
changing unit to brake fluid
reservoir (10) Brake fluid changing equipment, see GOTIS
Raise vehicle with lifting
6
platform
AR00.60-P-
1000GZ
Replace
The new brake fluid must escape via the bleed
7 Replace brake fluid
hose free of bubbles.
AR42.10-P-
Bleed brake system
0010GZ
Front axle:
*BA42.10-
Bleed screw to brake caliper P-1001-10L
Rear axle
*BA42.10-
Bleed screw to brake caliper P-1001-10L
8 Lower vehicle
Lift/jack up vehicle AR00.60-P-
1000GZ
Detach brake fluid changing
Brake fluid changing equipment, see GOTIS
9 unit from brake fluid
reservoir (10)
Correct fluid level in brake *BF42.10-
10 Brake fluid
fluid reservoir (10) P-1001-01G
Screw cap (11) onto brake
11
fluid reservoir (10)
AR88.40-P-
moving to upright position
1000GZ
and closing


BRAKE FLUID
Filling capacity Liters approx. 0,8
Sheet
Sheet
BB00.40-P-0331-00A
BRAKE TESTING ON TEST STAND - AP42.00-P-4290GZ
MODEL 164
MODIFICATION NOTES
"Turn ignition key to position 1" and "Brake test per axle must not last longer than 10 Step
2.5.06
seconds" note added 1
Checking
Risk of death caused by Do not insert your hand into rotating parts.
Wear closed and snug-fitting work clothes. AS00.00-
body parts being pulled in by
Safeguard areas with rotating vehicle parts and Z-0019-
rotating vehicle wheels and
dynamometer rollers against unauthorized access. 01A
roller dynamometer rollers
Safeguard roller dynamometer from unauthorized
access.
Turn ignition key to position 1.
Brake test on each axle must not last longer than
Drive the vehicle onto the approx. 10 seconds, otherwise the drive train or brake
brake test stand and measure system could be damaged.
1 and note deceleration values Permissible deviation from the higher value:
of the service brake on the maximum 25 %.
front and rear axles If the braking effect is uneven or inadequate, establish
and rectify the cause subject to a separate repair
order:
?
AP42.10-P-
Checking brake lining thickness.
4253A
Operate parking brake Permissible deviation from the higher value:
handlever and measure maximum 50 %.
2
deceleration values of If the braking effect is uneven or inadequate:
parking brake ?
AP42.20-
Bed in parking brake as per specifications, where
P-4290-
required:
01BA
Adjusting parking brake.
If the braking effect is uneven or inadequate,
establish and rectify the cause subject to a separate
AR42.20-
repair order: Check parking brake cables for ease of P-0540GZ
movement and damage, if necessary check the
condition of the parking brake shoes, expansion
locks, parking brake drums of the brake disks: ?
AR42.10-
Remove/install brake disc.
P-0220GZ
Drive vehicle off the brake
3
test stand
BRAKE SYSTEM - INSPECT FLUID LEVEL - AP42.10-P-4210GZ
MODEL 164
Fig. 87: Identifying Brake Fluid Expansion Reservoir

Checking
swallowing brake fluid. Risk of appropriately marked containers. Wear AS42.50-Z-
injury caused by brake fluid coming protective clothing and eye protection 0001-01A
into contact with skin and eyes when handling brake fluid.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
0003-01A
Open engine hood and raise to vertical
1
position
Opening engine hood, moving to AR88.40-P-
upright position and closing 1000GZ
The fluid level must lie between the
"MIN" and "MAX" markings stamped in
Check fluid level in expansion the expansion reservoir (1).
2
reservoir (1) If the fluid level is too low, determine
and rectify the cause subject to a separate
repair order ?
AP42.10-P-
Checking brake lining thickness.
4253A
AR42.10-P-
Check brake system for leaks.
0100-01GZ
*BF42.10-P-
Brake fluid 1001-01G
3 Close engine hood
Opening engine hood, moving to AR88.40-P-
upright position and closing 1000GZ
BRAKE FLUID
Filling capacity Liters approx. 0,8
Sheet
Sheet
BB00.40-P-0331-00A
MEASURE THICKNESS OF THE BRAKE PADS - AP42.10-P-4253-01GZ

Fig. 88: Identifying Brake Pad Check Gauge (211 589 06 23 00)
Fig. 89: Identifying Gauge Adapter (164 589 10 23 00)

Measurement possible at the front axle with floating caliper brake system on
 model 164, 169, 203, 204, 209, 245, 251
Measurement possible at the rear axle with floating caliper brake system on
 Model 164, 204, 216, 221, 230, 251
Where possible measurement to be at front axle with 6-piston and rear axle with 4-piston fixed-caliper
brake system on
 Model 204, 209, 230
1. Position slide (1) on the drive plate (2).
Before each measurement position the slide (1) on the drive plate (2) in order to avoid measurement
errors!
Fig. 90: Identifying Brake Pad Gauge, Brake Lining Wear Symbol And Bracket
Measurement on front axle without gauge adapter (011) on model 169, 204, 245
2. Insert measuring drift (3) in the test bore of the brake lining carrier at the outer brake pad (4).
3. Position the brake pad check gauge (010) on the brake lining carrier so that red ring (5) lies on flat.
4. Remove the brake pad check gauge (010) and read off the measured value on the slide (1).
Read off the value on the scale provided with the brake lining wear symbol (A) otherwise a false value
will be determined!
Fig. 91: Measuring Brake Pads Thickness

Measurement on front axle without gauge adapter (011)
Measurement on front axle without gauge adapter (011) On model 203, 209 as well as model 204, 230
with 6-pistonfixed brake calipers and measurement at the rear axle on vehicles with 4-piston-fixed brake
calipers
2 Position brake pad check gauge (010) on outer brake pad (4) as shown.
3 Press brake pad check gauge (010) towards the brake pad (4) until as large a part as possible of the
of the red ring (5) lies on flat.
In the process the brake pad check gauge (010) must be at right angles to the friction surface of the
brake disk.
4 Remove the brake pad check gauge (010) and read off the measured value on the slide (1).
will be determined!

Measurement on front axle with gauge adapter (011) on model 164, 251
2 Pull check gauge adapter (011) out of the bracket (012) and connect up to the end stop on the
measuring drift (3).
3 Mount the tip of the check gauge adapter (011) on the friction surface of the brake disk.
4 Position brake pad check gauge (010) on the floating brake caliper (6) as shown so that as large a
part of the red ring (5) lies on flat.
In the process the brake pad check gauge (010) must be at right angles to the friction surface of the
brake disk.
will be determined!

Measurement on rear axle without gauge adapter (011) on model 164, 204, 216, 221, 230, 251 except
vehicles with 4-piston fixed-caliper brake system
2 Insert measuring drift (3) in the test bore of the brake lining carrier at the outer brake pad (4).
3 Position the brake pad check gauge (010) on the brake lining carrier so that red ring (5) lies on flat.
will be determined!

BED IN PARKING BRAKE ACCORDING TO INSTRUCTIONS. - AP42.20-P-4290-01BA
When the parking brake is operated the catch of the pedal or handlever must not lock in position
1. Driving on dry road, initial speed approx. 50 km/h.
Operate the pedal or parking brake handlever 2 to 3 times with 100 to 200 N and brake the vehicle to a
standstill.
Since the brake lamps do not light up, particular attention must be paid to following traffic!
2. Driving on dry road at a constant speed of approx. 50 km/h. Actuate the parking brake pedal or handlever
with a force of max. 100 N for 10 seconds.
3. Drive on the dynamometer or function test stand at a constant speed of 50 km/h (3rd gear).
Actuate the parking brake pedal or handlever with a force of 100 N for 10 seconds. The specified force
must not be exceeded.
4. On the brake test stand operate the pedal or parking brake handlever for approx. 2 minutes with a constant
force of 150 to 200 N.
Do not lock the parking brake pedal or handlever!
When bedding in the brakes, heat causes the brake disc bowl to expand, reducing the operating forces.
The bedding-in procedure can be repeated when the parking brake has cooled.
5. If the parking brake does not release satisfactorily after the test, or pulls to one side after bedding in the
brakes and adjusting (maximum permissible deviation from higher value: 50%), check brake shoes and
brake cables and replace if necessary.
The German specifications specify a minimum retardation of 20% for the parking brake.
The retardation is the ratio of the sum of the braking forces at the wheels to the gross weight.
A maximum deviation of 50% from the higher value is permissible. The regulations for other countries
should be observed in each case.
TIGHTENING TORQUES: PASSENGER CARS: BRAKES - HYDRAULIC AND MECHANICAL
SYSTEMS - BA42.00-Z-9999AZ
MODEL all
Rear axle fixed MODEL 124, 129, 140, 163, 170, 171, 199, 202, 203, 208, 209, 210, BA42.10-P-
caliper 211, 215, 219, 220, 230, 240... 1000-01A
Rear axle fixed MODEL 216, 221 BA42.10-P-
caliper 1000-01B
Front axle fixed MODEL 129, 140, 163, 171, 199, 202, 203, 208, 209, 210, 215, 220, BA42.10-P-
brake caliper 230, 240... 1000-02A
Front axle fixed MODEL 211... BA42.10-P-
brake caliper 1000-02C
Front axle fixed MODEL 219.322 /356 /357 /375 /372 /376 /377 BA42.10-P-
brake caliper 1000-02D
Front axle fixed MODEL 216, 221 BA42.10-P-
brake caliper 1000-02E
Front axle MODEL 124, 163, 170, 171, 202, 203, 208, 209, 210, 211... BA42.10-P-
floating caliper 1000-03A
Front axle MODEL BA42.10-P-
floating caliper 168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-03B
414
Front axle MODEL 220.083 /084 /087 /183 /184 /187 BA42.10-P-
floating caliper 1000-03D
Front axle MODEL 169, 245 BA42.10-P-
floating caliper 1000-03E
Front axle MODEL 164 BA42.10-P-
floating caliper 1000-03F
floating caliper 1000-03H
Front axle MODEL 216, 221 BA42.10-P-
floating caliper 1000-03I

floating caliper 1000-03J
Brake lines, MODEL 129, 140, 163, 170, 171, 202, 203, 208, 209, 210, 211, 215, BA42.10-P-
brake hoses 220, 230, 240... 1000-04A
Brake lines, MODEL BA42.10-P-
brake hoses 168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-04C
414
Brake lines, MODEL 199 BA42.10-P-
brake hoses 1000-04F
Brake lines, MODEL 169, 245 BA42.10-P-
brake hoses 1000-04H
brake hoses 1000-04I
Brake lines, MODEL 164.1 /8 BA42.10-P-
brake hoses 1000-04J
Brake lines, MODEL 216, 221 BA42.10-P-
brake hoses 1000-04K
brake hoses 1000-04L
Master brake MODEL 129, 140, 163, 170, 171, 202, 203, 208, 209, 210, 215, 220 BA42.10-P-
cylinder 1000-05A
Master brake MODEL BA42.10-P-
cylinder 168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-05C
414
Master brake MODEL 199.376 BA42.10-P-
cylinder 1000-05F
Master brake MODEL 169, 245 BA42.10-P-
cylinder 1000-05G
Master brake MODEL 164.1 /8 BA42.10-P-
cylinder 1000-05H
Master brake MODEL 251 BA42.10-P-
cylinder 1000-05I
Master brake MODEL 216, 221 MODEL 211, 219 ABR BA42.10-P-
cylinder 1000-05J
Master brake MODEL 204 BA42.10-P-
cylinder 1000-05K
Brake disks, MODEL 129, 140, 163, 170, 171, 199, 202, 203, 208, 209, 210, 211, BA42.10-P-
brake caliper 215, 220, 230, 240... 1000-06A
dust shield
Brake disks, MODEL BA42.10-P-
brake caliper 168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-06C
dust shield 414
Brake disks, MODEL 169, 245 BA42.10-P-
brake dust 1000-06E

shield
Brake disks, MODEL 219 BA42.10-P-
brake caliper 1000-06F
dust shield
Brake disks, MODEL 216, 221 BA42.10-P-
brake cover 1000-06G
plate
Brake disks, MODEL 204 BA42.10-P-
brake cover 1000-06H
plate
Brake carrier MODEL WDB168.032, 9BM168.032, BA42.10-P-
168.006 /007 /008 /009 /031 /033 /035 /109 /131 /132 /133 /135, 414 1000-07A
Brake cylinder MODEL 168.006 /007 /008 /009 /031, 9BM168.032, 168.033 /131 BA42.10-P-
1000-08B
Brake cylinder MODEL 169.0 BA42.10-P-
1000-08D
Front axle MODEL 164.1 /8 BA42.10-P-
brake disks 1000-11A
Rear axle brake MODEL 168.032 /035 /109 /132 /133 /135, 414 BA42.10-P-
disks 1000-13A
Rear axle brake MODEL 164.1 /8 BA42.10-P-
disks 1000-13B
Rear axle brake MODEL 251 BA42.10-P-
disks 1000-13C
brake hoses 1000-14A
Drum brake MODEL 168.006 /007 /008 /009 /031 /033 /131 BA42.10-P-
1000-16B
Rear axle MODEL 163, 230... BA42.10-P-
floating caliper 1000-17A
Rear axle MODEL WDB168.032, 168.035 /109 /132 /133 /135, 414 BA42.10-P-
floating caliper 1000-17C
Rear axle MODEL 211 (except 211.076 /276 /077 /277) BA42.10-P-
floating caliper 1000-17D
Rear axle MODEL 220... BA42.10-P-
floating caliper 1000-17E
Rear axle MODEL 169, 245 BA42.10-P-
floating caliper 1000-17G
Rear axle MODEL 219.322 /356 /357 /372 /375 BA42.10-P-
floating caliper 1000-17H
Rear axle MODEL 164.1 /8 BA42.10-P-
floating caliper 1000-17I
Rear axle MODEL 251 BA42.10-P-
floating caliper 1000-17J

Rear axle MODEL 216, 221 BA42.10-P-
floating caliper 1000-17K
Rear axle MODEL 204 BA42.10-P-
floating caliper 1000-17L
Supporting MODEL 163 BA42.10-P-
plate 1000-18A
Cooling duct MODEL 199.376 BA42.10-P-
1000-20A
Parking brake MODEL 129, 140, 163, 170, 171, 202, 203, 208, 209, 210, 211, 215, BA42.20-P-
220, 230, 240 1000-01A
Parking brake MODEL BA42.20-P-
168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-01C
414
Parking brake MODEL 199 BA42.20-P-
1000-01F
1000-01G
1000-01H
Parking brake MODEL 164.1 /8 BA42.20-P-
1000-01I
1000-01J
Parking brake MODEL 216, 221 BA42.20-P-
1000-01K
1000-01L
Front wheel MODEL 129, 140, 163, 170, 171, 199, 202, 203, 208, 209, 210, 211, BA42.30-P-
speed sensor 215, 220, 230, 240 1000-01A
Front axle rpm MODEL 168.006 /007 /008 /009 /031 /032 /033 /109 /131 /132 /133, BA42.30-P-
sensor 414 1000-01C
Front axle rpm MODEL 169, 245 BA42.30-P-
sensor 1000-01F
Front wheel MODEL 164.1 /8 BA42.30-P-
speed sensor 1000-01G
Front wheel MODEL 219 BA42.30-P-
speed sensor 1000-01H
Front axle rpm MODEL 251 BA42.30-P-
sensor 1000-01I
Front wheel MODEL 216, 221 BA42.30-P-
speed sensor 1000-01J
Rear axle rpm MODEL 129, 140, 170, 171, 202, 203, 208, 209, 210, 211, 219, 240 BA42.30-P-
sensor 1000-02A
Rear axle rpm MODEL BA42.30-P-

sensor 168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-02B
414
Rear axle rpm MODEL 199.376 BA42.30-P-
sensor 1000-02D
Rear axle rpm MODEL 169, 245 BA42.30-P-
sensor 1000-02F
Rear axle rpm MODEL 164.1 /8 BA42.30-P-
sensor 1000-02G
Rear axle rpm MODEL 251 BA42.30-P-
sensor 1000-02H
Rear axle rpm MODEL 216, 221 BA42.30-P-
sensor 1000-02I
Hydraulic unit MODEL BA42.30-P-
168.006 /007 /008 /009 /031 /032 /033 /035 /109 /131 /132 /133 /135, 1000-03A
414
Acceleration MODEL 129, 140, 163, 170, 202, 208, 210 BA42.40-P-
slip regulation 1000-01A
(ASR)
Acceleration MODEL 215, 220, 230 BA42.40-P-
Slip Regulation 1000-01B
(ASR)
Electronic MODEL 129, 140, 203, 209, 210 BA42.45-P-
stability 1000-01A
program (ESP)
Electronic MODEL 163, 170, 171, 199, 202, 203, 208, 209, 215, 220.. BA42.45-P-
stability 1000-01B
program (ESP)
Electronic MODEL 202 with ENGINE 605, 611 BA42.45-P-
stability 1000-01C
program (ESP)
Electronic MODEL 211 BA42.45-P-
stability 1000-01D
program (ESP)
Electronic MODEL 171, 203, 240.078 /079 /178 /179 BA42.45-P-
stability 1000-01E
program (ESP)
Stability 1000-01H
Program (ESP)
Electronic MODEL 169, 245 BA42.45-P-
Stability 1000-01I
Program (ESP)
Electronic MODEL 164.1 /8 BA42.45-P-
stability 1000-01J
program (ESP)
stability 1000-01K
program (ESP)
Electronic MODEL 216, 221 BA42.45-P-
stability 1000-01L
program (ESP)
Sensotronic MODEL 211, 230, 240 BA42.46-P-
Brake Control 1000-01A
(SBC)
Sensotronic MODEL 219 BA42.46-P-
Brake Control 1000-01B
(SBC)
Brake MODEL 211, 230, 240.078 /079 /178 /179 BA42.46-P-
Operating Unit 1000-02A
(BOU)
Brake MODEL 219 BA42.46-P-
operating unit 1000-02B
(BOU)
Brake system MODEL 163 BA42.50-P-
hydraulics 1000-01A
Brakes - MODEL 220 with CODE (Z07) Top protection BA42.50-P-
hydraulic 1000-01B
system
Brake system - MODEL 199.376, 211, 219, 230, 240 BA42.50-P-
hydraulics 1000-01D
BRAKE SYSTEM - BA42.10-P-1000
Brake lines, brake hoses - BA42.10-P-1000-04J
Model 164
MODIFICATION NOTES
18.1.06 Brake line to floating brake caliper

BA42.10-P-1002-04J Brake pipe to brake hose Nm 15
Master brake cylinder - BA42.10-P-1000-05H

Model 164

BA42.10-P-1002-05H Bolt, effect diverting plate to master brake cylinder Nm 14
BA42.10-P-1003-05H Bolt, reservoir to master brake cylinder Nm 4
Front axle brake disks - BA42.10-P-1000-11A
Model 164
FRONT AXLE BRAKE DISKS

BA42.10-P-1001-11A Locking bolt, brake disk to front axle Nm 10
Rear axle brake disks - BA42.10-P-1000-13B
Model 164
REAR AXLE BRAKE DISKS

BA42.10-P-1001-13B Locking bolt, brake disk to rear axle Nm 10
PARKING BRAKE - BA42.20-P-1000-01I
Model 164
PARKING BRAKE
BA42.20-P-1001-01I Bolt for pedal assembly of parking brake to A-pillar Nm 20
SPEED SENSORS - BA42.30-P-1000
Front wheel speed sensor - BA42.30-P-1000-01G
Model 164

Rear axle rpm sensor - BA42.30-P-1000-02G

Model 164
REAR AXLE RPM SENSOR

BA42.30-P-1001-02G Self-locking bolt of rear axle rpm sensor to wheel carrier Nm 8
ELECTRONIC STABILITY PROGRAM (ESP) - BA42.45-P-1000-01J
Model 164

BA42.45-P-1003-01J Bolt, ESP hydraulic unit to bracket Nm 8
CABIN AIR FILTERS Dust Filter - 164 Chassis
CABIN AIR FILTERS
Dust Filter - 164 Chassis
IDENTIFICATION
MODEL IDENTIFICATION
164 CHASSIS MODEL IDENTIFICATION

Year Model
2006-09 ML350
2006-07 ML500
2008-09 ML550
2007-09 ML63
2007-09 GL320
2007-09 GL450
2008-09 GL550
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is Dust Filter.
CABIN AIR FILTER
NOTE: Numbers in parenthesis refer to numbers in illustrations.
Removal & Installation
1. The dust filter is located in the passenger compartment, behind the glove compartment.
2. Open glove compartment. Move CD changer (arrow) to closing position (if equipped). See Fig. 1.
Remove instrument panel side paneling (2) using a long wedge.
Fig. 1: Removing Glove Compartment

3. Remove bolts. See Fig. 1. Remove glove compartment downward and unplug electrical connector for
glove compartment illumination.
4. Release cover (2) of dust filter housing (1) in direction of arrow and remove. See Fig. 2. Noting direction
of installation, remove dust filters (3 and 4). Install in reverse order.
Fig. 2: Removing Dust Filter

5. Install glove compartment and check CD changer actuation button (4) for proper function.
2006-2008 ACCESSORIES & BODY, CAB Central Locking System - 164 Chassis
Central Locking System - 164 Chassis
BASIC KNOWLEDGE
TAILGATE REMOTE ACTUATION, FUNCTION - GF80.20-P-0001GZ
MODEL 164.1 /8, 251.0 /1 with CODE (890) Automatic rear-end door
Rear-end door remote actuation, general
The rear-end door can be opened and closed automatically via the rear-end door actuation feature. Opening and
closing is performed via the rear-end door hydraulic pump (M51/1) which is actuated by the rear-end door
closing control unit (N121/1).
Manual operation of the rear-end door is possible, but requires increased force, since the hydraulic system
also has to be moved.
The rear-end door actuation feature comprises the following subfunctions:
 Opening angle limitation (garage position)

 Blockage detection
 Anti-pinch protection
 Normalizing
Further partial functions are described in separate documents:
 Tailgate opening, function

 Tailgate closing, function
Opening angle limitation (garage position)
The opening angle can be limited by a control menu in the instrument cluster (A1). The garage position can be
set as the new end position (maximum opening position) if required to prevent damage to the tailgate from
extending transport items (ski box, surfboard, etc.).
Lockup recognition
The rear-end door closing control unit recognizes the status and any change in the speed of the rear-end door
with the aid of the rear-end door opening angle recognition sensor (B24/16). When closing, the tailgate
hydraulic pump is reversed and the tailgate is returned to the initial position.
When opening, the tailgate hydraulic pump is switched off and the tailgate remains in the momentary position.
Obstruction protection
The left tailgate closing obstruction sensor strip (B86/1) and right tailgate closing obstruction sensor strip
(B86/2) secure on both sides of the tailgate. The obstruction sensor strips are read in and evaluated by the rear-
end door closing control unit.
The pinch protection strips can have the following statuses:#
 Standby
 Obstruction sensor strip defective
 Obstruction
If a defective obstruction sensor strip is recognized, an automatic closing operation is interrupted and is not
performed.
Synchronizing
Calibration is required for:
 Initial startup
 System components replacement
 Adjustment work on system components
A required normalization is only possible if previously denormalized with STAR DIAGNOSIS (provided
that the system has already been normalized previously).
Battery disconnection (G1) does not lead to denormalization.
Normalization function sequence
Downstop synchronization:
Completely close rear-end door and keep closed. The lower stop is considered to be normalized if the signal
"Rear-end door closed" from the rear-end door locking unit (A72) on the rear-end door closing unit is actuated
for min. t = 0.5 s.
To store the upper calibration limit, it is necessary for the opening angle limitation to be switched off in the
instrument cluster.
Up-stop synchronization:
Actuate rear-end door open/close switch, driver (S15/3) until the rear-end door is completely opened.
The rear-end door closing control unit enables the rear-end door opening angle recognition sensor to recognize
when the rear-end door (lock-up recognition) is completely opened and thereby normalizes the upper stop.
Tailgate remote control, location of components Model 164 GF80.20-P-0001-01GZ

Model 251 GF80.20-P-0001-01RT
Tailgate remote actuation, block diagram GF80.20-P-0001-02GZ
Tailgate opening, function GF80.20-P-1010GZ
Tailgate closing, function GF80.20-P-2001GZ
Tailgate remote control, location of components - GF80.20-P-0001-01GZ
Fig. 1: Identifying Tailgate Remote Control Components Location - Shown On Model 164.1
Tailgate remote actuation, block diagram - GF80.20-P-0001-02GZ
Shown on vehicle up to 31.5.07

Fig. 2: Tailgate Remote Actuation Block Diagram - Shown On Vehicle Up To 31.5.07

CENTRAL LOCKING (CL), FUNCTION - GF80.20-P-0005GZ
MODEL 164
Function
The central locking (CL) controls the "remote-control opening and closing" function of the vehicle. The CL and
the convenience feature are components of the drive authorization system. These procedures also apply
analogously to the Keyless Go version. Detailed information is available in the Keyless Go description.
Operation
The central locking system can be operated in various manners:
 With the transmitter key (A8/1)

 With the left interior CL switch (S85/5) and right interior CL switch (S85/6)
 By opening a vehicle door from inside
 "Remote door unlock" (RDU) (USA only); for details see LCT emergency call system description.
The CL cannot be operated with the mechanical key Only the driver door can be opened with the mechanical
key. Detailed information on opening and closing the rear-end door automatically is given in the system
description.
An alarm is triggered on vehicles with anti-theft alarm system (ATA) code 551.
Automatic functions
 Automatic locking
 Speed-dependent locking and
 Relocking (40 s)
 Emergency opening after crash recognition
Central locking (CL), location of with spare wheel holder/spare wheel, GF80.20-P-0005-
components code 849 01GX
Except spare wheel holder/spare GF80.20-P-0005-
wheel, code 849 01GZ
with spare wheel holder/spare wheel, GF80.20-P-0005-
Central locking (CL), block diagram
code 849 10GX
Except spare tire holder/spare tire, GF80.20-P-0005-
code 849 10GZ
Operating central locking with transmitter with spare wheel holder/spare wheel, GF80.20-P-
key, function code 849 2002GX
Except spare tire holder/spare tire, GF80.20-P-
code 849 2002GZ
GF80.20-P-
Unlocking by opening one door, function
3004GZ
Locking/unlocking vehicle with inside GF80.20-P-
switch, function 3009GZ
GF80.20-P-
Unlock with emergency release, function
3014GZ
GF80.20-P-
Automatic locking, function
4009GZ
Central locking (CL), location of components - GF80.20-P-0005-01GX
Illustrated on model 164.8 as of production period 01.06.2006

Fig. 3: Identifying Central Locking (CL) Components Location - Illustrated On Model 164.8 As Of
Production Period 01.06.2006
Central locking (CL), location of components - GF80.20-P-0005-01GZ
Shown on model 164.1 without spare wheel holder/spare wheel, code 849
Fig. 4: Identifying Central Locking (CL) Components Location - Shown On Model 164.1
Central locking (CL), block diagram - GF80.20-P-0005-10GX
Shown on model 164.8 as of production period 01.06.2006

Fig. 5: Identifying Central Locking (CL) Block Diagram - Shown On Model 164.8 As Of Production
Period 01.06.2006
Central locking (CL), block diagram - GF80.20-P-0005-10GZ
Shown on spare wheel holder/spare wheel, code 849

Fig. 6: Central Locking (CL) Block Diagram - Shown On Spare Wheel Holder/Spare Wheel, Code 849
TABLE OF CONTENTS, FUNCTION DESCRIPTION, REAR-END DOOR REMOTE CONTROL -

GF80.20-P-0991GZ
Tailgate remote actuation, function GF80.20-P-0001GZ

Model GF80.20-P-0001-
Tailgate remote control, location of components
164 01GZ
Model GF80.20-P-0001-
251 01RT
GF80.20-P-0001-
Tailgate remote actuation, block diagram
02GZ
Tailgate opening, function GF80.20-P-1010GZ
Tailgate closing, function GF80.20-P-2001GZ
Overview of system components for tailgate remote control,
GF80.20-P-9992GZ
CONTENTS, FUNCTION DESCRIPTION OF CENTRAL LOCKING (CL) - GF80.20-P-0996GZ
MODEL 164
GF80.20-P-
Central locking (CL), function
0005GZ
with spare wheel holder/spare GF80.20-P-0005-
Central locking (CL), location of components
wheel, code 849 01GX
code 849 01GZ
with spare wheel holder/spare GF80.20-P-0005-
Central locking (CL), block diagram
wheel, code 849 10GX
code 849 10GZ
Operating central locking with transmitter with spare wheel holder/spare GF80.20-P-
key, function wheel, code 849 2002GX
Except spare tire holder/spare tire, GF80.20-P-
code 849 2002GZ
GF80.20-P-
Unlocking by opening one door, function
3004GZ
Locking/unlocking vehicle with inside switch, GF80.20-P-
function 3009GZ
GF80.20-P-
Unlock with emergency release, function
3014GZ
GF80.20-P-
Automatic locking, function
4009GZ
Overview of system components for central GF80.20-P-
locking (CL) 9997GZ
REAR-END DOOR CLOSING CONTROL UNIT, COMPONENT DESCRIPTION - GF80.20-P-1003GZ
Location
The tailgate closing control unit is located in the right area of the spare tire well.
Fig. 7: Identifying Rear-End Door Closing Control Module - Shown On Model 164.1
Task
The rear-end door closing control unit is the master control unit for the rear-end door remote actuation and is
connected to the controller area network bus class B (passenger compartment) (CAN-B) to exchange data.
The following components are read in discretely
 Tailgate opening angle recognition sensor (B24/16)

 Left tailgate closing obstruction sensor strip (B86/1)
 Right tailgate closing obstruction sensor strip (B86/2)
 RWTS button (S62/26)
The following components are actuated discretely
 tailgate closing warning buzzer (H4/60)

 Tailgate hydraulic pump (M51/1)
Storing positions
 Upper and lower end positions (synchronization of tailgate)

 Opening angle limitation (garage position)
OPENING ANGLE RECOGNITION SENSOR, COMPONENT DESCRIPTION - GF80.20-P-1005GZ
Location
The rear-end door opening angle recognition sensor is integrated into the gas-filled spring strut on the rear-end
door.
Task
 Sensing rear-end door opening angle

 Recording speed changes of rear-end door
Fig. 8: Identifying Rear-End Door Opening Angle Recognition Sensor - Shown On Model 164.1
REAR-END DOOR HYDRAULIC PUMP, COMPONENT DESCRIPTION - GF80.20-P-1006GZ
Location
The rear-end door hydraulic pump is located in the trunk in the right area of the spare tire well.
Task
The rear-end door hydraulic pump opens and closes via the hydraulic mechanism of the rear-end door to its
corresponding end position. Moreover, the rear-end door hydraulic pump controls the flow rate of the hydraulic
oil for starting or stopping the rear-end door faster or slower.
Fig. 9: Identifying Rear-End Door Hydraulic Pump - Shown On Model 164.1

REAR-END DOOR CLOSING SWITCH, COMPONENT DESCRIPTION - GF80.20-P-1007GZ
MODEL 164.1 /8, 251.0 /1 with CODE (890) Automatic rear-end door with CODE (889) Keyless Go
Location
The RWTS button is located at the bottom of the rear-end door next to the rear lock.
Task
The rear-end door closes when pressing the left button (1).
The rear-end door is closed and the vehicle is locked when the right button (2) on the RWTS button is pressed.
Fig. 10: Identifying RWTS Button - Shown On Model 164.1

OPEN REAR-END DOOR SWITCH, COMPONENT DESCRIPTION - GF80.20-P-1008GZ
Location
The rear-end door switch is located on the inside of the driver door (bottom).
Task
When the rear-end door switch is actuated, the rear-end door can be opened and closed from the passenger
compartment.
The open status of the rear-end door is indicated by a LED integrated into the rear-end door switch (up to
31.5.07).
On vehicles as of 1.6.07 the LED is eliminated.

Fig. 11: Identifying Driver-Side Opening And Closing Driver-Side Tailgate Switch - Shown On Model
164.1
TAILGATE OPENING, FUNCTION - GF80.20-P-1010GZ
Fig. 12: Tailgate Opening Function Diagram

Function requirements, general
 Circuit 30
 System synchronized
 Speed = 0 km/h
 Spare tire holder open in 90° position
(on model 164 with code (849) Spare tire holder/spare tire)
Open tailgate
the rear-end door function consists of the following functions:
 Opening rear-end door via rear-end door handle switch

 Opening rear-end door via rear-end door switch
 Opening rear-end door via transmitter key
During the entire rear-end door closing operation, the rear-end door closing warning buzzer is actuated by
the rear-end door closing control unit once each second.
The open status of the rear-end door is indicated by an LED integrated into the rear-end door switch (up to
31.5.07). On vehicles as of 1.6.07 the LED is eliminated.
Opening rear-end door via rear-end door handle switch
Additional function requirements
 Central locking (CL) unlocked
Function sequence
Actuation of the tailgate handle switch is read in by the rear SAM control unit. The rear SAM control unit
transmits this message to the CAN-B and simultaneously actuates the rear-end door locking unit to unlock the
rear-end door. The tailgate closing control unit reads in the message and starts the tailgate hydraulic pump. The
hydraulic cylinder is charged with oil and opens the tailgate with the multiple-joint hinge.
The rear-end door closing control unit controls the hydraulic operation via the opening angle recognition sensor.
When the opening angle recognition sensor reaches the determined final switch-off angle, the rear-end door
closing control module switches off the rear-end door hydraulic pump.
Opening rear-end door via rear-end door switch
Additional function requirements
Central locking (CL) unlocked
 Central locking (CL) unlocked
Function sequence
The request is read in by the left front door control unit via the rear-end door switch and transmitted to the
CAN-B.
The rear SAM control unit transmits this message to the CAN-B and simultaneously actuates the rear-end door
locking unit to unlock the rear-end door. The tailgate closing control unit reads in the message and starts the
tailgate hydraulic pump. The hydraulic cylinder is charged with oil and opens the tailgate with the multiple-joint
hinge.
When the rear-end door switch is actuated again, the opening operation is interrupted. The rear-end door
remains in the current position.
The opening operation can be continued with any control element on the rear-end door remote control.
Opening rear-end door via transmitter key
Function sequence
When the button on the transmitter key is actuated (t > 0.5 s), it transmits a radio signal to the roof antenna
module; from there, it is relayed to the rear SAM control unit and stored on the CAN-B bus. The EIS control
unit checks the access authorization of the transmitter key. If the transmitter key is valid, the rear SAM control
unit actuates the rear-end door closing unit to unlock the rear-end door. The tailgate closing control unit reads in
the message and starts the tailgate hydraulic pump. The hydraulic cylinder is charged with oil and opens the
tailgate with the multiple-joint hinge.
When the button on the transmitter key is actuated again, the opening operation is interrupted. The rear-end
door remains in the current position.
The opening operation can be continued with any control element on the rear-end door remote control.
A1 GF54.30-P-
Model 164 6000GZ
GF54.30-P-
Model 251
6000RT
A8/1
GF80.57-P-
Transmitter key, component description in case of Model
6010GZ
164
in case of Model GF80.57-P-
251 6010RT
GF80.20-P-
Opening angle recognition sensor, component description B24/16
1005GZ
GF80.20-P-
Rear-end door hydraulic pump, component description M51/1
1006GZ
N10/8 GF54.21-P-
Rear SAM control unit, component description
Model 164 7030GZ
GF54.21-P-
Model 251
7030RT
N69/1 GF72.29-P-
Left front door control unit, component description
Model 164 4141GZ
GF72.29-P-
Model 251
4141RT
Electronic ignition/starter switch control unit (EIS), component N73 GF80.57-P-
GF80.57-P-
Model 251
6000RT
N93 GF54.21-P-
Central gateway control unit, component description
Model 164 4170GZ
GF54.21-P-
Model 251
4170RT
GF80.20-P-
Rear-end door closing control unit, component description N121/1
1003GZ
GF80.20-P-
Open rear-end door switch, component description S15/3
1008GZ
TAILGATE CLOSING, FUNCTION - GF80.20-P-2001GZ
Shown with code (889) Keyless Go
Fig. 13: Tailgate Closing Function Diagram

Function requirements, general
 Circuit 30
 System synchronized
 Speed = 0 km/h
 Spare tire holder open in 90° position
(on model 164 with code (849) Spare tire holder/spare tire)
Close rear-end door
The rear-end door function consists of the following functions:
 Closing rear-end door via RWTS button

 Closing rear-end door via rear-end door switch
 Closing rear-end door via transmitter key
During the entire rear-end door closing operation, the rear-end door closing warning buzzer is actuated by
the rear-end door closing control unit once each second.
The closed status of the rear-end door is indicated by switching off the LED integrated into the rear-end door
switch (up to 31.5.07). On vehicles as of 1.6.07 the LED is eliminated.
Closing rear-end door via RWTS button
Function sequence
The rear-end door closing control unit reads in the actuation of the RWTS button and actuates the rear-end door
hydraulic pump. The rear-end door is closed via the hydraulic cylinder and the multiple-joint hinge.
When the rear-end door arrests in the catch on the rear-end door closing unit, the rear-end door closing control
unit switches off the rear-end door hydraulic pump.
On model 164.8 the rear-end door hydraulic pump is momentarily actuated
(t = 0.5 s) in the opening direction.
The rear-end door closing unit then completely closes the rear-end door with power closing in both cases.
On vehicles with code (889) Keyless Go, the central locking (CL) can also be locked depending on the
actuation of the RWTS button.
Closing rear-end door via rear-end door switch
Function sequence
Actuation of the rear-end door switch is read in by the left front door control unit and relayed via CAN-B to the
rear-end door closing control unit which actuates the rear-end door hydraulic pump. The rear-end door is closed
via the hydraulic cylinder and the multiple-joint hinge.
unit switches off the rear-end door hydraulic pump.
When the rear-end door switch is actuated again, the closing operation is interrupted.
The rear-end door remains in the current position.
The closing operation can be continued with any control element on the rear-end door remote control.
Closing rear-end door via transmitter key
Function sequence
When the button on the transmitter key is actuated (t > 0.5 s), it transmits a radio signal to the roof antenna
module; from there, it is relayed to the rear SAM control unit and stored on the CAN-B bus. The EIS control
unit checks the access authorization of the transmitter key. If the transmitter key is recognized as valid, the rear-
end door hydraulic pump is actuated by the rear-end door closing control unit. The rear-end door is closed via
the hydraulic cylinder and the multiple-joint hinge.
unit switches off the rear-end door hydraulic pump..
When the button on the transmitter key is actuated again, the closing operation is interrupted.
The rear-end door remains in the current position.
The closing operation can be continued with any control element on the rear-end door remote control.
A1 GF54.30-P-
Model 164 6000GZ
GF54.30-P-
Model 251
6000RT
A8/1 GF80.57-P-
Transmitter key, component description
in case of Model 164 6010GZ
GF80.57-P-
in case of Model 251
6010RT
GF80.20-P-
1005GZ
GF80.20-P-
1006GZ
N10/8 GF54.21-P-
Model 164 7030GZ
GF54.21-P-
Model 251
7030RT
N69/1 GF72.29-P-
Model 164 4141GZ
GF72.29-P-
Model 251
4141RT
Electronic ignition/starter switch control unit (EIS), N73 GF80.57-P-
component description Model 164 6000GZ
GF80.57-P-
Model 251
6000RT
N93 GF54.21-P-
Model 164 4170GZ
GF54.21-P-
Model 251
4170RT
GF80.20-P-
1003GZ
GF80.20-P-
Open rear-end door switch, component description S15/3
1008GZ
S62/26
GF80.20-P-
Rear-end door closing switch, component description With CODE (889)
1007GZ
Keyless Go
Without code (889) GF80.20-P-
Keyless Go 1007GZA
OPERATING CENTRAL LOCKING WITH TRANSMITTER KEY, FUNCTION - GF80.20-P-2002
Operating central locking with transmitter key, function - GF80.20-P-2002GX
MODEL 164 with CODE (849) Spare wheel holder/spare wheel
Illustrated on model 164.8 as of production period 01.06.2006

Fig. 14: Operating Central Locking With Transmitter Key Function Diagram - Illustrated On Model
164.8
Definition for selective/global unlocking
Unlock selectively:
Only the driver door and the fuel filler flap are unlocked
Only the next actuation of the "Unlock" transmit button unlocks the entire vehicle.
Unlock globally:
The entire vehicle is unlocked.
Preset "Selective" or "Global"
Depending on the setting on the transmitter key, the vehicle is unlocked globally or selectively when the
"Unlock" button in the transmitter key is pressed. Changeover is possible by simultaneously actuating the
"lock" and "unlock" buttons on the transmitter key for approx. 5 s. The indicator lamp on the transmitter key
comes on twice for confirmation.
Function sequence for locking or unlocking
When the "Lock and unlock" button on the transmitter key is actuated, it transmits a signal to the roof antenna
module via radio. This is relayed to the EIS control unit via the rear SAM control unit. Parallel to the radio
signal, an infrared signal is transmitted to the left or right front IR receiver (precise aiming required).
The right front IR receiver is installed on the Japanese version only.
This signal is read in by the left front door control unit and transmitted to the EIS control unit via CAN-B.
In both cases, the EIS control unit checks the access authorization of the transmitter key.
If the access authorization is valid, the EIS control unit transmits the "Lock or unlock" command to the front
door control unit, the front SAM control unit and rear SAM control unit via CAN B. Then they actuate the
corresponding CL motors in the side door, the rear-end door as well as the spare wheel carrier.
The opening request of the rear-end door switch external operation is disabled or enabled by the rear SAM
control unit.
When unlocking, the interior lights is switched on by the overhead control panel control unit
If the driver door is opened during locking, the driver door is not locked An open passenger door is locked
Function sequence for opening rear-end door
Generally only the rear-end door and the spare wheel carrier are unlocked.
When the "Rear-end door remote opening" transmit button is actuated, the transmitter key transmits a radio
signal to the roof antenna module.
This is relayed to the EIS control unit via the rear SAM control unit. Parallel to the radio signal, an infrared
signal is transmitted to the left front IR receiver (precise aiming required).
The right front IR receiver is only installed on the Japanese version.
This signal is read in by the left front door control unit and transferred to the EIS control unit. In both cases, the
EIS control unit checks the access authorization of the transmitter key. If the access authorization is valid, the
EIS control unit transmits the "Open rear-end door" command to the rear SAM control unit. It actuates the rear-
end door locking unit in the rear-end door lock and parallel to this, the spare wheel carrier CL motor in the spare
wheel carrier, to release electrically.
The spare wheel carrier can only be unlocked with the handle on the spare wheel carrier and can be pivoted
manually until it arrests in the 90° position.
In this position, the open spare wheel carrier switch transmits the signal to the rear SAM control module, that
the rear-end door can be unlocked.
When the rear-end door is remotely opened with the transmitter key, the central locking (CL) remains
inactive (no unlocking). The interior central locking and ATA function display switch is not enabled
Once the rear-end door has been closed, it can only be opened by again operating the transmitter key.
Visual feedback
After locking or unlocking, a visual feedback is accomplished via the turn signal lamps.
 Flashing 3 times when locking (doors and rear-end door must be closed)
 Flashing once when unlocking
The function is controlled by the rear SAM control unit as Blinkmaster.
The individual turn signal lamps are actuated by the front SAM control unit, rear SAM control unit and the front
door control units.
Interior actuation of CL:
After locking, the interior CL switches are deactivated. If the transmitter key is inserted into the EIS control
unit, the interior CL switches are reactivated and the fuel filler flap automatically unlocked.
GF80.57-P-
6010GZ
With USA version, GF82.62-P-
Roof antenna module, component description
code 494 3127GZU
GF80.30-P-
Infrared remote control receiver, component description
6000GZ
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
GF72.29-P-
4141GZ
GF72.29-P-
Right front door control unit, component description
4142GZ
GF54.21-P-
Front SAM control unit, component description
7010GZ
GF54.21-P-
7030GZ
Operating central locking with transmitter key, function - GF80.20-P-2002GZ
MODEL 164
Shown on model 164.1 without spare wheel holder/spare wheel, code 849
Fig. 15: Operating Central Locking With Transmitter Key Function Diagram - Shown On Model 164.1
Preset "Selective" or "Global"
Depending on the setting on the transmitter key, the vehicle is unlocked globally or selectively when the
"Unlock" button in the transmitter key is pressed. Changeover is possible by simultaneously actuating the
"Lock" and "Unlock" buttons on the transmitter key for approx. 5 s. The indicator lamp on the transmitter key
comes on twice for confirmation.
Unlock globally:
The entire vehicle is unlocked.
Unlock selectively:
Only the driver door and the fuel filler flap are unlocked
Only the next actuation of the "Unlock" transmit button unlocks the entire vehicle.
Function sequence for locking or unlocking
When the "Lock and unlock" button on the transmitter key is actuated, it transmits a signal to the roof antenna
module via radio.
signal is transmitted to the left front IR receiver (precise aiming required). This signal is read in by the left front
door control unit and transmitted to the EIS control unit via CAN-B.
If the access authorization is valid, the EIS control unit transmits the "Lock or unlock" command to the front
door control unit, the front SAM control unit and rear SAM control unit via CAN B. They then actuate the
corresponding CL motors.
The opening request of the rear-end door switch external operation is disabled or enabled by the rear SAM
control unit.
When unlocking, the interior lights is switched on by the overhead control panel control unit
If the driver door is opened during locking, the driver door is no locked An open passenger door is locked
Function sequence for rear-end door remote opening
When the "Rear-end door remote opening" transmitter button is pressed, the transmitter key sends a radio signal
to the left antenna amplifier module.
signal is transmitted to the left front IR receiver (precise aiming required).
This signal is read in by the left front door control unit and transferred to the EIS control unit.
If the access authorization is valid, the EIS control unit transmits the "Open rear-end door" command to the rear
SAM control unit. It actuates the rear-end door CL motor in the rear-end door lock for electrically unlocking of
the rear-end door.
When the rear-end door is remotely opened with the transmitter key, the central locking (CL) remains
inactive (no unlocking). The interior central locking and ATA function display switch is not enabled
Once the rear-end door has been closed, it can only be opened by again operating the transmitter key.
Visual feedback
After locking or unlocking, a visual feedback is accomplished via the turn signal lamps.
The function is controlled by the rear SAM control unit as Blinkmaster.
Actuation of the individual turn signal lamps is accomplished by the front SAM control unit, rear SAM control
unit and the front door control units
 flashing 3 times when locking (doors and trunk lid must be closed)
 flashing once when unlocking
Interior actuation of CL:
After locking, the interior CL switches are deactivated. If the transmitter key is inserted into the EIS control
unit, the interior CL switches are reactivated and the fuel filler flap automatically unlocked.
GF80.57-P-
6010GZ
With USA version, code GF82.62-P-
494 3127GZU
GF80.30-P-
6000GZ
Electronic ignition switch (EIS) control unit, component GF80.57-P-
description 6000GZ
GF72.29-P-
4141GZ
GF72.29-P-
4142GZ
GF54.21-P-
7010GZ
GF54.21-P-
7030GZ
HEADLAMP SWITCH-OFF DELAY, FUNCTION - GF80.20-P-2003GZ

MODEL 164.1 /8
Function
The headlamp switch-off delay serves to illuminate the area surrounding the vehicle after exiting the vehicle.
The time interval can be adjusted in the instrument cluster (A1).
The time interval can be set in increments of 15 s, from t = 0 s to t = 60 s.
 Headlamp switch-off delay activated via instrument cluster

 Rain/light sensor (B38/2) signals "Darkness"
 Rotary light switch (S1) in "AUTO" position (with and )
Function sequence
When changing from circuit 61 ON to circuit 15 OFF, the headlamp switch-off delay function is activated for t
= 60s, if the function prerequisites are fulfilled. The time is independent of the time interval set on the
instrument cluster.
When a door or the rear-end door is opened, the time for the headlamp switch-off delay is restarted. This applies
each time a door is opened within the expiration time. When the last door is closed, the time interval selected in
the instrument cluster is activated.
If the headlamp switch-off delay is active, the front SAM control unit (N10) transmits the corresponding signal
to the instrument cluster, whereupon the warning buzzer (A1h1) and circuit 58d are suppressed.
When the parking lamp or the low beam is only activated due to the rotary light switch in the background of the
headlamp switch-of delay, the warning buzzer remains activated.
The headlamp switch-off delay activates the following lamps:
 Left standing and parking lamp (E1e3)

 Right standing and parking lamp (E2e3)
 Left front fog lamp (E5/1)
 Right fog lamp (E5/2)
 Left rear side-marker lamp (E1e6) (only and )
 Right rear side-marker lamp (E2e6) (only and )
 Taillamp and rear fog lamp (E3e2) (on model 164.1)
 Left stop lamp (E3e4) (on model 164.8 without code (849) Spare tire holder/spare tire)
 Taillamp, side-marker lamp, left parking lamp (E3e8) (without code (849) Spare tire holder/spare tire)
(with code (849) Spare tire holder/spare tire)
 Taillamp and right rear fog lamp (E4e2) (on model 164.1)
 Right stop lamp (E4e4)
(on model 164.8 without code (849) Spare tire holder/spare tire)
 Taillamp, side-marker lamp, right parking lamp (E4e8) (without code (849) Spare tire holder/spare tire)
 Stop lamp and right taillamp (E4/5e4)
 Left license plate lamp, rear-end door (E19/3)
(without code (849) Spare tire holder/spare tire)
 Right license plate lamp, rear-end door (E19/4)
(without code (849) Spare tire holder/spare tire)
 Left license plate lamp, spare tire carrier (E19/5)
 Right license plate lamp, spare tire carrier (E19/6)
Function abort
When the ignition is switched on and off, the headlamp switch-off delay function is interrupted until the next
change from circuit 61 ON to circuit 15 OFF.
When the anti-theft alarm system (with code (551) Anti-theft alarm system (ATA)) is triggered, the
headlamp switch-off delay is also interrupted.
Deactivate function
When the time interval is set to "0 s" in the instrument cluster the headlamp switch-off delay feature is
deactivated.
Instrument cluster, component description A1 GF54.30-P-6000GZ

Rain/light sensor, component description B38/2 GF54.21-P-6000GZ
Front SAM control unit, component description N10 GF54.21-P-7010GZ
Rotary light switch, component description S1 GF82.10-P-4106GZ
UNLOCK BY OPENING ONE DOOR, FUNCTION - GF80.20-P-3004GZ
MODEL 164
Unlock
The vehicle doors can always be opened from the inside regardless of the status of the central locking (CL) The
corresponding door lock is then unlocked mechanically.
Special case
A globally unlocked vehicle is locked with the left interior CL switch (S85/5), the right interior CL switch
(S85/6) or the automatic locking/relocking function.
In this case, the vehicle is unlocked globally when the driver or passenger door is opened from inside.
Control is performed in the EIS control unit (N73).
The status of the driver and front passenger door is transmitted by the left front door control unit (N69/1) and
right front door control unit (N69/2) via controller area network bus, class B (interior compartment) (CAN B).
Adjustments rear doors locks
On national version the rear door locks can only be opened with the inside door handle in the unlocked
state.
Unlocking a rear door:
 with the transmitter key (A8/1)

 with left interior CL switch or with right interior CL switch
 by opening the driver or front passenger door after automatic locking, if the vehicle was unlocked
globally
 by pulling a locking pin on the corresponding rear door
Left front door control unit, component description GF72.29-P-4141GZ

Right front door control unit, component description GF72.29-P-4142GZ
Electronic ignition switch (EIS) control unit, component description GF80.57-P-6000GZ
LOCKING/UNLOCKING VEHICLE WITH INSIDE SWITCH, FUNCTION - GF80.20-P-3009GZ
MODEL 164
Function
The signals from the left interior CL switch (S85/5) and right interior CL switch (S85/6) are read in by the door
control units and transmitted to the controller area network bus, class B (passenger compartment) (CAN B)
The EIS control module (N73) reads in the signals and actuates the locking and locking the central locking (CL)
depending on the:
 CL status
 Door status (signals of rotary tumbler switch in CL motors via CAN B)
Fuel filler flap remains unlocked when locking with the CL inner actuation switch.
The following situations are possible:
Driver door open.
 All doors, except driver door, are locked

 Fuel filler flap remains open
Passenger door or driver and passenger door open:
 Locking disabled
Locking from outside with transmitter key (A8/1):
 Only locking allowed
Unlocking from outside with remote control key:
 If no door is open, full function.

Electronic ignition/starter switch control unit (EIS) component description GF80.57-P-6000GZ
UNLOCK WITH EMERGENCY RELEASE, FUNCTION - GF80.20-P-3014GZ
MODEL 164
The "Emergency opening" function unlocks the vehicle doors after an accident. This function is actuated by the
restraint systems control unit (N2/7)The crash message is relayed to the controller area network bus, class B
(interior compartment) (CAN B) via the central gateway control unit (N93).
After a waiting time of 8 to 11 s, the corresponding control units of the vehicle are unlocked.
The front SAM control unit (N10) and the rear SAM control unit (N10/8) then actuate the corresponding motor
to unlock the door locks.
The "Emergency opening" function has priority over all other central locking functions (CL).
Front SAM control unit, component description GF54.21-P-7010GZ

Rear SAM control unit, component description GF54.21-P-7030GZ
AUTOMATIC LOCKING, FUNCTION - GF80.20-P-4009GZ
MODEL 164
Speed-dependent locking
 Function in instrument cluster (A1) activated
The doors are locked at a speed of approx. 15 km/h and the trunk lid at a speed of approx. 3 km/h.
In this case, the EIS control unit (N73) transmits the "Locking" command to the controller area network bus,
class B (interior compartment) (CAN B).
The door control units, the front SAM control unit (N10) and the rear SAM control unit (N10/8) then actuates
the corresponding motor in the "Locking" direction.
The rear SAM control unit deactivates the rear-end door handle (S88/9).
The vehicle can be unlocked by opening the driver and passenger door from inside or by actuating the left
interior CL switch (S85/5) or right interior CL switch (S85/6).
If, after locking, the vehicle is unlocked with the CL inner actuation switch, the vehicle also remains unlocked
above the speed threshold.
If a door is opened and then closed again following automatic locking, when the vehicle speed is greater than
the speed threshold, the door in question is locked again after it is closed.
Relocking
The "Relocking" function is actuated by the EIS control unit, if the vehicle is unlocked and none of the doors or
the trunk lid are opened within 40 s Relock is confirmed by visual feedback signal
The status of the doors is evaluated by the rotary tumbler switches installed in the CL motor and the door
control units, the front SAM control unit and the rear SAM control unit via CAN B.
With anti-theft alarm system (ATA) code 551:

The anti-theft alarm system (ATA) is armed again when relocking

OVERVIEW OF SYSTEM COMPONENTS FOR TAILGATE REMOTE CONTROL, COMPONENT

A1 GF54.30-P-
Model 164 6000GZ
GF54.30-P-
Model 251
6000RT
A8/1 GF80.57-P-
Model 164 6010GZ
GF80.57-P-
Model 251
6010RT
GF80.20-P-
1005GZ
GF80.20-P-
1006GZ
N10/8 GF54.21-P-
Model 164 7030GZ
GF54.21-P-
Model 251
7030RT
N69/1 GF72.29-P-
Model 164 4141GZ
GF72.29-P-
Model 251
4141RT
Electronic ignition/starter switch control unit (EIS), N73 GF80.57-P-
component description Model 164 6000GZ
GF80.57-P-
Model 251
6000RT
N93 GF54.21-P-
Model 164 4170GZ
GF54.21-P-
Model 251
4170RT
GF80.20-P-
1003GZ
GF80.20-P-
Open rear-end door switch, component description S15/3 1008GZ

S62/26
GF80.20-P-
Rear-end door closing switch, component description With code (889) Keyless
1007GZ
Go
Without code (889) GF80.20-P-
Keyless Go 1007GZA
Table of contents, function description, rear-end door GF80.20-P-
remote control 0991GZ
OVERVIEW OF SYSTEM COMPONENTS FOR CENTRAL LOCKING (CL) - GF80.20-P-9997GZ
MODEL 164
GF80.57-P-
6010GZ
With USA version, GF82.62-P-
code 494 3127GZU
GF80.30-P-
6000GZ
GF72.29-P-
4141GZ
GF72.29-P-
4142GZ
GF54.21-P-
7010GZ
GF54.21-P-
7030GZ
GF80.20-P-
Contents, function description of central locking (CL)
0996GZ
INFRARED REMOTE CONTROL RECEIVER, COMPONENT DESCRIPTION - GF80.30-P-6000GZ
MODEL 164
Location
The IR receiver unit is located in the driver door handle

Fig. 16: Identifying Left Front IR Receiver And Right Front IR Receiver - Shown On Model 164.1
Task
The front left or front right IR receiver receives the signals from the transmitter key (A8/1) and relays them to
the left front door control unit (N69/1).
The right front IR receiver is only installed on the Japanese version.
Receiver signals
 Locking and unlocking central locking (CL)

 Rear-end door remote opening
 Automatic rear-end door, code 890
 Power window convenience feature
 Vent window convenience feature (with power side vent windows, code 848)
 Tilting/sliding roof convenience feature (with power glass tilting/ sliding roof, code 414)
CONVENIENCE FEATURE (CF), FUNCTION - GF80.45-P-0003GZ
MODEL 164
Fig. 17: Convenience Feature (CF) Function Diagram

General
The convenience feature includes the following functions
 Convenience closing/opening with transmitter key

 Convenience closing/opening via recirculated air
 Convenience closing via keyless go (KG)
(only with code 889 Keyless Go)
All windows and the tilting/sliding roof (SR) can be closed or opened with the convenience closing/opening
function.
 No overvoltage or undervoltage
 All doors closed and
 No lockup recognition
Convenience closing/opening with transmitter key
 Press "Lock or unlock" button on transmitter key for longer than 1 s while pointing at left front IR
receiver.
On the Japanese version, this function is also possible on the front passenger door via the IR receiver unit.
Function sequence
When the "Lock or unlock" button on the transmitter key is actuated (longer than 1 s) it transmits the infrared
"Convenience closing/ opening" command to the left front IR receiver (precise aiming required)
This signal is read in by the left front door control unit and transmitted to the EIS control unit via CAN-B.
The EIS control unit checks the access authorization of the transmitter key.
If the access authorization is valid, the EIS control unit transmits the command "Convenience closing/opening"
to door control units, the front SAM control unit and the overhead control panel control unit.
They then actuate the corresponding power window motor and the SR drive unit.
When the "Lock or unlock" button is released the convenience opening/closing of the power window motors
and SR drive unit is terminated immediately
Convenience opening/closing via recirculated air button
 Actuate recirculated air switch on AAC control and operating unit or on comfort AAC control and
operating unit
The convenience opening feature with recirculated air is accomplished only when previously closed with
convenience closing via recirculated air. When closing with convenience function, the momentary windows
positions and the tilting/sliding roof position are stored
Function sequence
When the recirculated air switch on the AAC control and operating unit or comfort AAC control and operating
unit is pressed for a longer time, the "Convenience closing/opening" command is transmitted to the door control
units, front SAM control unit and overhead control panel control unit via CAN B bus. They then actuate the
corresponding power window motor and the SR drive unit.
When the recirculated air switch is pressed again the corresponding power window motors and the SR drive
unit are automatically moved to the positions before the convenience opening/closing function.
When the recirculated air switch is actuated again the convenience opening/closing of the power window
motors and the SR drive unit is stopped immediately.
Convenience closing via keyless go (KG)
 Press and hold one of the door handle switches
The convenience closing function can be only be accomplished via the door handle switch.
Function sequence
When the corresponding door handle switch is actuated for a longer time, it transmits the "Convenience closing"
command to the keyless go control unit.
It relays the "Convenience closing" command to the EIS control unit via KG bus.
If the access authorization is valid, the EIS control unit transmits the command "Convenience closing" to the
door control units, the front SAM control unit and the overhead control panel control unit They then actuate the
corresponding power window motor and the SR drive unit.
By pulling the door handle, closing of the windows and closing of the tilting/sliding roof is terminated.
The power window motors and the SR drive unit are actuated in the opening direction for approx. 2 s.
Convenience feature (CF), networking of GF80.45-P-

components 0003-02GZ
GF80.57-P-
Transmitter key, component description 6010GZ

Infrared remote control receiver, component GF80.30-P-
description 6000GZ
GF72.29-P-
Power window motor, component description
6030GZ
Front SAM control unit, component GF54.21-P-
description 7010GZ
Rear SAM control unit, component GF54.21-P-
description 7030GZ
With code 580 Automatic air
Automatic air conditioning pushbutton control GF83.40-P-
conditioning, except code 494 USA
unit, component description 3000GZE
version
With code 580 Automatic air GF83.40-P-
conditioning and code 494 USA version 3000GZU
Except code 494 USA version,
Comfort automatic air conditioning control GF83.40-P-
With code 581 Comfort automatic air
and operating unit, component description 3010GZE
conditioning
With code 581 Comfort air conditioning GF83.40-P-
and code 494 USA version 3010GZU
Model 164.8 With code 581 Comfort
automatic air conditioning
GF83.40-P-
With code 582 Rear air conditioning
3010RTU
system
With code 494 USA version
Left front door control unit, component GF72.29-P-
description 4141GZ
Right front door control unit, component GF72.29-P-
description 4142GZ
Keyless Go control unit, component GF80.61-P-
With code 889 Keyless Go
description 4200GZ
Overhead control panel control unit, GF82.20-P-
Electronic ignition/starter switch control unit GF80.57-P-
(EIS) component description 6000GZ
Convenience feature (CF), networking of components - GF80.45-P-0003-02GZ

Fig. 18: Identifying Networking Of Components Of Convenience Feature (CF)

TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR CONVENIENCE FEATURE (CF) -

GF80.45-P-0999GZ
MODEL 164
Convenience feature (CF), function GF80.45-P-0003GZ

Convenience feature (CF), networking of components GF80.45-P-0003-02GZ
Survey of system components for convenience actuation (CF) GF80.45-P-9998GZ
OVERVIEW OF SYSTEM COMPONENTS FOR CONVENIENCE ACTUATION (CF) - GF80.45-P-

9998GZ
MODEL 164
GF80.57-P-
6010GZ
Infrared remote control receiver, component GF80.30-P-
description 6000GZ
GF72.29-P-
Power window motor, component description
6030GZ
description 7010GZ
description 7030GZ
With code 580 Automatic air
Automatic air conditioning pushbutton GF83.40-P-
conditioning, except code 494 USA
control unit, component description 3000GZE
version
With code 580 Automatic air GF83.40-P-
Except code 494 USA version,
With code 581 Comfort automatic air
conditioning
With code 581 Comfort automatic air GF83.40-P-
Model 164.8 With code 581 Comfort
GF83.40-P-
With code 582 Rear air conditioning
3010RTU
system
description 4141GZ
description 4142GZ
Keyless Go control unit, component GF80.61-P-
With code 889 Keyless Go
description 4200GZ
Electronic ignition/starter switch control unit GF80.57-P-
(EIS) component description 6000GZ
Table of contents, function description for GF80.45-P-
convenience feature (CF) 0999GZ
ANTI-THEFT ALARM SYSTEM (ATA [EDW]), FUNCTION - GF80.50-P-0001GZ
MODEL 164 with CODE (551) Anti-theft alarm system (ATA [EDW])
The anti-theft alarm system (ATA), code 551 monitors all relevant inputs for their non-actuated state.
If a change of status is detected at one of the monitored inputs, an audible and visual alarm is given.
The acoustic signals are output by the alarm signal horn (H3) (only USA version, code 494) or by the alarm
signal horn with additional battery (H3/1) (except USA version, code 494)
The visual signals are output by the exterior lights.
The rear SAM control unit (N10/8) is the master control unit for the ATA.
The ATA, when armed, monitors:
 the doors
 the rear-end door
 the engine hood
 the position change of the vehicle
 motions in interior compartment (with interior monitoring (only with ATA) code 882)
 the alarm signal horn with additional battery (except USA version, code 494)
On vehicles with radio remote control with panic switch, code 763, an alarm can also be triggered manually
Anti-theft alarm system (ATA [EDW]), block diagram GF80.50-P-0001-01GZ

Anti-theft alarm system (ATA), location of components GF80.50-P-0001-02GZ
Activate anti-theft alarm system, function GF80.50-P-2002GZ
Anti-theft alarm system (ATA [EDW]), block diagram - GF80.50-P-0001-01GZ

Fig. 19: Anti-Theft Alarm System (ATA [EDW]) Block Diagram

Anti-theft alarm system (ATA), location of components - GF80.50-P-0001-02GZ
Fig. 20: Identifying Anti-Theft Alarm System (ATA) Components Location

TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF ANTI-THEFT ALARM SYSTEM

(ATA) - GF80.50-P-0999GZ
Anti-theft alarm system (ATA [EDW]), function GF80.50-P-0001GZ

GF80.50-P-0001-
Anti-theft alarm system (ATA [EDW]), block diagram
01GZ
GF80.50-P-0001-
Anti-theft alarm system (ATA), location of components
02GZ
Activate anti-theft alarm system, function GF80.50-P-2002GZ
USA version, code GF80.50-P-
Trigger alarm with panic switch, function
494 3014GZU
Deactivate anti-theft alarm system, function GF80.50-P-2003GZ
Trigger anti-theft alarm system, function GF80.50-P-2004GZ
Overview of system components for anti-theft alarm system
GF80.50-P-9998GZ
(ATA)
ACTIVATE ANTI-THEFT ALARM SYSTEM, FUNCTION - GF80.50-P-2002GZ
Fig. 21: Activate Anti-Theft Alarm System Function Diagram

Activate anti-theft alarm (ATA)
 Lock central locking (CL) with transmitter key

 Lock CL with relocking function
 Vehicle locked via Keyless Go (KG) (with Keyless Go, code 889)
Partial activation of ATA
The towing sensor or interior protection (with interior monitoring (with ATA only), code 882) can be switched
off for the next activation of the ATA.
Switch off towing sensor and/or interior protection

The towing sensor and/or interior protection can be deactivated for the next arming cycle via the menu in the
instrument cluster.
The rear SAM control unit ensures that deactivation commands are not processed after the command "ATA
activated" is set. The current status of deactivation of the interior protection sensor and towing sensor are
transmitted via the instrument cluster. This deactivation is possible as long as the vehicle is not locked.
Alarm inputs
The ATA evaluates the following alarm inputs:
 Rear door locking unit

 Alarm signal horn with additional battery (H3/1) (except USA version, code 494)
 Alarm signal horn (H3) (only USA version, code 494)
 Right front door rotary tumbler microswitch (M14/5s1)
 Left front door rotary tumbler microswitch (M14/6s1)
 Left rear door rotary tumbler microswitch (M14/8s1)
 Right rear door rotary tumbler microswitch (M14/9s1)
 Spare wheel carrier "locked" switch (only spare wheel holder/ spare wheel, code 849)
 EDW hood switch
Only with interior monitoring (with ATA only), code 882:
 Interior protection sensor (B44)

 Left rear window glass breakage sensor (B39)
 Right rear window glass breakage sensor (B39/1)
The state of the alarm inputs is checked cyclically If all checks within 10 s indicate the non-actuated state, the
corresponding input is armed. Alarm inputs switched to non-actuated state later, are also armed after 10 s.
Towing sensor
The towing sensor is activated 10 s after the locking command from the EIS control unit and after closing of the
last door and of the rear-end door, provided that it is not deselected for the next closing cycle on the instrument
cluster. If the inclination sensor is defective, the remaining ATA is still fully operable. Determination of this
reference position requires 10 s, therefore a towing sensor alarm cannot be accepted before expiration of this
time. When the towing sensor function is activated, the ATA inclination sensor determines the current reference
position, with which the relative vehicle inclination is compared during the activated time period.
When the maximum vehicle inclination is exceeded with regard to the reference position, a towing sensor alarm
is triggered.
The inclination sensor is integrated in the rear SAM control unit.

Interior protection and glass breakage (except USA version, code 494)
The interior protection sensor is activated 10 s after closing of the last door and of the rear-end door, provided
that it is not deselected for the next closing cycle on the instrument cluster. The adaptation phase for the interior
protection then requires approx. 30 s. The interior protection alarm input is then permitted as an alarm source
only, when the overhead control panel control unit recognizes a properly functioning interior protection sensor.
The status of the interior protection is returned each time a command transmitted from the overhead control
panel control unit is received by the interior protection sensor. With this status feedback, the following replies
can be returned to the overhead control panel control unit:
 Interior protection sensor fully operational

 Interior protection sensor defective
 Interior protection sensor activated/disarmed
 interior protection sensor alarm
If a defective interior protection sensor is recognized by the overhead control panel control unit, the remaining
ATA function is fully ensured, regardless of this error. The corresponding DTC's are stored in the DTC memory
of the overhead control panel control unit.
Alarm signal horn with additional battery (except USA version, code 494)
The alarm signal horn with additional battery can be activated in two different manners:
1. All doors and the rear-end door are closed: In this case, the alarm signal horn with additional battery is
activated by the siren command SET CLOSE.
2. At least one door or the rear-end door is open: In this case, the alarm signal horn with additional battery is
activated by the siren command SET OPEN.
When the alarm signal horn with additional battery is activated, it is cyclically actuated by the rear SAM control
unit. This serves for recognition of an interruption in communication, consequently triggering an ATA alarm.
When this pause time is exceeded, the alarm signal horn with additional battery triggers automatically an
acoustic alarm.
Special case: Driver door
When the anti-theft alarm system (ATA) is activated and the driver door is still open, the left front door CL
motor is not actuated and the door remains unlocked. This has the effect that the vehicle key cannot be trapped
in the vehicle unintentionally. After closing the driver door, the door status is indicated to the rear SAM control
unit and the alarm input is included in the check cycle; a plausible ATA alarm can occur If the driver door is
opened without previously activating the ATA, the alarm is triggered.
Special case: Rain closing (with power glass tilting/sliding roof, code 414, except USA version, code 494)
When the rain/light sensor (B38/2) moves the tilting/sliding roof to the tilt position with the vehicle parked, the
interior protection sensor is suppressed. After rain closing, the ATA is reset to the same status as before closing
Special case: Convenience opening/closing function
The windows and the tilting/sliding roof (with power glass tilting/ sliding roof, code 414) can be opened and
closed with the transmitter key via the convenience opening/closing function. On this convenience function the
ATA can be in the activation phase or is already in the armed state The alarm is deactivated for the duration of
the convenience function so that the motions of the windows and tilting/sliding roof do not trigger an alarm.
After the convenience opening/closing function the ATA is reset to the same status as before the function
Feedback after successful activation Visual
The activated ATA is displayed with an LED in the ATA function display (N72/1e2) in the upper control panel
control unit
Implausible opening/closing command
Repeated or continuous presence of the lock/unlock commands has no effect on the function of the ATA. When
the opening and closing commands are transmitted indiscriminately, the signal last received determines the
function status.
Automatic relocking
The automatic relocking is actuated by the EIS control unit, if the vehicle is unlocked and none of the doors or
the rear-end door are opened within 40 s. In this case the vehicle relocks automatically. Relocking is not
signaled by the turn signal lamps. The interior protection and the towing sensor are set to the same state as
before the last unlocking procedure.
The ATA is armed when relocking
Automatic rear-end door remote release
The rear-end door remote release is a convenience function offering the driver the possibility to open the rear-
end door with the transmitter key. Since the rear-end door is also an alarm input and this function should also be
available when the vehicle is locked, it is necessary that the ATA supports the rear-end door function so that no
alarm is generated and after completion of the rear-end door remote release, the ATA is reset to its original
state.
Disarm automatic rear-end door remote release
Only the alarm inputs for the rear-end door, interior protection and towing sensor are disarmed by the rear-end
door remote control; all other ATA alarm inputs remain armed, i.e. actuated.
Rearm after automatic rear-end door remote release
If the rear-end door is relocked after rear-end door remote release, the rear-end door, interior protection and
towing sensor alarm inputs are rearmed.
Central locking (except USA version, code 494)

The central locking is a convenience function allowing the driver to close the windows and the tilting/sliding
roof (power glass tilting/ sliding roof, code 414) with the transmitter key via infrared keyless go control. With
this convenience function, the ATA can be in the arming phase or is already in the armed state. It is necessary to
deactivate the interior protection for the duration of the convenience function so that the movements of the
windows and of the tilting/sliding roof do not cause erroneous alarms of the interior protection. After rain
closing, the interior protection is always rearmed unless it has been previously deactivated in the instrument
cluster.
Disarming interior protection with central locking (except USA version, code 494)
The central locking is included by the EIS control unit on keyless go system or via an infrared command by the
left front door control unit N69/1.
As soon as the rear SAM control unit (with armed ATA only) receives a convenience message from one of
these CAN subscribers, it transmits the corresponding message to the overhead control panel control unit for
deactivating the interior protection.
Rearming interior protection with central locking (except USA version, code 494)
Regardless of how long the convenience feature button on the transmitter key is actuated, the convenience
message is transmitted for max. 25 s by the corresponding control unit. The interior protection alarm input is
rearmed after completion of the central locking and a waiting time of 10 s or is reset to the same state as before
the central locking When the central locking function is completed, max. 35 s expire before the interior
protection is rearmed.
The waiting time of 10 s ensures that an interrupted and resumed central locking operation does not lead to the
interior protection being armed again too quickly and then having to be disarmed again (e.g.: Short IR
communication malfunction).
Deactivate anti-theft alarm GF80.50-P-

system, function 2003GZ
Trigger anti-theft alarm GF80.50-P-
system, function 2004GZ
Rear SAM control unit, GF54.21-P-
With AIRmatic (air suspension with level adjustment and
adaptive damping system (ADS), code 489 and offroad
unit, component description 6040GZE
package, code 430, except USA version, code 494
GF54.21-P-
adaptive damping system(ADS) code 489, offroad package,
6040GZU
code 430 and USA version, code 494
GF54.21-P-
adaptive damping system (ADS), code 489, except offroad
6040GZ
package, code 430
Model 164.8 with AIRmatic (air suspension with level GF54.21-P-
adjustment and adaptive damping system (ADS), code 489 6040GZA
and with USA version, code 494

Left front door control unit, GF72.29-P-
Infrared remote control
GF80.30-P-
receiver, component
6000GZ
description
Interior protection sensor, With interior monitoring (only with ATA), code 882, GF80.50-P-
component description except USA version, code 494 6000GZ
Alarm signal horn, GF80.50-P-
Except USA version, code 494
Alarm signal horn, GF80.50-P-
USA version, code 494
component description 6030GZU
Electronic ignition switch
GF80.57-P-
(EIS) control unit,
6000GZ
Transmitter key, component GF80.57-P-
description 6010GZ
Overhead control panel
GF82.20-P-
control unit, component
5216GZ
description
Roof antenna module, Except USA version, code 494 and Japanese version, code GF82.62-P-
component description 498 3127GZ
GF82.62-P-
USA version code 494
3127GZU
GF82.62-P-
Japanese version, code 498
3127GZJ
DEACTIVATE ANTI-THEFT ALARM SYSTEM, FUNCTION - GF80.50-P-2003GZ
Deactivate anti-theft alarm system (ATA)
 Unlock central locking (CL) with transmitter key (A8/1) or

 Insert transmitter key into EIS control unit (N73) or
 Unlock via Keyless Go (KG) (with Keyless Go, code 889).
The corresponding signals for the EIS control unit are read in via the controller area network bus, class B
(interior) (CAN B) by the rear SAM control unit (N10/8) The rear SAM control unit deactivates the ATA.
GF80.57-P-
6010GZ
GF54.21-P-
7030GZ
Electronic ignition switch (EIS) control unit, GF80.57-P-

GF80.50-P-
Alarm signal horn, component description With USA version, code 494
6030GZU
Model 164.1 except USA GF80.50-P-
Alarm signal horn, component description
version, code 494 6020GZ
TRIGGER ANTI-THEFT ALARM SYSTEM, FUNCTION - GF80.50-P-2004GZ
Fig. 22: Trigger Anti-Theft Alarm System Function Diagram

 Anti-theft alarm system (ATA) activated.
Alarm actuation via contact switch
If
 the rear-end door locking unit,

 the right front door rotary tumbler microswitch (M14/5s1),
 the left front door rotary tumbler microswitch (M14/6s1),
 the left rear door rotary tumbler microswitch (M14/8s1),
 the right rear door rotary tumbler microswitch (M14/9s1),
 the ATA engine hood switch,
 the spare wheel carrier "locked" switch (S151/1) (only spare wheel holder/spare wheel, code 849), or with
interior monitoring (only with ATA) code 882 (except USA version, code 494):
 the interior protection sensor (B44),
 the left rear window glass breakage sensor,
 the right rear window glass breakage sensor,
 the rear window glass breakage sensor
exit the non-actuated state for longer than 0.5 s, an acoustic and visual alarm is triggered.
Alarm actuation by alarm signal horn with additional battery (except USA version, code 494)
The alarm signal horn is actuated cyclically by the rear SAM control unit
If no answer is received from the alarm signal horn within approx. 1 s, an alarm is triggered.
Alarm signal horn (only USA version, code 494)
The alarm signal horn is a passive component and is actuated by the rear SAM control unit. There is no
communication between the rear SAM control unit and the alarm signal horn
Alarm triggering by towing sensor
If an inclination movement is recognized on the vehicle and is considered to be alarm-relevant by the ATA
inclination sensor, integrated in the rear SAM control unit, an alarm is triggered.
If the position change (e.g. tire defect) is very slow, the reference position is adapted to the vehicle position
to avoid the inclination sensor outputting a false alarm.
Alarm actuation by interior protection (with interior monitoring (only with ATA) code 882) (except USA
version, code 494)
If a movement in the vehicle interior is recognized and considered to be alarm-relevant, an alarm is output. An
alarm actuated by the interior protection sensor is transmitted via the serial interface to the overhead control
panel control unit. The overhead control panel control unit relays the alarm via the CAN-B to the rear SAM
control unit.
Alarm actuation by glass breakage sensors (with interior monitoring (only with ATA) code 882) (except
USA version, code 494)
If an interruption of the glass breakage sensor loop is recognized by the interior protection and relayed to the
overhead control panel control unit, an alarm is output. The overhead control panel control unit relays the alarm
via the CAN-B to the rear SAM control unit.
Alarm actuation by communication loss to alarm signal horn with additional battery (except USA
version, code 494)
If a reply from the alarm signal horn with additional battery is not received by the ATA after a cyclic command
with three repetitions (the cycle time is between 350 ms and 450 ms), an alarm is output. In the event of
communication loss or loss of power supply, the alarm signal horn with additional battery automatically outputs
an acoustic alarm.
Alarm actuation when voltage is too low
The operating voltage of the ATA is between 8.5 V and 15.5 V. It is possible to drop below a value of 8.5 V
when the battery discharges continuously If the operating voltage is below 8.5 V, it is no longer possible to
output a visual alarm. Due to this fact, an ATA alarm can no longer be output according to the definition.
Alarm memory
Triggered alarms (max. 15) are stored in the rear SAM control unit and the central gateway control unit (N93).
The alarm memory can be read out with STAR DIAGNOSIS. The alarm memory of the diagnosis system in the
central gateway control unit offers additional information such as the window position and the operating
voltage.
Repeated alarm
An alarm is only repeated when a new alarm procedure is accomplished after the active acoustic alarm is
terminated. Triggering the alarm again results in an extension of the visual and/or acoustic alarm. In the case of
repetition the same activation times apply as for a new actuation.
Acoustic alarm (except USA version, code 494)
The acoustic alarm is output by the alarm signal horn with additional battery. The alarm is automatically
controlled by the alarm signal horn with additional battery. An alarm can be started and stopped by the rear
SAM control unit The alarm signal horn with additional battery can trigger an acoustic alarm automatically, due
to a communication loss to the rear SAM control unit or due to the loss of supply voltage. The alarm duration is
then determined by the alarm signal horn with additional battery.
The type and duration of the alarm is coded via diagnosis and stored in the alarm signal horn with additional
battery Diagnosis of the alarm signal horn with additional battery is accessible via the rear SAM control unit.
The ATA alarm is started by the rear SAM control unit and terminated by the alarm signal horn with additional
battery automatically (exception: alarm interruption).
Acoustic alarm (only USA version, code 494)
The acoustic alarm is output by the alarm signal horn. An alarm can be started and stopped by the rear SAM
control unit.
Visual alarm
All visual signals are output via the vehicle and interior illumination. The alarm output is controlled by the rear
SAM control unit.
The type and duration of the visual alarm are stored as maps in the rear SAM control unit. The ATA alarm
requests have priority over all normal light requests.
The visual signals are output via:

 the turn signal lamps,

 the turn signal indicator lamps and
 the outside mirror turn signal lamps.

description 7010GZ
description 7030GZ
Right front door control unit, GF72.29-P-
Interior protection sensor, With interior monitoring (only with ATA), code GF80.50-P-
component description 882, except USA version, code 494 6000GZ
Alarm signal horn component GF80.50-P-
description 6020GZ
Alarm signal horn, component GF80.50-P-
With USA version, code 494
description 6030GZU
TRIGGER ALARM WITH PANIC SWITCH, FUNCTION - GF80.50-P-3014GZU
MODEL 164 with CODE (551) Anti-theft alarm system (ATA [EDW]) with CODE (494) USA version
Switch on/off panic alarm
Fig. 23: Trigger Alarm With Panic Switch Function Diagram - Switch On/Off Panic Alarm
Trigger panic alarm
When the "PANIC" transmitter button on the transmitter key is pressed for approx. 2 s, this signal is transmitted
to the roof antenna module via radio. This is relayed to the EIS control unit via the rear SAM control unit.
Parallel to the radio signal, an infrared signal is transmitted to the left front IR receiver (precise aiming
required). This signal is read in by the left front door control unit and transmitted via CAN B to the EIS control
unit which checks the access authorization.
In both cases, the EIS control unit checks the access authorization of the transmitter key. If the access
authorization is valid, the EIS control unit transmits the request "Panic alarm" to the CAN B. The rear SAM
control unit triggers a visual and acoustic alarm regardless of the ATA status.
The panic alarm has priority over the ATA alarm.
Terminate panic alarm
 Actuate "PANIC" button on transmitter key or

 insert transmitter key into EIS control unit
Visual alarm
All visual signals are output via the vehicle and interior illumination for 180 s. The alarm output is controlled by
the rear SAM control unit.
Visual signals are output via:
 the taillamps and rear fog lamps,

 the front fog lamps (with bi-xenon headlamp unit with integrated asymmetric curve illumination, code
616),
 the low beams (except bi-xenon headlamp unit with integrated asymmetric curve illumination, code 616).
Acoustic alarm
Acoustic panic alarm is performed for 185 s by the:
 Alarm signal horn

Infrared remote control receiver, component description GF80.30-P-6000GZ
Alarm signal horn, component description GF80.50-P-6030GZU
Transmitter key, component description GF80.57-P-6010GZ
Overhead control panel control unit, component description GF82.20-P-5216GZ
Roof antenna module, component description GF82.62-P-3127GZU
ALARM SIGNAL HORN, COMPONENT DESCRIPTION - GF80.50-P-6030GZU

MODEL 164 with CODE (551) Anti-theft alarm system (ATA [EDW]) with CODE (494) USA version
Location
The alarm signal horn is installed in the center of the firewall.
Fig. 24: Identifying Alarm Signal Horn - Shown On Model 164.1

Task
The alarm signal horn outputs acoustic signals via the anti-theft alarm (ATA) system.
Function
The alarm request is transmitted by the rear SAM control unit (N10/8).
OVERVIEW OF SYSTEM COMPONENTS FOR ANTI-THEFT ALARM SYSTEM (ATA) - GF80.50-

P-9998GZ

Upper control panel control With AIRmatic (air suspension with level adjustment and GF54.21-P-
unit, component description adaptive damping system (ADS), code 489, except 6040GZ
offroad package, code 430
GF54.21-P-
adaptive damping system (ADS), code 489, offroad
6040GZU
package, code 430 and USA version, code 494
GF54.21-P-
adaptive damping system (ADS), code 489 and offroad
6040GZE
package, code 430, except USA version, code 494
Model 164.8 with AIRmatic (air suspension with level
GF54.21-P-
adjustment and adaptive damping system (ADS), code
6040GZA
489 and with USA version, code 494
Infrared remote control
GF80.30-P-
receiver, component
6000GZ
description
Electronic ignition switch
GF80.57-P-
(EIS) control unit, component
6000GZ
description
Transmitter key, component GF80.57-P-
description 6010GZ
Overhead control panel control GF82.20-P-
unit, component description 5216GZ
Roof antenna module, Except USA version, code 494 and Japanese version, GF82.62-P-
component description code 498 3127GZ
GF82.62-P-
3127GZU
GF82.62-P-
With Japanese version, code 498
3127GZJ
Interior protection sensor, With interior monitoring (only with ATA) code 882, GF80.50-P-
component description except USA version, code 494 6000GZ
Alarm signal horn component GF80.50-P-
description 6020GZ
Alarm signal horn, component GF80.50-P-
description 6030GZU
Table of contents for function
GF80.50-P-
description of anti-theft alarm
0999GZ
system (ATA)
DRIVE AUTHORIZATION SYSTEM LEVEL 3 (DAS [FBS] 3), FUNCTION - GF80.57-P-0003GZ
MODEL 164
Fig. 25: Function Diagram Of Drive Authorization System Level 3 (DAS [FBS] 3)
Description
The drive authorization system stage 3 (DAS 3) is a system combination of control units consisting of:
 EIS control unit

 ME control unit
 VGS control unit
 Intelligent servo module for DIRECT SELECT
The encrypted data is exchanged between the transmitter key and the EIS control unit via infrared signal The
code is computed in dialog between the transmitter key and the EIS control unit using the Hash method.
The corresponding Hash value of the transmitter key is transmitted to control units by the EIS control unit.
Check, release and feedback is performed separately by each control unit.
Hash function
The encrypted base module is a so-called Hash function. The most important property of the Hash function is
the one-way characteristic. This means that another number can be calculated using the Hash function from an
initial number, however that calculation of the initial number in the opposite order is practically impossible.
Function
When inserted into the EIS control unit, the power supply to the transmitter key is established inductively via a
coil in the EIS control unit so that the vehicle can be started even when the transmitter key battery is discharged.
Bi-directional infrared communication is accomplished between the transmitter key and the EIS control unit
The function buttons of the transmitter key are not active as long as the key is inserted in the EIS control unit
Transmitter key in position "A"

 The inductive energy transmission to the voltage supply of the transmitter key is switched on.
 Encrypted data exchange between transmitter key and EIS control unit for identification.
The next Hash values are calculated in the transmitter key. After completion of the calculation, the energy
transmission is switched off. After positive identification the following is performed:
 Release of lift solenoid for rotary lock in EIS control unit for transmitter key (up to 31.5.07)
 Key position recognition switched on
 Wake-up of controller area network bus class B (interior compartment) (CAN-B) and CAN-C
 Output of circuit 15C
As of 1.6.07 the rotary lock in the EIS control module is eliminated. It is not possible to active any terminals
with an incorrect transmitter key or a transmitter key which is not functioning properly. The note "Key does not
belong to vehicle" appears in the instrument cluster.
Transmitter key in position "B"
 Actuation of circuit 15R

 Output of status circuit 15R to CAN-B and CAN-C
The transmitter key cannot be removed in position "B".
Transmitter key in position "C"
 Circuit 15 is actuated
 Output of status circuit 15 and circuit 15X to CAN-B and CAN-C
 Encrypted request for ME-SFI Control unit
 Encrypted request for VGS control unit
 Encrypted request for intelligent servo module for DIRECT SELECT
The transmitter key cannot be removed in position "C".
Transmitter key in position "D"
 Actuation of starter (M1) via ME-SFI control unit

 Output of status for circuit 50 to CAN-B and CAN-C
 C. 15X is removed from CAN-B and CAN-C until c. 50 is again off and the engine is running (c. 61)
The transmitter key automatically returns to position "C" when released
Take vehicle out of operation
Turning transmitter key back to left switches off the engine.

The following functions are implemented in the EIS control unit:
Transmitter key in position "B"
 Switch off signals circuit 15 and 15X

 Adjust CAN C communication
Transmitter key in position "A"
 Open load switch circuit 15R

 Transmitter key can be removed (selector lever in position P).
 The P-position of the transmission is actuated by the intelligent servo module for DIRECT SELECT.
 Key-P-function: When the transmitter key is removed, the EIS control module requests the intelligent
servo module for DIRECT SELECT to shift to drive stage "P" via the CAN-C
With code (889) Keyless Go:
When the driver door is open, the EIS control module sends a request to the intelligent servo module for
DIRECT SELECT via CAN-C to shift to drive stage "P".
 The emergency P path of the intelligent servo module for DIRECT SELECT is actuated by an error in the
EIS control module or in the intelligent servo module for DIRECT SELECT. To ensure this function, a
back-up battery is present, in addition to the primary power network The emergency P path is actuated via
a switch in the EIS control module in the intelligent servo module for DIRECT SELECT, releasing a
spring mechanism, making it possible to shift to transmission position "P.
The EIS control unit can request a new check for identification of the transmitter key during restart without
removing the key.
Memory block, memory block number, key dependency
The EIS control unit has 8 so-called key rails for operating 8 transmitter keys. One memory block number each
is assigned to key rails 1, 2 and 3. The third memory block number is used when the key assignment is switched
off and for key rails 3 to 8. The memory block number is required for key-dependent storage (e.g. adjusting the
air conditioning or the instrument cluster (A1)).
Output of memory block number to CAN-B
Output of the memory block number is performed by the EIS control unit by:
 Open central locking (CL) with transmitter key

 Insert or remove transmitter keys from EIS control unit
GF80.57-P-0003-
Drive authorization system, stage 3 (DAS 3), location of components
01GZ
GF80.57-P-0003-
Drive authorization system, stage 3 (DAS 3), block diagram
02GZ
Transmitter key, component description A8/1 GF80.57-P-6010GZ
Electronic ignition/starter switch control unit (EIS), component
N73 GF80.57-P-6000GZ
description
Drive authorization system, stage 3 (DAS 3), location of components - GF80.57-P-0003-01GZ
Fig. 26: Identifying Drive Authorization System Stage 3 (DAS 3) Components Location
Drive authorization system, stage 3 (DAS 3), block diagram - GF80.57-P-0003-02GZ
Fig. 27: Block Diagram Of Drive Authorization System Stage 3 (DAS 3)

CONTENTS, FUNCTION DESCRIPTION OF DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS

3) - GF80.57-P-0999GZ
MODEL 164
Drive authorization system, stage 3 (DAS 3), function GF80.57-P-0003GZ

Drive authorization system, stage 3 (DAS 3), location of components GF80.57-P-0003-01GZ
Drive authorization system, stage 3 (DAS 3), block diagram GF80.57-P-0003-02GZ
Survey, system components, drive authorization system, stage 3 (DAS 3), GF80.57-P-9998GZ
ELECTRONIC IGNITION/STARTER SWITCH CONTROL UNIT (EIS), COMPONENT

MODEL 164
Fig. 28: Identifying EIS [EZS] Control Unit

Location
The EIS control unit is located in the cockpit on the right next the steering column below the instrument cluster
(A1).
Task
 Drive authorization functions according to drive authorization system stage 3 (FBS 3)

 Control of central locking (CL)
 Infrared (IR) communication with transmitter key (A8/1) in inserted state and inductive energy
transmission onto transmitter key
 Transmission of request data (key identification) for releasing the ME-SFI control unit (N3/10) and the
intelligent servo module for DIRECT SELECT (A80) according to DAS 3
 Rotation-angle dependent activation of circuits 15R, 15, 50
 Output of terminals to controller area network bus class C (engine compartment) (CAN-C) and controller
area network bus class B (interior compartment) (CAN-B)
 Locking transmitter key in turned position
 Transmitter key returns from start to drive position
 Prevention of turning an invalid transmitter (rotary lock) (up to 31.5.07)

 Assignment of transmitter key to memory functions
 Key-P-function: When the transmitter key is removed, the EIS control module requests the intelligent
servo module for DIRECT SELECT to shift to drive stage "P" via the CAN-C
On vehicles with code (889) Keyless Go:
 Key-P-function:
When the driver door is open, the EIS control module requests the intelligent servo module for DIRECT
SELECT to shift to drive stage "P" via the CAN-C.
 Interface to keyless go control unit (N69/5) via CAN-B for keyless go access and keyless go operation
 Holding and reading in start/stop button for keyless go operation
General information:
 The limit switch for c. 15R and c. 15 are not installed in the EIS control unit. The rear SAM control unit
(N10/8) switches c. 15R and the front SAM control unit (N10) switches c. 15.
 The "Keyless lock function" is replaced with "key-P function".
 The "Remote door unlock" function is enabled in the EIS control unit by variant coding
 The EIS control unit is not a gateway.
As of 1.6.07 the rotary lock in the EIS control module is eliminated. It is not possible to active any terminals
with an incorrect transmitter key or a transmitter key which is not functioning properly. The note "Key does not
belong to vehicle" appears in the instrument cluster.
TRANSMITTER KEY, COMPONENT DESCRIPTION - GF80.57-P-6010GZ
MODEL 164
Fig. 29: Identifying Transmitter Key Component Location

Design
The transmitter key consists of an electronic key and a mechanical key (7). The electronic key contains an FM
radio transmitter, an infrared transmitter/receiver, a computer chip and transmitter button (1, 2, 3, 6) as well as
two button cells. The mechanical key (7) can be unlocked and removed with the unlock slider (5).
Locking central locking (CL)
Actuate "Lock" transmitter button (1):
 Press once (locking CL globally)

 Press and hold down while pointing at IR receiver (convenience closing)
Unlocking central locking (CL)
Actuate "Unlocking" (2) transmitter button
 Pressing once when set to "Selective" (driver door and fuel filler flap are unlocked)
 Press once when set to "global" (unlocks all)
 Press twice when set to "selective" (unlocks all)
 Press and hold down while pointing at IR receiver (convenience closing)
On USA version, code 494 two IR receivers are installed. Left front IR receiver (A26/1) and right front IR
receiver (A26/2).
Switches unlocking from "selective" to "global" or vice versa
 Hold "Lock" button (1) and "Unlock" button (2) simultaneously for approx. 5 s until the "Battery control"
LED (4) flashes twice.
Panic alarm
With radio remote control with panic switch, code 763 Actuate "Panic alarm" (6) transmitter button:
 Press approx. 2 s (trigger panic alarm)

 Press approx. 0.5 s (terminate panic alarm)
Open/close rear-end door transmitter button (RWTS)
Actuate "Rear-end door closing" transmitter button (3)
 Press approx. 0.5 s (open/close trunk lid)
Drive authorization stage 3 (DAS 3)
When the transmitter key is inserted into the EIS control module, it is supplied with power via an induction coil.
Data is exchanged via the infrared transmission and receiving unit for the purpose of verifying drive
authorization.
Unlock/lock vehicle doors or unlock trunk lid
When the transmitter button (1, 2 or 3) is pressed, a radio signal is transmitted by the transmitter key. Parallel to
the radio signal, an infrared signal is transmitted to the IR receiver If the signal is valid, the vehicle doors are
unlocked or lock and the trunk lid is unlocked
Mechanical key
The mechanical key (7) can be removed from the transmitter key after actuating the unlock slider (5).When the
driver door is unlocked with the mechanical key (7) the CL is not actuated
An alarm is not triggered on vehicles with anti-theft alarm system (ATA) code 551.
Convenience feature (CF)
The signals for convenience actuation are only transmitted via infrared, not via radio.
Battery check
When the transmitter button (1, 2 or 3) is actuated the "Battery control" LED (4) comes on momentarily and
indicates thereby the proper state of the batteries (two button cells) in the transmitter key
Panic alarm
With radio remote control with panic switch, code 763 When the "Panic alarm" transmitter button (6) is pressed
for approx. 2 s the panic alarm is started, the panic alarm is interrupted when the transmitter button (6) is
reactuated or when the transmitter key is inserted in the key opening on the EIS control module
Keyless Go (KG) (with Keyless Go, code 889)
Communication with the vehicle via inductive signals and radio signals. Determine request location in relation
to vehicle.
SURVEY, SYSTEM COMPONENTS, DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3), -

GF80.57-P-9998GZ
MODEL 164

Contents, function description of drive authorization system stage 3 (DAS 3) GF80.57-P-0999GZ
KEYLESS GO, FUNCTION - GF80.61-P-0005GZ
The Keyless Go system (KG) allows access to the vehicle and starting the vehicle engine without using the
transmitter key (A8/1). It is sufficient to just carry the Keyless Go transmitter key It is not necessary to actuate
or insert the remote control key into the EIS control module (N73)
Unlock
The vehicle can be unlocked by:
 pulling any door handle
(global or selective opening).
 pulling the rear-end door handle
(only rear-end door is opened).
Lock
The vehicle can be locked by:

 Actuation of left front door handle switch (S17/19), left rear door handle switch (S17/20), right rear door
handle switch (S17/21) or right rear door handle switch (S17/22) on outer door handle.
 actuation of rear-end door Keyless Go button (S62/21) on rear-end door
The standard central locking (CL) remote control function is maintained parallel to the Keyless Go (KG)
functions.
On vehicles with code 551 anti-theft alarm system (ATA) the antitheft alarm system (ATA) functions in the
same manner as when locking/unlocking the CL with the transmitter key
The engine can be started or switched off by pressing the Keyless Go start/stop button in the EIS control unit
unless a Keyless Go transmitter key is inside the vehicle.
It is also possible to start or switch off the engine "normally" with the transmitter key via the EIS control unit
after removing the start/stop button
Start engine and switch off
This function is performed by inserting the start/stop button into the EIS control unit (N73).
Locating areas of transmitter key
In the following areas, the transmitter key is located and checked for validity when the system is activated
Vehicle surroundings
 Outer range (A) is covered by the left rear door Keyless Go antenna (A2/39).
 Outer range (B) is covered by the right rear door Keyless Go antenna (A2/41).
 Outer range (C) is covered by the trunk Keyless Go antenna (A2/35).
Fig. 30: Identifying Vehicle Surroundings Area

Passenger compartment
 The inner area of vehicle (D) is covered by the Keyless Go cockpit antenna (A2/60) and the Keyless Go
interior antenna (A2/61)
 The outer areas on the opposite side (A, B and C) are also covered.
Sequence of position determination
The remote control requests a message from the antennas in a fixed sequence when the Keyless Go system
(KG) is activated. From these messages, the transmitter key can determine its position in relation to the vehicle
(different signal amplitudes) and can transmit it to the Keyless Go (N69/5) control unit via the roof antenna
module (A2/93).
Keyless Go, location of components GF80.61-P-0005-01GZ

Keyless Go block diagram GF80.61-P-0005-02GZ
Unlock, function GF80.61-P-2009GZ
Lock, function GF80.61-P-2010GZ
Engine start/stop, function GF80.61-P-3012GZ
Keyless Go, location of components - GF80.61-P-0005-01GZ

Fig. 31: Identifying Keyless Go Components Location - Shown On Model 164.1

Keyless go block diagram - GF80.61-P-0005-02GZ

Fig. 32: Keyless Go Block Diagram

CONTENTS, FUNCTION DESCRIPTION OF KEYLESS GO - GF80.61-P-0996GZ
MODEL 164 with CODE (889) Keyless Go
Keyless Go, function GF80.61-P-0005GZ

Keyless Go, location of components GF80.61-P-0005-01GZ
Keyless Go block diagram GF80.61-P-0005-02GZ
Unlock, function GF80.61-P-2009GZ
Lock, function GF80.61-P-2010GZ
Engine start/stop, function GF80.61-P-3012GZ
Survey of system components for Keyless Go (KG) GF80.61-P-9995GZ
UNLOCK, FUNCTION - GF80.61-P-2009GZ
Illustrated on model 164.1, function sequence for door handle control point
Fig. 33: Unlock Function Diagram - Illustrated On Model 164.1, Function Sequence For Door Handle
Control Point
 Circuit 30
Possible system activation
 Pulling at a door handle.

 Pulling rear-end door handle.
Function sequence for door handle control point
The capacitive sensor in the door handle recognizes when the corresponding door handle is pulled slightly and
transmits a signal to wake up the Keyless Go control unit and the Keyless Go system (KG)
The Keyless Go control unit transmits a signal via the Keyless Go cockpit antenna and Keyless Go interior
compartment antenna to mute all transmitter keys in the interior compartment for a certain period of time.
Moreover, the Keyless Go control unit causes the Keyless Go transmitter key to transmit its authorization via
the left rear door Keyless Go inductive antenna.
This access authorization is received by the roof antenna module and is relayed to the Keyless Go control unit.
The Keyless Go control unit transmits this message to EIS control unit via the CAN-B bus
The EIS control unit checks the access authorization; after positive check, it transmits the "Unlocking"
command via the CAN-B bus. If a door handle is now pulled within 0.5 s, the Hall sensor in the door recognizes
this and the Keyless Go control unit activates the servo motor of this door.
All door locks are equipped with a servo motor to accelerate unlocking. This motor is directly actuated by
the Keyless Go control unit to open to rotary tumbler. The CL motors are responsible for opening the doors.
The actuation of the central locking depends on the adjustment of the transmitter key
Possible adjustments:
 Unlock CL globally
 Unlock CL selectively
Driver door control point: Selective unlocking
Passenger door control point or rear door: Global unlocking
A button for pressing is located on the corresponding outer side of the door handle; the vehicle is locked or
convenience closed with this button. A capacitive sensor with which the vehicle is unlocked in the event of
contact, is located on the inside of each door handle Each door handle is read in by the Keyless Go control unit
with two lines.
Function sequence for rear-end door handle control point
When the rear-end door handle is pulled the rear-end door handle switch (S88/9) is actuated. The procedure is
recognized by the rear SAM control unit and relays the message to the Keyless Go system (KG) via the CAN-B
bus. Then, the Keyless Go control unit requests the Keyless Go transmitter key to transmit its authorization via
the Keyless Go trunk antenna. This authorization is relayed to the Keyless Go control unit by the roof antenna
module. The Keyless Go control unit transmits the message to the EIS control unit, it checks the access
authorization and transmits the "Unlocking" command via CAN-B bus. The further function sequence is the
same as for the door handle control point.

Keyless Go control unit, component description GF80.61-P-4200GZ
LOCK, FUNCTION - GF80.61-P-2010GZ
Illustrated on model 164.1, function sequence for door handle control point
Fig. 34: Lock Function Diagram - Illustrated On Model 164.1, Function Sequence For Door Handle
Control Point
 C. 15 OFF
 All doors closed
 Transmitter key outside of vehicle
 The transmitter key is located in the vicinity (radius approx. 1 m) of a door handle.
Possible system activation
 Actuate corresponding button on door handle

 Actuate rear-end door Keyless Go button
Function sequence for door handle control point
The capacitive sensor in the door handle recognizes when the corresponding door handle is pulled slightly and
transmits a signal to wake up the Keyless Go control unit and the Keyless Go system (KG)
The Keyless Go control unit transmits a signal via the Keyless Go cockpit antenna and Keyless Go interior
compartment antenna to mute all transmitter keys in the interior compartment for a certain period of time.
Then a Keyless Go transmitter key should be recognized in the outer range, otherwise locking is not performed.
The access authorization from the Keyless Go transmitter key are received by the roof antenna module and are
relayed to the Keyless Go control unit The Keyless Go control unit transmits this message to EIS control unit
via the CAN-B bus
The EIS control unit checks the access authorization, after positive check it transmits the "Locking" command
via the CAN-B bus. The "Locking" command is transmitted to the left and right front door control unit as well
as to the rear SAM control unit. They then lock the door locks, the tank flap and the rear-end door electrically.
Errors occurring when locking are indicated by the instrument cluster (A1).
Function sequence for rear-end door Keyless Go button control point
When the rear-end door Keyless Go button is pressed the Keyless Go system (KG) is woken up The further
function sequence is the same as for the door handle control point.
Convenience closing
When the corresponding door handle switch is actuated for longer than t > 1.5 s, the "Convenience closing"
command is transmitted to the CAN-B bus.
The windows and tilting/sliding roof (SR) (with power glass tilting/ sliding roof, code 414) are also closed.
The convenience closing function is interrupted by pulling the door handle The windows and the
tilting/sliding roof are actuated in the opening direction for approx. 2 s.

ENGINE START/STOP, FUNCTION - GF80.61-P-3012GZ
MODEL 164 with CODE (889) Keyless-Go.

Fig. 35: Engine Start/Stop Function Diagram - Shown On Model 164.1

Function
The engine can be started or switched off by pressing the start/stop button.
Start engine
 The transmitter key is located in the vehicle interior

 Selector lever is in position "P" or "N"
 Service brake applied
Function sequence
When the start/stop button is pressed, the KEYLESS-GO system (KG) is woken up and the signal "Start
engine" is transmitted to the EIS control unit
Parallel to this, the KEYLESS-GO control unit searches for and wakes up a valid transmitter key via the
KEYLESS-GO cockpit antenna and the KEYLESS-GO interior antenna. The position of the transmitter key is
transmitted to the KEYLESS-GO control unit via the roof antenna module. The KEYLESS-GO control unit
transmits the access authorization code to the EIS control unit via CAN B.
If the access authorization is valid, circuit 15R and circuit 15 are switched on, if not already switched off, and
the engine is started.
If the start/stop button is pressed, without the foot brake being operated, circuit 15R is switched on. Repeated
actuation actuates circuit 15. Repeated pressing switches off the circuit 15. If the driver door is closed, circuit
15C remains active for approx. 30 minutes.
Errors occurring are output by the instrument cluster If a transmitter key is not recognized in the interior
compartment when starting, the instrument cluster indicates "Key not recognized" and the start attempt is
interrupted (circuit 15R and circuit 15 remain off). If the selector lever is not in position "P" when an attempt is
made to start, the instrument cluster indicates "Selector lever to P or N".
Additional circuit switching operations are given in the table below.
Switch off engine
 Selector lever is in position "P" or "N"
The position of the transmitter key is not checked.
Function sequence
The engine can be switched off any time by pressing the start/stop button the EIS control unit.
While driving, the start/stop button must be actuated for at least 3 s to shut off the engine.
Parallel to this, the selector lever position is checked.
The engine is switched off through circuit 15. When the driver door is closed, circuit 15R remains active and
the steering is unlocked.
If the selector lever is not in position "P" when the engine is switched off, an audible warning signal sounds and
the following text appears in the instrument cluster: "Selector lever to P or N". If the selector lever is not in
position "P" or "N" when an attempt is made to switch the engine off and the transmitter key is recognized, the
text "Selector lever to P or N" appears in the instrument cluster.
If a door is opened when the engine is running and the vehicle is standing still, the EIS control unit checks the
key when restarting If a transmitter key is not recognized in the interior compartment of the vehicle, the
instrument cluster indicates "Key not recognized" The engine remains on, however, the car should be taken to a
workshop without delay. If the transmitter key is available, the vehicle should be restarted with the transmitter
key.
If the functions described are activated via the start/stop button and a valid transmitter key is inserted in the EIS
control unit, the transmitter key is given priority if the selector lever is in position "P". If running, the engine is
switched off.
If, after starting the engine, the transmitter key can no longer be located in the vehicle interior (system error or
transmitter key not present), the instrument cluster outputs a warning message for approx. 5 s.
This is repeated every 5 km. After traveling > 20 km, a continuous warning message is output and an
intermittent gong sounds.
Vehicles up to 31.5.07:
Next time the vehicle stops (v = 0 km/h) the engine is automatically switched off.
Vehicles as of 1.6.07:
These warning messages are maintained until the driver switches off the engine (no automatic engine switch-
off).
In this case, it is not possible to start the engine on either version.
Actuation with Status after actuating Status after actuating

start/stop button Status after actuating start/stop button start/stop button
Initial status: Preconditions: Preconditions:
start/stop button
Prerequisite:  Driver door is opened  Driver door remains
 Circuit 15R
Off, after operating closed after operating
 Selector lever in
pushbutton pushbutton,
 Circuit 15 position "P" or
Off and "N"  Service brake not  Service brake not
actuated when actuated when
 Engine Off
operating pushbutton. operating pushbutton.
Circuit 15 On, engine is
started Requirement:
1st actuation Circuit 15R On Circuit 15R On
 Service brake
operated
Circuit 15R On, engine
is switched off
2nd actuation Requirement: Circuit 15 On Circuit 15 On
 Doors closed
Circuit 15 On, engine is

3rd actuation Circuit 15 Off Circuit 15 Off
started
Circuit 15R Off Circuit 15R Off
Circuit 15C On Circuit 15C Off
Requirement:
 Service brake
operated
Transmitter key, component description A8/1 GF80.57-P-6010GZ

Keyless-Go control unit, component description N69/5 GF80.61-P-4200GZ
Electronic ignition switch control unit (EIS), component description N73 GF80.57-P-6000GZ
KEYLESS GO CONTROL UNIT, COMPONENT DESCRIPTION - GF80.61-P-4200GZ
Shown on model 164.1 Left rear door
Location
The Keyless Go control unit is located in the right rear in the trunk below the window.
Fig. 36: Identifying Keyless Go Control Unit - Shown On Model 164.1 Left Rear Door
Task
The Keyless Go control unit has the purpose to read in, evaluate and actuate data.
The Keyless Go control unit has the following purposes:
Scan
 Left front door Keyless Go door handle (A17/1)

 Right front door Keyless Go door handle (A17/2)
 Left rear door Keyless Go door handle (A17/3)

 Right rear door Keyless Go door handle (A17/4)
A button for pressing is located on the corresponding outer side of the door handle; the vehicle is locked or
convenience closed with this button. A capacitive sensor is located on the inside of each door handle with which
the control unit initiates a contact for key search. The Hall sensor recognizes when a door handle is pulled; this
opens the vehicle door and the servo opening is actuated. Each door handle is read in by the Keyless Go control
unit with two lines and processed.
Read in switches on rear-end door
 Rear-end door Keyless Go button (S62/21)
Actuate
 Right front door CL motor (M14/5)

 Left front door CL motor (M14/6)
 Left rear door CL [ZV] motor (M14/8)
 Right rear door CL [ZV] motor (M14/9)
Only the servomotors really present in the CL motors are actuated They act on the rotary tumbler of the lock
to unlock the door. A limit switch sensing the position of the servo motor, is also read in and processed.
Actuation and evaluation
 Keyless Go trunk antenna (A2/35)

 Left rear door Keyless Go antenna (A2/39)
 Right rear door Keyless Go antenna (A2/41)
 Keyless Go cockpit antenna (A2/60)
 Interior Keyless Go antenna (A2/61)
The CL antenna in the roof antenna module is also read in (A2/93). The CL antenna is actuated directly via a
splitter for the Keyless Go request. The Keyless Go antenna operates at a frequency of 125 kHz.
The Keyless Go key transmits at the following frequencies: ECE with 433.92 MHz and USA with 315 MHz.
Signal inputs and signal outputs
Discrete inputs
 Circuit 30
 Circuit 31
 Door handles
 Microswitch for servo motors (in door locks)

 Close button for rear-end door
 Roof antenna module
 Keyless Go antennas
Discrete outputs
 Servo motors for actuating rotary tumblers (in door locks)

 Door handles
 Roof antenna module
 Keyless Go antennas
SURVEY OF SYSTEM COMPONENTS FOR KEYLESS GO (KG) - GF80.61-P-9995GZ
MODEL 164 with CODE (889) Keyless Go

Contents, function description of Keyless Go GF80.61-P-0996GZ
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CENTRAL LOCKING, CONVENIENCE
FEATURE, DRIVE AUTHORIZATION SYSTEM - AR80.00-Z-9164AA
MODEL 164
Remove/install fuel filler flap CL AR80.20-P-

MODEL 164
element 2300GZ
Remove/install Keyless Go control AR80.35-P-
unit 0001GZ
AR80.35-P-
Check batteries for transmitter key MODEL 164 with CODE (889) Keyless go
4205GZ
AR80.35-P-
Check batteries for transmitter key MODEL 164 except CODE (889) Keyless go
4205GZA
Remove/install batteries for AR80.35-P-
MODEL 164 with CODE (889) Keyless go
transmitter key 4210GZ
Remove/install batteries for AR80.35-P-
MODEL 164 except CODE (889) Keyless go
transmitter key 4210GZA
Remove/install ATA alarm signal MODEL 164 with CODE (551) Anti-theft AR80.50-P-
siren alarm system (ATA [EDW]) 9840GZ
Remove/install electronic ignition AR80.57-P-
switch control unit MODEL 164 1000GZ
REMOVE/INSTALL FUEL FILLER FLAP CL ELEMENT - AR80.20-P-2300GZ
MODEL 164
Fig. 37: Identifying Fuel Filler Flap CL Element Components - Shown On Model 164.1
Remove/install

Risk of explosion caused by fuel igniting, risk of smoking. Pour fuels only into
poisoning caused by inhaling and swallowing suitable and appropriately AS47.00-Z-
fuel as well as risk of injury to eyes and skin marked containers. 0001-01A
caused by contact with fuel. Wear protective clothing when
handling fuel.
AR88.60-P-
1 Remove tank recess
2000GZ
Turn locks (5) to horizontal position and remove
2.1 Model 164.1
side load compartment paneling (6)
AR68.30-P-
2.2 Remove right rear side paneling Type 164.8 4800RT
3 Remove metal clip (3) with cord (2)

4 Remove insulating mats in right rear side section So that cord (2) can be laid.
Until inner retaining clips (1)
Slide fuel filler flap CL motor (M14/10) toward
5 and outer retaining clips (4) are
front of vehicle
loosened.
Remove plug from fuel filler flap CL motor
6
(M14/10) at bottom.
Remove fuel filler CL motor (M14/10) toward
7.1 Model 164.1
inside in direction of load compartment
Remove fuel filler flap CL motor (M14/10)
7.2 Type 164.8
toward outside through tank opening.
REMOVE/INSTALL KEYLESS GO CONTROL UNIT - AR80.35-P-0001GZ
Fig. 38: Identifying Keyless Go Control Unit Components - Shown On Model 164.1
MODIFICATION NOTES
26.7.06
"Disconnect/connect ground line for battery" and "Perform basic programming" Steps 2 and
eliminated 7
Remove/install
Notes on avoiding damage to electronic components due to electrostatic AH54.00-P-0001-

discharge 01A
1 Open tailgate
2 Remove cover (1)
3 Unscrew nuts (2) and expose keyless go control unit (N69/5)
Disconnect electrical connector (3, 4, 5) as well as antenna cable
4
connector (6)
CHECK BATTERIES FOR TRANSMITTER KEY - AR80.35-P-4205
Check batteries for transmitter key - AR80.35-P-4205GZ
Fig. 39: Identifying Inspection Window, Lock Button, Release Button And Trunk Lid Remote Release
Button
Check
Hold lock button (2), release button (3) or Ensure that the LED in the inspection
1 trunk lid release button (4) for longer window (1) comes on momentarily If
than one second necessary: ?
AR80.35-P-
Replace batteries for transmitter key.
4210GZ
Check batteries for transmitter key - AR80.35-P-4205GZA
Fig. 40: Identifying Inspection Window, Lock Button, Release Button And Trunk Lid Remote Release
Button
Check
Hold lock button (2), release button (3) Ensure that the LED in the inspection
1 or trunk lid release button (4) for longer window (1) comes on momentarily If
than one second necessary: ?
AR80.35-P-
Replace batteries for transmitter key.
4210GZA
REMOVE/INSTALL BATTERIES FOR TRANSMITTER KEY - AR80.35-P-4210

Remove/install batteries for transmitter key - AR80.35-P-4210GZ
Fig. 41: Identifying Batteries Components For Transmitter Key

Remove/Install

AH54.00-
P-0001-01A
Slide lock (6) to side (arrow A) and
1 pull out mechanical key (5) (arrow
B)
2 Actuate lock (8) with mechanical Carefully remove battery compartment to

key (arrows C and D) while pulling prevent damaging electrical contacts!
battery compartment (9) out of Installation: Battery compartment should

transmitter key (arrow E) arrest in transmitter key
Do not damage or contaminate contact
Carefully slide out battery (10) in spring
3
direction of arrow (F) Installation: Observe polarity (positive sign
points upward)
Carefully slide out battery (11) in spring
4
direction of arrow (G) Installation: Observe polarity (positive sign
points upward)
Ensure that the LED in the inspection
Ensure that battery functions window (1) comes on momentarily when the
6 lock button (2), the release button (3) or the
properly
trunk lid remote release button (4) is pressed
for longer than one second.
Remove/install batteries for transmitter key - AR80.35-P-4210GZA
Fig. 42: Identifying Batteries Components For Transmitter Key

Remove/Install

AH54.00-
P-0001-01A
Slide lock (6) to side (arrow A) and

1 pull out mechanical key (5) (arrow
B)
Actuate lock (8) with mechanical Carefully remove battery compartment to
key (arrows C and D) while pull prevent damaging the electrical contacts!
2
battery compartment (9) out of Installation: Battery compartment should
transmitter key (arrow E) arrest in transmitter key
Carefully slide battery (10) and
spring
3 battery (11) in direction of arrow
(F) in sequence Installation: Observe polarity (positive sign
points upward)
Ensure that the LED in the inspection
Ensure that battery function window (1) comes on momentarily when the
5 lock button (2), the release button (3) or the
properly
trunk lid remote release button (4) is pressed for
longer than one second.
REMOVE/INSTALL ATA ALARM SIGNAL SIREN - AR80.50-P-9840GZ

Fig. 43: Identifying ATA Alarm Signal Siren Components - Shown On Model 164.1 With Engine 272
Remove/install
Partially loosen engine partition

1 In right area.
wall seal (1)
Remove wiring harness (5) from
2.1 If present.
bracket (4)
Unscrew bolts (2) and remove Installation: The cover (3) has an additional retaining lug
3 in the rear area. It should reach into a corresponding lug in the
cover (3).
bottom section of the dividing wall.
Unscrew nut 86) and remove
4
alarm signal horn (H3)
Unscrew bolts (7) to disconnect
5 alarm signal horn (H3)
electrically.
6 Remove alarm signal horn (H3)
REMOVE/INSTALL ELECTRONIC IGNITION SWITCH CONTROL UNIT - AR80.57-P-1000GZ
MODEL 164
Fig. 44: Identifying Electronic Ignition Switch Control Unit Components - Shown On Model 164.1
MODIFICATION NOTES
"Disconnect/connect ground line for battery" and "Perform basic programming" Steps 2 and
26.7.06
eliminated 8
Remove/install

AH54.00-P-
0001-01A
Only when replacing EIS control unit
(N73).
Installation: Transfer basic data from
Transfer basic data for EIS control STAR DIAGNOSIS to EIS control module
1
unit (N73) in STAR DIAGNOSIS (N73).
On vehicles with power glass tilting/sliding
roof, code 414 it is essential to perform the
teach-in run for anti-pinch protection of
sliding roof.
*WH58.30-Z-
1048-13A
AR82.60-P-
2 Remove radio (A2) Do not disconnect electrically 7502GZ
Unscrew trim ring (1) with claw
Claw-type wrench for ignition / starter
3 wrench from ignition/starter Fig. 45
switch. switch trim ring
Remove EIS control module Access through radio installation shaft.
4 (N73) from instrument panel Installation: Ensure correct installation
bottom section (2) toward rear. position.
Unplug electrical connectors (3)
5 and remove electronic ignition
switch control unit (N73)
Fig. 45: Identifying Claw-Type Wrench For Rosette On Ignition Switch (210 589 00 07 00)

Number Designation
2006-2008 HVAC Climate Control - 164 Chassis
2006-2008 HVAC
Climate Control - 164 Chassis
DESCRIPTION & OPERATION

DIAGNOSIS TREE FOR ODOR COMPLAINT - SI83.00-P-0004-01A
Fig. 1: Diagnosis Tree For Odor Complaint (1 Of 2)

Fig. 2: Diagnosis Tree For Odor Complaint (2 Of 2)

GENERAL INFORMATION
NOTES ON HANDLING REFRIGERANT R134A - AH83.30-N-0003-01A
Air conditioning with refrigerant R134a
The refrigerant R134a is colorless and odorless.
At normal temperatures it is neither toxic nor flammable, and will not explode in the air, no matter what its
mixing ratio.
The R134a refrigerant may only be used in air conditioning systems for which R134a has been specifically
approved.
The refrigerant R134a must not be mixed with other refrigerants (e.g. R12).
The refrigerant R134a does not contain any chlorofluorocarbons (CFC). In contrast to other refrigerants (e.g.
R12) it is not hazardous to the environment at normal temperatures. The refrigerant R134a does not damage the
earth's ozone layer.
Despite these benefits, refrigerant R134a may only be extracted by experts with suitable extraction, recycling
and filling equipment that includes integral disposal and reprocessing capabilities.
CONDUCT IF AIR CONDITIONING SYSTEM IS DAMAGED OR LEAKING - AH83.30-N-0004-01A
All models
The air conditioning system should never be operated if it is damaged or when there is evidence of refrigerant
loss.
In the event that refrigerant is lost, lubrication can fail. This will lead to damage of the refrigerant compressor.
Evacuate damaged and/or leaking air conditioning refrigerant circuits as quickly as possible using extraction,
processing and recharging equipment with integral disposal and reprocessing capabilities.
PROTECT AIR CONDITIONING CIRCUIT AND COMPONENTS FROM MOISTURE WHEN

CARRYING OUT REPAIR WORK - AH83.30-N-0005-01A
All models fitted with air conditioning
Do not carry repair operations out on the air conditioning circuit in the open air during moist weather.
Moisture in the refrigerant circuit reduces the system's refrigeration output and leads to damage to the
components. The acidic substances produced by moisture within the system decompose the desiccant in the
fluid reservoir and damage the entire system.
After separating/unscrewing refrigerant lines, immediately seal off the connection openings so that they are
airproof using suitable stop plugs (parts kit).
Replace the fluid reservoir every time you open up the refrigeration circuit.
Always store all spare components in a dry, sealed-off area. Do not remove stop plugs in new components until
just before they are installed. Use special care when handling the receiver/dryer with its integral desiccation
unit.
When a receiver/dryer is left open, the dryer unit quickly becomes saturated with moisture, rendering it useless.
Check drier cartridge packaging for damage. Dispose of drier cartridges with damaged packaging.
Install the desiccant cartridge no later than 20 minutes after opening the packaging.
Further protection against moisture is provided by carefully evacuating the air conditioning system following
repair operations. By generating vacuum in the system, the evacuation process removes any moisture that might
have penetrated into the system.
PROTECT AIR CONDITIONING CIRCUIT AND COMPONENTS FROM MOISTURE WHEN

CARRYING OUT REPAIR WORK - AH83.30-P-0005-01P
Model 164, 199, 209, 251
Model 203 with code (580a) Automatic air conditioning
Model 203 with CODE (581b) Convenience automatic air-conditioning
Do not carry repair operations out on the air conditioning circuit in the open air during moist weather.
Moisture in the refrigerant circuit reduces the system's refrigeration output and leads to damage to the
components. The formation of acid in the circuit, which is caused by moisture, decays the desiccant cartridge in
the condenser and damages the entire system.
After disconnecting or unscrewing refrigerant lines, immediately seal all connection apertures air tight with
suitable plugs (parts kit).
Install a new desiccant cartridge every time you open up the refrigeration circuit.
Always store all spare components in a dry, sealed-off area. Do not remove plugs in new components until just
before they are installed.
Check drier cartridge packaging for damage. Dispose of drier cartridges with damaged packaging.
Install the desiccant cartridge no later than 20 minutes after opening the packaging.
Further protection against moisture is provided by carefully evacuating the air conditioning system following
repair operations. By generating suction within the system, the vacuum evacuation process removes any
moisture that might have penetrated into the system during servicing.
BASIC KNOWLEDGE
VENTILATION SYSTEM, FUNCTION - GF83.10-P-2000
Ventilation system, function - GF83.10-P-2000GZ
MODEL 164 except CODE (582) Rear air conditioner
Shown on model series 164.1 with comfort automatic air conditioning, code 581
Function
The ventilation system prevents windows from misting up, provides oxygen to the occupants and ensures that
uniform and pleasant temperatures in the interior are reached quickly.
In the normal mode, when the vehicle is stationary or in order to increase the air flow, the ventilation of the
interior is achieved with assistance of the blower. Fresh air is drawn into the air conditioner housing via the air
inlet in the engine hood and via the fresh/recirculated air flap (fresh air position).
Fig. 3: Identifying Ventilation System - Model 164

The air can be guided through the air ducts and through the air outlet into the interior compartment, depending
on the settings on the AAC control and operating unit (N22) or comfort AAC control and operating unit
(N22/7). In the air recirculation mode, air is drawn out of the vehicle interior through the fresh air and air
recirculation flaps (recirculated air position) and blown into the air conditioner housing.
In order to prevent the windows from fogging up, the defroster flaps, as well as the air recirculation flap, are
closed and the footwell flaps opened completely 2 min after switching off the ignition. After starting the engine,
the defroster flaps and footwell flaps remain in this position for 30 s. The air recirculation flap is immediately
adjustable.
GF83.10-P-
Blower, component description
2050GZ
GF83.10-P-
Blower regulator, component description With automatic air conditioning, code 580
2051GZ
With comfort automatic air conditioning, GF83.10-P-
code 581 2051GZK
GF83.10-P-
Actuator motors, component description With automatic air conditioning, code 580
2201GZ
With comfort automatic air conditioning, GF83.10-P-

code 581 2201GZK

Automatic air conditioning pushbutton Except USA version, code 494, With GF83.40-P-
control unit, component description automatic air conditioning, code 580 3000GZE
With USA version, code 494, With GF83.40-P-
automatic air conditioning, code 580 3000GZU
Except USA version, code 494, With
comfort automatic air conditioning, code
581
With USA version, code 494, With
GF83.40-P-
comfort automatic air conditioning, code
3010GZU
581
Ventilation system, function - GF83.10-P-2000RTK
MODEL 251.1 /0 with CODE (581) Comfort automatic air conditioning with CODE (582) Rear air
conditioner
MODEL 164.8 with CODE (581) Comfort automatic air conditioning with CODE (582) Rear air
conditioner
Shown on model series 251
Function
The ventilation system prevents windows from misting up, provides oxygen to the occupants and ensures that
uniform and pleasant temperatures in the interior are reached quickly.
During normal operation, when the vehicle is stationary or to increase the air volume, ventilation is carried out
with the assistance of the front blower, the rear blower and, in the case of additional rear systems, with a well
"rear blower".
Fig. 4: Identifying Ventilation System - Model 251.1

Fresh air is drawn into the air conditioner housing via the air inlet in the engine hood and via the
fresh/recirculated air flap (fresh air position).
Depending on the preselection at the comfort AAC [KLA] control and operating unit (N22/7), the air is directed
through air ducts and via air outlets into the vehicle interior. In the air recirculation mode, air is drawn out of the
vehicle interior through the fresh air and air recirculation flaps (recirculated air position) and blown into the air
conditioner housing.
In order to prevent the windows from fogging up, the defroster flaps and the air recirculation flap are closed and
the footwell flaps opened completely 2 min after switching off the ignition. After starting the engine, the
defroster flaps and footwell flaps remain in this position for 30 s. The air recirculation flap is immediately
adjustable.
GF83.10-P-
2050RT
Blower, component description Except model 164.8
GF83.10-P-
2050RTH
GF83.10-P-
2051RTK
Blower regulator, component description Except model 164.8
GF83.10-P-
2051RTH
GF83.10-P-
Actuator motors, component description
2201RTK
Model 251 except code 494 USA version
and operating unit, component description 3010RT
Model 251.1 with code 494 USA version, GF83.40-P-
Model 164.8 with code 494 USA version 3010RTU
BOOSTER BLOWER, COMPONENT DESCRIPTION - GF83.10-P-2040GZ
MODEL 164 with CODE (581) Comfort automatic air conditioning
Shown on model series 164.1
Fig. 5: Identifying Booster Blower Component Location - Shown On Model Series 164.1
Location
The booster blower is located between the two front seats below the center tunnel.
Design
 Booster adapter
 Booster blower motor (M2/1)
 Rear air distribution flap actuator motor (M2/21)
 Booster blower electronic blower controller (N29/2)
 Center rear interior temperature sensor (B10/7)
Task
The booster blower is used to improve the aeration of the rear passenger compartment.
BOOSTER ADAPTER, COMPONENT DESCRIPTION - GF83.10-P-2041GZ
MODEL 164 with CODE (580) Automatic air conditioning

Fig. 6: Identifying Booster Adapter Component Location - Shown On Model 164.1

Location
The booster adapter is located between the two front seats below the center tunnel.
Design
 Booster adapter
Task
The rear air distribution flap actuator motor in the booster adapter serves for selected guidance of the air flow in
the rear passenger compartment.
BLOWER, COMPONENT DESCRIPTION - GF83.10-P-2050
Blower, component description - GF83.10-P-2050GZ
MODEL 164
Fig. 7: Identifying Blower Component Location - Model 164

Location
The blower motor is located on the right below the glove compartment in the A/C housing.
Task
The blower motor blows fresh air or air from the interior compartment through the A/C housing into the vehicle
interior.
Function
Depending on the blower stage:
 the AAC control and operating unit (N22) or

 the comfort AAC control and operating unit (N22/7) sends a control signal, via the Local Interconnect
Network (LIN), to the blower regulator (A32n1).
The blower regulator then regulates the operating voltage for the blower regulator, depending on the control
signal.
Blower, component description - GF83.10-P-2050RTH
conditioner
conditioner

Fig. 8: Identifying Blower Component Location - Shown On Model Series 251

Location
The rear air conditioning blower motor is located in the left rear directly at the rear air conditioner.
Task
The rear air conditioning blower motor blows fresh air or air from the interior compartment through the rear AC
housing into the vehicle interior.
Function
Depending on the blower stage:
 the comfort AAC [KLA] control and operating unit (N22/7) or

 the RCP [HBF] control unit (N72/2) sends a control signal via the local interconnect network (LIN) to the
rear air conditioning blower regulator (N29/7).
The rear air conditioning blower regulator then regulates the operating voltage for the rear air conditioning
blower motor depending on the control signal.
BLOWER REGULATOR, COMPONENT DESCRIPTION - GF83.10-P-2051
Blower regulator, component description - GF83.10-P-2051GZ

Fig. 9: Identifying Blower Regulator Component Location - Model 164 With Code (580)
Location
The blower regulator is located on the right below the glove compartment and is attached directly to the blower
motor (A32m1).
Task
For exchanging data via the local interconnect network (LIN), the blower regulator is connected to the AAC
[KLA] control and operating unit (N22).
The blower regulator regulates the blower motor's voltage supply depending on the particular blower stage set at
the AAC [KLA] control and operating unit.
Function
The AAC [KLA] control and operating unit relays a control voltage of 0 to 100 % to the blower regulator. This
then regulates the operating voltage for the blower motor depending on the control voltage applied from 0 to
100 %. This facilitates control of the blower motor speed from 0 - 100 %.
The blower motor regulator (operating voltage) is influenced by the following factors:
 Blower output setting (AUTO/manual)

 AC OFF (ON/OFF)
 Mode status (heating, cooling)
 Intensity of sun
 Vehicle speed
 Window, sliding roof, tilting roof positions
 Ambient temperature
 Fresh air/air recirculation flap actuator motor
 Flap positions (air distribution)
 Residual engine heat utilization function, stationary ventilation function
 Version coding
Blower regulator, component description - GF83.10-P-2051GZK

Fig. 10: Identifying Blower Regulator Component Location - Model 164 With Code (581)
Location
The blower regulator is located on the right below the glove compartment and is attached directly to the blower
motor (A32m1).
Task
For exchanging data via the local interconnect network (LIN), the blower regulator is connected to the comfort
AAC [KLA] control and operating unit (N22/7).
The blower regulator regulates the blower motor's voltage supply depending on the particular blower stage set at
the comfort AAC [KLA] control and operating unit.
Function
The comfort AAC [KLA] control and operating unit relays a control voltage of 0 to 100 % to the blower
regulator. This then regulates the operating voltage for the blower motor depending on the control voltage
applied from 0 to 100 %. This facilitates control of the blower motor speed from 0 - 100 %.

 AC OFF (ON/OFF)
 Sun intensity, direction of solar radiation
 Vehicle speed
 Window, sliding roof, tilting roof positions
 Ambient temperature
 Air humidity (dew point)
 Pollutant concentration
 Fresh air/air recirculation flap actuator motor

 Version coding
Blower regulator, component description - GF83.10-P-2051RTH
conditioner
conditioner
Fig. 11: Identifying Blower Regulator Component Location - Shown On Model Series 251
Location
The blower regulator is located in the left rear and is directly attached to the rear air conditioning blower motor
(M2/29) of the rear air conditioner.
Task
The rear air conditioning blower regulator is connected to the comfort AAC [KLA] control and operating unit
(N22/7) via local interconnect network (LIN) for data exchange purposes. The rear air conditioning blower
regulator regulates the voltage supply of the blower motor depending on the blower stage set on the comfort
AAC [KLA] control and operating unit or on the RCP [HBF] control unit (N72/2).
Function
The comfort AAC [KLA] control and operating unit sends a control voltage of 0 to 100 % to the rear air
conditioning blower regulator. This then regulates the operating voltage for the blower motor depending on the
control voltage applied from 0 to 100 %. This facilitates control of the blower motor speed from 0 - 100 %.

 AC OFF (ON/OFF)
 Position of windows, tilting/sliding roof or panoramic sliding roof
 Vent windows position
 Outside temperature
 Air humidity (dew point)
 Pollutant concentration
 Version coding
EMISSIONS SENSOR, COMPONENT DESCRIPTION - GF83.10-P-2191GZ
Fig. 12: Identifying Emissions Sensor Component Location - Shown On Model Series 164.1
Location
The emissions sensor is installed on the right firewall.
Task
The values of the emissions sensor are processed by the front air conditioning. It senses the concentration of the
air pollutants carbon monoxide and nitrogen oxide. The comfort AAC [KLA] control and operating unit
(N22/7) uses the measured values of the emissions sensor to control the recirculated air. If the air pollutant
concentration is too high, only the inside air is recirculated and the supply of outside air is prevented.
ACTUATOR MOTORS, COMPONENT DESCRIPTION - GF83.10-P-2201
Actuator motors, component description - GF83.10-P-2201GZ
Fig. 13: Identifying Actuator Motors Component Location - Model 164 With Code (580)
Location
The actuator motors are located in the A/C housing.
Task
General determinations on actuator motor and flap controls
Continuous positioning of the flaps.
The following release function is realized for each flap in the automatic air conditioning to prevent the actuator
motors from operating continuously in the controlled range.
Release function: This is a position which, once set, must change so much up to the next change, e.g. blower
stage temperature setting, that the release value above or below is exceeded or dropped below.
Final values are approached directly (0 %, 100 %).
Anti-fogging function
The anti-fogging function prevents the windshield and side windows from fogging up after starting the engine
by blowing the moist air, immediately after starting, into the vehicle footwell instead of against the windows.
Center outlet flap actuator motor
The center outlet flap actuator motor actuates the air flaps for controlling the air flow to the center nozzle.
The center outlet flap actuator motor is actuated by the AAC control and operating unit (N22) depending on the
air outlet temperature desired at the center nozzle.
Actuation for "Defrost" Center outlet flap 0 % (closed)

Actuation for "Rest" according to control
Actuation for "0" remain in previous condition
Actuation for ignition OFF remain in previous condition
Automatic air flap control
The air flaps are opened according to a defined characteristic up to 100 % by the center outlet flap actuator
motor, depending on the following values:
 Blending air flap setting

 Evaporator temperature
 Footwell flap position
Air flap control via the center nozzle
In manual mode the air flap settings are determined by the selector on the center nozzle.
Left blending air flap actuator motor and right blending air flap actuator motor
The left and right blending air flap actuator motor serves for adjustment of the heating and air conditioning
ventilation temperature.
The left and right blending air flap actuator motors are actuated according to a defined characteristic by the
AAC control and operating unit depending on the position of the temperature selector wheel and the actual
interior temperature thereby moving the blending air flaps. The flaps open or close the air passage through the
heater heat exchanger in order to mix heated and fresh or cooled air in the correct proportions required to
achieve the desired interior temperature.
The set flap angle for the blending air flaps is determined by the AAC control and operating unit, depending on
the following information:
 regulated target temperature on the temperature selector wheel

 the in-car temperature measured by the in-car temperature sensors
Blending air flaps closed No air through mixing chamber and therefore no air heating
Blending air flaps opened All air passes through the mixing chamber with maximum air heating
Left and right defroster flaps actuator motor
The left and right defroster flaps actuator motors actuate the defroster vent flap for control of the air flow to the
windshield defroster vents and side window defroster vents. The window defroster button on the AAC control
and operating unit can be pressed to actuate the left and right defroster flaps actuator motors via LIN bus,
thereby actuating the defroster vent flaps. With "defrosting" and "0", the defroster vent flaps are 100% open.
Manual flap control (12 o'clock partitioning through actuation of air distributor duct button)
1 o'clock 2 o'clock 3 o'clock 4 o'clock 5 o'clock 6 o'clock

100% 100 % 100 % 67 % 21 % 0%
0% 0% 0% 23 % 65 % 100 %
Automatic flap control
The defroster vent flaps are opened linearly up to 100 % depending on the following values:

 Relative humidity
Left and right footwell flaps actuator motor
The left and right footwell flaps actuator motors actuate the footwell flaps for control of the air flow to the front
and rear footwells.
When the air distribution buttons on the AAC control and operating unit are pressed, the left and right footwell
flap actuation motors are actuated over the LIN bus, thereby actuating the footwell flaps, which can assume the
following positions depending on the requirements:
Actuation for "Defrost" Footwell flaps 0 % (closed)

Actuation for "0" no change
Manual flap control (12 o'clock partitioning through actuation of air distributor duct button)

29% 72 % 100 % 100 % 100 % 100 %

54% 30 % 0% 0% 0% 0%
Automatic footwell flap control
The footwell flaps are opened linearly up to 100 %, depending on the following values:

Fresh air/air recirculation flaps actuator motor
The fresh air/recirculated air flap actuator motor facilitates the closing or opening of the fresh air supply by
actuating the fresh air/ recirculated air flaps. The fresh and air recirculation flaps actuator motor is actuated by
pressing the air recirculation switch (N22s2) on the AAC control and operating unit.
In air recirculation mode, the recirculation flap is open and the fresh air flap is closed. Air is drawn out of the
vehicle interior into the A/C housing by the blower.
In fresh air mode, the fresh air flap is open and the recirculated air flap is closed. Fresh air is drawn into the
automatic air conditioning housing by the blower.
When the air recirculation switch is actuated manually, the system immediately switches to 100 % recirculated
air for a limited time.
This is displayed by the function LED. Time limit function:
 after 30 min at outdoor temperatures above approx. 7°C,

 after 5 min at outside temperatures below approx. 7°C,
 after 5 min following AC OFF.
100 % automatic recirculated air is possible for 30 min after switching ON the ignition. After expiration of this
time, the system goes to a 80 % recirculated air or fresh air, depending on the conditions.
If automatic recirculated air is required after engine ON, fresh air will be circulated initially for 30 seconds.
Then, operation is first continued automatically with 80 % recirculated air and 10 s later, also with 100 %
automatically recirculated air, depending on the requirement.
Tunnel function
Activation of the tunnel function:
Only possible where the recirculated air LED is not illuminated. Actuation of the air recirculation switch for
longer than 1.5 s Reaction: fresh air and air recirculation flaps are driven into air recirculation position. Now the
4 windows and the tilting/sliding roof are closed in a staggered manner.
If the recirculated air LED is canceled manually or by the automatic timer, the fresh air and air recirculation flap
goes to the fresh air position, however, the windows and sliding roof remain closed.
Deactivation of tunnel function:
Only possible where the recirculated air LED is illuminated. Actuation of the air recirculation switch for longer
than 1.5 s Reaction: Fresh air and air recirculation flaps are driven into fresh air position. Now the 4 windows
and the tilting/sliding roof are opened in a staggered manner.
If the recirculated air LED is reset manually (actuation of air recirculation switch for less than 1.5 s), the fresh
air and air recirculation flap is moved to the recirculated air position.
Special functions of the fresh air/air recirculation control:
 The function AC OFF does not allow any automatic nor emissions-controlled recirculated air.
 Only fresh air mode is possible in the defrosting function.
 In the function "0" 100 % recirculated air applies.
 Manual recirculated air is deleted after ignition OFF.
 Manual or automatic recirculated air is possible in the "Rest" position.
Actuator motor, component description - GF83.10-P-2201GZK
MODEL 164 with CODE (581) Comfort automatic air conditioning except CODE (582) Rear air
conditioner
Fig. 14: Identifying Actuator Motor Component Location - Model 164 With Code (581)
Location
The actuator motors are located on the A/C housing and are located at the respective positions as shown in the
picture above.
Task
General information on actuator motors and flap control
To prevent the actuator motors from continuously running in the controlled range, the following release
function is implemented for each flap in the automatic air conditioning.
Release function: Once a position has been adjusted, then until the next change, the specified temperature of the
blown in air for example must change by so much that the release value going above or below it is either not
reached or exceeded. Final values are approached directly (0 %, 100 %).
thanks to the fact that moist air is not guided directly against the windows after starting, but instead into the
footwell of the vehicle.
Left center air flap actuator motor and right center air flap actuator motor
The left center air flap actuator motor and the right center air flap actuator motor operate the particular air flap
that controls the air flow to the center nozzles separately for left and right.
Depending upon the desired air outlet temperature at the center nozzle, the left center air flap actuator motor and
the right center air flap actuator motor are actuated via the comfort AAC [KLA] control and operating unit
(N22/7).
Actuation during "Defrosting" Center outlet flaps 0 % (closed)

Actuation during "Rest" According to regulation
Actuation during "0" Retain current position
Actuation during ignition OFF Retain current position
Depending upon the following variables, the air flaps can be opened up to 100 % by the left center air flap
actuator motor and the right center air flap actuator motor in line with a defined characteristic:

The left blending air flap actuator motor and the right blending air flap actuator motor are used to set the
ventilation temperature of the heater and the air conditioning separately for left and right. The actuator motors
of the blending air flaps are actuated via the comfort automatic air conditioning control and operating unit
depending on the temperature buttons selected and the actual interior temperature according to defined
characteristics and move the blending air flaps. The flaps open or close the passage of air through the heating
system heat exchanger in order to mix hot air with fresh air or cooled air in order to achieve the desired in-car
temperature.
The specified flap angles of the blend air flaps are determined by the comfort automatic air conditioning control
and operating unit as a function of the following information:
 Regulated target temperature on the temperature selector wheel

 The in-car temperature measured by the in-car temperature sensors
Blend air flaps closed No air flows through the mixing chamber and thus no heating of the air
Blend air flaps open All air flows through the mixing chamber with maximum heating of air
Left defroster vent flap actuator motor and right defroster vent flap actuator motor
The left defroster vent flap actuator motor and the right defroster vent flap actuator motor operate the particular
defroster vent flap that controls the air flow to the windshield defroster vent and the side window defroster vents
separately for each side. By pressing the window defrost switch on the comfort AAC control and operating unit,
the defroster vent flap actuator motors are actuated and the defroster vent flaps are operated, which then adopt
the following positions at various requirements:
Actuation during "Defrosting" Defroster vent flap open 100 %.

Actuation during "0" Defroster vent flap open 100 %.
Manual flap control (division as clock by actuating the air distribution wheel)

100 % 100 % 100 % 67 % 21 % 0%
0% 0% 0% 23 % 65 % 100 %
The defroster vent flaps are opened in line with the following variables linear up to 100 %:

Left footwell flap actuator motor and right footwell flap actuator motor
The left footwell flap actuator motor and the right footwell flap actuator motor operate the particular footwell
flap that controls the air flow to the front footwell and the rear legroom separately for each side.
By pressing the footwell air distribution button in the comfort AAC control and operating unit, the left footwell
flap actuator motor and the right footwell flap actuator motor are actuated. The footwell flaps adopt the
following positions at various requirements:
Actuation during "Defrosting" Footwell flaps 0 % (closed)

Actuation during "Rest" According to regulation
Actuation during "0" No change

29% 72 % 100 % 100 % 100 % 100 %
54% 30 % 0% 0% 0% 0%
The footwell flaps are opened in line with the following variables linear up to 100 %:

The fresh air/air recirculation flaps actuator motor is used to close or open the fresh air supply by actuating the
fresh air/air recirculation flaps.
The fresh air/air recirculation flaps actuator motor is actuated by pressing the air recirculation switch (N22/7s2)
on the comfort AAC control and operating unit.
In recirculation mode, the recirculation flap is open and the fresh air flap is closed.
Air is suctioned from the vehicle interior into the comfort automatic air conditioning housing by the blower.
In fresh air mode, the fresh air flap is open and the recirculated air flap is closed. Fresh air is suctioned into the
comfort automatic air conditioning housing by the blower.
If the air recirculation switch is operated manually, the system immediately enters time-limited 100 %
recirculated air. This is displayed by the function LED. Time limit function:
 after 30 min with outside temperature above approx. 7°C,

 after 5 min with outside temperature below approx. 7°C,
 after 5 min with AC OFF.
100 % automatic recirculated air is possible for one time only for 30 min after ignition is switched "ON". After
the time has elapsed, the system switches to 80 % recirculated air mode or fresh air mode, depending on the
conditions.
Then 80 % automatic recirculated air is supplied first and 10 s later as required also 100 % automatic
recirculated air.
Tunnel function
Only possible where the recirculated air LED is not illuminated. Pressing the air recirculation switch for more
than 1.5 s Reaction: fresh air and air recirculation flaps are driven into air recirculation position. Now the 4
windows and the tilting/sliding roof are closed in a staggered manner.
If the recirculated air-LED is extinguished manually or by the automatic timer, the fresh air and air recirculation
flap moves to the fresh air position, however, the windows and the sliding roof remain closed.
Only possible where the recirculated air LED is illuminated.
Pressing the air recirculation switch for more than 1.5 s Reaction: fresh air and air recirculation flaps are driven
into fresh air position. Now the 4 windows and the tilting/sliding roof are opened in a staggered manner.
If the recirculated air LED is reset to manual mode (pressing the air recirculation switch for less than 1.5 s),
only the fresh air/air recirculation flap is set to recirculated air position.
 No manual or automatic recirculated air is possible in the rest function.
Actuator motors, component description - GF83.10-P-2201RTK
conditioner
conditioner
Fig. 15: Identifying Actuator Motors Components (1 Of 2)

Fig. 16: Identifying Actuator Motors Components (2 Of 2)

Location
The actuator motors are located on the A/C housing and are located at the respective positions as shown in the
picture above.
Task
General information on actuator motors and flap control

The following release function is realized for each flap in the automatic air conditioning to prevent the actuator
motors from operating continuously in the controlled range.
Release function: This is a position which, once set, must change so much up to the next change, e.g. blower
stage temperature setting, that the release value above or below is exceeded or dropped below.
Final values are approached directly (0 %, 100 %).
thanks to the fact that moist air is not guided directly against the windows after starting, but instead into the
footwell of the vehicle.
Left center air flap actuator motor and right center air flap actuator motor
The left center air flap actuator motor and the right center air flap actuator motor operate the particular air flap
that controls the air flow to the center nozzles separately for left and right.
Depending upon the desired air outlet temperature at the center nozzle, the left center air flap actuator motor and
the right center air flap actuator motor are actuated via the comfort AAC [KLA] control and operating unit
(N22/7).
Actuation for "Defrost" Center outlet flaps 0 % (closed)

Actuation for "0" remain in previous condition
Actuation for ignition OFF remain in previous condition
Depending upon the following variables, the air flaps can be opened up to 100 % by the left center air flap
actuator motor and the right center air flap actuator motor in line with a defined characteristic:

The left blending air flap actuator motor and the right blending air flap actuator motor are used to set the
ventilation temperature of the heater and the air conditioning separately for left and right. The actuator motors
of the blending air flaps are actuated via the comfort automatic air conditioning control and operating unit
depending on the temperature buttons selected and the actual interior temperature according to defined
characteristics and move the blending air flaps. The flaps open or close the passage of air through the heating
system heat exchanger in order to mix hot air with fresh air or cooled air in order to achieve the desired in-car
temperature.
The specified flap angles of the blend air flaps are determined by the comfort automatic air conditioning control
and operating unit as a function of the following information:
 regulated target temperature on the temperature selector wheel

 in-car temperature measured by the in-car temperature sensors
Blending air flaps closed No air through mixing chamber and therefore no air heating
Blend air flaps open All air flows through the mixing chamber with maximum heating of air
Left defroster vent flap actuator motor and right defroster vent flap actuator motor
The left defroster vent flap actuator motor and the right defroster vent flap actuator motor operate the particular
defroster vent flap that controls the air flow to the windshield defroster vent and the side window defroster vents
separately for each side. By pressing the window defrost switch on the comfort AAC control and operating unit,
the defroster vent flap actuator motors are actuated and the defroster vent flaps are operated, which then adopt
the following positions at various requirements:
Actuation during "Defrosting" Defroster vent flap open 100 %.

Actuation for "0" Defroster vent flap open 100 %.

100% 100 % 100 % 67 % 21 % 0%
0% 0% 0% 23 % 65 % 100 %
The defroster vent flaps are opened linearly up to 100 % depending on the following values:

Left footwell flap actuator motor and right footwell flap actuator motor
The left footwell flap actuator motor and the right footwell flap actuator motor operate the particular footwell
flap that controls the air flow to the front footwell and the rear legroom separately for each side.
By pressing the footwell air distribution button in the comfort AAC control and operating unit, the left footwell
flap actuator motor and the right footwell flap actuator motor are actuated. The footwell flaps adopt the
following positions at various requirements:
Actuation for "Defrost" Footwell flaps 0 % (closed)

Actuation for "0" no change

29% 72 % 100 % 100 % 100 % 100 %
54% 30 % 0% 0% 0% 0%
The footwell flaps are opened linearly up to 100 %, depending on the following values:

The fresh air/air recirculation flaps actuator motor is used to close or open the fresh air supply by actuating the
fresh air/air recirculation flaps.
The fresh air/air recirculation flaps actuator motor is actuated by pressing the air recirculation switch (N22/7s2)
on the comfort AAC control and operating unit.
In air recirculation mode, the recirculation flap is open and the fresh air flap is closed.
Air is suctioned from the vehicle interior into the comfort automatic air conditioning housing by the blower.
In fresh air mode, the fresh air flap is opened and the recirculated air flap is closed. Fresh air is suctioned into
the comfort automatic air conditioning housing by the blower.
If the air recirculation switch is operated manually, the system immediately enters time-limited 100 %
recirculated air. This is displayed by the function LED. Time limit function:
 after 30 min at outdoor temperatures above approx. 7°C,

 after 5 min at outside temperatures below approx. 7°C,
 after 5 min following AC OFF.
100 % automatic recirculated air is possible for one time only for 30 min after ignition is switched "ON". After
the time has elapsed, the system switches to 80 % recirculated air mode or fresh air mode, depending on the
conditions.
Then, operation is first continued automatically with 80 % recirculated air and 10 s later, also with 100 %
automatically recirculated air, depending on the requirement.
Tunnel function
Only possible where the recirculated air LED is not illuminated. Actuation of the air recirculation switch for
longer than 1.5 s Reaction: fresh air and air recirculation flaps are driven into air recirculation position. Now the
4 windows and the tilting/sliding roof are closed in a staggered manner.
If the recirculated air LED is extinguished manually or by the automatic timer, the fresh air and air recirculation
flap moves to the fresh air position, however, the windows and the sliding roof remain closed.
Only possible where the recirculated air LED is illuminated. Actuation of the air recirculation switch for longer
than 1.5 s Reaction: Fresh air and air recirculation flaps are driven into fresh air position. Now the 4 windows
and the tilting/sliding roof are opened in a staggered manner.
If the recirculated air LED is reset to manual mode (pressing the air recirculation switch for less than 1.5 s),
only the fresh air/air recirculation flap is set to recirculated air position.
 No manual or automatic recirculated air is possible in the rest function.
COOLANT SHUTOFF MOTOR, COMPONENT DESCRIPTION - GF83.20-P-2117RT
conditioner
conditioner
Shown on BR 251
Fig. 17: Identifying Coolant Shutoff Motor Component Location - Shown On BR 251
Location
The rear air conditioning coolant shutoff motor is located in the left rear above the wheelhouse.
Task
If only front air conditioning functions are selected via the comfort AAC (KLA) control and operating unit
(N22/7), the coolant shutoff motor shuts off the coolant supply to the rear air conditioning.
HEATING SYSTEM HEAT EXCHANGER, COMPONENT DESCRIPTION - GF83.20-P-3123GZ
MODEL 164
Location
The heating system heat exchanger is located behind the instrument panel in the A/C housing.
Task
The heating system heat exchanger warms the air flow, which is directed to the vehicle interior via the various
defroster, ventilation and heater vents.
Fig. 18: Identifying Heating System Heat Exchanger Component Description

Function
Heated coolant flows through the heating system heat exchanger when heat is required.
The heat is conducted to the outside via the coiled pipes and lamella. This in turn warms the passing air flow,
which is directed to the vehicle interior via the various defroster, ventilation and heater vents.
DEW POINT SENSOR, COMPONENT DESCRIPTION - GF83.30-P-2129GZ
Shown on BR 164.1
Location
The dew point sensor is located down at the front of the automatic air conditioning box.
Fig. 19: Identifying Dew Point Sensor Component Description - Shown On BR 164.1
Task
The dew point sensor is used to sense the air humidity.
Design
The dew point sensor comprises the following elements:
 Measuring cell for humidity

 Electrical connector
 Electronic printed circuit board with processor
Function
The dew point sensor measures the air humidity of the suctioned air and forwards this measured value to the
comfort AAC [KLA] control and operating unit (N22/7), thereby allowing it to regulate a demand-based, not
too dry interior climate. The calculated measured value is additionally placed by the comfort AAC control and
operating unit on the CAN interior. The left front door control unit (N69/1) and the right front door control unit
(N69/2) read in this value to obtain the most favorably adjusted heated outside mirror.
AUTOMATIC AIR CONDITIONING (AAC), FUNCTION - GF83.40-P-0001GZ
Description
The automatic air conditioning (AAC) controls the equipment to achieve the interior temperature desired by the
driver and passengers. The automatic air conditioning is available immediately after starting the engine. The
system operates on the basis of the humidity and temperature. The ambient air is first cooled down by adding
cooled air from the evaporator, even at low outdoor temperatures and then passes through the heat exchanger
where it is heated up to the desired temperature.
The automatic air conditioning regulates the interior temperature and air distribution separately for the driver
and passenger seats.
The system has the following subfunctions:
Heating circuit
The coolant is heated up by the engine. When heat is required, heated coolant passes through the heating system
heat exchanger where heat is transferred to the interior air. The coolant returns back to the coolant pump via the
heater return.
Refrigerant circuit
The refrigerant compressor (A9) driven by the engine compresses the refrigerant vapor which is cooled down in
the condenser. As it cools down, the refrigerant liquefies and is cleansed of impurities in the subsequent fluid
reservoir. The cleaned liquid refrigerant is injected into the evaporator where it evaporates, cools down and
absorbs heat from the air that is flowing past, thus cooling the air. The refrigerant compressor aspirates the
refrigerant which has turned gaseous on account of the heat absorption and then compresses it yet again.
Ventilation
The ventilation system ventilates the interior of the vehicle. The air is drawn in by the blower motor (A32m1)
and passes through the various air ducts to the air distribution flaps which distribute it in the vehicle interior.
Control
The electronic control for the automatic air conditioning is accomplished by various control units and
temperature sensors connected with one another by the Control Area Network bus, class B (interior
compartment) (CAN B), Control Area Network bus, class C (engine compartment) (CAN C) and Local
Interconnect Network (LIN). The desired temperature is achieved or maintained at a constant level by cooling
or heating the air.
Engine residual heat utilization system
Utilization of the residual engine heat makes it possible to heat the vehicle even with the ignition "OFF". To do
so the system utilizes the residual heat from the engine and guides it via the blower into the passenger
compartment. The residual engine heat utilization feature is possible only when the ignition is "OFF".
Defrosting function
The defrosting function serves for keeping the windows free of fog and ice or quickly eliminating fogged
windows by actuating the defroster outlet flap to the full open position and closing the footwell flaps.
Additionally, the refrigerant compressor is switched on, the position of the fresh air flaps is set to fully open,
and the coolant circulation pump (M13) is actuated plus additional heating with the PTC heater booster (R22/3)
(with diesel engines).
AC-OFF function
The compressor is switched off (no cooling capacity). The transition cycle is accomplished to prevent the
windows from fogging up. The defroster flaps are opened wider. Function feedback is accomplished with a red
LED.
Recirculated air, function
Momentarily actuating the air recirculation button closes the main air flap to prevent air entering from outside.
This ensures that the air circulates only in the interior compartment, keeping out unpleasant odors or pollution
gases.
The LED indicator comes on during operation. In the automatic mode, the control program can activate the
recirculated air function.
Recirculated air convenience feature function
For easier operation, the windows and the tilting/sliding roof (SHD) (with power glass tilting/sliding roof, code
414) are closed automatically when the air recirculation switch (N22s2) is pressed for more than 1.5 s.
When the air recirculation switch is actuated again, the windows and tilting/sliding roof (SR) return
automatically to the previous positions.
With model 164.8, the left rear and right rear vent windows are actuated at the same time as part of the
recirculated air convenience feature.
OFF function
The air conditioning is switched off, the flap positions are maintained.
Automatic air conditioning (AAC) component GF83.40-P-0001-

locations 01GZ
networking 02GZ
Except rear air conditioner,
Ventilation system, function GF83.10-P-2000GZ
code 582
Refrigeration cycle function GF83.40-P-2001GZ
Residual engine heat utilization function GF83.75-P-2000GZ
Automatic air conditioning (AAC) component locations - GF83.40-P-0001-01GZ
Fig. 20: Identifying Automatic Air Conditioning (AAC) Component Locations - Shown On Model 164.1
Automatic air conditioning (AAC) component networking - GF83.40-P-0001-02GZ
Fig. 21: Automatic Air Conditioning (AAC) Component Networking - Communication Diagram
CONVENIENCE AUTOMATIC AIR CONDITIONING (C-AAC), FUNCTION - GF83.40-P-0004
Convenience automatic air conditioning (C-AAC), function - GF83.40-P-0004GZ
MODEL 164 with CODE (581) Comfort automatic air conditioning except CODE (582) Rear air
conditioner
Function
The comfort automatic air conditioning (C-AAC) controls the interior temperature desired by the driver and the
passengers. The comfort automatic air conditioning is operational immediately after the engine is started and
produces the last stored temperature-controlled condition before the vehicle was locked. System operation is
sensitive to moisture and temperature; even at low outside temperatures the ambient air is first cooled down by
way of the evaporator's supply of cold air, and then routed through the heat exchanger and set to the desired
passenger compartment temperature.
The C-AAC regulates the interior temperature separately for all 4 seat areas; the air distribution duct separately
for driver and passenger side.
The comfort automatic air conditioning can be summarized with the subfunctions listed below:
 Heater circuit
The coolant is heated up by the engine. When heat is required, heated coolant passes through the heating
system heat exchanger where heat is transferred to the interior air. The coolant returns back to the coolant
pump via the heater return.
 Refrigerant circuit
The refrigerant compressor (A9) driven by the engine compresses the refrigerant vapor which is cooled
down in the condenser. The refrigerant liquefies during cooling. The liquid refrigerant passes through the
expansion valve into the evaporator, where it evaporates, cools down and removes the heat from the air
that is flowing past, therefore cooling it down. The refrigerant compressor aspirates the refrigerant which
has turned gaseous on account of the heat absorption and then compresses it yet again.
 Ventilation
The ventilation system ventilates the interior of the vehicle. The air is drawn in by the blower motor
(A32m1) and passes through the various air ducts to the air distribution flaps which distribute it in the
vehicle interior.
 Control
The comfort automatic air conditioning is controlled electronically via various control units and
temperature sensors, which are interconnected via the Controller Area Network bus class B (interior)
(CAN-B), the Controller Area Network Bus Class C (engine compartment) (CAN-C), and the local
interconnect network (LIN). The desired temperature is achieved or maintained at a constant level by
cooling or heating the air.
 Residual engine heat utilization
The residual engine heat utilization makes it possible to heat or only ventilate the vehicle even when the
engine is switched off. The system makes use of the residual heat of the engine for this purpose.
 Defrosting function
windows by actuating the defroster vent flap to the full open position and closing the footwell flaps.
Additionally, the refrigerant compressor is switched on, the position of the fresh air flaps is set to fully
open, and the coolant circulation pump (M13) is actuated plus additional heating with the PTC heater
booster (R22/3) (with diesel engines).
 AC OFF function
This function blocks the refrigerant compressor's cut-in. This takes place manually when the button on the
comfort AAC [KLA] control and operating unit (N22/7) is pressed. The active AC OFF function is
displayed by an LED.
 Recirculated air, function
The recirculated air function interrupts the fresh air supply from the outside by closing the fresh air/air
recirculation flap. This causes the air to circulate (closed windows and sliding roof assumed) in the
interior only and keeps unpleasant odors or pollutants at bay. The comfort automatic air conditioning is
equipped with an automatic recirculation control.
 Emission-controlled recirculated air, function
The emissions sensor (B31) transmits the pollutant values of the ambient air to the comfort AAC control
and operating unit. The comfort AAC control and operating unit decides on the position of the air
recirculation flap together with the dew point sensor (B11/12).
 Recirculated air convenience feature function
For easier operation, the windows and the tilting/sliding roof (SHD) (with power glass tilting/sliding roof,
code 414) are closed automatically when the air recirculation switch (N22/7s2) is pressed for more than
1.5 s. When the air recirculation switch is actuated again, the windows and tilting/sliding roof (SR) return
automatically to the previous positions.
Comfort automatic air conditioning (C-AAC) location of components GF83.40-P-0004-03GZ

Comfort automatic air conditioning (CAAC) networking of components GF83.40-P-0004-01GZ
Ventilation system function GF83.10-P-2000GZ
Refrigeration cycle function GF83.40-P-2001GZ
Residual engine heat utilization function GF83.75-P-2000GZ
Comfort automatic air conditioning (CAAC) networking of components - GF83.40-P-0004-01GZ

Fig. 22: Comfort Automatic Air Conditioning (CAAC) Networking Of Components - Communication
Diagram
Comfort automatic air conditioning (C-AAC) location of components - GF83.40-P-0004-03GZ
Shown on BR 164.1
Fig. 23: Identifying Comfort Automatic Air Conditioning (C-AAC) Location Of Components - Shown On
BR 164.1
Convenience automatic air conditioning (C-AAC), function - GF83.40-P-0004RT
conditioner
conditioner
Function
The comfort automatic air conditioning (C-AAC) controls the interior temperature desired by the driver and the
passengers. The comfort automatic air conditioning is operational immediately after the engine is started and
produces the last stored temperature-controlled condition before the vehicle was locked. System operation is
sensitive to humidity and temperature; even at low outside temperatures the ambient air is first cooled down by
way of the evaporator's supply of cold air, and then routed through the heat exchanger and set to the desired
passenger compartment temperature.
The C-AAC [K-KLA] controls the interior temperature separately for all 6 seats.
The comfort automatic air conditioning can be summarized with the subfunctions listed below:
 Heating circuit
The coolant is heated up by the engine. When heat is required, heated coolant passes through the heating
system heat exchanger where heat is transferred to the interior air. The coolant returns back to the coolant
pump via the heater return. The rear air conditioner is assisted by the rear AC additional circulation
pump.
Refrigerant circuit
The refrigerant compressor (AC compressor) driven by the engine compresses the gaseous refrigerant, which is
thereby heated up and routed to the condenser. The refrigerant's compression heat is then withdrawn on the
surface of the condenser. The refrigerant liquefies when it cools down. Chemical and mechanical impurities are
removed from the refrigerant in the downstream fluid reservoir. After cleaning, the liquid refrigerant is injected
into the evaporator located in the fresh air flow. The refrigerant evaporates and cools down. Through this
evaporation process heat is extracted from the fresh air flowing past from outside over the tube and fin system
so that air cools down. The air humidity carried along is converted to condensed water, which is routed to the
outside. The air is thus dried. The refrigerant compressor aspirates the refrigerant which has turned gaseous on
account of the heat absorption and then compresses it yet again.
If required, the engine fan is switched on as well in the process. Cool air can be routed into the passenger
compartment through the various air vents when the engine is running and the blower switched on.
The degree of cooling intensity is dependent upon the previously set in-car temperature and the blower output.
A second evaporator is added to the refrigeration circuit in the form of the rear air conditioner.
 Ventilation
The ventilation system ventilates the interior of the vehicle. During normal operation, when the vehicle is
stationary or in order to increase the air volume, ventilation is carried out with the assistance of the "front
blower", the "booster blower" and also a "rear blower" belonging to the C-AAC. The air is led through
various air ducts to the air distribution vents, through which it is distributed in the vehicle interior.
 Control
The comfort automatic air conditioning is controlled electronically via various control units and
temperature sensors, which are interconnected via the Controller Area Network bus class B (interior)
(CAN-B), the Controller Area Network Bus Class C (engine compartment) (CAN-C), and the local
interconnect network (LIN). The desired temperature is achieved or maintained at a constant level by
cooling or heating the air.
 Engine residual heat utilization system
The residual engine heat utilization makes it possible to heat or only ventilate the vehicle even when the
engine is switched off. To do so the system utilizes the residual heat from the engine and guides it via the
blower into the passenger compartment. The residual engine heat utilization feature is possible only when
the ignition is "OFF".
 Defrosting function
windows by actuating the defroster outlet flap to the full open position and closing the footwell flaps.
Additionally, the refrigerant compressor is cut in, the fresh air flap is set to fully open and the coolant
circulation pump (M13) and the rear AC additional circulation pump (M13/1) as well as the PTC heater
booster (R22/3) (on diesel engines) are actuated.
 AC-OFF function
This function blocks the refrigerant compressor's cut-in. This takes place manually when the button on the
comfort AAC [KLA] control and operating unit (N22/7) is pressed. The active AC OFF function is
displayed by an LED.
 Recirculated air, function
When the air recirculation switch (N22s2) is actuated momentarily (t < 1.5 s), the fresh air supply is
interrupted from outside by closing the fresh and air recirculation flap. This causes the air to circulate
(closed windows and sliding roof assumed) in the interior only and keeps unpleasant odors or pollutants
at bay. The function LED is illuminated during operation. The comfort automatic air conditioning is
equipped with an automatic recirculation control.
 Remote control for rear AC functions
When the REAR button on the comfort AAC control and operating unit (N22/7) is pressed, the operating
unit symbol appears in the front display. The blower setting is not visible. The rear temperatures can be
set on the keyboard.
The function is stopped automatically, if operation is not performed within approx. t = 5 s or the REAR
button is pressed again. When the AUTO button or the REAR Button is pressed, the REAR operation can
be stopped.
 Emission-controlled recirculated air, function
The emissions sensor (B31) transmits the pollutant values of the ambient air to the comfort AAC control
and operating unit. The comfort AAC control and operating unit decides on the position of the air
recirculation flap together with the dew point sensor (B11/12).
This function is not available with A/C OFF.
OFF function
The air conditioning is switched off, the flap positions are maintained.
 Recirculated air convenience feature function

code 414) or the panoramic sliding roof (with panoramic sliding roof, code 413) are closed automatically
when the air recirculation switch (N22/7s2) is pressed for more than 1.5 s. If the air recirculation switch is
actuated again, the windows, the tilting/sliding roof (SHD) and the panoramic sliding roof automatically
return to their previous positions.
The left vent window motor (M21/8) and right vent window motor (M21/9) are actuated via
recirculated air convenience feature.
 AUTO button, function
When the AUTO button is actuated, the AUTO mode is activated and the red LED in the AUTO button
comes on. In automatic mode, the blower output and air distribution are controlled automatically, in
addition to temperature control. Manually resetting the blower or the air distribution, terminates the
AUTO mode. When the vehicle is restarted, the function last set is activated.
The blower level is higher on the US version than on the ECE version. In the event of maximum
cooling output, "MAX COOL" is additionally shown in the USA version.
GF83.40-P-0004-
Comfort automatic air conditioning (C-AAC) location of components
03RT
Comfort automatic air conditioning (CAAC) networking of GF83.40-P-0004-
components 01RT
Ventilation system, function GF83.10-P-2000RTK
Model
Residual engine heat utilization function GF83.75-P-2000RT
251
Model
GF83.75-P-2000GZ
164
Comfort automatic air conditioning (CAAC) networking of components - GF83.40-P-0004-01RT

Fig. 24: Comfort Automatic Air Conditioning (CAAC) Networking Of Components - Communication
Diagram
Comfort automatic air conditioning (C-AAC) location of components - GF83.40-P-0004-03RT
Shown on BR 251
Fig. 25: Identifying Comfort Automatic Air Conditioning (C-AAC) Location Of Components - Shown On
BR 251
CONVENIENCE AUTOMATIC AIR CONDITIONING (C-AAC) FUNCTIONAL DESCRIPTION

TABLE OF CONTENTS - GF83.40-P-0996GZ
Convenience automatic air conditioning (CAAC), Except rear air conditioner, GF83.40-P-
function code 582 0004GZ
164.8 with rear air GF83.40-P-
conditioner, code 582 0004RT
Comfort automatic air conditioning (C-AAC) location Except rear air conditioner, GF83.40-P-0004-
of components code 582 03GZ
164.8 with rear air GF83.40-P-0004-
Comfort automatic air conditioning (CAAC) Except rear air conditioner, GF83.40-P-0004-
networking of components code 582 01GZ
164.8 with rear air GF83.40-P-0004-

Except rear air conditioner, GF83.10-P-
Ventilation system function
code 582 2000GZ
164.8 with rear air GF83.10-P-
conditioner, code 582 2000RTK
GF83.40-P-
Refrigeration cycle function
2001GZ
GF83.75-P-
Residual engine heat utilization function
2000GZ
Overview of system components of the comfort GF83.40-P-
automatic air conditioning (C-AAC) 9998GZ
TABLE OF CONTENTS, AUTOMATIC AIR CONDITIONING (AAC) FUNCTION DESCRIPTION -

GF83.40-P-0999GZ
GF83.40-P-
Automatic air conditioning (AAC), function
0001GZ
locations 01GZ
networking 02GZ
Ventilation system function
code 582 2000GZ
GF83.40-P-
Refrigeration cycle function
2001GZ
GF83.75-P-
Residual engine heat utilization function
2000GZ
Survey of automatic air conditioning (AAC), GF83.40-P-
system components 9992GZ
REFRIGERATION CYCLE FUNCTION - GF83.40-P-2001GZ
MODEL 164

Fig. 26: Identifying Refrigeration Cycle Function - Shown On Model 164.1

Function
The refrigerant compressor is driven by the engine and compresses the refrigerant vapor which is thereby heated
up, and then passes into the condenser where it is cooled.
The refrigerant's compression heat is then withdrawn on the surface of the condenser. While cooling down, the
refrigerant liquefies.
When the refrigerant flows through the fluid reservoir it is cleansed of any chemical and mechanical impurities.
The liquid refrigerant passes through the expansion valve into the evaporator located in the fresh air flow. The
refrigerant is then vaporized.
This evaporation process removes heat from the fresh air flowing through the system of tubes and fins from the
outside, cooling it. The air humidity carried along is converted to condensed water, which is routed to the
outside. The air is thus dried.
The refrigerant compressor aspirates the refrigerant which has turned gaseous on account of the heat absorption
and then compresses it yet again.
The refrigerant pressure sensor monitors the pressure of the refrigerant.
GF83.40-P-
Condenser, component description
2188GZ
Except rear air conditioner, code GF83.40-P-
Evaporator, component description
582 2189GZ
Except rear air conditioner, code GF83.40-P-

Expansion valve, component description
582 2190GZ
GF83.40-P-
Fluid reservoir, component description
2196GZ
Component description of refrigerant In vehicles with engine 113, 272, GF83.55-P-
compressor 273 2108GZ
Refrigerant pressure sensor, component GF83.40-P-
description 2193GZ
AUTOMATIC AIR CONDITIONING BOX, COMPONENT DESCRIPTION - GF83.40-P-2010GZ
Fig. 27: Identifying Automatic Air Conditioning Box Component Location - Model 164 With Code (580)
Location
The automatic air conditioning box is below the instrument panel.
Task
The automatic air conditioning box distributes the air that is required to ventilate the vehicle to the relevant air
ducts and vents depending on the interior temperature that is required.
The air ducting depends on various operating conditions such as:
 Heating mode
 Cooling mode
 Normal mode
 Blending air mode
COMFORT AUTOMATIC AIR CONDITIONING BOX, COMPONENT DESCRIPTION - GF83.40-P-

2011GZ

Fig. 28: Identifying Comfort Automatic Air Conditioning Box Component Location - Model 164 With
Code (581)
Location
The automatic air conditioning box is below the instrument panel.
Task
The automatic air conditioning box distributes the air that is required to ventilate the vehicle to the relevant air
ducts and air outlets depending upon the desired interior temperature.
The air ducting depends on various operating conditions such as:
 Heating mode
 Cooling mode
 Normal mode
 Blending air mode
 Pollutant-controlled air recirculation mode
 Humidity-controlled cooling mode
CONDENSER, COMPONENT DESCRIPTION - GF83.40-P-2188GZ
MODEL 164
Location
The condenser is located behind the radiator grille, immediately in front of the radiator.
Task
The condenser transforms the state of aggregation of the refrigerant coming from the evaporator from gaseous
into liquid.
Fig. 29: Identifying Condenser Component Location - Shown On Model Series 164.1
Function
In the condenser, the hot coolant is pressed in from above, coming from the refrigerant compressor (A9). Coiled
pipes and fins absorb this heat extremely rapidly and give it off into the outside air flowing through the
condenser.
This in turn cools the refrigerant. While the refrigerant is cooling down to a specific, pressure-sensitive
temperature, the refrigerant condenses and is liquefied. The liquid refrigerant exits at the bottom of the
condenser and flows into the fluid reservoir.
EVAPORATOR, COMPONENT DESCRIPTION - GF83.40-P-2189
Evaporator, component description - GF83.40-P-2189GZ
Location
The evaporator is located in the A/C housing behind the instrument panel.
Task
The evaporator serves for cooling, dehumidifying and purifying the interior compartment air.
Design
Disk evaporator made from soldered semicircular disks with corrugated ribs.
Fig. 30: Identifying Evaporator Component Description - Model 164 Except Code (582)
Function
The liquid refrigerant under high pressure is injected into the evaporator through the expansion valve.
The refrigerant evaporates, thereby absorbing the quantity of heat required for evaporation from the air flowing
past the evaporator.
The soldered semicircular disks with corrugated ribs provide a large evaporation surface and guarantee rapid
heat exchange. The humidity which condenses during the air cooling process is diverted by way of condensed
water drainage hoses into the open.
Evaporator, component description - GF83.40-P-2189RTK
conditioner
conditioner
Location
The evaporator of the rear air conditioning is located in the rear AC housing at the left rear.
Task
The evaporator serves for cooling, dehumidifying and purifying the interior compartment air.
Design
Disk evaporator made from soldered semicircular disks with corrugated ribs.
Fig. 31: Identifying Evaporator Component Description - Model 251.1 /0 With Code (581)
Function
The liquid refrigerant under high pressure is injected into the evaporator through the expansion valve.
The refrigerant evaporates, thereby absorbing the quantity of heat required for evaporation from the air flowing
past the evaporator.
The soldered semicircular disks with corrugated ribs provide a large evaporation surface and guarantee rapid
heat exchange. The humidity which condenses during the air cooling process is diverted by way of condensed
water drainage hoses into the open.
EXPANSION VALVE, COMPONENT DESCRIPTION - GF83.40-P-2190
Expansion valve, component description - GF83.40-P-2190GZ
Location
The expansion valve is located in the engine compartment at the left rear.
Task
The expansion valve sprays liquid refrigerant into the evaporator. The injection quantity depends on the
pressure and temperature of the refrigerant supplied.
Fig. 32: Identifying Expansion Valve Component Location - Shown On Model Series 164.1
Function
When the refrigerant compressor (A9) is switched on, the pressure in the evaporator decreases causing a
diaphragm in the expansion valve to arch. The diaphragm motion is transferred to a linkage.
The linkage presses the valve ball out of its seat opening the valve.
The opened valve enables the refrigerant to be sprayed into the evaporator.
Since the motion of the diaphragm depends on the suction pressure, as well as the temperature at the evaporator
outlet, only the quantity of refrigerant which can evaporate optimally is injected.
Expansion valve, component description - GF83.40-P-2190RTK
conditioner
conditioner
Shown on BR 251
Location
The expansion valve is located in the left rear at the rear air conditioner.
Task
The expansion valve sprays liquid refrigerant into the evaporator. The injection quantity depends on the
pressure and temperature of the refrigerant supplied.
Fig. 33: Identifying Expansion Valve Component Location - Shown On BR 251

Function
When the refrigerant compressor (A9) is switched on, the pressure in the evaporator decreases causing a
diaphragm in the expansion valve to arch. The diaphragm motion is transferred to a linkage.
The linkage presses the valve ball out of its seat opening the valve.
The opened valve enables the refrigerant to be sprayed into the evaporator.
Since the motion of the diaphragm depends on the suction pressure, as well as the temperature at the evaporator
outlet, only the quantity of refrigerant which can evaporate optimally is injected.
ENGINE/AC ELECTRIC SUCTION FAN, COMPONENT DESCRIPTION - GF83.40-P-2192GZ
MODEL 164
Location
The suction fan is located behind the radiator.
Task
The suction fan serves for cooling the coolant from the engine and the refrigerant from the air conditioning.
Fig. 34: Identifying Engine/AC Electric Suction Fan Location - Shown On Model Series 164.1
Function
The request for actuation of the suction fan comes from the ME control unit (N3/10) or from the AAC control
and operating unit (N22) or from the comfort AAC control and operating unit (N22/7).
The suction fan is controlled by the ME control unit.
REFRIGERANT PRESSURE SENSOR, COMPONENT DESCRIPTION - GF83.40-P-2193GZ
MODEL 164
Location
The refrigerant pressure sensor is located in the engine compartment at the front left on the high pressure line
between the refrigerant compressor (A9) and condenser.
Fig. 35: Identifying Refrigerant Pressure Sensor Components - Shown On Model 164.1
Task
The refrigerant pressure sensor serves for measuring the refrigerant pressure. The reading is read in by the AAC
control and operating unit (N22) or comfort AAC control and operating unit (N22/7).
FLUID RESERVOIR, COMPONENT DESCRIPTION - GF83.40-P-2196GZ

MODEL 164
Location
The fluid reservoir is located below the condenser (1).
Task
 Filtering chemical and mechanical impurities out of the refrigerant

 Volume storage for the refrigerant
 Draining of the refrigerant
Fig. 36: Identifying Fluid Reservoir Components - Shown On Model Series 164.1
Function
The liquefied refrigerant enters the fluid reservoir under pressure and flows through a stainless-steel fabric layer
to the filter block.
The filter block can absorb a specific amount of water.
The filter block's pores are matched exactly to the molecular size of the refrigerant. Thus the refrigerant can
flow through the filter block.
All other substances are held back and retained. The cleansed refrigerant then flows through a rising pipe to the
expansion valve.
AUTOMATIC AIR CONDITIONING PUSHBUTTON CONTROL UNIT, COMPONENT

DESCRIPTION - GF83.40-P-3000GZU
MODEL 164 with CODE (580) Automatic air conditioning with CODE (494) USA version
Location
The AAC control and operating unit is located on the instrument panel.
Fig. 37: Identifying Automatic Air Conditioning Pushbutton Control Unit, Component Description
Design
The AAC control and operating unit contains the following controls and displays:
 Driver side temperature dial (1)

 Automatic button (2)
 Window defrost button (3)
 Increase air volume button (4)
 Headroom air distribution button (5)
 REAR button (6)
 Passenger side temperature dial (7)
 A/C Rest button (8)
 Center air distribution button (9)
 Footwell air distribution button (10)
 Air volume indicator (11)
 Reduce air volume button (12)

 Rear window heating button (13)
 Air recirculation switch (N22s2)
 In-car temperature sensor (N22b1)
 OFF button (14)
The AAC control and operating unit allows the following control actuations:
 Switching the air conditioning system on and off

 Interior compartment temperature selection cold/warm separate for left and right
 Manual blower control
 Manual air distribution
 Automatic blower control and air distribution
 Air recirculation mode
 Defrost function
 Rear window heater
 Residual engine heat utilization system
The AAC control and operating unit takes over control of the following:
Discreet:
 Coolant circulation pump (M13)

 Refrigerant compressor (A9)
Via the Control Area Network bus, class B (interior compartment) (CAN B):
 Heated rear window (R1) via rear SAM control module (N10/8)
 Engine and A/C electric suction fan with integrated control (M4/7) via the central gateway control unit
(N93) on the ME control unit N3/10)
 Recirculated air operation for windows and tilting/sliding roof (left front door control unit (N69/1), right
front door control unit (N69/2), front SAM control unit (N10), rear SAM control unit, and overhead
control panel control unit (N70))
Via Local Interconnect Network (LIN):
 Blower regulator (A32n1)

 Fresh air flap/recirculated air flap actuator motor (M2/5)
 Left blending air flap actuator (M2/6)
 Right blending air flap actuator (M2/7)
 Rear shutoff flap actuator motor (M2/12)
 Footwell flap actuator motors left and right (M2/15)

 Defroster vent flap actuator motors left and right (M2/16)
 Center air outlet flap actuator motor (M2/22)
The following sensor signals are read in by the AAC control and operating unit:

 Evaporator temperature sensor (B10/6)
 Sun sensor (B32)
 Left side outlet temperature sensor (B10/31)
 Right side outlet temperature sensor (B10/32)
 Left center outlet temperature sensor (B10/33)
 Right center outlet temperature sensor (B10/34)
 Left footwell temperature sensor (B10/35)
 Right footwell temperature sensor (B10/36)
 Outside temperature indicator temperature sensor (B10/5)
 Refrigerant pressure sensor (B12)
 Emissions sensor (B31)
Via CAN B:
 Overhead control panel control unit

 Rain/light sensor (B38/2)
 EIS control unit (N73)

 Circuit status
 Central gateway control unit and via ME control unit

 Motor speed
 Coolant temperature sensor (B11/4)
 Instrument cluster (A1)

 Vehicle speed
 C. 58d
 Left front door control unit, right front door control unit and front SAM control unit
 Position of side windows

 Status of rotary tumbler in doors

 Position of tilting/sliding roof
Control possibilities
Left temperature selector wheel/right temperature selector wheel
The desired temperature setting for the left and right sides can be set by turning the associated temperature
selector wheel.
Air distribution buttons
The air distribution into the individual areas can be controlled by pressing the particular button.
Increase air volume button /Decrease air volume button
The air volume can be selected manually by actuating the appropriate button.
Air volume indicator
Indication is accomplished by LEDs coming on. The more LEDs illuminated, the greater the air volume flowing
into the vehicle interior.
Automatic button
The air volume and air distribution are regulated automatically when the automatic button is pressed.
When the automatic mode is activated, the indicator LED comes on.
For USA version, code 494, "MAX COOL" is additionally displayed with maximum cooling output.
OFF button
The automatic air conditioning (AAC) can be switched off completely or switched back on by pressing the OFF
button. The main air flap is closed or opened accordingly.
Residual heat button
The vehicle can be heated or ventilated only for up to 30 min by pressing the residual heat button. The function
is only possible with circuit 15 off or circuit 15C on. If there is low voltage, the residual heat function is
automatically switched off. The flaps are in automatic mode. The blower operates at a set fixed value. When the
residua heat mode is activated, the indicator LED comes on.
AC-OFF button
Pressing the AC-OFF button switches off the refrigerant compressor. All other functions are retained. When the
refrigerant compressor is switched off, the indicator LED comes on.
Rear window heater button

When a button is pressed, the air conditioning sends a switch-on request via the CAN B bus to the rear SAM
control unit; simultaneously, the indicator LED in the rear window heater button is switched on.
Air recirculation switch
When the air recirculation switch is pressed momentarily (t < 1.5 s), the main air flap is closed to prevent air
entering from outside.
The function LED is illuminated during operation. When pressed for a longer period (t > 1.5 s), the convenience
open/close window and tilting/sliding roof (SR) (on vehicles with power glass tilting/sliding roof, code 414)
function is activated.
With model 164.8, the left rear and right rear vent windows are actuated at the same time as part of the
convenience feature..
Window defrost button
The temperature is set to "maximum" and the air flow distributed to the defroster and side air outlets. All the
other flaps are closed.
The blower is controlled depending on the coolant temperature.
The indicator LED in the defrost button comes on.
COMFORT AUTOMATIC AIR CONDITIONING CONTROL AND OPERATING UNIT,

COMPONENT DESCRIPTION - GF83.40-P-3010
Comfort automatic air conditioning control and operating unit, component description - GF83.40-P-3010GZU
MODEL 164 with CODE (581) Comfort automatic air conditioning with CODE (494) USA version
Location
The comfort AAC control and operating unit is located in the instrument panel.
Fig. 38: Identifying Comfort Automatic Air Conditioning Control And Operating Unit, Component
Description
Design
The comfort automatic air conditioning control and operating unit includes the following controls and display
elements:

 Button for air distribution in left head area (3)
 Rear window heating button (6)
 Button for air distribution in right head area (7)
 REAR button (8)
 OFF/REST button (10)
 Button for air distribution in right footwell (11)
 Button for air distribution, center right (12)
 A/C Rest button (13)
 Display (14)
 Air recirculation switch (N22/7s2)
 Button for air distribution in left footwell (17)

 In-car temperature sensor (N22/7b1)
 MONO button (18)
The AAC control and operating unit is used to control the following:

 Cold/warm interior temperature programming separately for left and right
 Option for coupling the front passenger temperature selection with that of the driver-side
The comfort automatic air conditioning control and operating unit is used to actuate the following
Discreet:

 Heated rear window (R1) via rear SAM control module (N10/8)

 Left blending air flap actuator (M2/6)
 Right blending air flap actuator (M2/7)
 Left defroster vent flap actuator motor (M2/8)
 Right defroster vent flap actuator motor (M2/9)
 Left footwell flap actuator motor (M2/10)

 Right footwell flap actuator motor (M2/11)
 Left center air flap actuator motor (M16/23)
 Right center air flap actuator motor (M16/24)
 Diverter flap actuator motor (M16/27)
The comfort automatic air conditioning control and operating unit reads in the following sensor signals:

 Dual sun sensor (B32/3)
 Outside temperature indicator temperature sensor (B10/5)
 Dew point sensor (B11/12)
Via CAN B:


 Circuit status

 Motor speed

 Vehicle speed
 C. 58d

 Status of rotary tumbler in doors

 Position of tilting/sliding roof
selector wheel.
Display
The blower power or the active or inactive REAR function is shown in the display. In the event of maximum
cooling capacity, "MAX COOL" is additionally shown in the USA version.
Automatic button
The air volume and air distribution are regulated automatically when the automatic button is pressed. When the
automatic mode is activated, the indicator LED comes on.
OFF/ REST button
The comfort automatic air conditioning (C-AAC) can be switched off altogether and switched on again by
pressing the OFF/REST button. The main air flap is closed or opened accordingly. The REST function is only
available when the ignition is switched off or when the ignition/starter switch is in position 1. It is possible to
heat or only ventilate the vehicle for approx. 30 min. If there is low voltage, the residual heat function is
automatically switched off. The flaps are in automatic mode. The blower operates at a set fixed value. The
function feedback is provided with the aid of a red LED.
Residual heat button
AC-OFF button
REAR button
The REAR button can be used to change the rear temperature values via the comfort AAC control and operating
unit. When the rear button is pressed, the specified rear temperature values appear in the right temperature
selector wheel. The blower setting is not visible.
entering from outside. The function LED is illuminated during operation. When pressed for a longer period (t >
1.5 s), the convenience open/close window and tilting/sliding roof (SR) (on vehicles with power glass
tilting/sliding roof, code 414) function is activated.
Rear window heater button
When a button is pressed, the air conditioning sends a switch-on request via the CAN B bus to the rear SAM
control unit; simultaneously, the indicator LED in the rear window heater button is switched on.
Window defrost button
The temperature is set to "maximum" and the air flow distributed to the defroster and lateral nozzles. All the
other flaps are closed. The blower is controlled depending on the coolant temperature. The indicator LED in the
defrost button comes on.
Comfort automatic air conditioning control and operating unit, component description - GF83.40-P-3010RTU
MODEL 251.1 with CODE (581) Comfort automatic air conditioning with CODE (494) USA version with
CODE (582) Rear air conditioner
CODE (582) Rear air conditioner
Location
The comfort AAC control and operating unit is located in the instrument panel.
Fig. 39: Identifying Comfort Automatic Air Conditioning Control And Operating Unit, Component
Description - Shown On Model Series 251.1
Design
The comfort AAC control and operating unit contains the following controls and displays:

 Button for air distribution in left head area (3)
 Heated rear window switch (N22/7s1)
 Button for air distribution in right head area (6)
 REAR button (7)
 OFF button (9)
 Button for air distribution in right footwell (10)
 Button for air distribution, center right (11)
 AC-OFF Rest button (12)
 Display (13)
 Button for decreasing the air flow (14)
 Air recirculation switch (N22/7s2)
 Button for air distribution, center left (15)
 In-car temperature sensor (N22/7b1)

 MONO button (17)
The AAC control and operating unit is used to control the following:

 Cold/warm interior temperature programming separately for left and right
 Option for coupling the front passenger temperature selection with that of the driver-side
 Rear air conditioner remote control
The comfort AAC control and operating unit is used to actuate the following:
Discreet:

 Rear AC additional circulation pump (M13/1)
 Coolant shutoff motor (M16/41)
 Rear air conditioning blower regulator (N29/7)
 AC system shutoff valve (Y19/1)
 Heated rear window (R1) via rear SAM control unit (N10/8)

 Rear air conditioning blower regulator
 Dew point sensor (B11/12)

 Left blend air flap actuator (M2/6)
 Right blend air flap actuator (M2/7)
 Left defroster vent flap actuator motor (M2/8)
 Right defroster vent flap actuator motor (M2/9)
 Left footwell flap actuator motor (M2/10)
 Right footwell flap actuator motor (M2/11)
 Left center air flap actuator motor (M16/23)
 Right center air flap actuator motor (M16/24)
 Diverter flap actuator motor (M16/27)
 3rd seat row air distribution actuator motor (M16/43)
 3rd seat row blend air flap actuator motor (M16/44)
The following sensor signals are read in by the comfort AAC control and operating unit:

 Rear air conditioning evaporator temperature sensor (B10/11)
 Dual sun sensor (B32/3)
 Rear headroom AC temperature sensor (B10/37)
 Footwell rear AC temperature sensor (B10/38)
 Outside temperature indicator temperature sensor (B14)
Via LIN bus: dew point sensor (B11/12)
Via CAN B:


 Circuit status

 Motor speed

 Vehicle speed
 C. 58d

 Status of the rotary tumblers in the doors
 Position of the pop-out windows

 Position of the tilting/sliding roof
 Position of the panoramic sliding roof
selector wheel.
Display
The blower power or the active or inactive REAR function is shown in the display. "MAX COOL" is also
displayed at maximum cooling power.
Automatic button
OFF button
The comfort automatic air conditioning (C-AAC [K-KLA]) can be switched off completely and switched on
again by pressing the OFF button. The main air flap is closed or opened accordingly.
 Remote control for rear AC functions
When the REAR button on the comfort AAC control and operating unit (N22/7) is pressed, the operating
unit symbol appears in the front display. The blower setting is not visible. The rear temperatures can be
set on the keyboard. The function is stopped automatically, if operation is not performed within approx. t
= 5 s or the REAR button is pressed again. When the AUTO button or the REAR Button is pressed, the
REAR operation can be stopped.
REST button
AC-OFF button
REAR button
The REAR button can be used to change the rear temperature values via the comfort AAC control and operating
unit. When the rear button is pressed, the specified rear temperature values appear in the right temperature
selector wheel. The blower setting is not visible.
entering from outside. The function LED is illuminated during operation. When pressed for a longer period (t >
1.5 s), the convenience opening/closing of windows and the tilting/sliding roof (on vehicles with power glass
tilting/sliding roof, code 414) is activated.
Heated rear window switch
When the button is pressed, the comfort automatic air conditioning control and operating unit transmits a
switch-on request via CAN-B to the rear SAM control unit, and the function LED in the heated rear window
switch comes on at the same time.
Button for window defrosting

The temperature is set to "maximum" and the air flow distributed to the defroster and lateral nozzles. All the
other flaps are closed. The blower is controlled depending on the coolant temperature. The indicator LED in the
defrost button comes on.
REAR CONTROL PANEL CONTROL UNIT, COMPONENT DESCRIPTION - GF83.40-P-3020
Rear control panel control unit, component description - GF83.40-P-3020GZ
Location
The RCP control unit is located in the extension of the center console for the 2nd seat row.
Fig. 40: Identifying Rear Control Panel Control Unit, Component Description
Design

 OFF button (4)
Discrete inputs:
 C. 30
 C. 31
The RCP control unit is a CAN B bus subscriber.

The RCP control unit allows the following actions:
 Switching the temperature control ON and OFF

Operating possibilities
Automatic button
The air distribution can be controlled in the individual areas by actuating the corresponding button.
OFF button
The temperature control in the rear can be switched off completely or switched back on by pressing the OFF
button. The rear shut-off flap is opened or closed accordingly.
Rear control panel control unit, component description - GF83.40-P-3020GZK
MODEL 164 with CODE (581) Comfort automatic air conditioning with CODE (519) Rear audio system
with CODE (494) USA version
Location
The RCP [HBF] control unit is located in the extension of the center console near the 2nd seat row.
Fig. 41: Identifying Rear Control Panel Control Unit, Component Description - Model 164 With Code
(581)
Design
 Volume control for left headphones (1)

 Button for increasing the air flow (2)
 Air volume display (3)
 Temperature adjusting ring (4)
 Button for air distribution in head area (6)
 Volume control for right headphones (7)
 Plug socket for right headphones (8)
 Button for air distribution in footwell (9)
 OFF button (10)
 Plug socket for left headphones (12)
With the RCP [HBF] control unit it is possible to operate the following:
 Switching the temperature control on and off

 Cold/warm interior temperature selection separately for left and right
 Volume control of headphones separately for left and right
Discrete inputs:
 Tml. 30
 Term. 31
 Audio input, left
 Audio input, right
Discrete outputs:
 Plug socket for left headphones

 Plug socket for right headphones
 Volume control for left headphones
 Volume control for right headphones
The RCP [HBF] control unit is a participant of the CAN-B.
Control options
Temperature adjusting ring
The desired specified temperature for the rear compartment can be set by turning the temperature adjusting ring.
Button for increasing the air flow/button for decreasing the air flow
The air flow can be selected manually by pressing the particular button.
Air volume display
The display is by means of particular LEDs that are coming on.
The more LEDs are illuminated, the higher the air volume routed into the vehicle interior.
Automatic button
The air volume and the air distribution are controlled automatically when the Automatic button has been
pressed. When the automatic mode is activated, the function LED comes on.
OFF button
When the OFF button is pressed, the temperature control in the rear is switched off completely and on again.
The rear shutoff flap is closed or opened accordingly.

Headphones volume control
When the volume control is turned, the volume of the headphones can be selected based on the needs of the rear
passenger. The volume can be regulated separately for left and right.
Rear control panel control unit, component description - GF83.40-P-3020GZU
MODEL 164 with CODE (581) Comfort automatic air conditioning with CODE (494) USA version
Location
The RCP [HBF] control unit is located in the extension of the center console near the 2nd seat row.
Fig. 42: Identifying Rear Control Panel Control Unit, Component Description - Model 164 With Code
(581)
Design
 Button for increasing the air flow (1)

 Temperature adjusting ring (2)
 Button for air distribution in head area (4)
 Button for air distribution in footwell (5)
 OFF button (6)
 Air volume display (7)
With the RCP [HBF] control unit it is possible to operate the following:
 Switching the temperature control on and off

 Cold/warm interior temperature selection separately for left and right
Discrete inputs:
 Tml. 30
 Term. 31
The RCP [HBF] control unit is a participant of the CAN-B.
Control options
Temperature adjusting ring
The desired specified temperature for the rear compartment can be set by turning the temperature adjusting ring.
Button for increasing the air flow/button for decreasing the air flow
The air flow can be selected manually by pressing the particular button.
Air volume display
The display is by means of particular LEDs that are coming on.
The more LEDs are illuminated, the higher the air volume routed into the vehicle interior.
Automatic button
The air volume and the air distribution are controlled automatically when the Automatic button has been
pressed. When the automatic mode is activated, the function LED comes on.
OFF button
When the OFF button is pressed, the temperature control in the rear is switched off completely and on again.
The rear shutoff flap is closed or opened accordingly.

Rear control panel control unit, component description - GF83.40-P-3020RTU
CODE (582) Rear air conditioner with CODE (519) Rear audio system with CODE (872) Electrically
heated left and right rear seats
MODEL 164 with CODE (581) Comfort automatic air conditioning with CODE (494) USA version with
CODE (582) Rear air conditioner with CODE (519) Rear audio system with CODE (872) Electrically
heated left and right rear seats
Location
The RCP control unit is located next to the 2nd seat row in an extension of the center console.
Fig. 43: Identifying Rear Control Panel Control Unit, Component Description - Model 251.1 With Code
(581)
Design
 Left headphones volume control (1)

 Air volume indicator (3)
 Temperature dial (4)
 Right headphones volume control (7)

 Right headphones connecting socket (8)
 OFF button (10)
 Left headphones connecting socket (12)
 Heated seats button, 2nd seat row, left (13)
 Heated seats button, 2nd seat row, right (14)
The RCP control unit allows the following actions:
 Switching the temperature control ON and OFF

 Warm/cold interior temperature selection, separate for left and right
 Headphone volume control, separate for left and right
 Heated seats, separate controls for left and right
Discrete inputs:
 Circuit 30
 Circuit 31
 Left audio input
 Right audio input
Discrete outputs:
 Left headphone connecting socket

 Right headphone connecting socket
 Left headphone volume control
 Right headphone volume control
The RCP control unit is a CAN B bus subscriber.
Operating possibilities
Temperature dial
The required target temperature for the rear compartment can be selected by rotating the temperature dial.
Air volume indicator
The indication is accomplished by illuminating LEDs. The more LEDs illuminate, the greater the air volume
flowing into the vehicle interior.
Automatic button
OFF button
The temperature control in the rear can be switched off completely or switched back on by pressing the OFF
button.
The air distribution can be controlled in the individual areas by actuating the corresponding button.
Headphone volume control
The headphone volume that is required by the passenger in the rear can be adjusted by rotating the volume
control. The volume can be controlled separately for the right and left.
Heated seats button
The heat output for the relevant side can be regulated in three stages by pressing the heated seats button.
The HS [SIH], seat ventilation and steering wheel heater control unit (N25/7) is notified of the respective button
signal via CAN-B by the RCP [HBF] control unit.
SURVEY OF AUTOMATIC AIR CONDITIONING (AAC), SYSTEM COMPONENTS - GF83.40-P-

9992GZ
GF83.20-P-
Heating system heat exchanger, component description
3123GZ
GF83.40-P-
2188GZ
Evaporator, component description
code 582 2189GZ

Expansion valve, component description
code 582 2190GZ
GF83.40-P-
Fluid reservoir, component description
2196GZ
In vehicles with engine 113, GF83.55-P-
Component description of refrigerant compressor
272, 273 2108GZ
GF83.10-P-
2050GZ
GF83.10-P-
Blower regulator, component description
2051GZ
GF83.57-P-
In-car temperature sensor, component description
2127GZ
Evaporator temperature sensor, component description
code 582 2126GZ
GF83.40-P-
Refrigerant pressure sensor, component description
2193GZ
Outside temperature display temperature sensor, GF83.57-P-
GF83.10-P-
Booster adapter, component description
2041GZ
GF83.10-P-
Actuator motors, component description
2201GZ
GF83.40-P-
Engine/AC electric suction fan, component description
2192GZ
GF83.75-P-
Coolant circulation pump component description
2110GZ
GF83.70-P-
PTC heater booster, component description
4063GZ
Automatic air conditioning pushbutton control unit, GF83.40-P-
component description 3000GZU
Except USA version, code GF83.40-P-
494 3000GZE
GF83.57-P-
Sun sensor, component description
2128GZ
GF83.40-P-
Rear control panel control unit, component description
3020GZ
GF83.40-P-
Automatic air conditioning box, component description
2010GZ
GF54.21-P-
4170GZ
GF54.21-P-
7010GZ
GF54.21-P-
7030GZ
Table of contents, automatic air conditioning (AAC) GF83.40-P-
function description 0999GZ
OVERVIEW OF SYSTEM COMPONENTS FOR THE COMFORT AUTOMATIC AIR

CONDITIONING (CAAC) - GF83.40-P-9998GZ
Heating system heat exchanger, GF83.20-P-

GF83.40-P-
2188GZ
GF83.40-P-
Evaporator, component description Except code 582 Rear air conditioning system
2189GZ
Model 164.8 with code 582 Rear air conditioning GF83.40-P-
system 2189RTK
Expansion valve, component GF83.40-P-
Except code 582 Rear air conditioning system
description 2190GZ
Model 164.8 With code 582 Rear air conditioning GF83.40-P-
system 2190RTK
Fluid reservoir, component GF83.40-P-
description 2196GZ
Component description of GF83.55-P-
In vehicles with engine 113, 272, 273
refrigerant compressor 2108GZ
GF83.10-P-
2050GZ
system 2050RTH
Blower regulator, component GF83.10-P-
description 2051GZK
system 2051RTH
In-car temperature sensor, Model 164.1, Model 164.8 With code 582 Rear air GF83.57-P-
component description conditioning system 2127GZK
Evaporator temperature sensor, GF83.57-P-
system 2126RTK
Rear air conditioning housing Model 164.8 With code 582 Rear air conditioning GF83.50-P-
component description system 1000RT
Coolant shutoff motor component Model 164.8 With code 582 Rear air conditioning GF83.20-P-
description system 2117RT
Refrigerant pressure sensor, GF83.40-P-

Outside temperature display
GF83.57-P-
temperature sensor, component
4002GZ
description
Dew point sensor, component GF83.30-P-
description 2129GZ
Booster blower, component GF83.10-P-
description 2040GZ
Emissions sensor, component GF83.10-P-
description 2191GZ
Actuator motors, component GF83.10-P-
description 2201GZK
system 2201RTK
Engine/AC electric suction fan, GF83.40-P-
Coolant circulation pump GF83.75-P-
Additional circulation pump Model 164.8 With code 582 Rear air conditioning GF83.75-P-
component description system 2111RT
PTC heater booster, component GF83.70-P-
description 4063GZ
Comfort automatic air
GF83.40-P-
conditioning control and operating Except code 494 USA version
3010GZE
unit, component description
GF83.40-P-
3010GZU
Model 164.8 with code 582 Air conditioning in rear GF83.40-P-
With code 494 USA version 3010RTU
Comfort automatic air
GF83.40-P-
conditioning box, component
2011GZ
description
Rear control panel control unit, Except code 494 USA version, With code 519 Fond GF83.40-P-
component description Audio System 3020GZA
GF83.40-P-
Except code 494 USA version
3020GZE
GF83.40-P-
3020GZU
With code 582 Air conditioning in rear With code 494
USA version, With code 519 Fond Audio System, GF83.40-P-
With code 872 Electric seat heater for left and right 3020RTU
rear seat
With code 494 USA version, With code 519 Fond GF83.40-P-
Audio System 3020GZK
Dual sun sensor, component GF83.57-P-

description 2129GZ
GF80.57-P-
6000GZ
description
Central gateway control unit, GF54.21-P-
Convenience automatic air
GF83.40-P-
conditioning (C-AAC) functional
0996GZ
description table of contents
REAR AIR CONDITIONING HOUSING COMPONENT DESCRIPTION - GF83.50-P-1000RT
conditioner
conditioner
Fig. 44: Identifying Rear Air Conditioning Housing Component Description - Shown On Model Series
251
Location
The rear air conditioning housing is at the left rear behind the side paneling of the load compartment.
Design
The rear air conditioning housing is designed with the following components:
 Evaporator
 Rear air conditioning blower motor (M2/29)
 Rear air conditioning blower regulator (N29/7)
 Expansion valve
 3rd seat row air distribution actuator motor (M16/43)
 3rd seat row blend air flap actuator motor (M16/44)
Rear air conditioning normal mode Function
In normal mode when the rear air conditioning is switched off, recirculated air is drawn out of the rear interior
by the rear air conditioning blower motor via the rear air inlet into the rear AC housing. The recirculated air
flows through the evaporator (not cooled). Then the recirculated air is directed to the air outlets supplied with
air via the air distribution flap.
Rear air conditioning cooling mode Function
In cooling mode, when the rear air conditioning is switched on, recirculated air is drawn out of the rear interior
by the rear air conditioning blower motor via the rear air inlet into the rear AC housing. The recirculated air
enters the cooled evaporator and is cooled down. Next, the dried and cooled air is directed through the unheated
heater heat exchanger via the air distribution flap to the air outlets that are supplied with air.
The condensation is led to the outside via the condensation drain.
COMPONENT DESCRIPTION OF REFRIGERANT COMPRESSOR - GF83.55-P-2108GZ
ENGINE 113, 272, 273 in MODEL 164
Location
The refrigerant compressor is connected to the engine at the front left.
Task
The refrigerant compressor is responsible for induction and compression of the refrigerant.
Fig. 45: Identifying Component Description Of Refrigerant Compressor - Shown On Model Series 164.1
Fig. 46: Section View Of Refrigerant Compressor

Design
A total of 7 pistons are distributed around the circumference of the component and connected to the swash plate
by sliding shoes to ensure the same pitch. The swash plate is connected to the stop plate in the crankcase by 2
guide pins and mounted on the refrigerant compressor shaft so that it can move.
The stop plate and belt pulley are stuck on the refrigerant compressor shaft. The externally-controlled
refrigerant compressor control valve for adjustment of the swash plate is located in the rear section of the
housing.
Function
Operating mechanism
The rotary movement of the belt pulley is transmitted over the refrigerant compressor shaft to the stop plate,
which is permanently fastened to the refrigerant compressor shaft by way of a press fit. The rotation of the stop
plate is then transmitted to the pivoted swash plate by means of a hinged mechanism. The conversion of the
swash plate rotary motion into the oscillating piston movement takes place via two sliding shoes between the
piston and swash plate. The 7 pistons are connected at the circumference with the swash plate with the same
pitch. The evaporation tank on the pressure side and evaporation tank on the suction side reduce gas pulsation in
the refrigerant compressor by providing for uniform refrigerant flow. This helps to prevent noises in the
compression process
Volume regulation mechanism
The refrigerant compressor delivery rate is regulated by the externally-controlled refrigerant compressor control
valve by the regulation flow between 2 % (minimum delivery rate) and 100 % (maximum delivery rate). The
required control flow rate on the refrigerant compressor control valve is set by the AAC control and operating
unit (N22) or comfort AAC control and operating unit (N22/7) depending on the required refrigeration capacity.
The required refrigeration capacity is determined primarily by the vehicle interior temperature setting. As a
matter of principle, the swash plate position and, therefore, the variable delivery rate is determined by the
crankcase pressure, the diaphragm pressure in the refrigerant compressor control valve (approx. 2 bars) and the
suction pressure. These pressures are determined on the basis of the sensing, processing and evaluation of the
controlled variables in the air conditioning system.
The change in the suction pressure, depending on the control flow on the refrigerant compressor control valve,
causes a change in the crankcase pressure and therefore, adjustment of the swash plate either in the direction of
maximum delivery rate or variable delivery rate.
Automatic air conditioning OFF
When the automatic air conditioning is switched off with the A/C ON/OFF switch, the refrigerant compressor
control valve is opened completely. This allows refrigerant to flow unimpeded from the high pressure side into
the crankcase leading to an extremely rapid increase in the crankcase pressure. This causes the coil body for
closing the refrigerant compressor to move to the right against the valve plate until the refrigerant flow is shut
off completely on the suction side.
The coil body is designed so that the refrigerant flow is interrupted by closing the suction channel even when
the refrigerant compressor is switched on when the delivery rate decreases to less than 5 cm3 .
Internal refrigerant compressor lubrication when air conditioning switched off
The refrigerant compressor has an internal lubricant circuit to ensure lubrication of the mechanical moving parts
such as the sliding shoe, swash plate, front and rear radial shaft bearings, pistons and cylinder liner. Lubrication
is ensured by way of a minimum refrigerant compressor delivery rate. This delivery rate is regulated by 2
valves. The minimum refrigerant compressor delivery rate of 2 % when the refrigerant compressor is switched
off ensures that the refrigerant with the compressor oil present in the crankcase is transported through the bored
refrigerant compressor shaft.
The mixture of refrigerant and refrigeration oil enters the crankcase on the intake side where it is compressed
and then pumped into the refrigerant circuit on the pressure side. From the pressure side, the mixture of
refrigerant and refrigeration oil flows back through a valve into the crankcase.
The refrigerant compressor output is regulated depending on the air humidity
The regulation of the refrigerant compressor output depends on the air humidity measured by the dew point
sensor (B11/12). The air around the evaporator is no longer cooled down to approx. 3°C, as previously, in order
to then be heated back up to the desired temperature (Reheat mode). Reheat mode only takes place, if the
reheat-associated air dehumidification effect is required to keep the windows condensation-free when humidity
is high. Various regulations zones are differentiated depending on the relative air humidity.
Relative air humidity and operating condition
0 to 60 % No reheat mode
40 to 90% Reheat mode with variable temperature control between 0 and 12°C
80 to 100% Full reheat mode
Outside air humidity
If the outside air is extremely moist, the refrigerant compressor operates at maximum capacity, i.e. the
evaporator temperature is low (approx. 2°C), for maximum air dehumidification. In heating mode post heating
is accordingly performed using the heat exchanger.
Dry outside air
With dry outside air the refrigerant compressor operates with reduced power output, i.e. the evaporator
temperature can be up to approx. 14°C, if no lower outlet air temperature becomes necessary.
The air humidity control is installed only on vehicles with comfort automatic air conditioning, code
581.
EVAPORATOR TEMPERATURE SENSOR, COMPONENT DESCRIPTION - GF83.57-P-2126
Evaporator temperature sensor, component description - GF83.57-P-2126GZ
MODEL 164
Location
The evaporator temperature sensor is located on the left side of the A/C housing.
Fig. 47: Identifying Evaporator Temperature Sensor Component Location

Task
The evaporator temperature sensor measures the temperature of the air flowing past the evaporator. The reading
is read in directly by the AAC control and operating unit (N22) or comfort AAC control and operating unit
(N22/7).
Function
The evaporator temperature sensor is a temperature-dependent resistor. Controlled regulation of the refrigerant
compressor (A9e.) using the values received from the AAC control and operating unit or comfort AAC control
and operating unit, prevents the evaporator from icing up.
Evaporator temperature sensor, component description - GF83.57-P-2126RTK
conditioner
conditioner
Shown on BR 251
Location
The rear air conditioning evaporator temperature sensor is located at the top of the evaporator of the rear air
conditioner.
Fig. 48: Identifying Evaporator Temperature Sensor Component Description - Shown On BR 251
Task
The rear air conditioning evaporator temperature sensor measures the temperature of the air flowing past the
evaporator. The reading is read in directly by the comfort AAC [KLA] control and operating unit (N22/7).
Function
The evaporator temperature sensor is a temperature-dependent resistor. Controlled regulation of the refrigerant
compressor (A9) based on the values received from the comfort AAC [KLA] control and operating unit
prevents the evaporator from icing up.
IN-CAR TEMPERATURE SENSOR, COMPONENT DESCRIPTION - GF83.57-P-2127
In-car temperature sensor, component description - GF83.57-P-2127GZ
Location
The air conditioning temperature sensors are installed in the individual air outlet ducts, as shown in the figure.
Fig. 49: Identifying In-Car Temperature Sensor, Component Description

Location
The center outlet temperature sensors are installed as shown in the figure.
Fig. 50: Identifying Left And Right Center Outlet Temperature Sensor
Task
The temperature sensors measure the temperature of the air flowing out of the specific air flap and transfer this
value to the AAC control and operating unit (N22).
The temperature reading for the exiting air is compared with the settings on the temperature selector wheel by
the AAC control and operating unit. The blending air flap is readjusted, depending on the result. In addition,
this also measures the recirculated interior temperature.
In-car temperature sensor, component description - GF83.57-P-2127GZK
MODEL 164.1 with CODE (581) Comfort automatic air conditioning
conditioner
Location
The air conditioning temperature sensors are installed in the individual air outlet ducts, as shown in the figure.
Fig. 51: Identifying In-Car Temperature Sensor, Component Description

Location
The center outlet temperature sensors are installed as shown in the figure.
Fig. 52: Identifying Left And Right Center Outlet Temperature Sensor
Location
The center rear interior temperature sensor is installed as follows in the adjoining picture.
Fig. 53: Identifying Center Rear Interior Temperature Sensor

Fig. 54: Identifying Rear Headroom A/C Temperature Sensor

Task
The temperature sensors measure the temperature of the discharged air at the particular air flap and forward
them to the comfort AAC [KLA] control and operating unit (N22/7).
The comfort AAC control and operating unit compares the measured temperature value of the discharged air to
the setting on the temperature selector wheel. The blending air flap is readjusted, depending on the result. In
addition, this also measures the recirculated interior temperature.
SUN SENSOR, COMPONENT DESCRIPTION - GF83.57-P-2128GZ
Location
The sun sensor is located behind the instrument cluster (A1) in the instrument panel.
Fig. 55: Identifying Sun Sensor, Component Description

Task
The sun sensor measures the intensity of the sun radiation acting on the vehicle. The interior temperature and
blower speed are adapted according to the intensity.
The reading is read in directly by the AAC control and operating unit (N22).
DUAL SUN SENSOR, COMPONENT DESCRIPTION - GF83.57-P-2129GZ
Location
The dual sun sensor is located on the dashboard behind the center nozzles.
Fig. 56: Identifying Dual Sun Sensor, Component Description

Task
The dual sun sensor is only processed by the comfort AAC [KLA] control and operating unit (N22/7). The dual
sun sensor is capable of measuring the intensity of the radiation (brightness) of the solar radiation with the aid
of a photodiode. The dual sun sensor differentiates between left and right solar incidence, in other words it has
two photodiodes. The interior temperature and the blower stage are adjusted based on the intensity of the light.
OUTSIDE AIR TEMPERATURE SENSOR, COMPONENT DESCRIPTION - GF83.57-P-4000GZ
MODEL 164
Location
The outside air temperature sensor is located in the left section of the front bumper.
Task
To record the outside temperature.
Function
The temperature sensor changes its resistance depending on the outside temperature. The sensor is read in by
the AAC [KLA] control and operating unit (N22).
Fig. 57: Identifying Outside Air Temperature Sensor Component Location - Shown On Model 164.1
OUTSIDE TEMPERATURE DISPLAY TEMPERATURE SENSOR, COMPONENT DESCRIPTION -

GF83.57-P-4002GZ
MODEL 164
Location
The temperature sensor is located on the left front bumper.
Task
To record the outside temperature.

Fig. 58: Identifying Outside Temperature Display Temperature Sensor Component Location
Function
The temperature sensor changes its resistance depending on the outdoor temperature. It is read in by the
instrument cluster (A1) and the reading is indicated on the multifunction display (A1p13).
PTC HEATER BOOSTER, COMPONENT DESCRIPTION - GF83.70-P-4063GZ
MODEL 164, 251
Shown on MODEL 164
Location
The PTC heater booster is installed on the side of the AC housing in the front.
Fig. 59: Identifying PTC Heater Booster Component Description - Shown On Model 164
Task
The PTC heater booster is actuated by the AAC [KLA] control and operating unit (N22) via the LIN bus. The
automatic air conditioning controls the heat output so that the battery is protected to the extent possible.
Function
The electric PTC heater booster (Positive Temperature Coefficient) has 1700 watts and is used to support the
heater. It is located in the AC housing. The fresh air flows into the interior compartment via the heater heat
exchanger and the PTC heater booster.
The PTC heater booster is installed in vehicles with diesel engine, since these engines produce too little
waste heat during cold start or with partial load.
RESIDUAL ENGINE HEAT UTILIZATION FUNCTION - GF83.75-P-2000GZ
MODEL 164
Function
The residual engine heat utilization feature makes it possible to continue to heat or simply ventilate the vehicle
with c. 15 Off or c. 15C. For this purpose, the system utilizes the residual engine heat by pumping the still hot
coolant through the heating system heat exchanger with the coolant circulation pump (M13) and blowing the
heated air into the vehicle interior with the blower motor (A32m1).
The coolant circulation pump is actuated by the AAC operating and control unit (N22) or comfort AAC
operating and control unit (N22/7).
Heating system heat exchanger, GF83.20-P-

GF83.10-P-
2050GZ
Model 164.8 with comfort automatic air
GF83.10-P-
conditioning, code 581
2050RTH
With rear air conditioner, code 582
Blower regulator, component GF83.10-P-
With automatic air conditioning, code 580
description 2051GZ
GF83.10-P-
With comfort automatic air conditioning, code 581
2051GZK
Actuator motors, component GF83.10-P-
With automatic air conditioning, code 580
description 2201GZ
With comfort automatic air conditioning, code GF83.10-P-
581, Except rear air conditioner, code 582 2201GZK
Model 164.8 with comfort automatic air
GF83.10-P-
conditioning, code 581
2201RTK
Coolant circulation pump component GF83.75-P-
description 2110GZ
Automatic air conditioning
Except USA version, code 494, With automatic air GF83.40-P-
pushbutton control unit, component
conditioning, code 580 3000GZE
description
With USA version, code 494, With automatic air GF83.40-P-
conditioning, code 580 3000GZU
Comfort automatic air conditioning
Except USA version, code 494, With comfort GF83.40-P-
control and operating unit,
automatic air conditioning, code 581 3010GZE
With USA version, code 494, With comfort GF83.40-P-
automatic air conditioning, code 581 3010GZU
Model 164.8 with USA version, code 494, With
GF83.40-P-
comfort automatic air conditioning, code 581,
3010RTU
GF80.57-P-
6000GZ
description
COOLANT CIRCULATION PUMP COMPONENT DESCRIPTION - GF83.75-P-2110GZ
MODEL 164
Location
The coolant circulation pump is located in the engine compartment at the front left.
Task
The coolant circulation pump acts as a backup when the engine is running or when the residual heat or the
stationary heater mode is switched on (with stationary heater, code 228) it pumps coolant through the heater
heat exchanger.
Fig. 60: Identifying Coolant Circulation Pump Component Description - Shown On Model 164.1
Function
The coolant circulation pump is controlled directly by the AAC control and operating unit (N22) or comfort
AAC control and operating unit (N22/7).
ADDITIONAL CIRCULATION PUMP, COMPONENT DESCRIPTION - GF83.75-P-2111RT
conditioner
conditioner
Shown on BR 251
Location
The rear AC additional circulation pump is located at the right front in the engine compartment.
Fig. 61: Identifying Additional Circulation Pump Component Description - Shown On BR 251
Task
The rear AC additional circulation pump is installed to support the coolant circulation pump (M13). The
circulation pumps cool the engine after the ignition has been switched off and transport the heating water in
residual heat mode.
Function
The additional circulation pump and the coolant circulation pump are directly actuated by the comfort AAC
[KLA] control and operating unit (N22/7).
SAFETY PRECAUTIONS
RISK OF EXPLOSION CAUSED BY WELDING OR SOLDERING WORK ON CLOSED AIR
CONDITIONING SYSTEM. RISK OF POISONING CAUSED BY INHALING OVERHEATED
REFRIGERANT VAPORS. RISK OF INJURY TO SKIN AND EYES CAUSED BY CONTACT WITH
LIQUID REFRIGERANT. - AS83.00-Z-0001-01A
Never perform welding work on or near a closed air conditioning system. No smoking or open flames.
Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on
the air conditioning system circuit only after the system has been discharged.
Potential risks
Risk of explosion
When closed air conditioning systems (charged or empty) become heated, high pressures are produced that can
ultimately cause the system to burst. For this reason, all welding and soldering operations on or near closed
air conditioning systems are prohibited. High pressure levels can combine with refrigerant vapors to produce a
mixture that is potentially explosive when exposed to atmospheric air.
Risk of poisoning
Refrigerant can decompose when overheated. The resulting substances are toxic and should never be inhaled.
Risk of injury
Refrigerant vapors are heavier than air; this means that escaping gases pose a risk of suffocation for anyone in a
work pit beneath the vehicle.
Contact with liquid refrigerant may cause chilblain-like damage to the skin (due to under-cooling).
 All welding, brazing and soldering operations on sealed air conditioning systems and in their
immediate vicinity are prohibited.
 Never smoke when working with refrigerant, never expose refrigerant to open flames.
 A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms
immediately and ventilate thoroughly.
 All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work
on the air conditioning circuit or components.
 Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging
refrigerant directly into the air is prohibited.
 Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment
facilities must be used for evacuating refrigerant.
 Even after the system has been evacuated, residual pressure may still be present in the system when
loosening couplings. Therefore, loosen the couplings carefully, so that the pressure can dissipate slowly.
 Avoid all contact with liquid refrigerant.
 Always wear safety glasses and protective gloves when working with refrigerant.
First aid measures
In case of eye contact
 Immediately flush with plenty of running water and consult a physician.
In case of skin contact
 Consult a physician immediately in case of frostbite. In case of inhalation

 of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm.
 If the victim's breathing is shallow, or the individual has stopped breathing altogether, tilt the head back
and administer artificial resuscitation. Call a doctor.
In case of ingestion
 Consult a physician immediately.
TROUBLE DIAGNOSIS
MUSTINESS, ROTTENNESS OR URINE ODOR FROM AIR CONDITIONING VENT - INTERIOR
CLEANING - AF83.00-P-5001A
MODEL 107, 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251, 460, 461, 463
MODIFICATION NOTES
17.11.06 Work procedure revised
OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text
P 831415 Clean air conditioning system
inside
Damage code Cause Remedy

83 432 65 The cause of an odor First process all
complaint can be the steps of the diagnosis
contamination of the tree "Odor" from the
interior, the ventilation Technology Guide
ducts or the evaporator "Vehicle climate control".
If an odor complaint
persists:
?
Mustiness, Perform cleaning using
rottenness or urine odor atomizer (ultrasonic).
can occur as a result. Prepare cleaning
as follows:
1 Allow vehicle to warm
up with air conditioning
system switched off
(observe operating
concept A/C-AC OFF)
for at least 30 min; heat
up interior (when vehicle
is stationary).
When doing so, make
sure that the blower is set

to speed 2-3, heating is
set to maximum,
recirculated air is
activated, vents are set to
the footwell and vehicle
is closed (doors,
windows, sliding roof).
This procedure is
used to dry out the
evaporator. The success
of the cleaning method is
only guaranteed when the
evaporator is dry.
2 Treat air conditioning
system using atomizer
(ultrasonic).
The evaporator
must be dried out before
the atomizer is used
(ultrasonic) (see
operation step 1).
The air
conditioning system must
always be OFF (observe
the operating concept
A/C - AC OFF) when the
following steps are
performed.
3 Remove all filters
installed in air
conditioning system.
The following
filters may be installed:
pollen filter, dust filter,
combination filter or
activated charcoal filter.
4 Close air recirculation
flap by means of
actuation "Close air
recirculation flap for
cleaning" in DAS.
If this menu item
is not available in the
DAS for the required
models, start the special
coding function (code

number) in the DAS
system and set the
manual recirculated air
function to "unlimited".
5 Place atomizer
(ultrasonic) in passenger
compartment on
passenger side; when
doing so, secure hose in
luggage net in such a way
that smoke which is
discharged is extracted
via footwell vents.
6 Start engine with air
conditioning system
switched off (observe
operating concept A/C -
ACOFF), press air
recirculation button, set
lowest blower speed and
set temperature to
minimum.
7 Switch on atomizer
(ultrasonic).
8 Close all windows and
doors.
9 Cleaning procedure is
complete when smoke is
no longer discharged
from atomizer
(ultrasonic) (approx. 20
min.).
Under certain
circumstances, the
cleaning process may be
interrupted briefly but
then continues
automatically.
10 When cleaning
procedure is finished,
switch off engine and
ignition, switch off
atomizer (ultrasonic) and
leave vehicle closed for
approx. 1 h.
11 Then open doors,

trunk lid / tailgate and
ventilate vehicle.
12 Open air recirculation
flap again if automatic
recirculated air function
has been deactivated by
coding, and set
recirculated air function
to "unlimited" again in
special coding.
13 Start vehicle again.
14 Switch on air
conditioning system, set
temperature to "LO", set
highest blower speed and
allow to run for approx.
10 min.
The evaporator is
flushed out. Only when
these instructions are
complied with exactly is
the climate control
system cleaned
completely and the odor
is eliminated.
All the filters
installed in the air
conditioning system must
be replaced after
cleaning.
If this interior cleaning
procedure was not
successful, see:
?
15 Continued measures: SI83.00-P-0004A
SI83.30-P-0008A
PARTS ORDERING NOTES

Part no. Designation Quantity
A 000 581 01 04 Atomizer (ultrasonic) 1
A 009 989 82 71 Interior cleaner (100 ml) 1
651 623 01 00 Technology Guide "Vehicle 1
climate control"
GRINDING OR FLOWING NOISE FROM THE AREA OF THE STEERING SYSTEM - AF83.55-P-
1000AG
ENGINE 112, 113 in MODELS 203, 209, 211, 220
OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text
P 131202 Replace V-belt, single-belt drive
P 831762 Evacuate refrigerant and check for
leaks, refill (when working on
system) all climate control
systems
P 611071 REMOVE AND INSTALL
FRONT PART OF BOTTOM
ENGINE COMPARTMENT
PANEL
P 837351 Remove/install compressor (after
check) all climate control systems
P 836524 Remove/install fluid reservoir,
inspect and replace if necessary
(system empty) all climate control
systems VEH as of model
refinement
P 836623 Replace desiccant cartridge
(system empty) all climate control
systems
Damage code Cause Remedy

83 421 36 Possibly the The refrigerant
refrigerant compressor compressor must not be replaced
because there is a suspicion of a
defect. First the test must be
carried out with a shorter poly-V-
belt
Proceed as follows in the process:
?
In isolated 1 Remove original poly-V-belt
cases grinding or (2390 mm).
flowing noises can be
heard from the area of
the steering system
(power steering
pump). This noise is
comparable to the
noise which the power
steering pump causes
when it draws in air.
2 Fit the poly-V-belt with the part
number A 011 997 86 or A 011
997 96 92 (both 2315 mm long) so
that the refrigerant compressor is
not driven at the same time (see
picture).
3 Start the engine and check
whether the noise is reproducible.
 If the noise is no longer

present, proceed with
operation step 4.
 If the noise continues,
proceed with operation step
5.
4 Replace refrigerant compressor.
Engine 112 in model 203, 209 AR83.55-P-5300T
with CODE (580a) Automatic air
conditioning
Engine 112 in model 203, 209
with CODE (581b) Comfort
Engine 646.951 in model 211.004 AR83.55-P-5300PV
Engine 646.961 in model 211.006/
606
616
Engine 112.913 in model
211.061 /261
265
270
211.076 /276
211.020 /022 /220 /222
211.084 /089 /284 /289
Engine 113.964, 156.980, AR83.55-P-5300GZ
272.967, 642.940 in model 164
with CODE (580) Automatic air
conditioning
with CODE (581) Comfort
5 If the refrigerant compressor is
not the cause of the noise, see
?
Noises when steering. AF46.00-P-1000AG
Belt drive
Fig. 62: Testing With Shorter Poly V-Belt

Fig. 63: Identifying Refrigerant Compressor

TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9113AB
ENGINE 113
Correct oil level in air ENGINE 104, 111, 112, AR83.55-P-5250E

conditioning system 113, 137, 155, 601, 602,
when replacing AC 604, 605, 606 ...
compressor
Correct oil level in air ENGINE 113, 156, 272, AR83.55-P-5250GZ
conditioning system 273, 629, 642 ...
when replacing AC
compressor
Correct oil level in air ENGINE 111, 112, 113, AR83.55-P-5250P
when replacing
refrigerant compressor
Remove/install ENGINE 113 ... AR83.55-P-5300AC
Removing and installing ENGINE 112, 113 in AR83.55-P-5300C
A/C compressor MODEL 129 with CODE
(581a) Automatic air
conditioning
Removing and installing ENGINE 104, 111, 112, AR83.55-P-5300E
A/C compressor 113, 604, 605, 611 ...
Removing and installing ENGINE 104, 111, 112, AR83.55-P-5300F
A/C compressor 113, 602, 604, 605, 606,
611 ...
Remove/install ENGINE 113, 156, 272, AR83.55-P-5300GZ
refrigerant compressor 642 ...
Remove/install ENGINE 113, 137 in AR83.55-P-5300M
refrigerant compressor MODEL 215 ENGINE
112, 113, 137, 613 in
MODEL 220
Remove/install ENGINE 113 ... AR83.55-P-5300Q
Remove/install ENGINE 113.9 in AR83.55-P-5300R
refrigerant compressor MODEL 230.475
Remove/install ENGINE 113, 156, 272, AR83.55-P-5300RT
Remove/install ENGINE 112, 113, 642, AR83.55-P-5300T
refrigerant compressor 646, 647 ...
Removing and installing ENGINE 113.967 in AR83.55-P-5300TY
A/C compressor MODEL 219.375
Remove/install ENGINE 113, 271, AR83.55-P-5300V

ENGINE 156
Correct oil level in air ENGINE 113, 156, 272, AR83.55-P-5250GZ

when replacing AC
compressor
Remove/install ENGINE 113, 156, 272, AR83.55-P-5300GZ
Remove/install ENGINE 113, 156, 272, AR83.55-P-5300RT
Remove/install ENGINE 156 in MODEL AR83.55-P-5300SMG
refrigerant compressor 216, 221
Remove/install ENGINE 156 ... AR83.55-P-5300TMG
TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9164AA
MODEL 164
Remove/install actuator motor for left AR83.10-P-

MODEL 164
defroster flap 2004GZ
Remove/install actuator motor for right AR83.10-P-
MODEL 164
defroster vent flap 2005GZ
Remove/install left footwell flap actuator AR83.10-P-
MODEL 164
motor 2006GZ
Remove/install actuator motor for right AR83.10-P-
MODEL 164
footwell flap 2007GZ
AR83.10-P-
Remove/install diverter flap actuator motor MODEL 164
2014GZ
Remove and install left center nozzle air AR83.10-P-
MODEL 164
flap actuator motor 2015GZ
Remove and install right center nozzle air AR83.10-P-
MODEL 164
flap actuator motor 2016GZ
AR83.10-P-
Remove/install rear air nozzle MODEL 164
4800GZ
AR83.25-P-
Remove and install heat exchanger MODEL 164
1100GZ
Remove/install/replace heating water AR83.25-P-
MODEL 164
circulation pump 1170GZ
AR83.25-P-
Remove and install blower motor MODEL 164
1200GZ
Remove/install water repellent over wiper AR83.25-P-
MODEL 164
system 1406GZ
Remove/install air inlet duct below engine MODEL 164 AR83.25-P-
hood 1407GZ
Drain, evacuate and refill air conditioning, AR83.30-P-
MODEL 164 ...
check function and check for leaks 1760GZ
MODEL 164, 169, 171, 203, 209, 211, 215,
AR83.30-P-
Check air conditioning system for leakage 216, 219, 220, 221, 230, 245, 251, 461,
1761PP
463 ...
MODEL 164, 169, 171, 199, 203, 209, 211,
AR83.30-P-
Repair refrigerant circuit 215, 216, 219, 220, 221, 230, 240, 245, 251,
1782A
461, 463 ...
Remove/install rear shutoff flap actuator AR83.30-P-
MODEL 164
motor 2008GZ
Remove/install fresh air/recirculated air AR83.30-P-
MODEL 164
stepper motor 2010GZ
Remove/install stepper motor for center air AR83.30-P-
MODEL 164
outlet in rear footwell flap 2120GZ
AR83.30-P-
Remove/install AC housing MODEL 164 ...
5200GZ
Disassemble/assemble air conditioner AR83.30-P-
MODEL 164 ...
housing 5201GZ
Remove and install refrigerant pressure MODEL 164 with CODE (580) Automatic AR83.30-P-
and temperature sensor air conditioning 5431GZ
AR83.30-P-
Remove/install expansion valve MODEL 164 ...
5520GZ
AR83.30-P-
Remove/install evaporator MODEL 164 ...
5540GZ
MODEL 164, 169, 171, 199, 209, 211, 219, AR83.30-P-
Check evaporator for leakage
221, 230, 240, 245, 251 ... 5550Q
MODEL 164, 169, 171, 203, 209, 211, 215, AR83.30-P-
Cleaning the evaporator
219, 220, 221, 230, 245, 251 ... 5555T
MODEL 164, 169, 171, 203, 204, 209, 211,
Clean evaporator and air conditioning AR83.30-P-
215, 216, 219, 220, 221, 230, 240, 245,
system on inside 5556A
251 ...
AR83.30-P-
Remove/install rear blower motor MODEL 164
5565GZ
AR83.30-P-
Remove/install fluid reservoir MODEL 164, 251 ...
6520GZ
AR83.30-P-
Remove/install fluid reservoir MODEL 164, 251 ...
6520RT
AR83.30-P-
Remove/install service valve MODEL 164 ...
6522GZ
Remove/install valve insert on service AR83.30-P-
MODEL 164 ...
valve 6523GY
AR83.30-P-
Install/remove condenser MODEL 164 ...
6540GZ
Remove/install refrigerant lines at AR83.30-P-

MODEL 164 ...
refrigerant compressor 7810GZ
Remove and install evaporator temperature AR83.30-P-
MODEL 164
sensor 8085GZ
Remove/install air outlet temperature MODEL 164 Side air outlets and center AR83.30-P-
sensor outlet 8087GZ
Remove/install air outlet temperature AR83.30-P-
MODEL 164 footwell
sensor 8087GZA
Remove/install air outlet temperature AR83.30-P-
MODEL 164 Rear footwell
sensor 8087GZB
Remove and install control and operating AR83.40-P-
MODEL 164
unit 6350GZ
AR83.40-P-
Remove and install sun sensor MODEL 164
6720GZ
MODEL 164 with CODE (581) Comfort AR83.40-P-
Remove and install air humidity sensor
automatic air conditioning 6740GZ
Remove/install refrigerant lines at the left MODEL 164.8, 251 with CODE (582) Rear AR83.50-P-
side wall air conditioner 6501RT
MODEL 164.8 with CODE (582) Rear air AR83.50-P-
Remove/install underfloor refrigerant lines
conditioner 6600GY
Remove/install rear air conditioning MODEL 164.8, 251 with CODE (582) Rear AR83.50-P-
refrigerant shutoff valve air conditioner 9000RT
MODEL 164.8, 251 with CODE (582) Rear AR83.50-P-
Remove and install rear AC housing
air conditioner 9020RT
MODEL 164.8, 251 with CODE (582) Rear AR83.50-P-
Disassemble/assemble rear AC housing
air conditioner 9030RT
Remove and install blower motor for rear MODEL 164.8, 251 with CODE (582) Rear AR83.50-P-
air conditioning air conditioner 9040GY
Remove and install rear air conditioning MODEL 164.8 with CODE (582) Rear air AR83.50-P-
pushbutton control unit conditioner 9070GY
system evaporator temperature sensor air conditioner 9080RT
evaporator air conditioner 9100RT
MODEL 164 with CODE (228) Stationary AR83.70-P-
Remove and install Telestart receiver
heater 0003GZ
Check Telestart transmitter
Stationary heater 0005GZ
Remove/install heater unit
Stationary heater 5302RT
Remove/install fuel metering pump
Stationary heater 5652RT
AR83.70-P-
Remove/install temperature sensor MODEL 164
5975GZ
Remove/install coolant circuit solenoid MODEL 164 with CODE (228) Stationary AR83.70-P-
valve heater 6000GZ
Remove and install heater unit exhaust MODEL 164, 251 with CODE (228) AR83.70-P-
system Stationary heater 7000RT
AR83.70-P-
Remove/install PTC heater booster MODEL 164 with ENGINE 642, 629
8000GZ
ENGINE 272
Correct oil level in air conditioning system when ENGINE 113, 156, 272, 273, 629, AR83.55-P-
replacing AC compressor 642 ... 5250GZ
ENGINES 271, 272, 646.8 in AR83.55-P-
Remove/install refrigerant compressor
MODEL 204.0/2 5300CW
AR83.55-P-
Remove/install refrigerant compressor ENGINE 113, 156, 272, 642 ...
5300GZ
AR83.55-P-
Remove/install refrigerant compressor ENGINE 113, 156, 272, 642 ...
5300RT
ENGINE 272 in MODEL
221.056 /156 AR83.55-P-
ENGINE 273 in MODEL 5300SX
221.071 /171
AR83.55-P-
Remove/install refrigerant compressor ENGINE 113, 271, 272 ...
5300V
ENGINE 273
Correct oil level in air conditioning system when ENGINE 113, 156, 272, 273, AR83.55-P-
replacing AC compressor 629, 642 ... 5250GZ
ENGINE 272 in MODEL
221.056 /156 AR83.55-P-
ENGINE 273 in MODEL 5300SX
221.071 /171
REMOVE/INSTALL ACTUATOR MOTOR FOR LEFT DEFROSTER FLAP - AR83.10-P-2004GZ
MODEL 164
Fig. 64: Identifying Actuator Motor For Left Defroster Flap Components
Remove/Install
AR68.10-P-
1 Remove top part of instrument panel
1020GZ
Carefully lift seal in area A and remove concealed Installation: Ensure
2 that seal is properly seated, if
bolts
necessary glue seal in place.
3 Remove upper part of A/C housing (1) upwards
Detach electrical connectors (2, 3, 4) from left
defroster vent flap actuator motor (M2/8), right
4
defroster vent flap actuator motor (M2/9) and diverter
flap actuator motor (M16/27)
Rechargeable battery-powered *WH58.30-Z-
5 Remove bolts (5)
drill/ screwdriver 1007-20A
6 Detach left defroster vent flap actuator motor (M2/8)
Menu item, Actuation,
8 Synchronize the actuator motors Normalization of actuator
motors.
memory 2000-04A
system 1048-13A

Number Designation
REMOVE/INSTALL ACTUATOR MOTOR FOR RIGHT DEFROSTER VENT FLAP - AR83.10-P-

2005GZ
MODEL 164
Fig. 65: Identifying Actuator Motor For Right Defroster Vent Flap Components
Remove/Install
AR68.10-P-
1020GZ
Carefully lift seal in area A and remove concealed Installation: Ensure
2 that seal is properly seated, if
bolts
necessary glue seal in place.
3 Remove upper part of A/C housing (1) upwards
Detach electrical connectors (2, 3, 4) from left
defroster vent flap actuator motor (M2/8), right
4
defroster vent flap actuator motor (M2/9) and diverter
Rechargeable battery-powered *WH58.30-Z-
5 Unscrew bolts (5)
6 Detach right defroster vent flap actuator motor (M2/9)
8 Synchronize the actuator motors Normalization of actuator
motors.
memory 2000-04A
system 1048-13A

Number Designation
REMOVE/INSTALL LEFT FOOTWELL FLAP ACTUATOR MOTOR - AR83.10-P-2006GZ
MODEL 164
Fig. 66: Identifying Left Footwell Flap Actuator Motor Components (1 Of 2)

Fig. 67: Identifying Left Footwell Flap Actuator Motor Components (2 Of 2)

Remove/install
AR68.10-P-
1 Remove instrument panel upper section 1020GZ

*BA68.10-P-
2 Unscrew bolts (1) and bolt (3)
1002-01B
*BA68.10-P-
1003-01B
3 Unscrew nut (2, 4, 5)
*BA68.10-P-
4 Unscrew bolts (6) and bolt (7)
1002-01B
*BA68.10-P-
1003-01B
5 Loosen bolts (8) Up to last thread.
*BA68.10-P-
1001-01B
Raise instrument panel crossmember (9) at To enable the left footwell air
6
lower attachment points pipe (11) to be removed.
*WH58.30-Z-
7 Remove bolts (10) Rechargeable drill/screwdriver
1007-20A
8 Remove left footwell air pipe (11)
Detach electrical connector (12) at left
9
footwell flap actuator motor (M2/10)
Menu item Actuation,
11 Normalize actuator motors
Normalization of actuator motors.
*WH58.30-Z-
1048-13A
INSTRUMENT PANEL SPECIFICATIONS

BA68.10-P-1001-01B Bolt, instrument panel crossmember to firewall Nm 30
BA68.10-P-1002-01B Bolt, instrument panel crossmember to A-pillar Nm 30
BA68.10-P-1003-01B Bolt, instrument panel crossmember to transmission tunnel Nm 30

Number Designation
REMOVE/INSTALL ACTUATOR MOTOR FOR RIGHT FOOTWELL FLAP - AR83.10-P-2007GZ
MODEL 164
Fig. 68: Identifying Actuator Motor For Right Footwell Flap Components (1 Of 2)
Fig. 69: Identifying Actuator Motor For Right Footwell Flap Components (2 Of 2)
Remove/install
To enable the right footwell

1 Set air conditioning to defrosting.
air pipe (11) to be removed.
AR68.10-P-
1020GZ
*BA68.10-P-
3 Remove screws (1) and screw (3)
1002-01B
*BA68.10-P-
1003-01B
4 Unscrew nut (2, 4, 5)

*BA68.10-P-
5 Remove screws (6) and screw (7)
1002-01B
*BA68.10-P-
1003-01B
6 Loosen bolts (8) Up to last thread.
*BA68.10-P-
1001-01B
Raise instrument panel crossmember (9) at To enable the right footwell
7
lower attachment points air pipe (11) to be removed.
*WH58.30-Z-
8 Remove bolts (10) Rechargeable drill / screwdriver
1007-20A
9 Remove right footwell air pipe (11)
Detach electrical connector (12) at right
10
footwell flap actuator motor (M2/11)
*WH58.30-Z-
1007-20A
13 Synchronize the actuator motors
Normalization of actuator motors.
*WH58.30-Z-
1048-13A


Number Designation
REMOVE/INSTALL DIVERTER FLAP ACTUATOR MOTOR - AR83.10-P-2014GZ
MODEL 164
Air conditioner housing removed for ease of illustration

Fig. 70: Identifying Diverter Flap Actuator Motor Components

Remove/install
on airbag or emergency 100°C. When working on these units, 0001-01A
tensioning retractor units. disconnect the power supply.
AH91.00-P-
work and welding on vehicles
0002-01M
with airbags and ETR units
Assessment of airbag and belt
AH91.00-P-
tensioner units in accident
0006-01B
vehicles
AH91.00-P-
0004-01A
AR54.10-P-
0003GZ
AR68.30-P-
2 Remove paneling on A-pillar. On left and right. 4050GZA
AR68.20-P-
2000GZ
Remove bottom section of AR68.10-P-
4
dashboard on driver's side 1505GZ
5
dashboard on front passenger side 1507GZ
Remove top part of instrument AR68.10-P-
6
panel 1020GZ
*BA46.10-P-
1001-03J
*BA91.60-P-
1010-01H
7 (1)
8 Unscrew bolt (2)
Remove diverter flap actuator
9
motor (M16/27)
11 Synchronize actuator motors
12 Read out fault memory and erase assembly work, test work, removed lines or a
simulation, must be processed and erased in
the fault memories after completing the work.
*WH58.30-Z-
1048-13A
AR00.19-P-
0200GZ
JACKET TUBE SPECIFICATIONS

BA46.10-P-1001-03J Bolt, upper jacket tube to body Nm 20
AIRBAG SPECIFICATIONS
BA91.60-P-1010-01H Nut, passenger airbag to instrument panel crossmember Nm 20

Number Designation
REMOVE AND INSTALL LEFT CENTER NOZZLE AIR FLAP ACTUATOR MOTOR - AR83.10-P-
2015GZ
MODEL 164
Shown on upper section of instrument panel on model 164.1, with comfort automatic air conditioning,
code 581
Fig. 71: Identifying Left Center Nozzle Air Flap Actuator Motor Components - Shown On Upper Section
Of Instrument Panel On Model 164.1
Remove/install
Remove instrument panel top section Place upper section of instrument panel AR68.10-P-
1 with the top side onto a suitable surface to
(1) 1020GZ
avoid any damage to it.
2 Unscrew bolt (2)
Remove actuator motor housing (3)
3 from upper section of instrument
panel (1)
Detach electrical connector (4) of
4 left center air flap actuator motor
(M16/23)
*WH58.30-Z-
5 Remove screws (5) Rechargeable drill / screwdriver
1007-20A
Remove left center air flap actuator
6
motor (M16/23)
Menu item, Actuation, Normalization
of actuator motors.
*WH58.30-Z-
1048-13A

Number Designation
REMOVE AND INSTALL RIGHT CENTER NOZZLE AIR FLAP ACTUATOR MOTOR - AR83.10-P-
2016GZ
MODEL 164
Shown on upper section of instrument panel on model 146.1, with comfort automatic air conditioning,
code 581
Fig. 72: Identifying Right Center Nozzle Air Flap Actuator Motor Components - Shown On Upper
Section Of Instrument Panel On Model 146.1
Remove/install
Place upper section of instrument panel

Remove instrument panel top section AR68.10-P-
1 with the top side onto a suitable surface to
(1) 1020GZ
avoid any damage to it.
2 Unscrew bolt (2)
Remove actuator motor housing (3)
3 from upper section of instrument
panel (1)
4 Detach electrical connector (4) of

right center air flap actuator motor
(M16/24)
*WH58.30-Z-
5 Remove screws (5) Rechargeable drill / screwdriver
1007-20A
Remove right center air flap actuator
6
motor (M16/24)
Menu item, Actuation, Normalization
of actuator motors.
*WH58.30-Z-
1048-13A

Number Designation
REMOVE/INSTALL REAR AIR NOZZLE - AR83.10-P-4800GZ
MODEL 164
Fig. 73: Identifying Rear Air Nozzle Components

Remove/install

AR68.20-P-
2 Remove rear center console (1)
2020GZ
Carefully bend clips (2, 3) outwards, risk of cracks
and fracture!
Long wedge Fig. 74
4 Unclip clips (4) Long wedge Fig. 74
Installation: Check foam gasket is correctly
5 Remove rear air outlet
seated.

REMOVE AND INSTALL HEAT EXCHANGER - AR83.25-P-1100GZ
MODEL 164
Shown on vehicle with Automatic air conditioning, code 580

Fig. 75: Identifying Heat Exchanger Components - Shown On Vehicle With Automatic Air Conditioning,
Code 580
Remove/install
AR20.00-P-
1 Drain coolant from radiator Engine 113, 272, 273
1142GZ
AR20.00-P-
Engine 156
1142GZS
AR20.00-P-
Engine 629
1142GZD
AR20.00-P-
Engine 642
1142GZB
Remove mounting bolts for instrument
2 See: ?
panel carrier
AR68.10-P-
Remove/install instrument panel carrier
1111GZ
Raise instrument panel carrier at lower To enable the heat exchanger (5) to be
3
attachment points pulled out.
4 Remove bolts (1)
Detach left footwell air pipe (2) and
5 Do not disconnect electrically
remove from working area
6 This helps to prevent the interior of the

Cover vehicle floor in the area of the vehicle from being soiled by leaking coolant
heat exchanger (5) with shop towels when removing the heat exchanger (5).
7 Release and expand line clamps (3)
Pull coolant lines (4) out of
8 connection fittings on heat exchanger
(5)
This serves to ensure that when the
heat exchanger (5) is removed from the heater
Seal heat exchanger openings (5)
or air conditioner housing, the vehicle interior
using suitable stop plugs and pull heat
9 is not soiled by escaping coolant.
exchanger (5) out of heater or air
conditioner housing Installation: Check that the heat
exchanger (5) is correctly seated in the heater
or air conditioner housing.
*WH58.30-Z-
Set of plugs for air conditioning system 1002-27A
Remove line clamps (3) with bolts and Installation: The line clamps (3) with
10
sealing rings (6) from coolant lines (4) bolts and sealing rings (6) must be replaced.
Use suitable plugs to seal coolant lines This helps to prevent the interior of the
11
(4) vehicle from being soiled by leaking coolant.

Number Designation
WH58.30-Z-1002-27A Set of plugs for air conditioning system 140 830 01 27
REMOVE/INSTALL/REPLACE HEATING WATER CIRCULATION PUMP - AR83.25-P-1170GZ
MODEL 164
To simplify illustration radiator crossmember removed
Fig. 76: Identifying Heating Water Circulation Pump Components

Main headlamps removed for better illustration. Shown on model 164.1

Fig. 77: Identifying Heating Water Circulation Pump Components - Shown On Model 164.1
Remove/install
Do not open cooling system unless coolant

Risk of injury to skin and eyes caused temperature is below 90°C. Open cap
by scalding from contact with hot coolant slowly and release the pressure. Do not pour AS20.00-Z-
spray. Risk of poisoning from coolant into beverage containers. 0001-01A
swallowing coolant. Wear protective gloves, protective clothing
and safety glasses.
AH20.00-N-
Notes on coolant
2080-01A
1
position 1000GZ
To do this, carefully open reservoir
2 Reduce pressure in cooling system
cover and close again.
3 Detach intake-air pipe (1) (arrow A) Only on left side.
5 Clamp off hot water hose (3, 4) Clamping device Fig. 78
*WH58.30-Z-
6 Release hose clamp (5, 6) Hose clamp pliers 1020-02A
Detach hot water hose (3, 4) from coolant
7 Collect escaping coolant.
circulation pump (M13)
Detach coolant circulation pump (M13)
8
from bracket
See: ?
10 Check coolant level, correct as required.
Drain/fill in coolant
AR20.00-P-
Engine 113, 272, 273
1142GZ
AR20.00-P-
Engine 156
1142GZS
AR20.00-P-
Engine 629
1142GZD
AR20.00-P-
Engine 642 1142GZB

AR20.00-P-
11 Inspect cooling system for leaks Engine 113, 272, 273
1010GZ
AR20.00-P-
Engine 156
1010GZS
AR20.00-P-
Engines 629, 642
1010GZB


Number Designation
WH58.30-Z-1020-02A Hose clamp pliers (length 235 mm, clamping range 40 mm)
REMOVE AND INSTALL BLOWER MOTOR - AR83.25-P-1200GZ
MODEL 164
Fig. 79: Identifying Blower Motor Components - Shown On Model 164.1

Remove/install
1 Move passenger seat back

Remove cover under instrument AR68.10-P-
3 Right side.
panel (1) 1520GZ
4
(3) from blower motor (A32m1)
5 Unscrew bolt (2)
6 Unclip wiring harness (arrow)
7 Remove blower motor (A32m1)
REMOVE/INSTALL WATER REPELLENT OVER WIPER SYSTEM - AR83.25-P-1406GZ
MODEL 164
Fig. 80: Identifying Water Repellent Over Wiper System Components

Remove/install
Risk of injury in the form of trapping or Always remove ignition key when
AS82.30-Z-
crushing, or even severing of limbs, if caught working on windshield wiper
0001-01A
in windshield wiper mechanism mechanism.
AR82.30-P-
1 Remove wiper arms
6100GZ
2 Detach rubber seal (1) from cover (5)
3 Detach rubber seal (2) from left and right
fender
4 Unclip washer fluid hose from clip (4)
Detach cover (5) on one side
in the opposite direction.
5 Remove cover (5) Installation: Lubricate upper
edge of cover (5) and windshield at
bottom with soapy water.
REMOVE/INSTALL AIR INLET DUCT BELOW ENGINE HOOD - AR83.25-P-1407GZ
MODEL 164
Fig. 81: Identifying Air Inlet Duct Below Engine Hood Components
Removing
Open engine hood and move to AR88.40-P-
1
upright position 1000GZ
2 Remove bolts (1)
Cable grommets (4) can fall out when the
4 Remove air inlet duct (3)
air inlet duct (3) is being removed.
Install
5.1 Insert cable grommets (4) If they have fallen out during removal.
6 Clip in air inlet duct (3)
7 Screw in bolts (1).
AR88.40-P-
8 Close engine hood
1000GZ

DRAIN, EVACUATE AND REFILL AIR CONDITIONING, CHECK FUNCTION AND CHECK FOR
LEAKS - AR83.30-P-1760GZ
MODEL 164 with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air
conditioning with CODE (582) Rear air conditioner
Fig. 83: Identifying Drain, Evacuate And Refill Air Conditioning Components - Illustrated On Model
164.186
MODIFICATION NOTES
12.7.06 Filling quantities added Step 7
5.1.07 Reference to document AR83.30-P-6520RT added Step 4
Draining
Risk of explosion caused
by welding or soldering
work on closed air
Never perform welding work on or near a closed air
conditioning system.
conditioning system. No smoking or open flames. Wear
Risk of poisoning AS83.00-
safety glasses and protective gloves. Work only in well
caused by inhaling Z-0001-
ventilated areas. Carry out repair work on the air
overheated refrigerant 01A
conditioning system circuit only after the system has been
vapors. Risk of injury to
discharged.
skin and eyes caused by
contact with liquid
refrigerant.
Procedure if air AH83.30-
conditioning system is N-0004-
damaged or leaking 01A
Protect air conditioning
AH83.30-
circuit and components
P-0005-
from moisture when
01P
carrying out repair work
AH83.30-
Notes on handling
Air conditioning with refrigerant R134a N-0003-
refrigerant R134a
01A
For all steps, proceed as
per the operating
instructions for the air
conditioning vacuum,
recycling and filling unit
for refrigerant R134a
Depending on the engine model, various
1 Unscrew plug (1, 3) installation positions are possible for the filling connection
of the high pressure line and for the filling connection of
the low-pressure line.
Connect the filling unit connection (6) to the
Connect the air filling connection of the high pressure line (2) and the
conditioning vacuum, filling unit connection (5) to the filling connection for the
2 recycling and filling unit low-pressure line (4)
for refrigerant R134a to Air conditioning vacuum, recycling and charging
the vehicle equipment for refrigerant R134a, refer to GOTIS
Make note of the amount of refrigerant

3 Extract refrigerant R134a compressor oil extracted.
Air conditioning vacuum, recycling and charging
equipment for refrigerant R134a, refer to GOTIS
Evacuate
Replace fluid reservoir
4 Only if refrigerant circuit has been opened.
(drier cartridge)
Model 164, 251/(except 164.177, 251.077 /177)
With automatic air conditioning, code 580 AR83.30-
With comfort automatic air conditioning, code 581 P-6520GZ
Model 164.177, 251.077 /177
With automatic air conditioning, code 580 AR83.30-
With comfort automatic air conditioning, code 581 P-6520RT
Clean refrigerant R134a Air conditioning vacuum, recycling and charging
5 and evacuate air equipment for refrigerant R134a, refer to GOTIS
conditioning system http://gotis.aftersales.daimlerchrysler.com
Charging
Strictly observe the specifications of the adhesive data
label (arrow A) of the air conditioning to prevent damage
Replace the quantity of
caused by overfilling or underfilling. The adhesive data
label of the air conditioning contains specific data for the
oil noted when
each vehicle. The AC compressor oil to be used is
evacuating the air
6 indicated in addition to the refrigerant quantity!
conditioning system with
new refrigerant If the wrong quantity of refrigerant compressor oil is
compressor oil, fill it into filled, then the refrigerant compressor may be damaged.
the refrigerant circuit Air conditioning vacuum, recycling and charging
equipment for refrigerant R134a, refer to GOTIS
Strictly observe the specifications of the adhesive data
label (arrow A) of the air conditioning to prevent damage
Fill air conditioning caused by overfilling or underfilling. The adhesive data
7
system label of the air conditioning contains specific data for the
each vehicle. The AC compressor oil to be used is
indicated in addition to the refrigerant quantity!
*BF83.00-
Air conditioning system/automatic climate control P-1001-
filling capacity
01F
*BF83.55-
Refrigerant compressor filling quantity P-1001-
01I
*BF83.55-
Additional quantity of oil to be added when system P-1002-
suddenly looses fluid (e.g. line ruptured) 01I
*BF83.55-
Additional oil filling quantity after replacing the P-1003-
condenser 01I
*BF83.55-
Additional oil filling quantity after replacing evaporator P-1004-
01I
*BF83.55-
Additional oil filling quantity after replacing the fluid P-1005-
reservoir 01I
*BF83.55-
Additional oil filling quantity after replacing the low- P-1006-
pressure line 01I
*BF83.55-
Additional oil filling quantity after replacing the high P-1007-
pressure line 01I
*BF83.55-
Additional oil filling quantity after replacing the P-1008-
refrigerant compressor 01I
*BF83.55-
Additional oil filling capacity in case of detectable P-1009-
leakage
01I
*BF83.55-
Additional oil filling quantity after replacing rear air P-1010-
conditioning evaporator
01I
*BF83.55-
Additional oil filling quantity after replacing rear AC P-1011-
lines 01I
*BF83.55-
Additional oil filling quantity after replacing evaporator P-1012-
(rear compartment) 01I
Additional filling capacity for refrigerant compressor
with rear air conditioning Air conditioning vacuum, *BF83.55-
recycling and charging equipment for refrigerant R134a, P-1013-
refer to GOTIS 01I
Perform pressure test on
8 equipment for refrigerant R134a, refer to GOTIS
AC system
Disconnect the filling
unit connection (6) from
the filling connection for
the high pressure line (2)
9 equipment for refrigerant R134a, refer to GOTIS
and the filling unit
connection (5) from the
filling connection for the
low-pressure line (4).
10 Screw on plug (1, 3) Replace damaged plugs!
Check
Check air conditioning

system for leakage with Air conditioning leak detector, refer to GOTIS
11
air conditioning leak http://gotis.aftersales.daimlerchrysler.com
detector.
AIR CONDITIONING SYSTEM/AUTOMATIC AIR CONDITIONING

Number Designation Model 164.1/8 Model 164.8 with
without air air conditioning
conditioning in in rear (code 582)
rear (code 582)
Refrigerant
g 970 1220
BF83.00- Filling capacity for air R134 a
P-1001- conditioning/automatic air Specifications
01F conditioning system BB00.40-P-0361- BB00.40-P-0361-
for Operating Sheet
00A 00A
Fluids
REFRIGERANT COMPRESSOR SPECIFICATIONS

Number Designation Refrigerant
compressor in
model 164
Compressor oil 3
cm 110
BF83.55-P-
Refrigerant compressor filling quantity Specifications for BB00.40-P-0362-
1001-01I Sheet
Operating Fluids 00A
Additional quantity of oil to be added Compressor oil 3
cm 40
BF83.55-P-
when system suddenly looses fluid (e.g. Specifications for BB00.40-P-0362-
1002-01I Sheet
line ruptured) Operating Fluids 00A
Compressor oil 3
cm 20
BF83.55-P- Additional oil filling quantity after
1003-01I replacing condenser Specifications for BB00.40-P-0362-
Sheet
Compressor oil cm3 40
1004-01I replacing evaporator Specifications for BB00.40-P-0362-
Sheet
1005-01I replacing fluid reservoir Specifications for BB00.40-P-0362-
Sheet
Compressor oil 3
cm 10
1006-01I replacing low-pressure line Specifications for BB00.40-P-0362-
Sheet
Compressor oil 3
cm 10
1007-01I replacing high-pressure line Specifications for BB00.40-P-0362-
Sheet
Compressor oil 3
cm 20
BF83.55-P- Additional oil filling quantity after Specifications for BB00.40-P-0362-

Sheet
1008-01I replacing refrigerant compressor Operating Fluids 00A
BF83.55-P- Additional oil filling capacity in case of
1009-01I detectable leakage Specifications for BB00.40-P-0362-
Sheet
1010-01I replacing rear air conditioning evaporator Specifications for Sheet
BB00.40-P-0362-
1011-01I replacing rear AC lines Specifications for BB00.40-P-0362-
Sheet
1012-01I replacing evaporator (rear compartment) Specifications for Sheet
BB00.40-P-0362-
BF83.55-P- Additional filling capacity for refrigerant
1013-01I compressor with rear air conditioning Specifications for BB00.40-P-0362-
Sheet
REMOVE/INSTALL REAR SHUTOFF FLAP ACTUATOR MOTOR - AR83.30-P-2008GZ
MODEL 164
Fig. 84: Identifying Rear Shutoff Flap Actuator Motor Components

Remove/install
Pull back until the screw on bottom section of AR68.20-P-

instrument panel (passenger side) can be accessed. 2000GZ
Remove screw on bottom
*BA68.20-P-
2 section of instrument panel
1003-01E
on passenger side
Remove glove AR68.10-P-
3
compartment 1400GZ
Remove center section of Remove from working area, do not disconnect AR68.10-P-
4
instrument panel electrically. 1030GZ
Remove bottom section of
AR68.10-P-
5 dashboard on front
1507GZ
passenger side
6
connector (1)
7 Unscrew bolt (2) Prevent screws (2) from falling.
Installation: When replacing the rear shutoff flap
actuator motor (M2/12) the position of the rear shutoff
Remove rear shutoff flap
8 flap must be adjusted using the drive plate to match the
actuator motor (M2/12)
position of the actuating drive in the rear shutoff flap
actuator motor (M2/12).
Carry out normalization of
the actuator motors with Menu item, Actuation, Normalization of STAR
10
read out fault memory, DIAGNOSIS, actuator motors.
clear
Connect STAR
AD00.00-P-
2000-04A
fault memory
*WH58.30-
Z-1048-13A
CENTER CONSOLE SPECIFICATIONS

BA68.20-P-1003-01E Nut, center console bracket to transmission tunnel Nm 8

Number Designation
REMOVE/INSTALL FRESH AIR/RECIRCULATED AIR STEPPER MOTOR - AR83.30-P-2010GZ
MODEL 164
Fig. 85: Identifying Fresh Air/Recirculated Air Stepper Motor Components

Remove/install
on airbag or emergency 100°C. When working on these units, 0001-01A
tensioning retractor units. disconnect the power supply.
AH91.00-P-
work and welding on vehicles
0002-01M
with airbags and ETR units
Assessment of airbag and belt
AH91.00-P-
tensioner units in accident
0006-01B
vehicles
AH91.00-P-
0004-01A
889:
1 the transmitter key from the EIS until ignition is switched off. Remove
2 m).
AR68.30-P-
2 Remove paneling on A-pillar. On left and right. 4050GZA
AR68.20-P-
2000GZ
4
dashboard on driver's side 1505GZ
5
dashboard on front passenger side 1507GZ
Remove retaining frame controls AR68.10-P-
6
in instrument panel center part 1031GZ
AR68.10-P-
7 Remove side air outlet On left and right. 1100GZ
AR68.10-P-
8 Remove center air outlet
1150GZ
Remove loudspeaker in AR82.62-P-
9.1 With sound system, code 810.
instrument panel 7833GZ
Remove top part of instrument AR68.10-P-
10
panel 1020GZ
11 Remove bolts (1) Secure screws against falling.
12
(2)
Detach fresh air/recirculated air
13
Normalize actuator motors with
15 Menu item, Actuation, Normalization
STAR DIAGNOSIS, read out
of actuator motors.
fault memory, clear
*WH58.30-
Z-1048-13A

Number Designation
REMOVE/INSTALL STEPPER MOTOR FOR CENTER AIR OUTLET IN REAR FOOTWELL FLAP
- AR83.30-P-2120GZ
-MODEL 164
Fig. 86: Identifying Stepper Motor For Center Air Outlet In Rear Footwell Flap Components
Remove/install
1 Remove center console AR68.20-P-

2000GZ
Detach electrical connector (1) of third row
2 footwell rear air conditioning actuator motor
(M16/39)
3 Unscrew bolt (2)
Detach third row footwell rear air conditioning
4
Carry out normalization of the actuator motors Menu item, Actuation,
6 with STAR DIAGNOSIS, read out actuator Normalization of fault memory,
motors. clear
memory 2000-04A
system 1048-13A

Number Designation
REMOVE/INSTALL AC HOUSING - AR83.30-P-5200GZ
Fig. 87: Identifying AC Housing Components (1 Of 7)







Remove/install

Risk of injury to skin and eyes caused temperature is below 90°C. Open cap slowly
by scalding from contact with hot and release the pressure. Do not pour coolant AS20.00-Z-
coolant spray. Risk of poisoning from into beverage containers. 0001-01A
and safety glasses.
Risk of explosion from welding or Never perform welding work on or near a
soldering work on closed air closed air conditioning system. No smoking or
conditioning system. Risk of poisoning open flames. Wear safety glasses and
AS83.00-Z-
from inhaling overheated refrigerant protective gloves. Work only in well
0001-01A
vapors. Risk of injury to skin and eyes ventilated areas. Carry out repair work on the
caused by contact with liquid air conditioning system circuit only after the
refrigerant. system has been discharged.
oxyhydrogen gas. Risk of poisoning
No fire, sparks, open flames or smoking.
and caustic burns caused by
Wear acid-resistant gloves, clothing and safety AS54.10-Z-
swallowing battery acid. Risk of injury
glasses. Only pour battery acid into suitable 0001-01A
caused by burns to skin and eyes from
and appropriately marked containers.
battery acid or when handling damaged
lead-acid batteries
AH00.00-N-
0001-01A
Conduct if air conditioning system is AH83.30-N-
All models
damaged or leaking 0004-01A
Protect air conditioning circuit and
AH83.30-N-
components from moisture when All models fitted with air conditioning
0005-01A
AH83.30-N-
Notes on handling refrigerant R134a Air conditioning with refrigerant R134a
0003-01A
1
position 1000GZ
Installation: Evacuate, refill air AR83.30-P-
2 Discharge air conditioning system conditioning system and check for proper
1760GZ
operation and tightness.
Air conditioning evacuation, recycling and *WE58.40-
charging unit for R134a refrigerant Z-1002-22A
AR09.10-P-
3.1 Remove air filter housing (1). Engine 113
1150GZ
AR09.10-P-
Engine 156
1150GZS
AR09.10-P-
Engines 272, 273
1150GZA
AR09.10-P-
Engine 629
1150GZD
AR01.10-P-
3.2 Remove engine cover Engine 642
2405GZB
Remove bolts (59) and take off heat
4 Only for engine 642.
shield (60).
Remove engine compartment sealing
5
(2)
Unscrew bolt (4, 5, 6) and remove *WH58.30-
6 Power screwdriver/drill
partition wall from left wheelhouse (3) Z-1007-20A
Unclip wiring harness from 2
7 Unclip wiring harness (7)
brackets.
Unscrew bolt (9, 10) and remove
8
partition wall from right wheelhouse (8)
Remove bolts (12, 13, 14, 15, 16, 17)
9 and remove partition wall on
wheelhouse, center (11)
Removal: Plug lines and expansion
Unscrew nut (18) and remove high
valve with plug
10 pressure line (19) as well as low
pressure line (20) from expansion valve Installation: Use new O-rings and
moisten with refrigerant compressor oil
*BA83.30-P-
1004-01I
*WH58.30-
Set of plugs for air conditioning system Z-1002-27A
Carefully open cap on coolant
expansion reservoir and then reclose
11 Reduce pressure in cooling system Installation: Check fluid level in
engine cooling system and corrosion/frost
protection, correct if required.
Unclamp heating water hoses (21) with
12 Clamping device Fig. 94
clamps
Loosen clamps with hose clamp pliers
Remove hose clamps and pull off hot Remove left hose upward from
13
water hoses (21) partition wall (arrow A).
Collect escaping coolant.
*WH58.30-
Hose clamp pliers Z-1016-02A
This helps to prevent the interior of
Close connection fittings of hot water
14 the vehicle from being soiled when removing
hoses (21) with suitable cap
the air conditioner housing (51).
Move the steering column in to the full
15 extent and move out the driver's seat to
the full extent
16 Disconnect battery ground cable Installation: Connect ground line of AR54.10-P-
Battery at end of overall work procedure. 0003GZ
AR68.20-P-
2000GZ
AR68.10-P-
1020GZ
*BA91.60-P-
1010-01H
*BA46.10-P-
1001-03J
AR46.10-P-
19 Remove jacket tube
0400GZ
*BA46.10-P-
1001-03J
*BA46.10-P-
1002-03J
20
and unclip cable (arrow B)
Disconnect right condensation water
drain hose (23) and left condensation
21
water drain hose (24) from AC housing
(51)
Disconnect keyless go cockpit antenna

22 Vehicles with keyless go, code 889.
(A2/60)
23 Remove damping mat (25)
Unclip cockpit fuse box (F3) from
24
bracket
from right side outlet temperature
25 sensor (B10/32) and electrical connector
(42) from left side outlet temperature
sensor (B10/31)
26 from evaporator temperature sensor
(B10/6)
Remove tie strap (31, 32, 33, 34, 35, 36,
27 37, 38, 39, 40, 41) and lay wiring
harness down to side
28 Remove cable straps (55) Only for engine 642.
Only for engine 642.
Remove nut (56) of positive lead and
29 remove positive lead from PTC heater Detach positive line cable from AC
booster housing (51) so that removal of AC housing
(51) is not hindered by the cable.
*BA83.70-P-
1001-02G
Only for engine 642.
Remove nut (57) of ground line and
30 remove ground line from PTC heater Detach ground line cable from AC
booster housing (51) so that removal of AC housing
(51) is not hindered by the cable.
*BA83.70-P-
1002-02G
32 Disconnect electrical connector (58) Only for engine 642.
Unscrew nuts (27, 28) and remove *BA68.20-P-
33
center console retaining bracket (26) 1003-01E
34 Remove center console air pipe (29)
Installation: Start with bolts (49), so
Remove bolts (46, 49, 50) and bolts (47,
that frame is fastened.
48), then lift out air conditioner housing
35 Installation: Ensure that air pipe
(51) with instrument panel crossmember
(52) guides (53) and guide (54) are seated
correctly.
*BA68.10-P-
1001-01B
*BA68.10-P-
1002-01B
*BA68.10-P-
1003-01B
AR00.19-P-
0200GZ


AIRBAG SPECIFICATIONS
BA91.60-P-1010-01H Nut, passenger airbag to instrument panel crossmember Nm 20
JACKET TUBE SPECIFICATIONS

BA46.10-P-1001-03J Bolt, upper jacket tube to body Nm 20
BA46.10-P-1002-03J Bolt, lower jacket tube to body Nm 20
AIR CONDITIONING SYSTEM CHART

BA83.30-P-1004-01I Nut, low- and high-pressure lines to expansion valve Nm 8
HEATER BOOSTER HEATER UNIT CHART

BA83.70-P-1001-02G Nut of positive lead to PTC heater booster Nm 8
BA83.70-P-1002-02G Nut of ground line to PTC heater booster Nm 15


Number Designation
WH58.30-Z-1016-02A Hose clamp pliers
WORKSHOP EQUIPMENT
WE58.40-Z-1002-22A Air conditioning service station
DISASSEMBLE/ASSEMBLE AIR CONDITIONER HOUSING - AR83.30-P-5201GZ
conditioning
Fig. 95: Identifying Air Conditioner Housing Components (1 Of 21)





















Remove/install
To enable removal of right

1 Set air conditioning to defrosting.
footwell air pipe (5).
AR83.30-P-
2 Remove air conditioner housing
5200GZ
3 Remove bolts (15)
4 Remove nuts (16) and nut (17)
5 Remove instrument panel crossmember (1)
6 Detach left air pipe (2) and right air pipe (3) Installation: Ensure
correct seating of gasket.
Detach electrical connector from dew point sensor

7 (B11/12) and fresh air/air recirculation flaps
8 Remove cable ties (18) Installation: replace tie
straps (18).
9 Unclip electrical line from clips (19)
Detach electrical connector from right blending
The PTC heater booster
air flap actuator motor (M2/7), from rear shutoff
11 (R22/3) is only available for
flap actuator motor (M2/12) and PTC heater
engines 629 and 642.
booster (R22/3)
Detach electrical connector from blower motor
13
(A32m1)
Detach electrical connector from left defroster
vent flap actuator motor (M2/8), from right
15 defroster vent flap actuator motor (M2/9), from
right footwell flap actuator motor (M2/11) and
from diverter flap actuator motor (M16/27)
Installation: Use new cable
16 Remove cable ties (23, 25)
strap.
Detach electrical connector from left footwell flap
18
19 Unclip electrical line from clip (26, 27)
*WH58.30-
20 Remove bolts (28, 29) Rechargeable drill / screwdriver
Z-1007-20A
Remove right footwell air pipe (5) and left
21
footwell air pipe (6)
Carefully lift seal in area A.
22 Remove hidden bolts in the A area Installation: Ensure that
seal is properly seated, if necessary
glue seal in place.
Remove upper part of air conditioner housing (4)
23
upwards
Installation: Observe
24 Pull off gasket (30) installation position of seal. Replace
gasket.
26 Release snap-in tabs (32)
27 Pull out heat exchanger (7)
28 Remove bolts (33) Only for engines 629 and 642.
Only for engines 629 and 642.

Installation: Check that
the PTC heater booster (R22/3) is
29 Withdraw PTC heater booster (R22/3)
correctly seated by looking through
the installation opening of the heat
exchanger (7).
*WH58.30-
30 Remove screws (34, 35, 36) Rechargeable drill / screwdriver
Z-1007-20A
Remove front section of air conditioner housing Installation: Check pilot
31
(8) upwards and to the front studs (37) are correctly seated.
*WH58.30-
Z-1007-20A
33 Remove blower motor (A32m1)
36 Release snap-in tab (42)
Remove upper section of recirculated air housing
37
(10) upwards
Installation: Check for
Remove lower section of air recirculation housing correct seating of lower section of
39
(11) upwards recirculated air housing on guides
(44).
40 Unclip clips (45)
*WH58.30-
41 Remove bolts (46, 47) Rechargeable drill / screwdriver
Z-1007-20A
*WH58.30-
42 Remove bolts (48, 49, 50) and bolt (51) Rechargeable drill / screwdriver
Z-1007-20A
Remove upper section of evaporator housing (12) Installation: Check that
43 upwards from lower section of evaporator housing upper section of evaporator housing
(14) (12) is correctly seated on the lower
section of evaporator housing (14).
Remove evaporator (13) upwards out of lower
44
section of evaporator housing (14)

Number Designation
REMOVE AND INSTALL REFRIGERANT PRESSURE AND TEMPERATURE SENSOR - AR83.30-

P-5431GZ

Shown on model 164.1 with engine 113.964
Fig. 116: Identifying Refrigerant Pressure And Temperature Sensor Components - Shown On Model
164.1 With Engine 113.964
Remove/install
Risk of explosion from welding Never perform welding work on or
or soldering work on closed air near a closed air conditioning
conditioning system. Risk of system. No smoking or open flames.
poisoning from inhaling Wear safety glasses and protective AS83.00-Z-
overheated refrigerant vapors. gloves. Work only in well ventilated 0001-01A
Risk of injury to skin and eyes areas. Carry out repair work on the
caused by contact with liquid air conditioning system circuit only
refrigerant. after the system has been discharged.
Conduct if air conditioning AH83.30-N-
All models
system is damaged or leaking 0004-01A
Protect air conditioning circuit
All models fitted with air AH83.30-N-
and components from moisture
conditioning 0005-01A
when carrying out repair work
Notes on handling refrigerant Air conditioning with refrigerant AH83.30-N-
R134a R134a 0003-01A
1
AR83.30-P-
2 Discharge air conditioning system
1760GZ
Air
conditioning
evacuation, *WE58.40-
recycling and Z-1002-22A
charging unit for
R134a refrigerant
3 Remove air hose (1)
4
(2)
Counterhold on line connection as
otherwise the line may be damaged!
Installation: Replace
sealing ring. Use refrigerant
Unscrew refrigerant pressure
5 compressor oil to wet thread on
sensor (B12) and remove
refrigerant pressure sensor (B12) and
sealing ring.
*BA83.30-
P-1003-01I
Only if refrigerant pressure
sensor (B12) is not immediately
installed.
Seal opening on pipeline The pipeline connection opening
6.1
connection using suitable plug must be sealed, as otherwise
penetrating dirt and moisture can
damage the components connected to
the refrigerant circuit.
Set of plugs for air conditioning *WH58.30-
system Z-1002-27A
Refill air conditioning system and
AR83.30-P-
8 inspect for leaks and proper
1760GZ
operation.
Air conditioning evacuation, *WE58.40-
recycling and charging unit for Z-1002-22A
R134a refrigerant

BA83.30-P-1003-01I Refrigerant pressure sensor to line Nm 10

Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL EXPANSION VALVE - AR83.30-P-5520GZ

Fig. 117: Identifying Expansion Valve Components - Shown On Model 164.1 (1 Of 4)




Remove/install
soldering work on sealed air closed air conditioning system. No
conditioning system. Risk of smoking or open flames. Wear safety
AS83.00-Z-
poisoning from inhaling overheated glasses and protective gloves. Work only in
0001-01A
refrigerant vapors. Risk of injury to well ventilated areas. Carry out repair work
skin and eyes caused by contact with on the air conditioning system circuit only
liquid refrigerant. after the system has been discharged.
All models
AH83.30-N-
0005-01A
AH83.30-N-
0003-01A
1 Discharge air conditioning system conditioning and check for proper
1760GZ
Air conditioning evacuation, recycling *WE58.40-
and charging unit for R134a refrigerant Z-1002-22A
AR09.10-P-
2.1 Remove air filter housing Engine 113
1150GZ
AR09.10-P-
Engine 156
1150GZS
Engine 272, 273 AR09.10-P-
1150GZA
AR09.10-P-
Engine 629
1150GZD
AR09.10-P-
2.2 Remove left-hand air filter housing Engine 642
1150GZB
Remove engine compartment sealing In the area of partition wall section
3
(1) (3).
4 Unscrew bolt (2)
5 Remove partition wall section (3)
6 Unscrew bolt (4) from bracket (5)
7 Unclip brackets (5)
8 Unscrew bolt (6)
The connection fitting openings must be
sealed, as otherwise penetrating dirt and
moisture can damage the components
Pull apart low-pressure line (7), close
9 connected to the refrigerant circuit.
openings
Installation: Replace sealing ring
and moisten with refrigerant compressor
oil.
Set of plugs for air conditioning *WH58.30-
system Z-1002-27A
Unclip low-pressure line (7), hot water
10
hose (8) and high pressure line (9)
11 Open catch (10) of rubber passage (11)
Remove low-pressure line (7) and hot Installation: Check correct
12 water hose (8) from rubber passage seating of rubber passage (11) in partition
(11) wall (12).
Unscrew nut (13) and remove Installation: Observe installation
13
retaining plate (14) position of retaining plate.
*BA83.30-P-
1004-01I
Remove low-pressure line (7) and high Installation: Replace sealing rings
14 pressure line (9) from expansion valve (17) and moisten with refrigerant
(16) compressor oil.
The openings of the low-pressure line
Seal openings of low-pressure line (7) (7) and high pressure line (9) must be
15 sealed, as otherwise dirt and moisture will
and high pressure line (9) as well
penetrate the components connected to the
refrigerant circuit.
*WH58.30-
Installation: Screw in bolts (15)
alternately, as otherwise the expansion
valve (16) may be tilted on the connection
fittings.
Installation: If the thread of bolts
Remove bolts (15) and remove (15) does not engage, pull out tapping plate
16
expansion valve (16) with pulling hooks, hold in place and screw
in bolts (15). Moisten bolts (15) with
refrigerant compressor oil.
*BA83.30-P-
1006-01I
The connection fitting openings must be
Remove sealing rings (17) and close sealed, as otherwise penetrating dirt and
17
openings of connection fittings moisture can damage the components
connected to the refrigerant circuit.
*WH58.30-

BA83.30-P-1006-01I Bolt, expansion valve to retaining plate Nm 5


Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL EVAPORATOR - AR83.30-P-5540GZ

conditioning
Illustrated on the removed air conditioner housing
Fig. 122: Identifying Evaporator Components

Remove/install
1 Disassemble AC housing (2) Blower motor (A32m1) does not need AR83.30-P-
not be electrically disconnected and removed. 5201GZ
Remove evaporator (1) upwards out
2
of air conditioner housing (2)
REMOVE/INSTALL REAR BLOWER MOTOR - AR83.30-P-5565GZ
MODEL 164
Fig. 123: Identifying Rear Blower Motor Components - Model 164 (1 Of 3)



Remove/install
AR68.20-P-
2000GZ
2 Remove bracket (1) upwards
3 Remove bolts (2)
4 Disconnect electrical connector (3, 4)
Installation: Replace nuts (5,
5 Undo nuts (5, 6)
6).
*BA68.20-P-
1003-01E
Pull air pipe to one side.
Remove booster blower motor (M2/1)
6 Installation: Check foam
with bracket (7) upwards
gaskets are correctly seated.


REMOVE/INSTALL FLUID RESERVOIR - AR83.30-P-6520GZ
MODEL 164, 251 / (except 164.177, 251.077 /177) with CODE (580) Automatic air conditioning with
CODE (581) Comfort automatic air conditioning with CODE (582) Rear air conditioner
Shown on MODEL 164
Fig. 126: Identifying Fluid Reservoir Components - Shown On Model 164

Shown in removed condition
Fig. 127: Identifying Fluid Reservoir Components - Shown In Removed Condition

Remove/install
Risk of explosion caused by welding Never perform welding work on or near a
or soldering work on closed air closed air conditioning system. No smoking
conditioning system. Risk of or open flames. Wear safety glasses and
AS83.00-Z-
poisoning caused by inhaling protective gloves. Work only in well
0001-01A
overheated refrigerant vapors. Risk of ventilated areas. Carry out repair work on
injury to skin and eyes caused by the air conditioning system circuit only
contact with liquid refrigerant. after the system has been discharged.
Procedure if air conditioning system is AH83.30-N-

AH83.30-P-
components from moisture when
0005-01P
AH83.30-N-
0003-01A
Drain, evacuate and refill air
AR83.30-P-
1 conditioning, check function and Model 164
1760GZ
check for leaks
AR83.30-P-
Model 251
1760RT
AR88.20-P-
2 Remove front bumper Model 164
2000GZ
AR88.20-P-
Model 251
2000RT
3 Unscrew bolt (1).
*BA83.30-
4 Remove bolts (2)
P-1002-01I
*BA83.30-
P-1002-01J
*BA83.30-
5 Unscrew bolt (3).
P-1001-01I
*BA83.30-
P-1001-01J
*WH58.30-
Installation: Use new fluid
reservoir (4).
Installation: The packaging of the new
fluid reservoir (4) must be undamaged.
Once the packaging of the new fluid
reservoir (4) has been opened, it must be
6 Remove fluid reservoir (4) installed within 20 minutes and the entire
refrigerant circuit sealed, as otherwise the
function of the fluid reservoir (4) can no
longer be guaranteed.
of refrigerant line and wet with compressor
oil.
The opening of the refrigerant line and
Use suitable plug to seal opening of fluid reservoir (4) must be closed otherwise
7 refrigerant line and suitable stop plug dirt and moisture ingress damages the
to seal opening of fluid reservoir (4) components which are connected to the

BA83.30-P-1001-01I Screw, high pressure line to fluid reservoir Nm 11
BA83.30-P-1002-01I Screw, fluid reservoir to condenser Nm 11

BA83.30-P-1001-01J Nut, high pressure line to fluid reservoir Nm 11
BA83.30-P-1002-01J Screw, fluid reservoir to condenser Nm 11

Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL SERVICE VALVE - AR83.30-P-6522GZ
Fig. 128: Identifying Service Valve Components

Remove/install

soldering work on closed air closed air conditioning system. No
conditioning system. Risk of smoking or open flames. Wear safety AS83.00-Z-
poisoning from inhaling overheated glasses and protective gloves. Work only in 0001-01A

All models
AH83.30-N-
0005-01A
AH83.30-N-
0003-01A
1 Discharge air conditioning system conditioning and check for proper 1760GZ
2 Unscrew cap (1)
Installation: Wet thread and
3 Remove service valve (2) sealing ring at service valve (2) with
compressor oil.
*BA83.30-
P-1005-01I

BA83.30-P-1005-01I Service valve at plug Nm 6
WORKSHOP EQUIPMENT
REMOVE/INSTALL VALVE INSERT ON SERVICE VALVE - AR83.30-P-6523GY

Fig. 129: Identifying Valve Insert On Service Valve Components - Shown On Model 164.1
Remove/install
AS83.00-Z-
0001-01A
All models
AH83.30-N-
0005-01A
AH83.30-N-
0003-01A
1 Discharge air conditioning system conditioning and check for proper 1760GZ
2 Unscrew cap (1)
3 Remove valve element (2) and moisten with refrigerant compressor
oil.
Valve wrench Fig. 130
The connection fitting opening must be
Close openings of connection fitting sealed, as otherwise penetrating dirt and
4
using suitable plug moisture can damage the components
*WH58.30-
Fig. 130: Identifying Valve Wrench (203 589 01 10 00)


Number Designation
WORKSHOP EQUIPMENT
INSTALL/REMOVE CONDENSER - AR83.30-P-6540GZ
Fig. 131: Identifying Condenser Components (1 Of 2)

Fig. 132: Identifying Condenser Components (2 Of 2)

Shown on vehicle with Airmatic (air suspension with level adjustment and adaptive damping system
ADS), code 489
Fig. 133: Identifying Condenser Components - Shown On Vehicle With Airmatic (1 Of 3)



Remove/install
AS00.00-Z-
0010-01A
platform. support points specified by the vehicle
manufacturer.
soldering work on closed air closed air conditioning system. No smoking
AS83.00-Z-
poisoning from inhaling overheated protective gloves. Work only in well
0001-01A
refrigerant vapors. Risk of injury to ventilated areas. Carry out repair work on
skin and eyes caused by contact with the air conditioning system circuit only

AH83.30-N-
0005-01A
AH83.30-N-
Notes on handling refrigerant R134a
0003-01A
1 Discharge air conditioning system conditioning system and check for proper
1760GZ
AR88.20-P-
2000GZ
AR62.30-P-
3 Remove upper radiator crossmember
2300GZ
Only on vehicles with diesel
4 Remove intercooler
engine.
AR09.41-P-
Engine 642.
6817GZB
AR09.41-P-
Engine 629.
6817GZD
Remove power steering cooler and Only for engine 156. Do not open
5
bind to the side cooling circuit.
Remove engine oil cooler and bind to Only for engine 156. Do not open AR18.30-P-
6
the side cooling circuit. 1000GZS
Only on vehicles with Airmatic
7 Unscrew bolt (2) (air suspension with level adjustment and
adaptive damping system ADS), code 489.
*BA32.22-P-
1006-03B
*BA62.30-P-
8 Unscrew nuts (3).
1004-02D
9 Remove bolts (4) Installation: Use new bolts (4).
Installation: Replace sealing rings
10 Unscrew nut (5) of refrigerant line and moisten with
refrigerant compressor oil.
*BA83.55-P-
1004-01R
11 Unscrew bolt (6)
*BA82.35-P-
12 Undo screw (7, 8)
1001-01B
Detach intake air pipes (9) from intake
13
air ducting (11) (arrows A)
Only pull far enough forward to

Pull bumper support (10) forwards
14 enable the intake air guide (11) to be
(arrows B)
removed.
15 Unclip clips (12)
Installation: Ensure that
Remove condenser (1) forward
16 condenser (1) is seated properly in guides
(arrows C) and upwards (arrows D)
(13).
The refrigerant line openings must be
17 Close openings of the refrigerant lines sealed, as otherwise penetrating dirt and
moisture can damage the components
*WH58.30-
AIR SUSPENSION SPECIFICATIONS

Number Designation Model 164.1/8 with AIRmatic, code
489
BA32.22-P-1006- Bolt, compressor bracket to
Nm 20
03B crossmember
FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

BA62.30-P-1004-02D Bolt, crossmember to crash box Nm 18 18
WINDSHIELD WASHER SYSTEM

BA82.35-P-1001-01B Bolt, washer fluid reservoir to front end assembly Nm 10

BA83.55-P-1004-01R Nut for refrigerant lines on drier Nm 8

Number Designation
WORKSHOP EQUIPMENT
REMOVE/INSTALL REFRIGERANT LINES AT REFRIGERANT COMPRESSOR - AR83.30-P-

7810GZ
conditioning
Fig. 136: Identifying Refrigerant Lines At Refrigerant Compressor Components - Shown On Model 164.1
Remove/install
platform.
or soldering work on closed air closed air conditioning system. No
conditioning system. Risk of poisoning smoking or open flames. Wear safety
AS83.00-Z-
caused by inhaling overheated glasses and protective gloves. Work only in
0001-01A
AH83.30-
Procedure if air conditioning system is
All models N-0004-
damaged or leaking
01A
Protect air conditioning circuit and AH83.30-
components from moisture when All models fitted with air conditioning N-0005-
carrying out repair work 01A
AH83.30-
N-0003-
01A
1 Remove left air intake duct Only for engine 642.
AR01.10-P-
2 Remove engine trim panel Only for engine 642. 2405GZB
AR83.30-P-
1760GZ
Only when removing the AR88.20-P-
refrigerant pressure line (6). 2000GZ
*BA83.55-
5 Remove bolt (1)
P-1005-01R
Model 164.8: Access through the
6 Remove bolt (2)
left front wheelhouse.
*BA83.55-
P-1003-01R
7 Remove refrigerant suction line (4) of refrigerant line and coat with compressor
oil.
Model 164.8: Access through the
8 Remove screw (3)
left front wheelhouse.
*BA83.55-
P-1003-01R
*BA83.55-
9 Unscrew nut (5)
P-1004-01R
10 Remove refrigerant pressure line (6) of refrigerant line and coat with compressor
oil.
The refrigerant line openings must be
Open the refrigerant lines with suitable sealed, as otherwise penetrating dirt and
11
plug and close with suitable stop plug moisture can damage the components
Evacuate the air conditioning system,
refill it, and then check the system to AR83.30-P-
13
make sure that it functions correctly 1760GZ
and does not leak.

164.1/8
BA83.55-P-1003-
Bolt, refrigerant lines to refrigerant compressor Nm 20
01R
Nut for refrigerant lines on drier Nm 8
BA83.55-P-1004-
01R
BA83.55-P-1005- Bolt for front refrigerant suction line to rear refrigerant suction
Nm 20
01R line
REMOVE AND INSTALL EVAPORATOR TEMPERATURE SENSOR - AR83.30-P-8085GZ
MODEL 164
Fig. 137: Identifying Evaporator Temperature Sensor Components - Shown On Model 164.1
Remove/install
Switch off ignition and On vehicles with Keyless Go, code 889: Press
store it in a location beyond its transmission range (at least
unit
2 m).
Remove cover below left of AR68.10-
2
instrument panel P-1500GZ
3 connector (1) at evaporator
temperature sensor (B10/6)
Pull evaporator temperature
4 sensor (B10/6) out of A/C
housing
REMOVE/INSTALL AIR OUTLET TEMPERATURE SENSOR - AR83.30-P-8087
Remove/install air outlet temperature sensor - AR83.30-P-8087GZ
MODEL 164
Side air outlets and center outlet

Fig. 138: Identifying Air Outlet Temperature Sensor Components - Shown On Model 164.1
Remove/install

Switch off ignition and remove the 889: Press Keyless Go start/stop button
1 transmitter key from the EIS [EZS] repeatedly until ignition is switched off.
control unit Remove transmitter key from vehicle and store
it in a location beyond its transmission range
(at least 2 m).
Only for left side outlet temperature AR68.10-
2.1 Remove side air outlet sensor (B10/31) or right side outlet temperature P-1100GZ
sensor (B10/32).
Only for left center outlet temperature AR68.10-
2.2 Remove center air outlet sensor (B10/33) or right center outlet
P-1150GZ
temperature sensor (B10/34).
Detach electrical connector (1) of left
Only for left side outlet temperature
side outlet temperature sensor (B10/31)
3.1 sensor (B10/31) or right side outlet temperature
or electrical connector (2) of right side
sensor (B10/32).
outlet temperature sensor (B10/32)
Detach electrical connector (3) of left
center outlet temperature sensor Only for left center outlet temperature
(B10/33) or electrical connector (4) of sensor (B10/33) or right center outlet

3.2 right center outlet temperature sensor temperature sensor (B10/34).
(B10/34)
Turn left side outlet temperature sensor Only for left side outlet temperature
(B10/31) or right side outlet temperature sensor (B10/31) or right side outlet temperature
4.1 sensor (B10/32) through 90° in sensor (B10/32).
counterclockwise direction, and remove Do not turn the printed circuit board, risk of
to one side cracks and fracture!
Turn left center outlet temperature sensor Only for left center outlet temperature
(B10/33) or right center outlet sensor (B10/33) or right center outlet
4.2 temperature sensor (B10/34) through 90° temperature sensor (B10/34).
in counterclockwise direction, and Do not turn the printed circuit board, risk of
remove to one side cracks and fracture!
Remove/install air outlet temperature sensor - AR83.30-P-8087GZA
MODEL 164
footwell
Fig. 139: Identifying Air Outlet Temperature Sensor - Shown On Model 164.1
Remove/install

Switch off ignition and remove the code 889:
1 transmitter key from the EIS [EZS] control Press Keyless Go start/stop button
unit repeatedly until ignition is switched off.

Remove cover beneath instrument panel Only for left footwell temperature AR68.10-
2.1
(left) sensor (B10/35). P-1500GZ
Remove cover below instrument panel Only for right footwell AR68.10-
2.2
(right) temperature sensor (B10/36). P-1520GZ
footwell temperature sensor (B10/35) or
3
disconnect electrical connector (2) from
right footwell temperature sensor (B10/36)
Turn left footwell temperature sensor
(B10/35) or right footwell temperature Do not turn the printed circuit board,
4
sensor (B10/36) through 90° risk of cracks and fracture!
counterclockwise and remove to one side
Remove/install air outlet temperature sensor - AR83.30-P-8087GZB
MODEL 164
Rear footwell
Blower motor removed for ease of illustration. Shown on model 164.1
Fig. 140: Identifying Air Outlet Temperature Sensor Components - Shown On Model 164.1
Remove/install

AR68.20-
P-2000GZ
Detach electrical connector (1)

from footwell rear AC temperature

3
sensor (B10/38)
Turn footwell rear AC temperature
sensor (B10/38) through 90° in Do not turn the printed circuit board, risk of
4
counterclockwise direction, and cracks and fracture!
remove to one side
REMOVE AND INSTALL CONTROL AND OPERATING UNIT - AR83.40-P-6350GZ
MODEL 164
Shown on model 164.1 with offroad package, code 430
Fig. 141: Identifying Control And Operating Unit Components - Shown On Model 164.1 With Offroad
Package, Code 430
MODIFICATION NOTES
26.7.06
removed 7
Remove/install


Unlatch the instrument panel-center part (1) at the Protect trim parts of the
1 bottom edge (arrows A) and pull forward out of instrument panel and center
the instrument panel console from scratches.
2 Remove bolts (2)
3 Separate electrical connector (3, 4, 5)
Remove AAC [KLA] control and operating unit
4
(N22)
REMOVE AND INSTALL SUN SENSOR - AR83.40-P-6720GZ
MODEL 164
Shown on vehicles with Parktronic system (PTS), code 220
Fig. 142: Identifying Sun Sensor Components - Shown On Vehicles With Parktronic System (PTS), Code
220
Remove/install
damage to electronic AH54.00-P-
All models
components due to 0001-01A
Switch off ignition and remove Keyless Go start/stop button repeatedly until ignition is
1 the transmitter key from the switched off. Remove transmitter key from vehicle and
EIS [EZS] control unit store it in a location beyond its transmission range (at
least 2 m).
Carefully pry sun sensor (B32)
2 upward out of cover of center Long wedge Fig. 74
cockpit speaker (centerfill) (2)
3
connector (1)

REMOVE AND INSTALL AIR HUMIDITY SENSOR - AR83.40-P-6740GZ
Components removed for better illustration. Shown on model 164.1
Fig. 144: Identifying Air Humidity Sensor Components - Shown On Model 164.1
Remove/install
AR68.10-P-
1 Remove cover below instrument panel (right)
1520GZ
Lift lock
3 Turn bracket (2) counterclockwise and pull out downwards
(arrow).
Remove dew point sensor (B11/12) by turning it clockwise
4
from bracket (2)
REMOVE/INSTALL UNDERFLOOR REFRIGERANT LINES - AR83.50-P-6600GY
MODEL 164.8 with CODE (582) Rear air conditioner
Fig. 145: Identifying Underfloor Refrigerant Lines Components (1 Of 2)

Fig. 146: Identifying Underfloor Refrigerant Lines Components (2 Of 2)

Remove/install
objects.
igniting, risk of poisoning caused by Pour fuels only into suitable and
AS47.00-Z-
inhaling and swallowing fuel and risk appropriately marked containers.
0001-01A
of injury to eyes and skin caused by Wear protective clothing when handling
contact with fuel. fuel.
AS00.00-Z-
slipping or toppling off of the lifting support plates at the lifting platform support
0010-01A
platform. points specified by the vehicle
manufacturer.
Always wear protective gloves when
Risk of injury from grazing or
working on or near sharp and non-deburred AS00.00-Z-
cutting body parts on sharp vehicle
vehicle parts. 0017-01A
parts
Deburr repair panels.
AS83.00-Z-
poisoning from inhaling overheated protective gloves. Work only in well
0001-01A
refrigerant vapors. Risk of injury to ventilated areas. Carry out repair work on
skin and eyes caused by contact with the air conditioning system circuit only after
liquid refrigerant. the system has been discharged.
AH83.30-P-
0005-01P
AH00.00-N-
0001-01A
AH83.30-N-
Notes on handling refrigerant R134a
0003-01A
1 Discharge air conditioning system conditioning system and check for proper 1760GZ
AR62.30-P-
2 Remove dome strut
2500GY
Only with model 164.8 with engine
3.1 Remove air filter housing
629, 273.
AR09.10-P-
Engine 629
1150GZD
AR09.10-P-
Engine 273
1150GZA
Only for model 164.8 with engine AR09.10-P-

3.2 Remove left air filter housing
642. 1150GZB
Remove charge air duct with left mass Only on model 164.8 with engine AR07.07-P-
4
air flow sensor 629. 1454GZD
*BA83.50-
5 Remove bolt (2)
P-1001-01D
*BA83.50-
6 Remove bolt (3)
P-1002-01D
Seal openings using sealing plugs.
7 Detach line connections Installation: Use new sealing
rings. Coat sealing rings with compressor
oil before installation.
*WH58.30-
AR00.60-P-
8 Raise vehicle
1000GZ
Remove exhaust system as of flange AR49.10-P-
9 Model 164.8 with engine 629, 642
connection 7280GZB
AR49.10-P-
Model 164.8 with engine 273
7280GZ
Remove propeller shaft on flange of
10 See: ?
transfer case
Remove/install propeller shaft
Mark position of propeller shaft
relative to transfer case flange to ensure the
AR41.10-P-
installation position ex factory can be
0050GZ
reached again during installation.
Suspend propeller shaft from
vehicle floor.
Slightly lower transmission and
11 See: ?
transfer case
AR28.10-P-
Remove/install transfer case
0100GZ
Remove front axle gear propeller
12 See: ?
shaft on flange of transfer case
Remove/install front-axle differential
propeller shaft
Mark position of front axle gear
propeller shaft relative to transfer case
AR41.10-P-
flange to ensure the installation position ex
0070GZ
factory can be reached again during
installation.
Suspend front axle gear propeller
shaft from vehicle floor.
13 Disconnect fuel lines, lower fuel tank See: ?

AR47.10-P-
Remove/install fuel tank
4100GZ
Remove fender liner in left rear AR88.10-P-
14
fender 1400GZ
Seal openings using sealing plugs.
Disconnect refrigerant lines at Installation: Use new sealing
15
connecting piece in the rear fender rings. Coat sealing rings with compressor
oil before installation.
*WH58.30-
The high pressure line and low-
16 Remove refrigerant lines pressure line can only be removed and
installed together.
REAR AIR CONDITIONING UNIT

164.8
BA83.50-P-1001- Connection fitting from rear pressure line to front pressure line of
Nm 8
01D rear air conditioning
BA83.50-P-1002- Connection fitting from rear intake line to front intake line of rear air
Nm 20
01D conditioning

Number Designation
REMOVE/INSTALL REAR AIR CONDITIONING REFRIGERANT SHUTOFF VALVE - AR83.50-P-

9000RT
MODEL 164.8, 251 with CODE (582) Rear air conditioner
Fig. 147: Identifying Rear Air Conditioning Refrigerant Shutoff Valve Components
Remove/install
AS83.00-Z-
0001-01A
All models
AH83.30-N-
0005-01A
AH83.30-N-
0003-01A
AR83.30-P-
1 Discharge air conditioning system Model 164.8
1760GZ
AR83.30-P-
Model 251
1760RT
Installation: Refill air
conditioning and check for proper
operation and leaktightness.
AR68.30-P-
2 Remove side paneling in trunk
4800RT
*BA83.30-P-
3 Unscrew nut (1)
1007-01J
The openings of the high pressure line
(2) and low-pressure line (3) must be
sealed, as otherwise dirt and moisture will
Detach high pressure line (2) and low-
4 penetrate the components connected to the
pressure line (3)
and coat with compressor oil.
*WH58.30-
*BA83.30-P-
6 Remove screws (5)
1008-01J
The openings of the high pressure line
(2) and low-pressure line (3) must be
sealed, as otherwise dirt and moisture will
penetrate the components connected to the

and coat with compressor oil.
7 Remove shutoff valve (6) Installation: Turn in screws (5)
alternately, as otherwise the shutoff valve
(6) may be tilted on the connection fitting.
*WH58.30-
AIR CONDITIONING SYSTEM

Number Designation Model Model
164.8 251
BA83.30-P-1007- Nut, low and high pressure lines to rear air conditioning
Nm 8 8
01J shutoff valve
BA83.30-P-1008-
Screw, shutoff valve to rear air conditioning retainer plate Nm 5 5
01J

Number Designation
REMOVE AND INSTALL REAR AC HOUSING - AR83.50-P-9020RT
Fig. 148: Identifying Rear AC Housing Components - Illustrated On Model 251


Shown on model 251


Remove/install
by scalding from contact with hot slowly and release the pressure. Do not AS20.00-Z-
coolant spray. Risk of poisoning from pour coolant into beverage containers. 0001-01A
and safety glasses.
AS83.00-Z-
0001-01A
All models
AH83.30-P-
0005-01P
AH83.30-N-
0003-01A
Carefully screw open cap of
1 Reduce pressure in cooling system coolant expansion tank somewhat and
reseal.
AR83.30-P-
2 Discharge air conditioning system Model 251
1760RT
AR83.30-P-
Model 164.8
1760GZ
AR68.30-P-
3 Remove side paneling in trunk Only on left side 4800RT
AR68.30-P-
4.1 Remove moldings from D-pillar Only on model 164.8. 4495GZ
5 Open cargo space floor

Remove spare wheel with vehicle tool
6 kit or Styrofoam insert with vehicle
tool kit from spare wheel well
Remove left panel of spare wheel well The rear air conditioning must be
7
and fold aside accessible from the spare wheel well.
Only vehicles with automatic rear-
end door, code 890 and with compressor
for multicontour seats.
Unclip hydraulic unit (2) from
Observe additional catch lug to
compressor for multicontour seats
8.1 compressor. If necessary, remove hydraulic
(arrows A) and place outside of
unit (2) together with compressor from
working area
spare wheel well and place to one side.
Do not disconnect hydraulic unit
(2) electrically nor hydraulically.
On vehicles without compressor
Detach hydraulic unit (2) from spare for multicontour seats.
8.2
wheel well and place to one side Do not disconnect hydraulic unit
(2) electrically nor hydraulically.
Quantity and location of mounting
9 Remove bolt (3) and nut (6, 7) elements varies depending on vehicle
model and equipment.
Remove upper air intake manifold (4),
The air ducting varies depending
10 lower air intake manifold (5) and air
on vehicle model and equipment.
intake manifold (8) on side
11 Clamp off heating water hoses (9) Clamping device Fig. 78
12 Detach hose clamps (10)
13 Remove hot water hoses (9)
*BA83.30-P-
14 Unscrew nut (11)
1004-01J
Removal: Seal low-pressure line
(12), high pressure line (13) and expansion
Pull out low-pressure line (12) and valve with stop plugs.
15
high pressure line (13) Installation: Use new sealing
rings and coat with refrigerant compressor
oil.
*WH58.30-
Disconnect electrical connector (14,
16
15)
17 Remove nut (16, 17)
Pull out rear AC housing (1) and Installation: Wet guide (18) with
18
remove upward liquid lubricant.
*BR00.45-
Antifriction agent Z-1010-06A



Number Designation Model 164.8 Model 251
BA83.30-P-1004-01J Nut, low- and high-pressure lines to expansion valve Nm 8 8

Number Designation
REPAIR MATERIALS
BR00.45-Z-1010-06A Antifriction agent A 000 989 03 67
DISASSEMBLE/ASSEMBLE REAR AC HOUSING - AR83.50-P-9030RT
Shown on rear air conditioning in model 251

Fig. 153: Identifying Rear AC Housing Components - Shown On Rear Air Conditioning In Model 251


Removing
AR83.50-P-
1 Remove rear air conditioning unit.
9020RT
2 Disconnect electrical connector (1, 2)
3 Unclip electrical lines from clips (3)
Disconnect electrical connector from rear
4 air conditioning evaporator temperature
sensor (B10/11)
Detach electrical connector from footwell
5
rear AC temperature sensor (B10/38)
Assembly: Observe
6 Remove bracket (4) toward front
installation position of bracket (4).
Unclip electrical lines from clip (5) and
7
clips (6)
8 Disconnect electrical connector (7, 8, 9)
Handymaster battery-powered *WH58.30-Z-
9 Remove bolts (10)
10 Remove blower motor (11)
14 Remove air line cover (15)
Assembly: Pay attention to

correct seating of heat exchanger

(17) before tightening bolts (16).
16 Pull out heat exchanger (17)
18 Unscrew bolt (19)
19 Open clips (20)
20 Open clip (21)
21 Open catch lug (22)
correct seating of catch lug (22).
Remove top section of rear AC housing
22 (23) from bottom section of rear AC
housing (24) straight upward
Pull evaporator (25) upward (arrow) out installation position of drain pan in
23
of bottom section of rear AC housing (24) bottom section of rear AC housing
(24).
24 Assemble in the reverse order
Install
AR83.50-P-
25 Install rear AC housing
9020RT

Number Designation
REMOVE AND INSTALL BLOWER MOTOR FOR REAR AIR CONDITIONING - AR83.50-P-
9040GY
Fig. 158: Identifying Blower Motor For Rear Air Conditioning Components - Illustrated On Model 251
Remove/install

Turn key in ignition switch to 889:
1
position "0". Press keyless go start/stop button repeatedly
Do not unscrew bolt from belt end AR68.30-P-
2 Remove side paneling in trunk
fitting. 4800RT
Unclip metal clip for electrical Do not disconnect connector
3
connector (2) electrically.
4 Remove bolts (1)
5
connectors (3).
Remove rear air conditioning
6
blower motor (M2/29)
REMOVE AND INSTALL REAR AIR CONDITIONING PUSHBUTTON CONTROL UNIT - AR83.50-
P-9070GY
MODEL 164.8 with CODE (582) Rear air conditioner

Fig. 159: Identifying Rear Air Conditioning Pushbutton Control Unit Components
Remove/install

electronic components due to All models P-0001-
Switch off ignition and remove the Press Keyless Go start/stop button repeatedly
1 transmitter key from the EIS [EZS] until ignition is switched off. Remove transmitter
control unit key from vehicle and store it in a location beyond
its transmission range (at least 2 m).
Open stowage compartment (2) or
2
ashtray in the center console
Position long wedge between stowage
compartment (2) or ashtray and center
3 console instrument frame (3) and Long wedge Fig. 74
remove stowage compartment (2) or
ashtray
4 Remove screws (4)
Installation: Ensure that the metal clips
Pull bottom center console instrument
5 frame (3) backwards, then pull up and (10) correctly latch into the catches in the center
console and that the rear air outlet (7) is correctly
remove from the center console
seated in the air tube.
Disconnect connector (5) from rear air
6 conditioning control and operating unit
(1)
Disconnect connector (6) from the 12
V sockets and remove center console
Place center console instrument frame (3) on a
7 instrument frame (3) with rear air
conditioning control and operating unit soft surface in order to avoid surface damage.
(1)
Installation: Retaining lugs (9) and side AR83.10-
8 Remove rear air outlet (7)
notches (8) must audibly engage. P-4800GZ
9 Remove bolts (11)
Remove rear air conditioning control
10
and operating unit (1)

REMOVE/INSTALL REAR AIR CONDITIONING SYSTEM EVAPORATOR TEMPERATURE

SENSOR - AR83.50-P-9080RT
Fig. 161: Identifying Rear Air Conditioning System Evaporator Temperature Sensor Components -
Illustrated On Model 251
Remove/install
On vehicles with Keyless Go, code 889: Press Keyless

Go start/stop button repeatedly until ignition is switched off.
1 transmitter key from the EIS [EZS]
control unit Remove transmitter key from vehicle and store it in a location
beyond its transmission range (at least 2 m).
2 Fold down rear seat, 3rd seat row Only on left side
Open cover for left side load
3
Detach electrical connector (1)
from rear air conditioning
4
evaporator temperature sensor
(B10/11)
Pull rear air conditioning
evaporator temperature sensor

5
(B10/11) out of rear AC housing
REMOVE/INSTALL REAR AIR CONDITIONING EVAPORATOR - AR83.50-P-9100RT
Shown on rear air conditioning system with heating function
Fig. 162: Identifying Rear Air Conditioning Evaporator Components - Shown On Rear Air Conditioning
System With Heating Function

Remove/install

AS83.00-Z-
0001-01A
All models
AH83.30-N-
0005-01A
AH83.30-N-
0003-01A
AR83.50-P-
1 Remove rear air conditioning unit.
9020RT
Model 251 with rear air conditioner, code AR83.50-P-
2.1 Remove heat exchanger
582 with heating function. 9110RT
Vehicles with rear air conditioner, code
582 without heating function.
2.2 Remove heat exchanger closing plate
A closing plate made from plastic
is installed in place of the heat exchanger.
*WH58.30-
3 Remove bolts (1) Handymaster cordless drill/driver Z-1007-20A
4 Unclip clip (2) and clips (3)
*WH58.30-
5 Remove screw (4, 5) Handymaster cordless drill/driver Z-1007-20A
6 Unlock catch lug (6)
Remove top section of rear AC
Installation: Ensure that guides
7 housing (7) straight upward from
bottom section of rear AC housing (8) are seated correctly.
Do not damage the evaporator slats
Pull evaporator (9) up and out of when removing the evaporator (9).
8
bottom section of rear AC housing (8) Check evaporator (9) for damage,
replace if required.

Number Designation
CORRECT OIL LEVEL IN AIR CONDITIONING SYSTEM WHEN REPLACING AC

COMPRESSOR - AR83.55-P-5250GZ
ENGINE 113, 156, 272, 273, 642, 629 in MODEL 164 with CODE (580) Automatic air conditioning with
CODE (581) Comfort automatic air conditioning with CODE (582) Rear air conditioner
ENGINE 113, 272, 642 in MODEL 251 with CODE (580) Automatic air conditioning with CODE (581)
Comfort automatic air conditioning with CODE (582) Rear air conditioner
Draining
conditioning system. Risk of or open flames. Wear safety glasses and AS83.00-
poisoning from inhaling overheated protective gloves. Work only in well Z-0001-
refrigerant vapors. Risk of injury to ventilated areas. Carry out repair work on the 01A
skin and eyes caused by contact with air conditioning system circuit only after the
liquid refrigerant. system has been discharged.
AH83.30-
Conduct if air conditioning system is
All models N-0004-
damaged or leaking
01A
components from moisture when P-0005-
carrying out repair work 01P
AH83.30-
Notes on handling refrigerant R134a Air conditioning with refrigerant R134a N-0003-
01A
Perform work involving compressor
oil rapidly since compressor oil is
hygroscopic.
Empty removed refrigerant
1 compressor into a suitable measuring
container
Undo all screws on new refrigerant
2
compressor
3 Drain new refrigerant compressor
Measure
Measure quantity of oil drained from
4
removed refrigerant compressor
Charging
Pour the quantity of oil drained from
the removed refrigerant compressor plus an 3
Fill new refrigerant compressor with
5 additional 10 cm of compressor oil into the
compressor oil
new refrigerant compressor. Always use new
compressor oil.
REMOVE/INSTALL REFRIGERANT COMPRESSOR - AR83.55-P-5300GZ
ENGINE 113.964, 156.980, 272.967, 642.940 in MODEL 164 with CODE (580) Automatic air
conditioning with CODE (581) Comfort automatic air conditioning
Fig. 165: Identifying Refrigerant Compressor Components

Fig. 166: Identifying Refrigerant Compressor Components - Shown On Engine 156.980

Remove/install
platform.
or soldering work on closed air closed air conditioning system. No
conditioning system. Risk of poisoning smoking or open flames. Wear safety
AS83.00-Z-
caused by inhaling overheated glasses and protective gloves. Work only in
0001-01A
AH83.30-
Procedure for a damaged or leaky air
All models N-0004-
conditioning system
01A
components from moisture when All models with air conditioning N-0005-
carrying out repair work 01A
AH83.30-
Notes on handling refrigerant R134a Air conditioning with refrigerant R134a N-0003-
01A
On vehicles with Keyless-Go, code
Turn key in ignition switch to position 889:
1
"0". Press keyless go start/stop button
AR83.30-P-
1760GZ
AR13.22-P-
3 Remove poly-V belt Engine 113.964
1202GZ
AR13.22-P-
Engine 156.980
1202GZS
AR13.20-P-
Engine 272.967
0001GZA
AR13.20-P-
Engine 642.940
0001GZB
AR09.10-P-
4 Remove air filter housing Engine 642.940
1050GZB
Detach lower engine compartment AR61.20-P-
5.1 Engine 113.964, 156.980, 272.967
paneling 1105GZ
AR94.30-P-
5.2 Remove noise encapsulation Engine 642.940
5300GZ
Disconnect refrigerant compressor Installation: Engine 642.940:
6
connector (A9x1) Note bracket for electrical line.
*BA83.55-
7 Remove bolt (1)
P-1003-01R
Detach refrigerant-pressure line (2) and
8 of refrigerant pressure line (2) and moisten
with refrigerant compressor oil.
*BA83.55-
9 Remove screw (3)
P-1003-01R
Detach refrigerant-suction line (4) and
10 of refrigerant suction line (4) and moisten
with refrigerant compressor oil.
The openings of the refrigerant-pressure

11 Seal openings of refrigerant-pressure line (2) and refrigerant-suction line (4)
line (2) and refrigerant-suction line (4) must be sealed, as otherwise any
using suitable sealing caps and stop penetrating dirt and moisture can damage
plugs components connected to the refrigerant
circuit.
12 Drain and catch oil Engine 156.980, refer to: ?
AP18.00-P-
Engine oil and filter change
0101GZ
13 Remove double clamp (6) Engine 156.980
Unscrew screw (7) from engine oil line
14 Engine 156.980
flange connection
Disconnect engine oil line flange Engine 156.980
15
connection Collect engine oil in reservoir.
*BA83.55-
16 Remove bolts (5)
P-1001-01R
Place refrigerant-pressure line (2)
17 Remove refrigerant compressor (A9) and refrigerant-suction line (4) to one side.
Remove refrigerant compressor (A9)
downwards
Check engine oil level and adjust
19 Engine 156.980, refer to: ?
correctly
AP18.00-P-
0101GZ
Refill air conditioning system and AR83.30-P-
20
inspect for leaks and proper operation. 1760GZ
Do an engine test run and check for
21
leaks

164.1/8
BA83.55-P-1001- Bolt, refrigerant compressor to timing case and left engine
Nm 20
01R support
BA83.55-P-1003-
Bolt, refrigerant lines to refrigerant compressor Nm 20
01R

MAINTENANCE
REPLACE DUST FILTER FOR HEATING/AIR CONDITIONING - AP83.00-P-8381GZ
MODEL 164.1 /8 with CODE (580) Automatic air conditioning
Fig. 168: Identifying Dust Filter For Heating/Air Conditioning Components


1 Remove glove compartment
AR68.10-P-
Remove/install glove compartment
1400GZ
Unlock cover (2) on dust filter housing
2 (1) in direction of the arrow and
remove
Installation: Replace dust filters
3 Remove dust filters (3, 4) (3, 4), do not clean.
Installation: Observe the
installation position (arrows) printed on
the dust filters (3, 4).

REPLACE COMBINATION FILTER - AP83.00-P-8384GZ
MODEL 164.1 /8 with CODE (581) Comfort automatic air conditioning
Fig. 169: Identifying Combination Filter Components


1 Remove glove compartment
AR68.10-P-
Remove/install glove compartment
1400GZ
Unlock cover (2) on combination filter
2 housing (1) in direction of the arrow
and remove
combination filters (3, 4), do not clean.
3 Remove combination filters (3, 4) Installation: Observe the
installation position (arrows) printed on
the combination filters (3, 4).
TIGHTENING TORQUES: PASSENGER CARS: CLIMATE CONTROL - BA83.00-Z-9999AZ
MODEL all
Heater MODEL 169.0 /3, 245.2 BA83.20-P-1000-

01B
Heat exchanger MODEL 199.376 BA83.25-P-1000-
shutoff motor 01A
Air conditioning MODEL 129, 140, 168, 170, 199.376, 202, BA83.30-P-1000-
208, 210, 211, 215, 220, 230, 240, 414.700 01A
Air conditioning MODEL 163 BA83.30-P-1000-
01B
Air conditioning MODEL 171, 203, 209 BA83.30-P-1000-
01D
Air conditioning MODEL 169.0 /3, 245.2 BA83.30-P-1000-
01G
Air conditioning MODEL 219 BA83.30-P-1000-
01H
Air conditioning MODEL 164.1 /8 BA83.30-P-1000-
01I
Air conditioning MODEL 164.1 /8, 251 BA83.30-P-1000-
01J
Air conditioning MODEL 216, 221 BA83.30-P-1000-
01K
Automatic air MODEL 199.376, 211, 230 BA83.40-P-1000-
conditioning 01A
Automatic air MODEL 219 BA83.40-P-1000-
conditioning 01B
Rear air MODEL 220 BA83.50-P-1000-
conditioning 01A
Rear air MODEL 221 BA83.50-P-1000-
conditioning 01C
Rear air MODEL 164.8, 251 with CODE (582) Rear air BA83.50-P-1000-
conditioning conditioner 01D
Refrigerant ENGINE 104, 111, 112, 113, 137, 155, 271, BA83.55-P-1000-
compressor 272, 273, 275, 602, 604, 605, 606, 612, 628, 01A
642 ...
AC compressor ENGINE 166.940 /960 /961 /990 /991 /995 BA83.55-P-1000-
01B
AC compressor ENGINE 611.960 /961 /962, BA83.55-P-1000-
612.961 /962 /963 /965 /966 /967 /990, 01C
613.960 /961
AC compressor ENGINES 668.940 /941 /942 /914 BA83.55-P-1000-
01D
Refrigerant ENGINE 628.960 /961 /962, 629 BA83.55-P-1000-
compressor 01E
Refrigerant ENGINE 111, 112, 113, 155 ... BA83.55-P-1000-
compressor 01F
AC compressor ENGINE 271 BA83.55-P-1000-
01G
Refrigerant ENGINE 646, 647, 648 ... BA83.55-P-1000-
compressor 01H
Refrigerant ENGINE 285 in MODEL 240 BA83.55-P-1000-
compressor 01K
Refrigerant ENGINE 272, 273 ENGINE 275 in MODEL BA83.55-P-1000-
compressor 216, 221 01M
Refrigerant ENGINE 266, 640 ... BA83.55-P-1000-
compressor 01N
Refrigerant ENGINE 266.920 /940 /960 /980 BA83.55-P-1000-
compressor 01O
Refrigerant ENGINE 113.967 /990, 272, 273 in MODEL BA83.55-P-1000-
compressor 219 ENGINE 272, 273 in MODEL 211 01P
Refrigerant MODEL 164.1 /8, 463 BA83.55-P-1000-
compressor 01R
Refrigerant MODEL 251 BA83.55-P-1000-
compressor 01S
Refrigerant ENGINE 156 in MODEL 209, 211, 216, 219, BA83.55-P-1000-
compressor 221 01T
Refrigerant MODEL 204 BA83.55-P-1000-
compressor 01U
Stationary heater MODEL 129, 163, 168, 170, 202, 203, 208, BA83.70-P-1000-
unit 209, 210, 215, 220, 230 ... 01A
Stationary heater MODEL 211, 240 with heater Thermo Top C BA83.70-P-1000-
unit 01C
Stationary heater MODEL 219 with heater Thermo Top C BA83.70-P-1000-
unit 01E
Stationary heater MODEL 164, 251 BA83.70-P-1000-
unit 01F
Heater booster MODEL 210 with ENGINE 602.982 with BA83.70-P-1000-
heater unit heater booster 02A
Heater booster MODEL 220.026 with ENGINE 613.960 BA83.70-P-1000-
heater unit MODEL 220.028 /06 /07 /12 /16 /17 /87 02B
Heater booster MODEL 203, 210, 461, 463 ... BA83.70-P-1000-
unit 02C
Heater booster MODEL 203.004 /006 /204 /206 /706 with BA83.70-P-1000-
heater unit ENGINE 611.962 MODEL 203.016 with 02E
ENGINE 612.962
Heater booster MODEL 169.0 /3, 245.2 BA83.70-P-1000-
unit 02F
Heater booster MODEL 164.1 /8 BA83.70-P-1000-
unit 02G
Heater booster MODEL 251 BA83.70-P-1000-
unit 02H
AIR CONDITIONING - BA83.30-P-1000
Air conditioning - BA83.30-P-1000-01I
Model 164

BA83.30-P-1001-01I Screw, high pressure line to fluid reservoir Nm 11
BA83.30-P-1002-01I Screw, fluid reservoir to condenser Nm 11
BA83.30-P-1003-01I Refrigerant pressure sensor to line Nm 10
BA83.30-P-1005-01I Service valve at plug Nm 6
BA83.30-P-1006-01I Bolt, expansion valve to retaining plate Nm 5
Air conditioning - BA83.30-P-1000-01J
Models 164, 251

Number Designation Model Model Model
164.1 164.8 251
BA83.30-P-
Nut, high pressure line to fluid reservoir Nm - - 11
1001-01J
BA83.30-P-
Screw, fluid reservoir to condenser Nm - - 11
1002-01J
BA83.30-P-
Refrigerant pressure sensor to line Nm - - 10
1003-01J
BA83.30-P- Nut, low- and high-pressure lines to expansion
Nm 8 8 8
1004-01J valve
BA83.30-P-
Service valve at plug Nm 6 6 6
1005-01J
BA83.30-P-
Bolt, expansion valve to retaining plate Nm - - 5
1006-01J
BA83.30-P- Nut, low and high pressure lines to rear air
Nm - 8 8
1007-01J conditioning shutoff valve
BA83.30-P- Screw, shutoff valve to rear air conditioning
Nm - 5 5
1008-01J retainer plate
REAR AIR CONDITIONING - BA83.50-P-1000-01D
Models 164, 251
REAR AIR CONDITIONING UNIT


164.8 251
BA83.50-P-1001- Connection fitting from rear pressure line to front pressure
Nm 8 8
01D line of rear air conditioning
BA83.50-P-1002- Connection fitting from rear intake line to front intake line of
Nm 20 20
01D rear air conditioning
BA83.50-P-1003-
Nut of rear suction and pressure line to expansion valve Nm 8 8
01D
REFRIGERANT COMPRESSOR - BA83.55-P-1000-01R
Model 164, 463
REFRIGERANT COMPRESSOR
164.1/8 463
BA83.55-P-1001- Bolt for refrigerant compressor to timing case and left
Nm 20 20
01R engine support
BA83.55-P-1002-
Bolt, refrigerant compressor to bracket Nm 20 20
01R
BA83.55-P-1003-
Bolt, refrigerant lines to refrigerant compressor Nm 20 20
01R
BA83.55-P-1004-
Nut for refrigerant lines on drier Nm 8 -
01R
BA83.55-P-1005- Bolt for front refrigerant suction line to rear refrigerant
Nm 20 20
01R suction line
BA83.55-P-1006- Refrigerant line separation point between refrigerant
Nm 8 -
01R compressor and heat exchanger
FORMS
QUESTIONNAIRE FOR ODOR COMPLAINT, FORM - OF83.00-P-3000-01A
MODEL 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 219, 220, 221, 230,
240, 245
Fig. 170: Questionnaire For Odor Complaint Form

2006-2008 ENGINE Crank Assembly - 164 Chassis
2006-2008 ENGINE
Crank Assembly - 164 Chassis
GENERAL INFORMATION
INTERFERENCE/PRECISION FIT OF CRANKSHAFT BEARING CAP - AH03.20-P-4351
Precision fit of crankshaft bearing cap - AH03.20-P-4351-02SX
 The crankshaft bearing caps are machined together with the crankcase and must not be interchanged.
 The crankshaft bearing caps are fitted on the side in the crankcase and must be mounted in the correct
installation position. If the installation position is correct, the semicircle will point (3) in the direction of
travel (arrow).
 The crankshaft bearing caps are numbered consecutively on the semicircles (3) beginning with the first
crankshaft bearing cap at the front.
Fig. 1: Identifying Crankshaft Bearing Caps Numbers

Interference fit of crankshaft bearing cap - AH03.20-P-4351-02VA
 The crankshaft bearing caps (main bearing cap (1), fitted bearing cap (2)) are machined together with the
crankcase and must not be exchanged with each other.
 The crankshaft bearing caps are fitted on the side in the crankcase and may only be mounted in one
location. If the correct installation position is achieved then the semicircles (3) are in the direction of
travel (arrow).
 The crankshaft bearing caps are numbered consecutively on the semicircles (3), beginning with the first
crankshaft bearing cap at the front.
Fig. 2: Identifying Main Bearing Caps, Fitted Bearing Cap & Semicircles
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY - AR03.00-Z-9113AB
ENGINE 113
Piston removal and ENGINE 112, 113... AR03.10-P-7021AV

installation
Piston removal and ENGINE 113.964 in AR03.10-P-7021GZ
installation MODEL 164.175
Piston removal and ENGINE 113.971 in AR03.10-P-7021RT
installation MODELS 251.075 /175
Piston removal and ENGINE 113.995 in AR03.10-P-7021RVK

Piston removal and ENGINE 113.967 in AR03.10-P-7021TY
installation MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Piston removal and ENGINE 113.989 in AR03.10-P-7021VT
Remove/install piston rings ENGINE 112, 113... AR03.10-P-7311BV
Removing/installing piston ENGINE 113.964 in AR03.10-P-7311GZ
rings MODEL 164.175
Removing/installing piston ENGINE 113.971 in AR03.10-P-7311RT
rings MODELS 251.075 /175
Remove/install piston rings ENGINE 113.967 in AR03.10-P-7311TY
MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Removing/installing piston ENGINE 113.989 in AR03.10-P-7311VT
rings MODEL 171.473
Replace front crankshaft ENGINE 112, 113... AR03.20-P-3000B
radial seal ring
Replace front crankshaft ENGINE 112, 113... AR03.20-P-3000BA
radial sealing ring
Replace front crankshaft ENGINE 113.964 in AR03.20-P-3000GZ
radial sealing ring MODEL 164.175
Replace front crankshaft ENGINE 113.971 in AR03.20-P-3000RT
radial sealing ring MODEL 251.075 /175
Replacing front crankshaft ENGINE 113... AR03.20-P-3000RVK
radial sealing ring
Replace front crankshaft ENGINE 113.967 in AR03.20-P-3000TY
radial sealing ring MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Replace rear crankshaft radial ENGINE 113.988 in AR03.20-P-3063AC
sealing ring MODEL 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Replace rear crankshaft radial ENGINE 112, 113... AR03.20-P-3063B
sealing ring
Replace rear crankshaft radial ENGINE 113.964 in AR03.20-P-3063GZ
seal MODEL 164.175
Replace rear crankshaft radial ENGINE 113.971 in AR03.20-P-3063RT
seal MODEL 251.075 /175
Replacing rear crankshaft ENGINE 113... AR03.20-P-3063RVK
radial seal
Replace rear crankshaft radial ENGINE 113.967 in AR03.20-P-3063TY

seal MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install crankshaft ENGINE 113.988 in AR03.20-P-4351AC
MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install crankshaft ENGINE 113... AR03.20-P-4351BV
Remove/install crankshaft ENGINE 113.964 in AR03.20-P-4351GZ
MODEL 164.175
Remove/install crankshaft ENGINE 113.971 in AR03.20-P-4351RT
MODELS 251.075 /175
Remove/install crankshaft ENGINE 113.995 in AR03.20-P-4351RVK
MODEL 230.472
Remove/install crankshaft ENGINE 113.967 in AR03.20-P-4351TY
113.990 in MODEL
219.376
Remove/install belt ENGINE 112, 113... AR03.30-P-1600C
pulley/vibration damper
Remove/install belt ENGINE 112, 113... AR03.30-P-1600CA
Remove/install belt ENGINE 113.964 in AR03.30-P-1600GZ
pulley/vibration damper MODEL 164.175
Remove/install belt ENGINE 113.971 in AR03.30-P-1600RT
pulley/vibration damper MODEL 251.075 /175
Remove/install belt ENGINE 113... AR03.30-P-1600RVK
Remove/install belt ENGINE 113.967 in AR03.30-P-1600TY
pulley/vibration damper MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install retaining lock ENGINE 112, 113, 137, AR03.30-P-5000B
for crankshaft / ring gear 275...
Removing/installing retaining ENGINE 113.964 in AR03.30-P-5000GZ
lock for crankshaft / ring gear MODEL 164.175 with
TRANSMISSION 722.901
Removing/installing the ENGINE 113.971 in AR03.30-P-5000RT
retaining lock for crankshaft / MODELS 251.075 /175
ring gear
Removing/installing the ENGINE 113.967 in AR03.30-P-5000TY
retaining lock for crankshaft / MODEL 219.375 ENGINE
ring gear 113.990 in MODEL
219.376
Remove/install flywheel / ENGINE 113.988 in AR03.30-P-8001AC

drive plate MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install flywheel / ENGINE 112, 113, 137... AR03.30-P-8001C
drive plate
Remove/install flywheel / ENGINE 113.964 in AR03.30-P-8001GZ
drive plate MODEL 164.175 with
TRANSMISSION 722.901
Remove/install flywheel / ENGINE 113.971 in AR03.30-P-8001RT
drive plate MODELS 251.075 /175
Remove/install flywheel / ENGINE 113.995 in AR03.30-P-8001RVK
drive plate MODEL 230.472
Remove/install flywheel / ENGINE 113.967 in AR03.30-P-8001TY
drive plate MODEL 219.375 ENGINE
113.990 in MODEL
219.376
ENGINE 156
Remove/install a piston ENGINE 156 AR03.10-P-

7021AMG
Remove/install piston ENGINE 156 AR03.10-P-
rings 7311AMG
Replace front ENGINE 156 in MODEL 164, AR03.20-P-3000GZS
crankshaft radial 251
sealing ring
Replace front ENGINE 156 in MODEL 216, AR03.20-P-3000SMG
crankshaft radial 221
sealing ring
Replace front ENGINE 156.982 in MODEL AR03.20-P-3000TMG
crankshaft radial 209.377 /477 ENGINE 156.983 in
sealing ring MODEL 211.077 /277, 219.377
Replace rear crankshaft ENGINE 156 in MODEL 164, AR03.20-P-3063GZS
radial seal 251
Replace rear crankshaft ENGINE 156 in MODEL 216, AR03.20-P-3063SMG
radial sealing ring 221
Replacing rear ENGINE 156.983 in MODELS AR03.20-P-3063TMG
crankshaft radial seal 211.077 /277, 219.377 ENGINE
156.982 in MODELS
209.377 /477
Remove/install ENGINE 156.980 /982 /983 /984 AR03.20-P-
crankshaft 4351AMG
Remove/install belt ENGINE 156 in MODEL 164, AR03.30-P-1600GZS

pulley/vibration 251
damper
Remove/install belt ENGINE 156 in MODEL 216, AR03.30-P-1600SMG
pulley/vibration 221
damper
Remove/install belt ENGINE 156.982 in MODEL AR03.30-P-1600TMG
pulley/vibration 209.377 /477 ENGINE 156.983 in
damper MODEL 211.077 /277, 219.377
Remove/install ENGINE 156 in MODEL 164, AR03.30-P-5000GZS
retaining lock for 251 with TRANSMISSION 722
crankshaft / ring gear
Remove/install ENGINE 156.982 in MODEL AR03.30-P-5000QBS
retaining lock for 209.377 with CODE (P98) Black
crankshaft / ring gear Series
Remove/install ENGINE 156 in MODEL 216, AR03.30-P-5000SMG
retaining lock for 221 with TRANSMISSION 722
crankshaft/ ring gear
Remove/install ENGINE 156 ... AR03.30-P-5000TMG
retaining lock for
crankshaft/ ring gear
Remove, install ENGINE 156 in MODEL 164, AR03.30-P-8001GZS
flywheel / drive plate 251 with TRANSMISSION 722
Remove, install ENGINE 156 in MODEL 216, AR03.30-P-8001SMG
flywheel/drive plate 221 with TRANSMISSION 722
Remove, install ENGINE 156.983 in MODELS AR03.30-P-8001TMG
flywheel / drive plate 211.077 /277, 219.377 ENGINE
156.982 in MODELS
209.377 /477
ENGINE 272
Remove/install piston ENGINE 272 in MODEL AR03.10-P-7021CV

204
Piston removal and ENGINE 272, 273 in AR03.10-P-7021GZA
installation MODEL 164, 251
Piston removal and ENGINE 272, 273 ... AR03.10-P-7021QB
installation
Remove, install pistons ENGINE 272, 273 in AR03.10-P-7021RX
MODEL 230
Remove/install piston ENGINE 273 in MODEL AR03.10-P-7021SX
216 ENGINE 272, 273 in
MODEL 221
Piston removal and ENGINE 272, 273 in AR03.10-P-7021TS

installation MODEL 211, 219 with
TRANSMISSION 722.9
Removing and installing ENGINE 272.942 in AR03.10-P-7021VA
a piston MODEL 171.454 ENGINE
272.963 in MODEL 171.456
Remove, install piston ENGINE 272, 273 Piston AR03.10-P-7311VA
rings removed
Remove/install balance ENGINE 272 in MODEL AR03.20-P-1000CV
shaft 204
Remove/install balance ENGINE 272 in MODEL AR03.20-P-1000GZA
shaft 164, 251
Remove, install balance ENGINE 272 in MODEL AR03.20-P-1000QB
shaft 203, 209
Remove, install balance ENGINE 272 in MODEL AR03.20-P-1000RX
shaft 230
Remove, install balance ENGINE 272 in MODEL AR03.20-P-1000SX
shaft 221
Remove, install balance ENGINE 272 in MODEL AR03.20-P-1000TS
shaft 211, 219
Remove, install balance ENGINE 272 in MODEL AR03.20-P-1000VA
shaft 171
Replace front crankshaft ENGINE 272 in MODEL AR03.20-P-3000CV
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000GZA
radial sealing ring MODEL 164, 251
Replace front crankshaft ENGINE 272, 273 ... AR03.20-P-3000QB
radial sealing ring
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000RX
radial sealing ring MODEL 230
Replacing the front ENGINE 273 in MODEL AR03.20-P-3000SX
crankshaft radial sealing 216 ENGINE 272, 273 in
ring MODEL 221
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000TS
radial sealing ring MODELS 211, 219
Replace front crankshaft ENGINE 272.942 /963 in AR03.20-P-3000VA
Replace rear crankshaft ENGINE 272 in MODEL AR03.20-P-3063CV
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063GZA
Replace rear crankshaft ENGINE 272, 273 ... AR03.20-P-3063QB
radial seal
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063RX

Replace rear crankshaft ENGINE 273 in MODEL AR03.20-P-3063SX
radial seal 216 ENGINE 272, 273 in
MODEL 221
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063TS
Replace rear crankshaft ENGINE 272.942 in AR03.20-P-3063VA
radial seal MODEL 171.454 ENGINE
272.963 in MODEL 171.456
Remove, install ENGINE 272 in MODEL AR03.20-P-4351CV
crankshaft 204
crankshaft MODEL 164, 251
Remove/install ENGINE 272, 273 ... AR03.20-P-4351QB
crankshaft
Remove/install ENGINE 272, 273 in AR03.20-P-4351RX
crankshaft MODEL 230
Remove/install ENGINE 272 in MODEL AR03.20-P-4351SY
crankshaft 221
crankshaft MODEL 211, 219 with
TRANSMISSION 722.9
Remove/install ENGINE 272.942 in AR03.20-P-4351VA
crankshaft MODEL 171.454 ENGINE
272.963 in MODEL 171.456
Remove/install belt ENGINE 272 in MODEL AR03.30-P-1600CV
pulley/vibration damper 204
Remove/install belt ENGINE 272, 273 in AR03.30-P-1600GZA
pulley/vibration damper MODEL 164, 251
Remove/install belt ENGINE 272, 273 ... AR03.30-P-1600QB
Remove/install belt ENGINES 272, 273 in AR03.30-P-1600RX
pulley/vibration damper MODEL 230
Remove/install belt ENGINE 273 in MODEL AR03.30-P-1600SX
pulley/vibration damper 216 ENGINE 272, 273 in
MODEL 221
Remove/install belt ENGINE 272, 273 in AR03.30-P-1600TS
pulley/vibration damper MODELS 211, 219
Remove/install belt ENGINE 272.942 /963 in AR03.30-P-1600VA
Remove/install retaining ENGINE 272 in MODEL AR03.30-P-5000CV
lock for crankshaft / ring 204.05 /25
gear
Remove/install retaining ENGINE 272 in MODEL AR03.30-P-5000CWX
lock for crankshaft / ring 204.08

gear
Remove/install retaining ENGINE 272, 273 in AR03.30-P-5000GZA
lock for crankshaft / ring MODEL 164, 251 with
gear TRANSMISSION 722.9
Remove/install retaining ENGINE 272, 273 ... AR03.30-P-5000QB
lock for crankshaft / ring
gear
Remove/install retaining ENGINES 272, 273 in AR03.30-P-5000RX
lock for crankshaft/ ring MODEL 230
gear
Remove/install retaining ENGINE 273 in MODEL AR03.30-P-5000SX
lock for crankshaft / ring 216 ENGINE 272, 273 in
gear MODEL 221
Remove/install retaining ENGINE 272, 273 in AR03.30-P-5000TS
lock for crankshaft / ring MODEL 211, 219
gear
Remove/install retaining ENGINE 272.942 in AR03.30-P-5000VA
lock for crankshaft / ring MODEL 171.454 ENGINE
gear 272.963 in MODEL 171.456
Remove, install ENGINE 272 in MODEL AR03.30-P-8001CV
flywheel / drive plate 204
Remove, install ENGINE 272, 273 in AR03.30-P-8001GZA
flywheel / drive plate MODEL 164, 251
Remove, install ENGINE 272 in MODEL AR03.30-P-8001QB
flywheel / drive plate 203, 209 ENGINE 273 in
MODEL 209
flywheel/drive plate MODEL 230
Remove, install ENGINE 273 in MODEL AR03.30-P-8001SX
flywheel / drive plate 216 ENGINE 272, 273 in
MODEL 221
Remove, install ENGINE 272, 273 in AR03.30-P-8001TS
flywheel / drive plate MODELS 211, 219
Remove/install ENGINE 272, 271 in AR03.30-P-8001V
flywheel / drive plate MODEL 171
ENGINE 273
Piston removal and ENGINE 272, 273 in AR03.10-P-7021GZA

installation MODEL 164, 251
Piston removal and ENGINE 272, 273 ... AR03.10-P-7021QB
installation
Remove, install pistons ENGINE 272, 273 in AR03.10-P-7021RX

MODEL 230
Remove/install piston ENGINE 273 in MODEL AR03.10-P-7021SX
216 ENGINE 272, 273 in
MODEL 221
Piston removal and ENGINE 272, 273 in AR03.10-P-7021TS
installation MODEL 211, 219 with
TRANSMISSION 722.9
Remove, install piston ENGINE 272, 273 Piston AR03.10-P-7311VA
rings removed
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000GZA
Replace front crankshaft ENGINE 272, 273 ... AR03.20-P-3000QB
radial sealing ring
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000RX
Replacing the front ENGINE 273 in MODEL AR03.20-P-3000SX
crankshaft radial sealing 216 ENGINE 272, 273 in
ring MODEL 221
Replace front crankshaft ENGINE 272, 273 in AR03.20-P-3000TS
radial sealing ring MODELS 211, 219
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063GZA
Replace rear crankshaft ENGINE 272, 273 ... AR03.20-P-3063QB
radial seal
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063RX
Replace rear crankshaft ENGINE 273 in MODEL AR03.20-P-3063SX
radial seal 216 ENGINE 272, 273 in
MODEL 221
Replace rear crankshaft ENGINE 272, 273 in AR03.20-P-3063TS
crankshaft MODEL 164, 251
crankshaft
crankshaft MODEL 230
Remove/install ENGINE 273 in MODEL AR03.20-P-4351SX
crankshaft 216, 221
crankshaft MODEL 211, 219 with
TRANSMISSION 722.9
Remove/install belt ENGINE 272, 273 in AR03.30-P-1600GZA
pulley/vibration damper MODEL 164, 251

Remove/install belt ENGINE 272, 273 ... AR03.30-P-1600QB
Remove/install belt ENGINES 272, 273 in AR03.30-P-1600RX
Remove/install belt ENGINE 273 in MODEL AR03.30-P-1600SX
pulley/vibration damper 216 ENGINE 272, 273 in
MODEL 221
Remove/install belt ENGINE 272, 273 in AR03.30-P-1600TS
pulley/vibration damper MODELS 211, 219
Remove/install retaining ENGINE 272, 273 in AR03.30-P-5000GZA
lock for crankshaft / ring MODEL 164, 251 with
gear TRANSMISSION 722.9
Remove/install retaining ENGINE 272, 273 ... AR03.30-P-5000QB
lock for crankshaft / ring
gear
Remove/install retaining ENGINES 272, 273 in AR03.30-P-5000RX
lock for crankshaft/ ring MODEL 230
gear
Remove/install retaining ENGINE 273 in MODEL AR03.30-P-5000SX
lock for crankshaft / ring 216 ENGINE 272, 273 in
gear MODEL 221
Remove/install retaining ENGINE 272, 273 in AR03.30-P-5000TS
lock for crankshaft / ring MODEL 211, 219
gear
Remove, install ENGINE 272, 273 in AR03.30-P-8001GZA
flywheel / drive plate MODEL 164, 251
Remove, install ENGINE 272 in MODEL AR03.30-P-8001QB
flywheel / drive plate 203, 209 ENGINE 273 in
MODEL 209
flywheel/drive plate MODEL 230
Remove, install ENGINE 273 in MODEL AR03.30-P-8001SX
flywheel / drive plate 216 ENGINE 272, 273 in
MODEL 221
flywheel / drive plate MODELS 211, 219
CONNECTING ROD BEARING/BOLTS/SCREWS - AR03.10-P-6111
Inspect connecting rod bolts - AR03.10-P-6111-01VA
TEST DATA FOR CONNECTING ROD BOLTS

BE03.10-P- connecting rod Thread dia. ø M8 x 1 8x1

1001-03A bolts Shank length when new mm 39.5 39.5
max. mm 40.5 40.5
Part no. - -
1. Measure length (L).
If the length (L) of the connecting rod bolts exceeds the maximum permissible dimension the
connecting rod bolts must be replaced.
Fig. 3: Identifying Shank Length (L)

Inspect connecting rod bolts - AR03.10-P-6111-01VT
TEST DATA FOR CONNECTING ROD BOLTS

Number Designation Engine Engine 112 except
113.987/988/98 112.951/976,
9/990/991/993 Engines 113.94/96/971/
980/981/982/984/986
BE03.10- connecting Thread dia. Ø M 8x1 8x1
P-1001- rod bolts Shank when new mm 41.7...42.3 47
03A length
max. mm 42.5 47.6
Part no. HWA -
113 038 01 71
1. Measure shank length (L).
If the shank length (L) of the connecting rod bolts exceeds the maximum permissible dimension
the connecting rod bolts must be replaced.
Fig. 4: Identifying Shank Length

Tightening connecting rod screws - AR03.10-P-6111-02VA
CONNECTING ROD
BA03.10-P-1001- Connecting rod Stage 1 Nm 5 5
01E bolt Stage 2 Nm 20 25
Stage 3 Angle ° 90 90
CONNECTING ROD
BA03.10-P-1001- Connecting rod Stage 1 Nm 25
01Q bearing cap on Stage 2 Angle ° 90
connecting rod Stage 3 Angle ° 10
1. Lubricate the thread and head contact surface of the bolt with engine oil.
2. Tighten connecting rod bolts to step 1.
If no torquing angle wrench is available, connecting rod screws can be torqued further by the
specified angle in a single operation using a wrench and tommy bar.
Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
Shown on engine 272

Fig. 5: Tightening Connecting Rod Bolts - Shown On Engine 272

Tightening conrod screws - AR03.10-P-6111-02VT
CONNECTING ROD
113.989 112.951/976,
Engine 113.940/941/942/
943/944/945/946/
948/960/961/962/
963/964/965/966/
967/968/971/980/
981/982/984/986/
987/988/990/991/
992/993
BA03.10-P- Connecting rod Step 1 Nm 5 5
1001-01E bolt 2nd stage Nm 25 25
Stage 3 Angle° 90 90
Fig. 6: Identifying External Torx Set (001 589 76 09 00)

1. Lubricate thread and bolt head contact surface of conrod bolts with engine oil.
2. Screw in conrod bolts and tighten to step 1 .
3. Tighten conrod bolts to step 2 .
4. Tighten conrod bolts using an angle wrench to step 3 .
If no torquing angle wrench is available, the conrod screws can be torqued further by the
Fig. 7: Locating Connecting Rod Bolts

Install, measure conrod bearings - AR03.10-P-6111-06VA
TEST VALUES FOR CRANKSHAFT BEARING CLEARANCE

BE03.20-P- Connecting rod Radial when mm 0.022...0.062 0.022...0.066
1002-04E bearing play new
Assignment of conrod bearings to conrod bearing journals on engine 272

Upper half Conrod Lower half Connecting rod Connecting rod bearing play
bearing cap (mm)
yellow yellow 0.026 - 0.066
blue red 0.026 - 0.066
red blue 0.026 - 0.066
1. Clean the bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing
journals with a chamois leather.
Blow out oil ducts in direction of oil flow with compressed air. Never use hard objects for
cleaning.
2. The assignment of conrods to the conrod bearing journals is indicated on the back of the conrod bearing
shells by a colored dot.
Only the assigned color combinations of the conrod bearing shells (see table) may be installed
together. The sequence of the individual color combinations on the connecting rod bearing journals can
be selected at random.
3. Insert connecting rod bearing shells (1) into connecting rod and connecting rod bearing cap (2).
The anti-twist locks (3) of the conrod bearing shells (1) must be located in the slots (4) of the
conrods (2) and the conrod bearing caps.
Fig. 8: Identifying Connecting Rod Bearing Shells, Connecting Rod Bearing Cap, Anti-Twist Locks
And Slots
Installing and gauging connecting rod bearings - AR03.10-P-6111-06VT
INSPECTION DATA FOR CRANKSHAFT BEARING CLEARANCE

113.987/988/98 112.951/976,
9/990/991/993 Engines 113.940/941/
942/943/944/ 948/960/961/
963/964/965/966/967/968/
971/980/981/ 984/986
BE03.20-P- Connecting radial when mm 0.022...0.067 0.022...0.067
1002-04E rod bearing new
play
CONNECTING ROD
113.989 112.951, Engines
113.940/941/942/
943/944/945/946/
948/960/961/962/
963/964/965/966/
967/968/971/980/
981/982/984/986/
987/988/990/991/
992/993
BA03.10-P- Connecting rod Stage 1 Nm 5 5

1001-01E bolt Stage 2 Nm 25 25

1. Clean the bearing points of conrod, conrod bearing caps and conrod bearing journals with a chamois
leather.
Blow through oil galleries in direction of flow oil with compressed air. Do not use any hard
objects for cleaning.
The assignment of the connecting rod bearings to the connecting rod journal is marked on the
rear of the connecting rod bearing shell (7) by a color dot. Only assigned color combinations of the
connecting rod bearing shell (7) may be installed with each other, yellow to yellow and red to blue. The
sequence of the individual color combinations on the conrod bearing journals can be selected at random.
2. Insert the connecting rod bearing shell (7) in the connecting rod (4) and in the connecting rod bearing cap.
The conrod bearing shell (7) with the oil drilling (arrow) must be installed in the conrod (4) otherwise
the conrod bearings will not be lubricated.
The anti-twist lock (8) of the connecting rod bearing shell (7) must be located in the groove (9)
of the connecting rod and of the connecting rod bearing cap.
Fig. 10: Locating Bearing Points Of Connecting Rod

3. Install the connecting rod bearing cap with the connecting rod bearing shell (7).
4. Lubricate thread and bolt head contact surface of conrod bolts with engine oil.
5. Screw in conrod bolts and tighten to Stage 1 .
6. Tighten conrod bolts to Stage 2 .
7. Tighten conrod bolts using an angle wrench to Stage 3 .
If no torquing angle wrench is available, the conrod screws can be torqued further by the
Fig. 11: Locating Connecting Rod Bolts

Mount connecting rod bearing - AR03.10-P-6111-08SX

BE03.20-P-1002- Connecting rod radial when new mm 0.022...0.066
04E bearing play
CONNECTING ROD
BA03.10-P-1001- Connecting rod bolt Stage 1 Nm 5
01E Stage 2 Nm 25
Stage 3 Angle ° 90
Assignment of connecting rod bearing to connecting rod journal for engine 273
Lower half of connecting rod Connecting rod bearing play
Upper half of connecting rod bearing cap (mm)
yellow yellow 0.022...0.066
blue red 0.022...0.066

red blue 0.022...0.066
1. Clean bearing points on connecting rod, connecting rod bearing caps and connecting rod journals with a
chamois leather.
Blow through oil ducts in direction of flow oil with compressed air. Do not use any hard objects
for cleaning.
2. The assignment of connecting rods to the connecting rod bearing journals is indicated on the back of the
connecting rod bearing shells by a colored dot.
Only assigned color combinations of the connecting rod bearing shells (see table) may be
installed together. The sequence of the individual color combinations on the connecting rod bearing
journals can be selected at random.
3. Insert connecting rod bearing shells (1) into connecting rod (2) and connecting rod bearing cap.
The anti-twist locks (3) of the connecting rod bearing shells (1) must be located in the cutouts (4) of
the connecting rod (2) and the connecting rod bearing cap.
Fig. 12: Identifying Bearing Shells, Connecting Rod, Anti-Twist Locks And Cutouts
4. Install connecting rod bearing cap with connecting rod bearing shells (1).
5. Spread engine oil onto the thread and bolt head contact surface of the connecting rod bolts.
6. Screw in connecting rod bolts and tighten to step 1.
8. Tighten connecting rod bolts using an angle wrench to Stage 3.
If no torquing angle wrench is available, the connecting rod screws can be torqued further by the
Fig. 13: Tighten Connecting Rod Bolts

PISTON REMOVAL AND INSTALLATION - AR03.10-P-7021
Remove/install a piston - AR03.10-P-7021AMG
ENGINE 156
Fig. 14: Identifying Piston Components

Fig. 15: Identifying Retaining Strap

Removing
toppling off the lifting and position four support
Risk of injury to skin Do not open cooling AS20.00-Z-0001-01A
and eyes caused by system unless coolant
scalding from contact temperature is below 90°
with hot coolant spray. C. Open cap slowly and
Risk of poisoning caused release the pressure. Do
by swallowing coolant. not pour coolant into

beverage containers.
Wear protective gloves,
protective clothing and
safety glasses.
Risk of explosion caused No fire, sparks, open AS47.00-Z-0001-01A
by fuel igniting, risk of flames or smoking.
poisoning caused by Only pour fuels into
inhaling and swallowing suitable and appropriately
fuel and risk of injury to marked containers.
eyes and skin caused by Wear protective clothing
contact with fuel when handling fuel.
Notes on self-locking All models AH00.00-N-0001-01A
nuts and bolts
1.1 Remove engine with Engine 156.980 in model AR01.10-P-2500GZS
front axle carrier 164, 251
1.2 Remove engine Engine 156.982 in model AR01.10-P-2400QMG
209
Engine 156.983 in model AR01.10-P-2400TMG
211, 219
Engine 156.984 in model AR01.10-P-2400SMG
216, 221
2 Detach engine from front Engine 156.980 in model AR01.10-P-2510GZS
axle carrier 164, 251
3 Remove automatic
transmission from the
engine
4 Mount engine onto
assembly stand
5 Remove cylinder heads Model 164, 251 AR01.30-P-5800GZS
Model 209, 211, 219 AR01.30-P-5800TMG
Model 216, 221 AR01.30-P-5800SMG
6 Remove oil pan bottom Model 164, 251 AR01.45-P-7555GZS
section
Model 209, 211, 219 AR01.45-P-7555TMG
Model 216, 221 AR01.45-P-7555SMG
7 Detach oil pan Model 164, 251 AR01.45-P-7500GZS
Model 209 AR01.45-P-7500QMG
Model 211, 219 AR01.45-P-7500TMG
Model 216, 221 AR01.45-P-7500SMG
8 Remove oil pump Model 164, 251 AR18.10-P-6020GZS
Model 209, 211, 219 AR18.10-P-6020TMG
Model 216, 221 AR18.10-P-6020SMG
9 Remove engine support
10 Remove refrigerant Disconnect

compressor connector at oil
temperature sensor
behind refrigerant
compressor.
11 Remove vacuum
reservoir at crankcase
12 Remove bolts from
crankcase subdivide (bed
plate)
13 Mount crankshaft bracket Crankshaft Fig. 17
on crankshaft bracket
14 Mark connecting rod (2) Connecting rod (2)
and connecting rod and connecting rod
bearing cap (1) at one bearing cap (1) are
side with markings (11) cracked. They must not
be mixed up amongst
each other or installed
laterally inverted as the
dimensional accuracy
would no longer be there.
15 Remove connecting rod
bearing cap (1)
16 Remove connecting rod Mark the pistons
(2) with pistons (3) from according to the cylinder
crankcase in the direction bores.
of cylinder head If pistons are
used, the direction of
travel arrows and
marking of pistons may
be no longer visible
because of carbon
deposits. For this reason,
remove carbon deposits
from pistons. If arrows
indicating direction of
travel on the pistons are
no longer recognizable,
these must be re-marked.
17 Remove circlip (4) for Do not damage
piston pin (5) the pistons, place a clean
rag underneath.
18 Push out piston pin (5)
from piston (3)
Install
19 Assign piston (3) to

cylinder bore
20 Lubricate piston pin (5)
and connecting rod bush
21 Align piston (3) and Install piston
connecting rod (2) with arrow pointing in
direction of travel.
22 Push piston pin (5) by
hand into piston (3)
23 Insert circlip (4) for Do not damage
piston pin (5) into groove pistons, place a clean rag
on piston (3) underneath.
24 Oil cleaned parts
(cylinder bores,
connecting rod bearing
journal, connecting rod
bearing shells and
pistons)
25 Place tensioning strap (6) Piston ring gaps
on piston (3) and tension must be offset 120°.
Tensioning strap Fig. 16
26 Install piston (3) in Observe arrow
direction of travel (in direction of travel) on
piston.
Rotate
crankshaft sufficiently so
that connecting rod does
not touch connecting rod
journal when piston is
inserted into cylinder
bore.
27 Inspect connecting rod If length of
bolts (7) connecting rod bolts
exceeds the maximum
permissible dimension,
connecting rod bolts must
be replaced!
Thread diameter and *BE03.10-P-1001-03A
shank length
28 Install connecting rod The anti-twist locks
bearings and fit (8) of connecting rod
connecting rod bearing bearing shells (10) must
cap (1) be located in grooves (9)
in connecting rod (2) and
cap.
Connecting rod (2)
and connecting rod
bearing cap are cracked
(broken). They must not
be mixed up amongst
each other or installed
laterally inverted as the
dimensional accuracy
would no longer be there.
29 Tighten connecting rod AR03.10-P-6111-02VA
bolts (7)
*BA03.10-P-1001-01Q
30 Crank crankshaft by hand
and check for
unobstructed movement
of the crankshaft
assembly
31 Remove crankshaft Crankshaft Fig. 17
bracket on crankshaft bracket
32 Install crankcase *BA03.20-P-1001-01J
subdivide (bed plate)
*BA03.20-P-1002-01J
33 Replace rear crankshaft Model 164, 251 AR03.20-P-3063GZS
radial sealing ring
Model 209, 211, 219 AR03.20-P-3063TMG
Model 216, 221 AR03.20-P-3063SMG
34 Install vacuum reservoir
35 Mount engine support *BA22.10-P-1001-02A
36 Attach refrigerant Disconnect plug
compressor connection at oil
temperature sensor.
37 Install oil pump Model 164, 251 AR18.10-P-6020GZS
Model 209, 211, 219 AR18.10-P-6020TMG
Model 216, 221 AR18.10-P-6020SMG
38 Attach oil pan Model 164, 251 AR01.45-P-7500GZS
Model 209 AR01.45-P-7500QMG
Model 211, 219 AR01.45-P-7500TMG
Model 216, 221 AR01.45-P-7500SMG
39 Attach oil pan bottom Model 164 AR01.45-P-7555GZS
section
Model 209, 211, 219 AR01.45-P-7555TMG
Model 216, 221 AR01.45-P-7555SMG
40 Mount on cylinder heads Model 164, 251 AR01.30-P-5800GZS
Model 209, 211, 219 AR01.30-P-5800TMG

Model 216, 221 AR01.30-P-5800SMG
41 Mount automatic
transmission on engine
42 Attach engine to front Engine 156.980 in model AR01.10-P-2510GZS
43.1 Install engine with front Engine 156.980 in model AR01.10-P-2500GZS
43.2 Install engine Engine 156.982 in model AR01.10-P-2400QMG
209
211, 219
216, 221
44 Perform basic Model 216, 221
programming
Model 164 AR00.19-P-0200GZ
Model 209 AR00.19-P-0200Q
Model 211 AR00.19-P-0200T
Model 219 AR00.19-P-0200TX
Model 251 AR00.19-P-0200RT
procedure or when
as it is running
45 Conduct engine test run
and check engine for
leaks
CHECK VALUES FOR CONNECTING ROD BOLTS

BE03.10-P- Connecting rod Thread ø mm 9x1
1001-03A bolts Shank length when new mm 40
max. mm 42.8
Part no. -
ENGINE SUPPORT (ENGINE SIDE)

BA22.10-P-1001- Bolt, engine support Stage 1 Nm 20
02A to crankcase Stage 2 Angle° 90
CRANKSHAFT BEARING CAP

BA03.20-P- Crankshaft bearing M9 Stage 1 Nm 20
1001-01J cap bolt (underpart Stage 2 Nm 32
of crankcase/ main Stage 3 Angle° 90
bearing threaded
Stage 4 Angle° 5
connection)
Stage 5 Angle° 90
Stage 6 Angle° 5
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 5
Stage 5 Angle° 90
Stage 6 Angle° 5
BA03.20-P- Crankcase lower M6 Nm 8.5
1002-01J section on
crankcase upper M8 Nm 20
section
CONNECTING ROD
01Q bearing cap on Stage 2 Angle° 90
connecting rod Stage 3 Angle° 10
Fig. 16: Identifying Retaining Strap (000 589 04 14 00)

Fig. 17: Identifying Crankshaft Bracket (156 589 00 40 00)

Piston removal and installation - AR03.10-P-7021GZ

Removing
Risk of death caused by Align vehicle between the columns of the lifting platform
vehicle slipping or and position the four support plates below the lifting AS00.00-Z-
toppling off of the lifting platform support points specified by the vehicle 0010-01A
platform. manufacturer.
AR01.10-P-
1 Remove engine
2400GZ
2 Detach automatic AR27.10-P-
transmission from engine 0500GZ

Remove oil pan top AR01.45-P-
3
section 7500GZ
Remove intake manifold with complete wiring AR01.30-P-
4 Take off cylinder head
harness during this step. 5800GZ
For this step, push back chain tensioner and take AR18.10-P-
5 Remove oil pump
off chain. 6020GZ
Remove connecting rod For this step, mark conrod (4) and connecting
6
bearing cap (5) rod bearing cap (5) on one side relative to each other.
Mark the pistons according to the cylinder bores.
Remove the connecting If pistons have been used (3), the arrows
rod (4) with the pistons indicating the direction of the travel and the markings on
7 (3) from the crankcase in the pistons may no longer be visible due to carbon
the direction of the deposits. For this reason, remove the carbon deposits
cylinder head from the pistons. If the arrows indicating direction of
travel on the pistons are no longer recognizable, these
must be re-marked.
Remove the circlip (1) Do not damage piston (3). Place a clean cloth
8
from the piston pin (2) underneath.
Push out the piston pin
9
(2) from the piston (3)
Install
Assign piston (3) to AR03.10-P-
10
cylinder bore 7021-02BV
*BE01.40-
Cylinder dia.
P-1001-01F
*BE03.10-
Piston diameter
P-1001-02D
*BE03.10-
Piston clearance
P-1002-02D
Oil piston pin (2) and
11
conrod bush
Assemble piston (3) and Install piston (3) with arrow in direction of
12
conrod (4) travel.
Push in piston pin (2) by
13
hand
Insert circlip (1) for
Do not damage piston (3). Place a clean cloth
14 piston pin (2) into the
groove on the piston (3) underneath.
Oil the cleaned parts

(cylinder bores,
15 connecting rod bearing
journal, connecting rod
bearing shells and
pistons)
Fit the tensioning strap
16 Piston ring gaps must be offset 120°.
(10) and tighten
Tensioning strap Fig. 16
Install piston (3) with Rotate crankshaft sufficiently so that the
17 arrow pointing in connecting rod (4) is not touching the connecting rod
direction of travel journal when the piston is inserted into the cylinder bore.
Inspect the conrod bolts AR03.10-P-
18
(6) 6111-01VT
*BE03.10-
Conrod bolts
P-1001-03A
The connecting rod bearing shell (7) with the oil
drilling (arrow) must be installed in the connecting rod
(4) otherwise the piston pins (2) will not be greased.
The anti-twist lock (8) on the connecting rod bearing
Install the conrod
shell (7) must be located in the grooves (9) of the AR03.10-P-
19 bearings and fit the
connecting rods (4) and of the connecting rod bearing cap 6111-06VT
conrod bearing cap (5)
(5).
connecting rod (4) and connecting rod bearing
cap (5) are cracked (arrow). They must not be installed
the wrong way round!
*BE03.20-
Connecting rod bearing play
P-1002-04E
AR03.10-P-
20 Tighten conrod bolts (6)
6111-02VT
*BA03.10-
P-1001-01E
External torx set Fig. 6
21 Rotate crankshaft To check for unobstructed movement.
 Ensure that the oil return shutoff valve is correctly
located.
AR18.10-P-
22 Install oil pump  Clean the oil pump strainer. 6020GZ
 Fill the oil pump with engine oil before installing,
so that oil is delivered at the initial startup.
AR01.30-P-
23 Fit the cylinder head
5800GZ
AR01.45-P-
24 Fit the oil pan top section
7500GZ
Fit the automatic AR27.10-P-
25
transmission 0500GZ
AR01.10-P-
26 Install engine
2400GZ
TEST DATA FOR CONROD BOLTS

Number Designation Engine 112 except 112.951/976, engine
113.94/96/971/980/981/982/984/986
Thread
M 8X1
dia. Ø
BE03.10-P- Conrod Shank When
mm 47
1001-03A bolts length new
Max. mm 47.6
Part no. -
TEST VALUES FOR CYLINDER BORE

Number Designation Engine 113.960/961/ 962/963/964/ 965/967/968/
971/980/981/ 982/984/987/ 988/989/990/ 991/992/993/
995
Standard
mm 97.000 to 97.015
marking X
BE01.40-P- Cylinder
Auxiliary stage
1001-01F dia. mm 97.050 to 97.065
marking
Repair size mm 97.250 to 97.265
TEST VALUES FOR PISTONS

Number Designation Engine 113.960/ 961/962/963/ 964/965/967/
968/971/980/ 981/982/984
Standard marking
mm 96.972 to 97.000
X
BE03.10-P-
Piston dia. Ø Auxiliary stage
1001-02D mm 97.022 to 97.050
marking
Standard marking
mm < or = 0.043
X
BE03.10-P- Piston
Auxiliary stage
1002-02D clearance mm < or = 0.043
marking
Repair size mm < or = 0.043
INSPECTION DATA OF CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 112 except 112.951/976, Engine
113.940/941/942/943/944/948/960/961/963/964/965/966/967/968/971/980/981
BE03.20- Connecting Radial
P-1002- rod bearing when mm 0.022...0.067
04E play new
CONNECTING ROD
Stage 1 Nm 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 25
Stage 3 Angle° 90


Assign standard size piston to cylinder bore - AR03.10-P-7021-02BV
Check values for cylinder bore

Number Designation Engines Engines
112.910/911 112.913/920/921/922/
923/940/941/942/943/
944/945/949
113.940/941/942/943/
945
BE01.40-P- Cylinder dia. Standard mm 83.200...83.215 89.900...89.915
1001-01F Marking X
Auxiliary stage mm 83.250...83.265 89.950 to 83.265
Marking
Repair size mm 83.450 to 83.465 90.150...90.165
Check values for cylinder bore

Number Designation Engines 113.960/961/
962/963/964/
965/967/968/
971/980/981/
982/984/987/
988/989/990/
991/992/993/ 995
BE01.40-P-1001- Cylinder dia. Standard Marking X mm 97.000 to 97.015
01F Auxiliary stage mm 97.050 to 97.065
Marking
Check values for pistons

Number Designation Engines Engines Engines
112.910/911 112.920/921/940 /941/942/943/944/945, 113.960/
113.940/941/942/944 961/962961/
962/ 963/
964/965965/
967/ 967/
968/971980/
981/ 980/
981/982984/
990/ 984
BE03.10- Piston Standard mm 83.175 to 89.872 to 89.902 96.972 to
P-1001- diameter Marking 83.195 97.000
02D X
Auxiliary mm 83.225 to 89.872 to 89.902 97.022 to
stage 83.245 97.050
marking
Repair mm 83.425 to 90.122 to 90.152 97.222 to
size 83.445 97.250
BE03.10- Piston Standard mm < or = 0.040 < or = 0.043 < or = 0.043
P-1002- clearance Marking
02D X
Auxiliary mm < or = 0.040 < or = 0.043 < or = 0.043
stage
Marking
Repair mm < or = 0.040 < or = 0.043 < or = 0.043
size
Check values for pistons

112.960/960/961 113.987/988/
961 AMG 989/990/991/
992/993/995
BE03.10-P- Piston diameter Standard mm 89.875 to 89.895 96.975 to 96.995
1001-02D Marking X
Auxiliary stage mm 89.925 to 89.945 97.025 to 97.045

Marking
Repair size mm 90.125...90.145 97.225...97.245
BE03.10-P- Piston clearance Standard mm < or = 0.04 0.005...0.040
1002-02D Marking X
Auxiliary stage mm < or = 0.04 0.005...0.040
Marking
Repair size mm < or = 0.04 0.005...0.040
The pistons marked with an "x" must only be installed in the cylinder bores likewise marked with "x".
1. The piston diameter on engines 112. 113 is stated in two tolerances. The two tolerances of the piston
diameters are distinguished one from the other by the letters "x" and The marking is located on
the top of the piston crown.
Shown on engine 112
Fig. 21: Identifying Piston Diameter On Engines

2. The cylinder bore diameter on engines 112, 113 is stated in two tolerances. The two tolerances of the
cylinder bore diameters are distinguished one from the other by the letters "x" and The marking
is located at the bottom right on the crankcase at the mount for the engine support.
Shown on engine 112

Fig. 22: Identifying Cylinder Bore Diameter On Engines

Piston removal and installation - AR03.10-P-7021GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 24: Identifying Retaining Strap

MODIFICATION NOTES
Remove, install engine with front axle carrier, added Steps 2, 37
18.10.05 Remove/install automatic transmission - added Steps 3, 36
Removing
Remove engine with AR01.10-P-
1
front axle carrier 2500GZA
Remove automatic AR27.10-P-
2 Model 164
transmission 0500GZA
AR27.10-P-
Model 251
0500RTA
Detach engine from front AR01.10-P-
3
axle carrier 2510GZA
Mount engine onto
4
assembly stand
Remove oil pan bottom AR01.45-P-
5
section 7555GZA
AR01.45-P-
6 Remove oil pan
7500GZA
AR18.10-P-
7 Remove oil pump
6020GZA
Remove oil baffle from
8
crankcase
Remove resonance intake AR09.20-P-
9
manifold 1961GZA
Remove right cylinder
AR01.30-P-
10 head and left cylinder Right cylinder head
5780GZA
head
AR01.30-P-
Left cylinder head
5770GZA
Mark connecting rod (2) Connecting rod (2) and connecting rod bearing cap (1)
and connecting rod are cracked. They must not be mixed up amongst each
11 bearing cap (1) at one other or installed laterally inverted as the dimensional
side with markings (11) accuracy would no longer be there!
Remove connecting rod
12
bearing cap (1)
Mark the pistons (3) according to the cylinder
bores.
Remove connecting rod If pistons are used (3), the arrows indicating the
(2) with pistons (3) from driving direction and the marking of the pistons (3) may
13
crankcase in the direction no longer be visible because of carbon deposits. For this
of cylinder head reason, remove carbon deposits from pistons (3). If
arrows indicating the driving direction on pistons (3) are
no longer recognizable then these must be newly marked.
Remove circlip (4) from Do not damage piston (3). Place a clean cloth
14
piston pin (5) underneath.
Push out piston pin (5)
15
from piston (3)
Install
Assign piston (3) to AR03.10-P-
16
cylinder bore 7021-02VA
*BE01.40-
Cylinder diameter
P-1001-01I
*BE03.10-
Piston diameter
P-1001-02D
*BE03.10-
Piston clearance
P-1002-02D
Lubricate piston pin (5)
17
and connecting rod bush
Align piston (3) and Install piston (3) with arrow in direction of
18
connecting rod (2) travel.
Push piston pin (5) by
19
hand into piston (3)
Insert circlip (4) for
Do not damage piston (3). Place a clean cloth
20 piston pin (5) into groove
on piston (3) underneath.
Oil cleaned cylinder
bores, connecting rod
21 bearing journals,
shells and pistons (3)
Place tensioning strap (6)
22 Piston ring gaps must be offset 120°.
on piston (3) and tension
Fig. 16
Observe arrow (in direction of travel) on piston

(3).
Install piston (3) in Rotate crankshaft so that connecting rod (2) is
23
direction of travel not touching connecting rod journal when inserting the
piston (3) into the cylinder bore!
Inspect connecting rod AR03.10-P-
24
bolts (7) 6111-01VA
*BE03.10-
Thread diameter and shank length
P-1001-03A
Install connecting rod
bearings and fit AR03.10-P-
25 Engine 272
connecting rod bearing 6111-06VA
cap (1)
Engine 273
The anti-twist lock (8) on connecting rod
bearing shell (10) must be located in grooves (9) of
connecting rods (2) and of connecting rod bearing cap
AR03.10-P-
(1).
6111-08SX
Connecting rod (2) and connecting rod bearing cap (1)
are cracked. They must not be mixed up amongst each
other or installed laterally inverted as the dimensional
accuracy would no longer be there!
*BE03.20-
P-1002-04E
Tighten connecting rod AR03.10-P-
26
bolts (7) 6111-02VA
*BA03.10-
P-1001-01E
Crank crankshaft by
hand and check for
27
of crankshaft assembly
*BA18.10-
28 Install oil deflector plate
P-1006-01B
AR18.10-P-
29 Install oil pump
6020GZA
AR01.45-P-
30 Installing oil pan
7500GZA
Install oil pan bottom AR01.45-P-
31
section 7555GZA
Install left cylinder head AR01.30-P-
32 Right cylinder head
and right cylinder head 5780GZA
AR01.30-P-
Left cylinder head
5770GZA
Install resonance intake AR09.20-P-
33
manifold 1961GZA
Remove engine from

34
assembly stand
Attach engine to front AR01.10-P-
35
Fit automatic AR27.10-P-
36 Model 164
transmission 0500GZA
AR27.10-P-
Model 251
0500RTA
Install engine with front AR01.10-P-
37

Thread Ø Ø M 8x1 8x1
Shank length when new mm 39.5 39.5
BE03.10-P-1001-03A Connecting rod bolts
max. mm 40.5 40.5
Part no. - -
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 272.91/92/94 Engine 272.96/97/98/99
Stage X mm 88.000 to 88.015 92.900 to 92.915
BE01.40-P-1001-01I Cylinder Ø Stage mm 88.100 to 88.115 93.000 to 93.015
Repair size mm 88.250 to 88.265 93.150 to 93.165
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 273.92 Engine 273.96
Stage X mm 92.900 to 92.915 98.000 to 98.015
BE01.40-P-1001-01I Cylinder Ø Stage mm 93.000 to 93.015 98.100 to 98.115
CHECK VALUES FOR PISTONS

272.91/92/94 272.96/97/98/99
Standard identification
mm 87.973 to 88.003 92.863 to 92.897
X
BE03.10-P-1001-
Piston Ø Auxiliary size
02D mm 88.073 to 88.103 92.963 to 92.997
marking
Standard identification
mm 0.003 to 0.042 0.003 to 0.052
X
BE03.10-P-1002- Piston
Auxiliary size
02D clearance mm 0.003 to 0.042 0.003 to 0.052
marking

Standard identification X mm 92.863 to 92.897 97.973 to 98.007
BE03.10-P-1001-02D Piston Ø Auxiliary size marking mm 92.963 to 92.997 98.073 to 98.107
Standard identification X mm 0.003 to 0.052 0.007 to 0.042
BE03.10-P-1002-02D Piston clearance Auxiliary size marking mm 0.003 to 0.052 0.007 to 0.042
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

BE03.20-P-1002-04E Connecting rod bearing play radial when new mm 0.022...0.066 0.022...0.066
CONNECTING ROD
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 20 25
OIL PUMP
BA18.10-P-1006-01B Bolt, oil baffle at crankcase Nm 9 9

Assigning a standard size piston to a cylinder bore - AR03.10-P-7021-02VA

272.91/92/94 272.96/97/98/99
BE01.40-P- Cylinder dia. Stage X mm 88.000...88.015 92.900...92.915
1001-01I Stage mm 88.100...88.115 93.000...93.015
Repair size mm 88.250...88.265 93.150...93.165

BE01.40-P- Cylinder dia. Stage X mm 92.900...92.915 98.000...98.015
1001-01I Stage mm 93.000...93.015 98.100...98.115
Repair size mm 93.150...93.165 98.250...98.265

272.91/92/94 272.96/97/98/99
BE03.10-P- Piston diameter Standard mm 87.973...88.003 92.863...92.897
1001-02D identification X
Auxiliary size mm 88.073...88.103 92.963...92.997
marking
Repair size mm 88.223...88.253 93.113...93.147
BE03.10-P- Piston Standard mm 0.003...0.042 0.003...0.052
1002-02D clearance identification X
marking
Repair size mm 0.003...0.042 0.003...0.052

BE03.10-P- Piston diameter Standard mm 92.863...92.897 97.973...98.007
1001-02D identification X
marking
Repair size mm 93.113...93.147 92.223...92.257
BE03.10-P- Piston Standard mm 0.003...0.052 0.007...0.042
1002-02D clearance identification X
marking
Repair size mm 0.003...0.052 0.007...0.042
1. Assign piston to the cylinder bore
Piston diameters are specified in two tolerances. The piston diameters are differentiated from
each other by the identification x or g. This is located on the top of the piston crown.
Pistons marked with x must only be installed in cylinder bores marked with x.
Fig. 26: Identifying Piston Diameter Identification Marking

Cylinder bore diameters are specified in two tolerances. The cylinder bore diameters are differentiated
from each other by the identification x or
Shown on engine 272
Fig. 27: Identifying Cylinder Bore Diameter Identification Marking - Shown On Engine 272
REMOVING/INSTALLING PISTON RINGS - AR03.10-P-7311
Remove/install piston rings - AR03.10-P-7311AMG
ENGINE 156
Fig. 28: Identifying Piston Rings Components

Removing
1 Remove pistons AR03.10-P-7021AMG
2 Using pliers, remove Pliers Fig. 29
compression rings from
piston (4)
3 Remove oil scraper ring The oil scraper
(3) from piston (4) ring is in three parts and
must be removed by
hand.
Install
4 Measure ring width of *BE03.10-P-1003-05D
compression rings
5 Measure end gap of AR03.10-P-7311-
compression rings 02AMG
*BE03.10-P-1002-05D
Feeler gauge
6 Using pliers, insert Pay attention to
compression rings into installation position of
piston (4) compression rings. The
"Top" marking or
manufacturer's
designation must face
towards piston crown (5).
Pliers Fig. 29
7 Measure side clearance of AR03.10-P-7311-
compression rings 01AMG

*BE03.10-P-1001-05D
Feeler gauge
8 Fit the oil scraper ring (3)
by hand
9 Install pistons The piston ring
gaps must be offset by
120°. AR03.10-P-
7021AMG
CHECK VALUES FOR PISTON RINGS

BE03.10-P-1001- Piston ring vertical Groove 1 mm 0.02 to 0.065
05D clearance Groove 2 mm 0.015 to 0.045
Groove 3 mm 0.01 to 0.013
BE03.10-P-1002- Piston ring end gap Groove 1 mm 0.2 to 0.35
05D Groove 2 mm 0.35...0.55
BE03.10-P-1003- Dimension Plain compression mm 102.2 x 1.2 x 3.45
05D ring
Taper-faced hook mm 102.2 x 1.75 x 3.9
scraper ring
Oil scraper ring mm 102.2 x 2.0 x 2.7

Measure end clearance of piston rings - AR03.10-P-7311-01AMG

BE03.10-P-1001- Piston ring vertical Groove 1 mm 0.02 to 0.065
05D clearance Groove 2 mm 0.015 to 0.045
1. Measure vertical clearance between compression ring and mounting groove in piston with a
feeler gauge for the compression ring concerned; replace compression ring or piston if necessary.
The end clearance of the oil scraper ring cannot be measured because of its three-part design. The
oil scraper ring must also be replaced when the compression rings are replaced.
Fig. 30: Measuring Vertical Clearance Between Compression Ring And Mounting Groove
Measure piston ring end clearance - AR03.10-P-7311-02AMG

BE03.10-P-1002- Piston ring end gap Groove 1 mm 0.2 to 0.35
05D Groove 2 mm 0.35...0.55
1. Clean cylinder wall.

2. Insert both compression rings, one after the other, above running surface in the cylinder bore, and
measure end gap with a feeler gauge; replace piston rings if necessary.
The end gap of the oil scraper ring cannot be measured because of its three-part design. The oil
scraper ring must also be replaced when the compression rings are replaced.
Fig. 31: Measuring Cylinder Barrel End Gap

Removing/installing piston rings - AR03.10-P-7311GZ
Fig. 32: Identifying Piston Rings Components - Model 164.175

Remove
AR03.10-P-
1 Remove pistons
7021GZ
Remove compression ring (plain
compression ring) (1) and
2 Pliers Fig. 29
compression ring (flat taper-faced
ring) (2) using pliers from piston (4)
3 Remove oil scraper ring (3) from The oil scraper ring is in three parts
piston (4) and must be removed by hand.

Installing
Measure ring width of compression
ring (plain compression ring) (1) *BE03.10-P-
4
and compression ring (flat taper- 1003-05B
faced ring) (2)
Measure end gap of compression
ring (plain compression ring) (1) AR03.10-P-
5
and compression ring (flat taper- 7311-02VT
faced ring) (2)
*BE03.10-P-
1002-05B
*WH58.30-Z-
Feeler gauge 1004-12A
Insert compression ring (plain Pay attention to the installation
compression ring) (1) and position of the compression rings. The
6 "Top" marking or manufacturer's
ring) (2) using pliers from piston (4) designation must face towards the piston
crown (5).
Measure side clearance from
compression ring (plain
AR03.10-P-
7 compression ring) (1) and from
7311-01VT
ring) (2)
*BE03.10-P-
1001-05B
*WH58.30-Z-
Feeler gauge 1004-12A
8 Fit the oil scraper ring (3) by hand
The piston ring gaps must be offset AR03.10-P-
9 Install pistons
by 120°. 7021GZ
INSPECTION DATA FOR PISTON RINGS

Number Designation Engines 113.960/961/ 962/963/964/
965/968/971
BE03.10-P- Piston ring vertical Groove 1 mm 0.012...0.060
1001-05B clearance Groove 2 mm 0.010...0.030
BE03.10-P- Groove 1 mm 0.200...0.350
Piston ring end gap
1002-05B Groove 2 mm 0.200...0.400
Plain compression ring mm 97.0 X 1.5 X 3.1
BE03.10-P-
Dimension Taper-faced hook
1003-05B mm 97.0 X 3.5 X 3.5
scraper ring


Number Designation
WH58.30-Z-1004-12A Feeler gauge
Measure end clearance of piston rings - AR03.10-P-7311-01VT

Number Designation Engines Engine 113.967 Engine
113.987/988/989 113.990/991/
992/995
BE03.10-P- Piston ring Groove 1 mm 0.020...0.065 0.033...0.070 0.020...0.065
1001-05B vertical
clearance Groove 2 mm 0.015...0.045 0.01...0.04 0.015...0.050

113.960/961/
962/963/964/
965/968/971
BE03.10-P-1001- Piston ring vertical Groove 1 mm 0.012...0.060
05B clearance Groove 2 mm 0.010...0.030

Number Designation
1. Measure the side clearance of the compression rings between the compression ring and the mounting
groove in the piston with a feeler gauge.
If the side clearance is beyond the permissible tolerance, replace compression rings or piston.
The end clearance of oil scraper ring cannot be checked because of its three-part design. The oil
scraper ring must also be replaced when compression rings are replaced.
Fig. 34: Identifying Side Clearance Of Compression Rings

Measure piston ring end clearance - AR03.10-P-7311-02VT

Number Designation Engines Engine 113.967 Engine
113.987/988/989 113.990/991/
992/995
1002-05B end gap Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400

113.960/961/
962/963/964/
965/968/971
BE03.10-P-1002- Piston ring end gap Groove 1 mm 0.200...0.350
05B Groove 2 mm 0.200...0.400

Number Designation

2. Insert the two compression rings one after the other into the unworn area of the cylinder barrel and
measure the end gap with a feeler gauge.
If the end gap is beyond the permissible tolerance, replace the compression rings.
The gap clearance of the oil scraper ring cannot be checked because of its three-part design. The
oil scraper ring must also be replaced when the compression rings are replaced.
Fig. 35: Measuring Cylinder Barrel End Gap

Remove, install piston rings - AR03.10-P-7311VA
ENGINE 272, 273
Fig. 36: Identifying Piston Rings Components

Removing
1 Using pliers, remove Pliers Fig. 29
compression rings (1, 2)
from piston (4)
2 Remove oil scraper ring The oil scraper
(3) from piston (4) ring (3) is in three parts,
and must be removed by
hand.
Install
3 Measure the width of the *BE03.10-P-1003-05D
compression rings (1, 2)
4 Measure the end gap of AR03.10-P-7311-02VA
compression rings (1, 2) *BE03.10-P-1002-05D
5 Using the pliers, fit the Note the
compression rings (1, 2) installation position of
to piston (4) compression rings (1, 2).
The "Top" marking or
manufacturer's
designation must face
towards the piston crown
(5).
Pliers
6 Measure the vertical AR03.10-P-7311-01VA
clearance of compression *BE03.10-P-1001-05D
rings (1, 2)
7 Fit the oil scraper ring (3)
by hand
TEST VALUES FOR PISTON RINGS

Engine
Engine 272.96/97/
Number Designation 272.91/92/94 98/99
BE03.10-P- Piston ring Groove 1 mm 0.03...0.08 0.02 to 0.07
1001-05D vertical Groove 2 mm 0.02...0.06 0.015 to 0.05
clearance Groove 3 mm - -
BE03.10-P- Piston ring end Groove 1 mm 0.2 to 0.35 0.2 to 0.35
1002-05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9
BE03.10-P- Dimension Plain compression mm 88.0 x 1.5 x 3.1 92.9 x 1.5 x 3.1
1003-05D ring
Taper-faced hook mm 88.0 x 1.75 x 3.5 92.9 x 1.75 x
scraper ring 3.7
Oil scraper ring mm 88.0 x 2.5 x 3.03 92.9 x 2.5 x
3.03

BE03.10-P- Piston ring Groove 1 mm 0.02 to 0.07 0.02 to 0.07
1001-05D vertical clearance Groove 2 mm 0.015 to 0.05 0.002 to 0.06
Groove 3 mm - -
1002-05D gap Groove 2 mm 0.3...05 0.3...0.5

Groove 3 mm 0.2...0.9 0.2...0.9
BE03.10-P- Dimension Plain compression mm 92.9 x 1.5 x 3.1 98.0 x 1.2 x 3.1
1003-05D ring
Taper-faced hook mm 92.9 x 1.75 x 98.0 x 1.5 x 3.7
scraper ring 3.7
Oil scraper ring mm 92.9 x 2.5 x 98.0 x 2.5 x
3.03 3.03

Measure vertical clearance of piston rings - AR03.10-P-7311-01VA

272.91/92/94 272.96/97/98/99
BE03.10-P- Piston ring Groove 1 mm 0.03...0.08 0.02 to 0.07
1001-05D vertical Groove 2 mm 0.02...0.06 0.015 to 0.05

BE03.10-P-1001- Piston ring Groove 1 mm 0.02 to 0.07 0.02 to 0.07
05D vertical clearance Groove 2 mm 0.015 to 0.05 0.002 to 0.06
Groove 3 mm - -

Number Designation
1. For the compression ring concerned, measure the vertical clearance between the compression ring and the
mounting groove in the piston with a feeler gauge; if necessary, replace the compression ring or piston.
The vertical clearance of the oil scraper ring cannot be measured because of its three-part design.
The oil scraper ring must also be replaced when the compression rings are replaced.
Fig. 38: Measuring Vertical Clearance Of Compression Ring And Mounting Groove In Piston With
Feeler Gauge
Measure piston ring end gap - AR03.10-P-7311-02VA

272.91/92/94 272.96/97/98/99
1002-05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9

BE03.10-P-1002- Piston ring end Groove 1 mm 0.2 to 0.35 0.2 to 0.35
05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9

Number Designation

2. Insert both compression rings, one after the other, above the running surface in the cylinder bore, and
measure the end gap with a feeler gauge; replace the piston rings if necessary.
The end gap of the oil scraper ring cannot be measured because of its three-part design. The oil
scraper ring must also be replaced when the compression rings are replaced.
Fig. 39: Measuring Piston Ring End Gap Using Feeler Gauge
REMOVE/INSTALL BALANCE SHAFT - AR03.20-P-1000GZA
Fig. 40: Identifying Balance Shaft Components

Fig. 41: Identifying Balance Weight

Remove/install

Risk of death caused by vehicle slipping vehicle lift and position four support AS00.00-Z-
or toppling off the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
Unscrew central bolt on belt pulley / AR03.30-P-
1
vibration damper for crankshaft 1600GZA
AR27.20-P-
2 Unscrew torque converter from driver
0100-01A
*BA27.20-
P-1002-01C
Fig. 42
Fig. 43
AR01.10-P-
3 Remove engine
2500GZA
AR27.10-P-
4 Detach transmission from engine Model 164
0500GZA
AR27.10-P-
Model 251
0500RTA
5 Mount engine onto assembly stand
AR01.45-P-
6 Remove oil pan
7500GZA
AR03.30-P-
7 Remove flywheel/drive plate
8001GZA
Remove end cover with crankshaft radial Installation: Replace the end AR03.20-P-
8
sealing ring cover with crankshaft radial sealing ring. 3063GZA
Turn engine at crankshaft in direction of
9 engine rotation to a 40° crank angle after
ignition TDC.
Do not damage cylinder head AR01.40-P-
10 Remove timing case cover
gaskets. 8000GZA
AR05.20-P-
11 Check basic position of camshafts
6010-01VB
Mark timing chain relative to camshaft Installation: Check position of
adjusters as well as the balance shaft timing chain based on the color coding.
12
wheel and mark crankshaft using color When replacing balance shaft
coding transfer color coding to the new part.
Pull tensioning rail bolts out of right
AR01.30-P-
13 cylinder head and remove tensioning rail
5800-04V
downwards
Fig. 44
Fig. 45
Pull out the slide rail pins (3) from the AR01.30-P-
14
right cylinder head 5800-04V
Fig. 44
Fig. 45
Remove camshaft adjuster (2) of the right No removal of cylinder head AR05.20-P-
15
cylinder bank cover for a removed tensioning rail. 7201GZC
Fix balance weight (4) on the
crankcase using a pin or drift.
Remove balance weight (4) at the rear of Installation: The balance
16
the engine from the balance shaft (5) weight (4) has an anti-twist lock and
only fits onto the balance shaft (5) in
one position only.
*BA03.20-
P-1002-02A
Installation: At a 40° crank
Press the timing chain on the balance angle after ignition TDC the fitted pin
shaft (5) downward and pull balance (8) is aligned with marking (9) on the
17
shaft (5) forwards and out of the crankcase and the notch (6) on the front
crankcase correctional weight must be aligned with
marking (7).
moving by itself.
clothes.
19 Check for oil leaks with engine running
TORQUE CONVERTER
722.9
Straight threaded
connection Nm 42
Stage
Nm 4
1
BA27.20-P-1002- Bolt, torque converter to
01C drive plate Stage
Helical cut Nm 30
2
Stage
Angle° 90
3
BALANCE SHAFT
Stage 1 Nm 15
BA03.20-P-1002-02A Bolt, balancing weight to balancing shaft Stage 2 Angle° 90
Length mm -


Fig. 44: Identifying Impact Extractor (116 589 20 33 00)

Fig. 45: Identifying Threaded Stud (116 589 01 34 00)

REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000
Replace front crankshaft radial sealing ring - AR03.20-P-3000GZ
Symbolic representation
Fig. 46: Identifying Center Bolt, Poly-V-Belt, Vibration Damper And Front Crankshaft Radial Sealing
Ring Components
Remove/Install

the hydraulic hoist and position the
Risk of death cased by vehicle slipping AS00.00-Z-
four support plates below the hoist
manufacturer.
When moving components, ensure that
jammed or pinched when removing, AS00.00-Z-
no body parts or limbs are within the
installing or aligning hoods, doors, trunk 0011-01A
lid/rear-end door or sliding roof.
AR88.40-P-
1 Open engine hood
1000GZ
AR09.10-P-
1150GZ
AR20.40-P-
3 Remove fan shroud
5000GZ
Attach guard plate for radiator /
4
condenser
WF58.50-P-
Guard plate for radiator / condenser
0110-01A
AR13.22-P-
5 Remove poly V-belt (2)
1202GZ
AR03.30-P-
6 Remove belt pulley/vibration damper (3)
1600GZ
Do not damage crankshaft and
mounting hole for crankshaft radial
7 Remove the crankshaft radial seal (4) seal. Use a clean cloth as a base.
Use a screwdriver to press out
crankshaft radial sealing ring (4)
Installation: install crankshaft AR03.20-P-
radial sealing ring (4) with sleeve. 3000-01B
Sleeve Fig. 48
Vehicle must be horizontal and
Check engine oil level and correct if standing on its wheels. Measuring AR18.00-P-
9
required. errors can occur if this requirement is 3035-01GZ
not observed.
Risk of accident caused by vehicle Secure vehicle to prevent it from
starting off by itself when engine is moving.
AS00.00-Z-
running. Risk of injury caused by Wear closed and snug-fitting work
0005-01A
contusions and burns when working in clothes.
engine during starting procedure Do not grasp hot or rotating parts.
In the event of oil loss determine

and eliminate cause, otherwise

malfunctions, transmission damage,
and serious environmental pollution
Conduct engine test run and check the may occur.
10
engine for oil leaks Determine oil leakage after
spraying the cleaned and dried
surrounding area with MB contrast
spray.
*BR00.45-Z-
MB contrast spray
1001-03A
Stored faults which may be
caused by disconnecting cables or by
required
*WH58.30-
Z-1048-13A


Number Designation
REPAIR MATERIALS
BR00.45-Z-1001-03A Crack detector A 000 989 03 59
Install front crankshaft radial seal - AR03.20-P-3000-01B


1. Deburr edge of mounting bore for crankshaft radial sealing ring at timing case cover.
2. Push the crankshaft radial sealing ring onto the side (a) of the sleeve (2).
Circumference and sealing lip of crankshaft radial seal as well as the mating contact surface on
the vibration damper must be free of oil and grease.
Fig. 49: Identifying Crankshaft Radial Sealing Ring Onto Side

3. Align groove of sleeve (2) to the Woodruff key of the crankshaft.
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the
crankshaft.
4. Push sleeve (2) onto crankshaft and press in crankshaft radial sealing about 2 mm.
If necessary, knock in sleeve (2) with light blows from a hammer until it is possible to
insert the central bolt (3).
5. Draw in sleeve (2) with central bolt (3) as far as the stop.
6. Detach sleeve (2).
The crankshaft radial sealing ring must be positioned at right angles to the crank journal otherwise
proper sealing is not assured.
Shown on engine 112
Fig. 50: Identifying Crankshaft Sleeve & Central Bolt

Repair size 1 is identified by a 3 mm wide shoulder on the contact surface.
7. Turn sleeve (2) and push onto the crankshaft with side of repair size 1 (b).
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the
crankshaft.
8. Draw in sleeve (2) with central bolt (3) as far as the stop.
9. Detach sleeve (2).
Shown on engine 112
Fig. 51: Locating Crankshaft Seal

10. Check installation location of the crankshaft radial sealing ring (1) to the crankpin (4).
The crankshaft radial sealing ring (1)must be positioned at right angles to the crank journal (4)
otherwise proper sealing is not assured.
The installation depth (B) of the crankshaft radial sealing ring (1) is preset through the
sleeve (2) and must not be altered subsequently.
Shown on engine 112
Fig. 52: Identifying Crankshaft Radial Sealing Ring To Crankpin

Replace front crankshaft radial sealing ring - AR03.20-P-3000GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 53: Identifying Belt Pulley / Vibration Damper And Front Crankshaft Radial Sealing Ring
Components
Remove/install
Vehicles with Keyless

Go, code 889:
1 Turn key in ignition lock to position "0" Press Keyless Go start/stop button
repeatedly until ignition is
switched off.
AR13.20-P-
2 Remove poly-V belt
0001GZA
Install retaining lock for crankshaft/starter ring AR03.30-P-
3
gear 5000GZA
AR03.30-P-
4 Remove belt pulley/vibration damper
1600GZA
Do not damage crankshaft and
Press out crankshaft radial sealing ring (5) from mounting bore. Use a clean rag as
5
mounting bore with a screwdriver a base while pressing out;
otherwise there can be leakage.
Installation: Install front AR03.20-P-
crankshaft radial sealing ring (5). 3000-01B
Fig. 54
Checking
Check contact surface of crankshaft radial Check for scoring and
galling; if necessary:?
6 sealing ring (5) on hub of belt pulley/vibration
Replace belt pulley/vibration
damper (2)
damper (2)
8 Check engine oil level, correct if required.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting
0005-01A
procedure or when working near the engine as it work clothes.
is running Do not touch hot or rotating parts.
9
engine for leaks
Fig. 54: Identifying Insertion Tool (272 589 00 14 00)

Replace front crankshaft radial sealing ring - AR03.20-P-3000GZS
Fig. 55: Identifying Front Crankshaft Radial Sealing Ring Components

Remove/install
Align vehicle between the columns

of the lifting platform and position
the four support plates at the lifting
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Do not tilt front engine cover, but
4 Remove front engine cover lift upwards vertically otherwise the
AR20.40-P-
5 Remove electric fan
5000GZS
6 Attach guard plate for radiator/condenser
WF58.50-P-
Guard plate for radiator/condenser
0110-01A
AR13.22-P-
7 Remove poly-V-belt
1202GZS
AR03.30-P-
8 Remove belt pulley/vibration damper
1600GZS
Do not damage crankshaft
and mounting hole for crankshaft
radial seal. Use a clean cloth as a
9 Remove crankshaft radial sealing ring (4)
base.
Use a screwdriver to press
out crankshaft radial sealing ring (4)
Installation: Install AR03.20-P-
crankshaft radial sealing ring (4) 3000-01B
with sleeve.
Sleeve Fig. 48
standing on its wheels. Measuring
errors can occur if this requirement
Check engine oil level and correct if
11 is not observed.
required.
Insert dipstick fully in the
dipstick guide tube and leave for at
least 3 seconds.
AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
near the engine as it is running Do not touch hot or rotating parts.
Conduct engine test run and check the engine
12 malfunctions, transmission damage,
for oil leaks
may occur.
Determine oil leakage after
spraying the cleaned and dried *BR00.45-
surrounding area with MB contrast Z-1001-03A
spray.
MB contrast spray

REPAIR MATERIALS
BR00.45-Z-1001-03A Crack detector A 000 989 03 59
REPLACE REAR CRANKSHAFT RADIAL SEAL - AR03.20-P-3063
Replace rear crankshaft radial seal - AR03.20-P-3063GZ
Fig. 57: Identifying End Cover, Rear Crankshaft Radial Seal, Drive Plate, Flex Plate And Bolts
Remove/Install


Risk of death cased by vehicle slipping or AS00.00-Z-
manufacturer.
AR27.10-P-
1 Remove automatic transmission
0500GZ
AR03.30-P-
2 Remove drive plate (3)
8001GZ
The crankshaft radial sealing
ring (2) at the end cover (1) cannot be
exchanged. This end cover (1) is fitted
at the factory and therefore must be AR01.40-P-
3 Remove end cover (1)
replaced. 8913GZ
Crankshaft radial sealing ring
(2) must not be pushed out when the
end cover (1) is fitted.
Installation: First of all install
4 Remove crankshaft radial seal (2) the end cover (1), then install the
crankshaft radial sealing ring (2):?
AR03.20-P-
Install crankshaft radial seal
3063-01B
Installation tool Fig. 80
Check engine oil level and correct if standing on its wheels. Measuring AR18.00-P-
6
required. errors can occur if this requirement is 3035-01GZ
not observed.
off by itself when engine is running. Risk moving.
AS00.00-Z-
0005-01A
when working in engine during starting clothes.
procedure Do not grasp hot or rotating parts.
Conduct engine test run and check the
engine for oil leaks
may occur.
Fig. 58: Identifying Installation Tool (111 589 08 43 00)

Installing rear crankshaft radial seal - AR03.20-P-3063-01B

1. Deburr edge of mounting hole around entire circumference for rear crankshaft radial sealing ring (4) and
clean mounting hole (arrow).
2. Fit internal component (1) of installation tool to crankshaft.
Fig. 60: Locating Crankshaft Radial Sealing Ring

3. Carefully push rear crankshaft radial sealing ring (4) over the internal component (1) of the
installation tool and the crankshaft journal.
Ensure that the sealing lip (6) of the rear crankshaft radial sealing ring (4) is not damaged or
compressed.
Circumference (5) and sealing lip (6) of the rear crankshaft radial sealing ring (4) as well as the mating
contact surface on the crankshaft must be free of oil and grease.
Fig. 61: Identifying Rear Crankshaft Radial Sealing Ring

4. Position the outer part (2) of the mounting tool.
Use outer part (2) with chamfer.
5. Screw in bolt (3) until a resistance is felt.

6. Detach the mounting tool.
Fig. 62: Identifying Crankshaft Radial Seal Mounting Tool

7. Check installation location of the crankshaft rear radial sealing ring (4).
The rear crankshaft radial sealing ring (4) must be positioned at right angles to the crankshaft (7)
otherwise proper sealing is not assured.
The clearance between the edge of the end cover (8) and the rear crankshaft radial sealing ring
(4) must be approx. 1 mm (dimension a) around the entire circumference.
Fig. 63: Identifying Crankshaft Rear Radial Sealing Ring

Replace rear crankshaft radial sealing ring - AR03.20-P-3063GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 64: Identifying End Cover, Rear Crankshaft Radial Seal And Bolts
Remove/install

slipping or toppling off the lifting
platform.
AH00.00-N-
0001-01A
Vehicles with Keyless Go, code
889:
repeatedly until ignition is switched off.
1 Remove key from the ignition lock
Remove the Keyless Go transmitter card
or transmitter key from vehicle and store
beyond reach of the transmitter (at least 2
m).
Remove automatic transmission AR27.10-P-
2 Model 164
together with torque converter 0500GZA
AR27.10-P-
Model 251
0500RTA
AR03.30-P-
3 Remove driven plate
8001GZA
Clean
Clean crankcase and oil pan in area of *BR00.45-
4 LU cleaner
end cover (4) Z-1028-04A
5 Unscrew bolts (4a, 4b)
Do not hit tool for prying off between
end cover (4) and crankcase; the sealing
Pry off end cover (4) with crankshaft surface will be damaged.
6
radial sealing ring (5) from crankcase Fit tool for prying off onto side
recess clearances of end cover (4). If
required heat up sealant with hot air gun.
Installation: Always follow
instructions in the notes on application of
sealant and on correct installation position
7 Remove end cover (4) of the crankshaft radial sealing ring (5) lip;
otherwise there can be leaks that can
damage the engine and the environment:?
Install rear crankshaft radial seal (5)
AR03.20-P-
Engine 272
3063-01VA
AR03.20-P-
Engine 273
3063-01SX
*BA01.40-
Engine 272 P-1004-01G
*BA01.40-
Engine 273 P-1003-01T
Fig. 66
Carry out an engine test run and check
9
the engine for leaks
AR00.19-P-
10 Perform basic programming Model 164
0200GZ
AR00.19-P-
Model 251
0200RT
CRANKCASE, TIMING CASE COVER, END COVER

BA01.40-P-1004-01G Bolt, end cover to crankcase or oil pan Nm 8

BA01.40-P-1003-01T Bolt, end cover to crankcase or oil pan Nm 9

REPAIR MATERIALS

cReinhold-Wurth-Str. 12-17
BR00.45-Z-1028-04A LU cleaner
Germany
Tel. +49-7940-15-0
Fax +49-7940-15-1000
www.wuerth.de
Installing rear crankshaft radial seal - AR03.20-P-3063-01SX

BA01.40-P-1003-01T Bolt, end cover to Nm 9
crankcase or oil pan

REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
81925 Munchen
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
The crankshaft radial sealing ring (1) is vulcanized into the end cover (2) and can only, therefore, be
replaced together with the end cover (2). Do not reuse the end cover (2) with the rear crankshaft radial sealing
ring (1) after removal.
The crankshaft radial sealing ring (1) has a protective lip (1s) in addition to the sealing lip (1d). The sealing lip
(1d), protective lip (1s) and contact surface (3a) at the crankshaft flange (3) must not be lubricated for
assembly!
Fig. 67: Identifying Crankshaft Flange, Contact Surface, Sealing Ring, Protective And Sealing Lip
1. Clean and degrease crankcase (4) and oil pan in the area of the applied sealant as well as contact
surface (3a) on the crankshaft flange (3).
The contact surface (3a) must not be cleaned using abrasive paper since this would damage the surface
of the crankshaft.
2. Clean and degrease sealing surface on new end cover (2).

3. Apply sealant in the form of a bead (A) with a height and width of 2.0 mm (±.5) mm to crankcase (4)and
oil pan.
Only use approved sealants. Do not spread bead (A). Mount end cover (2) with 5 minutes of
applying sealant.
Fig. 68: Identifying Applying Sealant Area On Crankcase

4. Mount end cover (2)with crankshaft radial sealing ring (1)on insertion tool (6).
Make sure that the protective lip (1s) faces towards the side applying the force and the sealing lip (1d)
faces in the direction of the crankcase. Leakage could occur otherwise at rear crankshaft radial sealing
ring (1).
The crankshaft radial sealing ring (1) can only be mounted on the insertion tool (6), if
insertion tool (6) is fitted together with insertion tool (7).
Fig. 69: Identifying Lip On Crankshaft Radial Sealing Ring And Insertion Tool
5. Separate insertion tool (7) from insertion tool (6).

6. Mount end cover (2)with crankshaft radial shaft sealing ring (1) and insertion tool (6) onto contact
surface (3a) on crankshaft flange (3).
Fig. 70: Identifying End Cover, Crankshaft Flange And Insertion Tool
Fig. 71: Identifying Crankshaft Radial Seal, Protective Lip, End Cover, Crankshaft Flange And
Crankcase
7. Tighten bolts (2a) gradually in crosswise pattern, then tighten the bolts (2b). Pay attention to tightening
torque.
8. Detach insertion tool (6)from crankshaft flange (3).

9. Carefully lift protective lip (1s) and check the correct installation position of sealing lip (1d).
A wrong installation position leads to leakage.
The sealing lip (1d) must point towards crankcase (4)all around its circumference.
10. Check the correct installation position of the protective lip (1s).
An incorrect installation position leads to premature wear of the crankshaft radial shaft sealing ring
(1).
The protective lip (1s) must point towards transmission housing around its entire circumference.
Install rear crankshaft radial sealing ring - AR03.20-P-3063-01VA

BA01.40-P-1004-01G Bolt for end cover on Nm 8
crankcase or oil pan

REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
The crankshaft radial sealing ring (1) is vulcanized in the end cover (2) and it can therefore only be
replaced together with the end cover (2). Do not reuse the end cover (2) with the crankshaft radial sealing ring
(1) after removal.
The crankshaft radial sealing ring (1) has both a lip (1d) and a protective lip (1s). The lip (1d), protective lip
(1s) and contact surface (3a) on the crankshaft flange (3) must not be lubricated for assembly purposes!
Fig. 73: Identifying Crankshaft Radial Sealing Ring, End Cover And Crankshaft Flange
1. Clean and degrease crankcase (4) and oil pan in the area of application of the sealing compound
as well as the contact surface (3a) on the crankshaft flange (3).
2. Clean and degrease the sealing surface on the new end cover (2).
3. Apply sealing compound in the form of a bead (A) with a height and width of 2.0 mm (± 0.5) mm on the
crankcase (4) and oil pan.
Use exclusively approved sealing compounds. Do not spread bead (A). Mount end cover (2)
within 5 minutes after applying the sealing compound.
Fig. 74: Identifying Sealing Bead

4. Mount end cover (2) with crankshaft radial sealing ring (1) on insertion tool (6).
Ensure that the protective lip (1s) points in the direction of the power takeoff side and the lip (1d)
points away from the power takeoff side. Leaks may otherwise at the crankshaft radial sealing ring (1).
The rear crankshaft radial sealing ring (1) can only be mounted on the insertion tool (6) if
the insertion tool (6) is fitted together with the insertion tool (7).
Fig. 75: Identifying Lip On Crankshaft Radial Sealing Ring And Insertion Tool
5. Separate insertion tool (7) from insertion tool (6).

6. Mount the end cover (2) with the crankshaft radial shaft sealing ring (1) and insertion tool (6) on
the contact surface (3a) on the crankshaft flange (3).
The contact surface (3a) must not be removed with an emery cloth, as this can destroy the surface of
the crankshaft and render the crankshaft unusable.
Fig. 76: Identifying End Cover, Crankshaft Flange And Insertion Tool
Fig. 77: Identifying Crankshaft Radial Shaft Sealing Ring Components

7. Tighten bolts (2a) stepwise diagonally and then tighten bolts (2b). Observe the tightening torque.
8. Detach the insertion tool (6) from the crankshaft flange (3).
9. Lift protective lip (1s) carefully and check for correct installation position of the lip (1d).
The lip (1d) must point over it whole extent towards the crankcase (4).
10. Check for correct installation position of the protective lip (1s).
An incorrect installation position leads to premature wear of the crankshaft radial sealing ring (1).
The protective lip (1s) must point over it whole extent towards the crankcase.
Replace rear crankshaft radial seal - AR03.20-P-3063GZS
Fig. 78: Identifying Rear Crankshaft Radial Seal, Drive Plate, Crankshaft And Bolts Location
Remove/install

toppling off the lifting platform. 0010-01A
manufacturer.
AH00.00-N-
0001-01A
1 Raise vehicle with lifting platform Model 164 AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR27.10-P-
2 Remove automatic transmission
0500GZS
Clean and degrease
Install retaining lock for crankshaft/starter sealing surfaces on crankshaft AR03.30-P-
3
ring gear radial sealing ring (1) and 5000GZS
mounting hole.
AR03.30-P-
4 Remove bolts (4) from drive plate (2)
8001GZS
*BA03.30-P-
1002-01Q
Do not damage sealing
Remove crankshaft radial sealing ring (1)
5 surfaces on crankshaft radial
using a suitable tool.
sealing ring (1) and crankshaft (3).
AR03.20-P-
Install rear crankshaft radial
3063-
sealing ring
01AMG
Installation tool Fig. 80
AS00.00-Z-
0005-01A
engine as it is running Do not touch hot or rotating parts.
7
for leaks
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR

Stage 1 Nm 20
BA03.30-P-1002-01Q Bolt, starter ring gear/drive plate to crankshaft Stage 2 Nm 45
Stage 3 Angle° 90

Installing rear crankshaft radial seal - AR03.20-P-3063-01AMG
Engine 156

Fig. 81: Identifying Shim, Bore Holes And Installation Tool

Fig. 82: Identifying Template Bore Holes

Fig. 83: Identifying Bore And Template Bore Hole

1. For an installation tool (111) without bore (111B):
Place shim (3s) as a template and align bore holes (3sS) to bore holes (111S) to have one above the other.
Select template bore hole (3B) and center-punch bore (111B), remove shim (3s).
Fix to bore (111B) with the diameter of the template bore hole (3B).
Fig. 84: Identifying Crankshaft Radial Seal, Press-In Bushing Screw, Crankshaft Flange And
Press-In Sleeve
4. Check edge for mounting hole on engine for ridging; deburr if necessary.
5. Lightly wet sealing lip and outer flank of crankshaft radial sealing ring (1) with oil.
6. Carefully push crankshaft radial sealing ring (1) onto crankshaft flange (3) contact surface and push
lightly into mounting hole.
Check for correct installation position of crankshaft radial sealing ring (1) in the process.
The sealing lip must point over the whole circumference to the engine.
7. Screw guide sleeve 03 (111F) for installation tool onto crankshaft flange (3).
8. Place press-in bushing (111)of installation tool onto crankshaft radial sealing ring (1) and screw
onto guide sleeve 03 (111F).
9. Press in crankshaft radial sealing ring (1) by turning press-in bushing screw (2) in mounting hole.
10. Loosen press-in bushing screw (2).
The protrusion of the edge of the mounting hole to crankshaft radial sealing ring (1) must be about 1
mm.
11. If the protrusion of the edge of the mounting hole to crankshaft radial sealing ring (1) is less than 1 mm:
proceed with pressing in procedure.
12. Detach the mounting tool.
DETERMINE CRANKSHAFT BEARING AXIAL PLAY - AR03.20-P-4291
Determine crankshaft bearing axial play - AR03.20-P-4291-03SX

BE03.20-P-1001- Main bearing play radial when new mm 0.022...0.046
04E axial when new mm 0.100...0.266
Fig. 85: Identifying Dial Indicator (001 589 32 21 00)

Fig. 86: Identifying Extension (366 589 00 21 05)

Fig. 87: Identifying Dial Indicator Holder (136 589 04 21 00)

Only the one washer disc thickness is used.
1. Install dial indicator (2) with dial indicator holder (1)

2. Press crankshaft with a screwdriver on one side up to support (arrow) and hold.
3. Set scale of dial gage (2) to zero.
4. Press crankshaft with a screwdriver on the other side up to support (arrow) and hold.
5. Read off measurement value at dial indicator (2).
The measured value corresponds to the axial play of the crankshaft.
Fig. 88: Identifying Dial Indicator With Extension And Dial Indicator Holder
Determine crankshaft bearing axial play - AR03.20-P-4291-03VA

Fig. 89: Identifying Dial Gauge (001 589 32 21 00)

Fig. 90: Identifying Extension (366 589 00 21 05)


Only a washer disc width is used.
1. Attach dial gage (2) with dial indicator holder (1).

2. Press the crankshaft by means of a screwdriver on one side up to the final position (arrow) and hold.

4. Press the crankshaft by means of a screwdriver on the other side up to the final position (arrow) and hold.
5. Read off measurement from the dial gage (2).
The read off measurement represents the crankshaft end play.
Fig. 92: Measuring End Play Of Crankshaft

Determine crankshaft bearing axial play - AR03.20-P-4291-03VT
TEST VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine Engine 112 except 112.951/976,
113.987/988/989/ Engines 113.940/941/ 942/943/944/
990/991/993 948/960/961/ 963/964/965/ 966/967/968/
971/980/981/ 984/986
radial
when mm 0.026...0.050 0.026...0.050
BE03.20-P- Main bearing new
1001-04E play axial
when mm 0.10...0.266 0.10...0.266
new
Connecting radial
BE03.20-P-
rod bearing when mm 0.022...0.067 0.022...0.067
1002-04E
play new


The thrust plates are assigned to the fitted bearing cap using the numbers 1 and 0 (arrow). These are
engraved on the journal of the crankshaft.
The fitted thrust plates must have the same identification and the oil grooves of the thrust plates must point to
the crankshaft journals.
Fig. 95: Locating Bearing Cap Number On Crankshaft Journal

Assignment of thrust washers to crankshaft M 112, 113

Crankcase Basic journal of the fitted Thrust washers Axial play
bearing of the crankshaft Crankshaft (mm)
Inscription Designation Marking
No Abbreviated
N 0 N 0.10 - 0.266
subdivision reference number
No Abbreviated
N1 1 N1 0.10 - 0.266
1. Install dial indicator (2) with extension and dial indicator holder (1).
2. Press crankshaft with a screwdriver on one side up to support (arrow) and hold.

4. Press crankshaft with a screwdriver on the other side up to support (arrow) and hold.
5. Read off the measured value on the dial indicator (2).
The measured value corresponds to the axial play of the crankshaft.
Fig. 96: Measuring Axial Play Of Crankshaft

INSTALL / GAUGE THE CRANKSHAFT BEARINGS - AR03.20-P-4341
Install / gauge the crankshaft bearings - AR03.20-P-4341-01VT

Number Designation Engine 112 except 112.951/976, Engines
113.940/941/942/943/944/948/960/961/963/964/965/966/967/968/971/980/981/984
radial
when mm 0.026 to 0.050
BE03.20- Main new
P-1001- bearing
04E play axial
when mm 0.10 to 0
new

Stage 1 Nm 20
BA03.20-P-1001-01D Crankshaft bearing cap bolt M8
Stage 2 Angle° 90
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Nm 30
Stage 1 Nm 5
BA03.20-P-1003-01D Crankshaft bearing cap bolt M10 Stage 2 Nm 30
Stage 3 °Angle 90
1. Blow through oil galleries in direction of flow oil with compressed air.
2. Clean the bearing points in the crankcase, main bearing cap and main bearing journal of crankshaft with a
chamois leather.
If a bearing damage has occurred, it may be necessary to remove any swarf from the connecting
rod bores, oil ducts, the crankshaft and crankcase casings as well as the crankcase! Do not use any hard
The top bearing shell halves are assigned to the basic journal of the crankshaft by means of a
colored ring on the rear of the upper bearing shell half and numbers (arrows) or center punch marks,
which are stamped into the crankcase.
Fig. 97: Locating Upper Bearing Shell On Crankcase

Only assigned color and numerical combinations (see table) may be fitted together.
Assignment of crankshaft bearing shell top halves (crankcase) M 112, 113

Diameter Main bearing bore Number or chisel Color coding for Order Main bearing
in crankcase punches bearing shell index play (mm)
68.500-68.506 1 blue 52 0.030-0.052
68.506-68.513 2 yellow 54 0.030-0.052
68.513-68.519 3 red 56 0.030-0.052
Assignment of crankshaft bearing shell bottom halves (bearing cap) M 112, 113
Diameter Main Laser inscription AM Color coding for Order Main bearing
bearing journal Crankshaft journal Front bearing shell index play (mm)
63.940-63.945 V purple 58 0.030-0.052
63.945-63.950 W white 57 0.030-0.052
63.950-63.955 R red 56 0.030-0.052
63.955-63.960 G yellow 54 0.030-0.052
63.960-63.965 b blue 52 0.030-0.052
The bottom halves of the bearing shells are assigned to the basic journal of the crankshaft by
means of the first letter of the respective color.
The color coding of the bottom halves of the bearing shells is located at the rear of the lower
bearing shell halves.
The initial letters of the particular colors are engraved on the journal of the crankshaft.
When installing the bearing shell halves, the order of the colors engraved on the journal of the
crankshaft must be maintained.
Fig. 98: Locating Bearing Shell Halves

Arrow identifies direction of travel.
 First letter "r": A bearing cap with the color coding red must be inserted in bearing cap "1".
 Second letter "b": A bearing cap with the color coding blue must be inserted in bearing cap "2".
 Third letter "v": A bearing cap with the color coding violet must be inserted in bearing cap "3".
 Fourth letter "w": A bearing cap with the color coding white must be inserted in bearing cap "4".
Fig. 99: Identifying Bearing Cap Direction Of Travel

3. Insert the bearing shell top halves (1) with oil drillings (2) and oil grooves (3) into the crankcase.
When doing this, ensure that the anti-twist locks (4) of the bearing shell halves (1) are located in
the recesses of the crankcase.
4. Insert the bearing shell bottom halves (7) into the bearing caps (6).
When doing this, ensure that the anti-twist locks (5) of the bottom bearing shell halves (7) are
located in the recesses of the bearing caps (6).
Fig. 100: Inserting Bearing Shell Top Halves With Oil Drillings And Oil Grooves Into Crankcase
5. The thrust plates are assigned to the bearing caps (6) using the numbers "1" and "0" (see table). These are
engraved on the journal of the crankshaft (arrowed).
The thrust washers installed must have the same designation.
Fig. 101: Locating Thrust Washers

Assignment of thrust washers to crankshaft M 112, 113

Crankcase Basic journal of the fitted Thrust washers Axial play

bearing of the crankshaft Crankshaft (mm)
Inscription Designation Marking
No Abbreviated
N 0 N 0,10-0,266
No Abbreviated
N1 1 N1 0.10-0.266
6. Insert crankshaft (15) into crankcase

7. Install top thrust washers (8).
The oil grooves (9) of the thrust plates (8) must point toward the crank webs (10).
Fig. 102: Installing Thrust Washers

8. Install bearing caps (6) according to their markings.
Installation: When installing the fit bearing cap (13), hold both thrust plates (8) tight. The anti-
twist locks (11) of the thrust plates (8) must be located in the slots (12) of the fit bearing cap (13). The oil
grooves (9) of the thrust plates (8) must point toward the crank webs (10).
Fig. 103: Installing Bearing Caps According To Their Markings

9. Moisten the thread and head contact surface of the bolts of the bearing caps with oil.
10. Tighten the bolts of the bearing caps as specified in the tightening pattern.
Note tightening torque and tightening angle of bearing cap bolts. If no torquing angle wrench is
available, the bearing cap bolts can be torqued further by the specified angle in a single operation using a
wrench and locking handle. Do not use a flexi-rod torque wrench for tightening in order to avoid any
angle errors.
11. Turn crankshaft to check for unobstructed movement.
Fig. 104: Identifying Bearing Cap Bolts Tightening Sequence

Install / gauge the crankshaft bearings - AR03.20-P-4341-01VTA

Number Designation Engine Engine 112 except 112.951/976, Engines
113.987/988/989/ 113.940/941/ 942/943/944/ 948/960/961/
990/991/993 963/964/965/ 966/967/968/ 971/980/981/
984/986
radial
when mm 0.026 to 0.050 0.026 to 0.050
Main new
BE03.20-P-
bearing
1001-04E axial
play
when mm 0.10 to 0.266 0.10 to 0.266
new

Stage 1 Nm 20
Stage 2 Angle° 90
Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 Angle° 90
1. Blow through oil galleries in direction of flow oil with compressed air.
2. Clean the bearing points in the crankcase, main bearing cap and main bearing journal of crankshaft with a
chamois leather.
rod bores, oil ducts, the crankshaft and crankcase casings as well as the crankcase! Do not use any hard
3. Insert the bearing shell top halves (1) with oil drillings (2) and oil grooves (3) into the crankcase.
When doing this, ensure that the anti-twist locks (4) of the bearing shell halves (1) are located in
Fig. 105: Inserting Bearing Shell Top Halves With Oil Drillings And Oil Grooves Into Crankcase
4. Insert the bearing shell bottom halves (7) into the bearing caps (6).
5. Mount bearing cap (6), tighten without rotation angle for measuring procedure .
located in the recesses of the bearing caps (6).
6. Measure and note the bearing diameter (actual dimension) at all four crankshaft bearings.
Subtract the radial bearing clearance of the individually measured bearing diameters from this.
7. Grind all four crankshaft bearing points to the calculated bearing diameter.
Note the assignment of the determined bearing diameters to the crankshaft bearing points.
8. Remove bearing cap (6) again.

9. Insert crankshaft into crankcase.
10. Measure the axial play of the crankshaft and examine the crankshaft contact point for wear.
Fig. 106: Installing Thrust Washers

Maintain the axial play of the crankshaft when the crankshaft is ground to repair size. If it is
necessary to grind the crankshaft at the contact point of the axial bearing (bearing point 3), to order thrust
washer parts kit repair size 1 and to measure the axial play of the crankshaft without thrust washer.
Add the axial bearing play to the thickness measured for the repair size thrust plate and subtract the
measured axial play without the repair thrust plate to obtain the dimension by which the crankshafts must
be ground at the contact point of the axial bearing (bearing point 3).
Fig. 107: Measuring Axial Play Of Crankshaft Without Thrust Washer

11. Remove crankshaft.

12. Grind the crankshaft at the contact point to the calculated dimension.
13. Insert crankshaft ground to repair dimension into crankcase.
14. Install the top repair thrust washers (8).
The oil grooves on the repair thrust washers (8) must point towards crank webs (10).
15. Install bearing caps (6) according to their markings.
When installing the fit bearing cap, hold both repair thrust plates (8) tight. The anti-twist locks
(11) of the repair thrust plates (8) must be located in the slots (12) of the fit bearing cap.
The oil grooves (9) of the thrust plates (8) must point toward the crank webs (10).
16. Moisten the thread and head contact surface of the bearing caps (6) bolts with oil.
17. Tighten bolts for the bearing caps (6) as specified in the tightening pattern .
Note specified torque and tightening angle of the bolts. If no torquing angle wrench is available,
the bolts can be torqued further by the specified angle in a single operation using a wrench and locking
handle. Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
18. Turn crankshaft to check for unobstructed movement.
Fig. 108: Identifying Bearing Caps Bolts Tightening Sequence

REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351
Remove/install crankshaft - AR03.20-P-4351AMG
ENGINE 156.980 /982 /983 /984

Fig. 109: Identifying Crankshaft Components

Fig. 110: Identifying Crankshaft Bottom Section And Bolts

Remove/install

Risk of poisoning caused release pressure. Do not
by swallowing coolant. pour coolant into
safety glasses.
by fuel igniting, risk of flames or smoking.
poisoning caused by Pour fuels only into
inhaling and swallowing suitable and appropriately
fuel and risk of injury to marked containers.
eyes and skin caused by Wear protective clothing
contact with fuel when handling fuel.
Notes on self-locking nuts All models AH00.00-N-0001-01A
and bolts
1.1 Remove engine with front Engine 156.980 in model AR01.10-P-2500GZS
1.2 Remove engine Engine 156.982 in model AR01.10-P-2400QMG
209
211, 219
216, 221
2 Detach engine from front Engine 156.980 in model AR01.10-P-2510GZS
3 Remove automatic
transmission from the
engine
4 Remove oil lines from
automatic transmission at
oil pan
5 Mount engine onto
assembly stand
6 Remove spark plugs Only if it is not
possible to crank engine
due to high compression.
Model 164, 251 AR15.12-P-1010GZS
Model 209, 211, 219 AR15.12-P-1010TMG
Model 216, 221 AR15.12-P-1010SMG
7 Turn engine at crankshaft Rotate engine at AR05.20-P-6010-
(5) in direction of engine crankshaft (5) in running 01AMG
rotation to a 40° crank direction until the 40°
angle after ignition TDC marking on pulley/
and check position of vibration damper

camshafts corresponds with marking
on timing case.
8 Remove timing case Do not damage AR01.40-P-8000AMG
cover cylinder head gaskets.
9 Remove flywheel/drive Model 164, 251 AR03.30-P-8001GZS
plate
Model 209, 211, 219 AR03.30-P-8001TMG
Model 216, 221 AR03.30-P-8001SMG
10 Remove oil pump Model 164, 251 AR18.10-P-6020GZS
Model 209, 211, 219 AR18.10-P-6020TMG
Model 216, 221 AR18.10-P-6020SMG
11 Remove oil pump chain
(6)
12 Remove vacuum reservoir
(7) at crankcase top
section (11)
13 Dismount both engine
supports (12)
14 Loosen bolts (14, 15) Installation:
from crankcase bottom Lubricate bearing shells
section (13) in reverse and check for
order of tightening unobstructed movement
procedure of crankshaft (5) by
turning.
Tightening procedure for AR03.20-P-4351-
crankcase bottom section 05AMG
*BA03.20-P-1001-01J
*BA03.20-P-1002-01J
15 Place match marks for The connecting
connecting rod (1) and rods have been cracked
connecting rod bearing during manufacture
cap (2) (arrow) (broken). The connecting
rod bearing caps (2) are
not interchangeable and
must not be installed in
the wrong direction.
16 Remove connecting rod Removal: Mark
bearing cap (2) connecting rod bearing
cap (2) and lower
shells (3) relative to each
other. Mark connecting
rod (1) and upper

shells (4) relative to each
other. While rotating the
crankshaft (5) ensure that
connecting rods (1) do not
tilt.
Installation:
Lubricate bearing shells
and check for
of crankshaft (5) by
turning. See: ?
Tighten connecting rod AR03.10-P-6111-02VA
screws
Connecting rod bolts *BE03.10-P-1001-03A
*BA03.10-P-1001-01Q
17 Remove rear crankshaft The installation AR03.20-P-3063-
radial sealing ring takes place before 01AMG
mounting the
flywheel/drive plate.
18 Take crankshaft (5) out of Removal: Take
crankcase top section (11) upper crankshaft bearing
shells (8) and thrust plates
(9) out of crankcase top
section (11). Mark thrust
plates (9) relative to
crankshaft fitted bearing.
Note bearing clearance.
Installation:
Check upper crankshaft
bearing shells (8) and
bottom crankshaft bearing
shell (10) for wear.
Main bearing play *BE03.20-P-1001-04E
Connecting rod bearing *BE03.20-P-1002-04E
play
20 Perform basic Model 216, 221
programming
Model 164 AR00.19-P-0200GZ
Model 209 AR00.19-P-0200Q
Model 211 AR00.19-P-0200T
Model 219 AR00.19-P-0200TX
Model 251 AR00.19-P-0200RT

procedure or when
as it is running
21 Conduct engine test run
and check engine for
leaks

BE03.20-P-1001- Main bearing play radial when new mm 0.024 to 0.044
04E axial when new mm 0.10 to 0.266
BE03.20-P-1002- Connecting rod radial when new mm 0.022 to 0.062
04E bearing play

BE03.10-P- Connecting rod Thread Ø M 9x1
1001-03A bolts Shank length when new mm 40
max. mm 42.8
Part no. -

bearing threaded
Stage 4 Angle° 5
connection)
5th stage Angle° 90
Stage 6 Angle° 5
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 5
Stage 5 Angle° 90
Stage 6 Angle° 5
BA03.20-P- Crankcase lower M6 Nm 8.5
1002-01J section to
crankcase upper M8 Nm 20
section
CONNECTING ROD
01Q bearing cap to Stage 2 Angle° 90
Tightening pattern for crankcase bottom section - AR03.20-P-4351-05AMG

bearing threaded
Stage 4 Angle° 5
connection)
Stage 5 Angle° 90
Stage 6 Angle° 5
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 5
Stage 5 Angle° 90
Stage 6 Angle° 5
1. Lubricate bolts for bearing cap at thread and bolt head contact surfaces.
2. Tighten bolts for bearing cap in the specified sequence.
If no torquing angle wrench is available for the final tightening, the bearing cap bolts can be
torqued further by the specified angle in a single operation using a wrench and locking handle. Do not use
a flexi-rod torque wrench for tightening in order to avoid any angle errors.
Tightening pattern for lower crankcase section

Fig. 111: Tightening Sequence Of Bearing Cap Bolts

Remove/install crankshaft - AR03.20-P-4351GZ
Fig. 112: Identifying Crankshaft Components

Removing
AH00.00-N-
0001-01A
External Torx set Fig. 6
the operating range of moving parts.
1
position 1000GZ
gas. Risk of poisoning and caustic burns smoking.
caused by swallowing battery acid. Risk of Wear acid-resistant gloves, clothing AS54.10-Z-
injury caused by burns to skin and eyes and goggles. Only pour battery acid 0001-01A
from battery acid or when handling into suitable and appropriately marked
damaged lead-acid batteries containers.
Insulate clamping device of the
ground line in order to prevent AR54.10-P-
2 Disconnect ground cable from battery
inadvertent contact with the ground 0003GZ
point of the battery.
AH54.10-P-
0001-01A
the and position the four support
plates below the lifting platform
manufacturer.
AR00.60-P-
1000GZ
AR61.20-P-
4 Remove engine compartment paneling
1105GZ
AR01.10-P-
5 Remove engine
2400GZ
Remove automatic transmission from the AR27.10-P-
6
engine 0500GZ
AR01.45-P-
7 Remove oil pan bottom section
7555GZ
AR01.45-P-
8 Dismount oil pan
7500GZ
9 Remove oil pump For this step, push back chain AR18.10-P-
tensioner and take off chain. 6020GZ
AR03.30-P-
10 Remove belt pulley / vibration damper
1600GZ
11 Remove driven plate AR03.30-P-
8001GZ
AR01.40-P-
12 Dismount end cover from the crankcase
8913GZ
AR01.40-P-
13 Remove timing case cover
8000GZ
While turning the crankshaft,
ensure that the connecting rods (11)
do not get jammed.
14 Remove connecting rod bearing cap (16) For this step, mark
connecting rod (11) and connecting
rod bearing cap on one side relative to
each other.
Follow release schematic,
see: ? AR03.20-P-
15 Take off crankshaft bearing caps (4, 10)
Tightening diagram of crankshaft 4351-02BV
bearing caps
Mark crankshaft bearing cap
Carefully pry out the crankshaft bearing and fitted bearing before removal.
16
caps (4, 10) and the fitted bearing (5). Lever out crankshaft bearing cap and
fitted bearing carefully.
17 Take crankshaft (1) out of the crankcase
Take crankshaft bearing shells (2) and
18
thrust washers (6) out of the crankcase
Installing
Oil the crankshaft journals
19 Insert crankshaft (1)
and crankshaft bearing shells.
AR03.20-P-
If a new crankshaft is being installed
4341-01VT
AR03.20-P-
If crankshaft is being repaired 4341-
01VTA
*BE03.20-
Main bearing play
P-1001-04E
The crankshaft bearing cap bolts
20 Take off crankshaft bearing caps (4, 10) must always be replaced otherwise
there is a risk of cranks and fracture.
Tighten all bolts according to AR03.20-P-
the tightening diagram. 4351-02BV
*BA03.20-
P-1001-01D
*BA03.20-
P-1002-01D
*BA03.20-
P-1003-01D
Torque wrench Fig. 116

If a new crankshaft is being AR03.20-P-
21.1 Check axial play of crankshaft
installed 4291-03VT
*BE03.20-
Main bearing play
P-1001-04E
*BE03.20-
P-1002-04E
Dial indicator holder Fig. 94
Dial indicator Fig. 85
AR03.10-P-
22 Inspect the connecting rod bolts (12) Test data: ?
6111-01VT
*BE03.10-
Connecting rod bolts
P-1001-03A
The connecting rod bearing shell
(13) with the oil drilling (arrow) must
be installed in the connecting rod (11)
otherwise the piston pins will not be
greased.
The anti-twist lock (14) on the
connecting rod bearing shell (13) must
Install the connecting rod bearings and fit be located in the grooves (15) of the AR03.10-P-
23
the connecting rod bearing cap (16) connecting rods (11) and of the 6111-06VT
connecting rod bearing cap (16).
The connecting rod (11) and
connecting rod bearing cap (16) are
cracked (broken) (see zoomed
section). They must not be installed on
the wrong side as the accuracy of fit
would no longer be given.
*BE03.20-
P-1002-04E
AR03.10-P-
24 Tighten connecting rod bolts (12)
6111-02VT
*BA03.10-
P-1001-01E
Turn crankshaft (1) to check for
25
unobstructed movement.
Replace radial sealing ring.
The sealing lip of the radial sealing AR01.40-P-
26 Fit bolt for end cover to crankcase
ring and its mating surface must not 8913GZ
be oiled or greased.
27 Install driven plate AR03.30-P-
8001GZ
Replace O-rings and radial AR01.40-P-
28 Install timing case cover
sealing ring. 8000GZ
AR03.30-P-
29 Install belt pulley/vibration damper
1600GZ
Ensure oil return flow check AR18.10-P-
30 Install oil pump
valve is correctly located. 6020GZ
AR01.45-P-
31 Fit oil pan
7500GZ
AR01.45-P-
32 Fit oil pan bottom section
7555GZ
AR05.10-P-
33 Check engine valve timing
6858GZ
AR27.10-P-
34 Mount automatic transmission on engine
0500GZ
AR01.10-P-
35 Install engine
2400GZ
AS00.00-Z-
0005-01A
Conduct engine test run and check the and eliminate cause, otherwise
engine for leaks whilst it is running
may occur.

Number Designation Engine 112 except 112.951/976, Engine
113.94/96/971/980/981/982/984/986
Thread
M 8X1
dia. Ø
BE03.10-P- Connecting When
mm 47
1001-03A rod bolts Shank new
length max. mm 47.6
Part no. -

Number Designation Engine 112 except 112.951/976, Engines 113.940/941/
942/943/944/ 948/960/961/ 963/964/965/ 966/967/968/
971/980/981/ 984/986
radial mm 0.026 to 0.050
when
new
BE03.20-P- Main bearing axial
1001-04E play when mm 0.10 to 0.266
new
radial
BE03.20-P- Connecting rod
when mm 0.022 to 0.067
1002-04E bearing play
new
CONNECTING ROD
Stage 1 Nm 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 25
Stage 3 Angle° 90

Stage 1 Nm 20
Stage 2 Angle° 90
Stage 1 Nm 5
BA03.20-P-1003-01D Crankshaft bearing cap bolt M10 Stage 2 Nm 30
Stage 3 °Angle 90



Fig. 116: Identifying Torque Wrench (001 589 72 21 00)

Tightening diagram of crankshaft bearing caps - AR03.20-P-4351-02BV
MODIFICATION NOTES
26.3.04 BA basic data removed
Tightening diagram
Tighten bolts of crankshaft bearing caps (1 to 26) in the order of the tightening diagram (1 to 26)
To loosen the bolts (1 to 26), proceed in the reverse sequence.

Fig. 117: Identifying Crankshaft Bearing Caps Bolts Tightening Sequence

Remove/install crankshaft - AR03.20-P-4351GZA
ENGINE 272, 273 in MODEL 164, 251
Shown without pulse wheels on camshaft adjusters
Fig. 118: Identifying Crankshaft Components (1 Of 2)

Fig. 119: Identifying Crankshaft Components (2 Of 2)

MODIFICATION NOTES
18.10.05 Remove, install engine with front axle carrier, added Steps 4, 58
Remove/install automatic transmission - added Steps 5, 57
Removing
platform.
manufacturer.
Drain off engine oil and screw in
1 Replace sealing ring.
oil drain screw again
*BA01.45-
P-1001-
01M
Remove engine with front axle AR01.10-P-
2
carrier 2500GZA
AR27.10-P-
3 Remove automatic transmission Model 164
0500GZA
AR27.10-P-
Model 251
0500RTA
Detach engine from front axle AR01.10-P-

4
carrier 2510GZA
Mount engine onto assembly
5
stand
AR03.30-P-
6 Remove flywheel/drive plate
8001GZA
Remove rear crankshaft radial AR03.20-P-
7
sealing ring 3063GZA
AR01.45-P-
8 Remove oil pan
7500GZA
AR18.10-P-
9 Remove oil pump
6020GZA
10 Remove oil pump chain (11)
11 Remove oil baffle from crankcase
12
manifold 1961GZA
Remove cylinder head covers AR01.20-P-
13 Left cylinder head cover
(12) 5013GZA
AR01.20-P-
Right cylinder head cover
5012GZA
Turn engine at crankshaft (7) in
the direction of engine rotation to
AR05.20-P-
14 a 40° crank angle after ignition
6010-01VB
TDC and check position of
camshafts
AR15.40-P-
15 Remove alternator Model 164
5032GZA
AR15.40-P-
Model 251
5032RTA
Chain tensioner with thread M24X1.5 (only for AR05.10-P-
16 Remove chain tensioner
engine 272) 7800GZA
Chain tensioner using thread M22X1.5
In case of engine 272 both chain AR05.10-P-
tensioners can be removed whereby for engine
7800GZA
273 only chain tensioner with thread M22X1.5 is
installed.
AR01.40-P-
17 Remove timing case cover Do not damage cylinder head gaskets. 8000GZA
Remove camshaft adjuster (13) at AR05.20-P-
18 Exhaust camshaft adjuster
right cylinder head 7201GZA
AR05.20-P-
Intake camshaft adjuster
7201GZC
Detach timing chain drive gear
19 Secure feather key (15).
(14) from crankshaft (7)
Mark connecting rod and Connecting rods have been cracked

connecting rod bearing cap (2) on during manufacture (broken). The connecting
20
one side relative to each other rod bearing caps (2) are not interchangeable and
(arrow). must not be installed in the wrong direction.
Mark connecting rod bearing cap (2)
and lower connecting rod bearing shells (3)
Remove connecting rod bearing relative to each other. Mark connecting rod
21 bearing cap (1) and upper connecting rod
cap (2)
bearing shells (4) relative to each other.
While rotating crankshaft (7) ensure that
connecting rods (1) do not get jammed.
Loosen crankshaft bearing cap (5)
bolts and crankshaft fitted bearing Bolt tightening procedure for crankshaft bearing
22
cap (6) in reverse order of cap(s):
tightening procedure
AR03.20-P-
Engine 272
4351-02VA
AR03.20-P-
Engine 273
4351-02SX
*BA03.20-
Bolt for crankshaft bearing cap
P-1001-01D
*BA03.20-
Side bolt for crankshaft bearing cap
P-1002-01D
*BA03.20-
Bolt for crankshaft bearing cap
P-1003-01D
Carefully pry-off crankshaft bearing cap
Remove crankshaft bearing cap (5) and crankshaft fitted bearing cap (6). Mark
23 (5) and crankshaft fitted bearing crankshaft bearing shells (10) relative to
cap (6) respective crankshaft bearing caps (5) and to
crankshaft fitted bearing cap (6).
Take crankshaft (7) out of
24
crankcase
Remove upper crankshaft bearing Assign upper crankshaft bearing shells
25 shells (8) and upper thrust (8) to respective crankshaft bearing. Mark thrust
washers (9) from crankcase plates (9) relative to crankshaft fitted bearing.
Install
When replacing upper crankshaft
Lubricate upper crankshaft
bearing shells (8), lower crankshaft bearing
26 bearing shells (8) and insert into
shells (10) or crankshaft (7):?
crankcase
Assign crankshaft bearing shells:
AR03.20-P-
Engine 272
4360-01VA
AR03.20-P-
Engine 273 4360-01SX
*BE03.20-
P-1001-04E
Insert crankshaft (7) into
27 Lubricate crankshaft journals.
crankcase
Lubricate thrust plates (9) without
retaining lugs and in insert into The oil grooves in thrust washers (9)
28
crankshaft fitted bearing in must point toward thrust collars of the (7).
crankcase crankshaft
Lubricate lower crankshaft
bearing shells (10) and lower When replacing upper crankshaft
thrust plates (9) with retaining bearing shells (8), lower crankshaft bearing
29
lugs and insert into crankshaft shells (10) or crankshaft (7):?
bearing cap (5) and crankshaft Assign crankshaft bearing shells:
fitted bearing cap (6)
AR03.20-P-
Engine 272
4360-01VA
AR03.20-P-
4360-01SX
Engine 273
*BE03.20-
P-1001-04E
The crankshaft bearing cap (5) and
Insert crankshaft bearing cap (5)
crankshaft fitted bearing cap (6) are numbered
30 and crankshaft fitted bearing cap
consecutively.
(6)
Fit of crankshaft bearing cap:
AH03.20-P-
Engine 272
4351-02VA
AH03.20-P-
Engine 273
4351-02SX
Bolts must be replaced, otherwise there is risk
Apply bolts for crankshaft of cracks and fracture. In doing so tighten all
31 bearing cap (5) and crankshaft bolts according to the tightening procedure:?
fitted bearing cap (6) Tightening procedure for crankshaft bearing
caps:
AR03.20-P-
Engine 272
4351-02VA
AR03.20-P-
Engine 273
4351-02SX
*BA03.20-
P-1001-01D
*BA03.20-
P-1002-01D
*BA03.20-
P-1003-01D
Rotate crankshaft (7) and check
32
for unobstructed movement
33 Determine crankshaft bearing Engine 272 AR03.20-P-
axial play 4291-03VA

AR03.20-P-
Engine 273
4291-03SX
*BE03.20-
Crankshaft bearing clearance
P-1001-04E
AR03.10-P-
34 Inspect Connecting rod bolts
6111-01VA
*BE03.10-
Connecting rod bolts
P-1001-03A
Mount connecting rod bearing
AR03.10-P-
35 and check connecting rod bearing Engine 272
6111-06VA
play
AR03.10-P-
Engine 273
6111-08SX
*BE03.20-
Crankshaft bearing clearance
P-1002-04E
AR03.10-P-
36 Tighten connecting rod screws
6111-02VA
*BA03.10-
P-1001-01E
Rotate crankshaft (7) and check
37
for unobstructed movement
Push timing chain drive gear (14)
38 Observe feather key (15).
onto crankshaft (7)
Engine 272
Check timing of engine and basic
Install camshaft adjuster (13) for position of balance shaft (16) at a 40° crank
right cylinder bank in doing so angle before ignition TDC. At a 40° crank angle
39.1
adjusting basic positions of before ignition TDC the feather key (15) is in
camshafts and balance shaft (16) line with marking (17) on crankcase and notch
(18) on balance shaft (16) is line with marking
(19).
AR05.20-P-
Exhaust camshaft adjuster
7201GZA
AR05.20-P-
7201GZC
Engine 273
Install camshaft adjuster (13) for
Check engine timings at a 40° crank
right cylinder head while
39.2 angle before ignition TDC. At a 40° crank angle
adjusting basic positions of
before ignition TDC the feather key (15) is in
camshafts
line with marking (17) on crankcase.
AR05.20-P-
Exhaust camshaft adjuster
7201GZA
AR05.20-P-
7201GZC
AR01.40-P-
40 Install timing case cover
8000GZA
Chain tensioner with thread M24X1.5 (only for AR05.10-P-
41 Installing chain tensioner
engine 272) 7800GZA
Chain tensioner using thread M22X1.5
In case of engine 272 both chain AR05.10-P-
tensioners can be removed whereby for engine 7800GZG
273 only chain tensioner with thread M22X1.5 is
installed.
AR15.40-P-
42 Install generator Model 164
5032GZA
AR15.40-P-
Model 251
5032RTA
AR01.20-P-
43 Install cylinder head covers (12) Left cylinder head cover
5013GZA
AR01.20-P-
Right cylinder head cover
5012GZA
AR09.20-P-
44 Install resonance intake manifold
1961GZA
*BA18.10-
45 Mount oil baffle on crankcase
P-1006-01B
Lay oil pump chain (11) on drive
46
gear
AR18.10-P-
47 Install oil pump
6020GZA
AR01.45-P-
48 Install oil pan
7500GZA
AR01.45-P-
49 Install oil pan bottom section
7555GZA
Installing rear crankshaft radial Replace rear crankshaft radial sealing AR03.20-P-
50
seal ring to obtain leaktightness. 3063GZA
AR03.30-P-
51 Install flywheel/drive plate
8001GZA
Remove engine from assembly
52
stand
AR01.10-P-
53 Attach engine to front axle carrier
2510GZA
AR27.10-P-
54 Fit automatic transmission Model 164
0500GZA
AR27.10-P-
Model 251
0500RTA
Install engine with front axle AR01.10-P-
55
carrier 2500GZA
*BF18.00-
P-1001-
56 Pour in engine oil
01M

radial when new mm 0.022 to 0.046 0.022 to 0.046
BE03.20-P-1001-04E Main bearing play
axial when new mm 0.100 to 0.266 0.100 to 0.266
BE03.20-P-1002-04E Connecting rod bearing play radial when new mm 0.022...0.066 0.022...0.066

Thread Ø Ø M8 X 1 8X1
Shank length when new mm 39.5 39.5
BE03.10-P-1001-03A Connecting rod bolts
max. mm 40.5 40.5
Part no. - -

Stage 1 Nm 20 20
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8
Stage 2 ° Angle 90 90
BA03.20-P-1002-01D Side bolt for crankshaft bearing cap M8 Nm 30 30
Stage 1 Nm 5 5
BA03.20-P-1003-01D Bolt for crankshaft bearing cap M10 Stage 2 Nm 30 30
CONNECTING ROD
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 20 25
OIL PUMP
BA18.10-P-1006-01B Bolt, oil baffle at crankcase Nm 9 9
OIL PAN
BA01.45-P-1001-01M Oil drain screw to oil pan Nm 30 30
ENGINE LUBRICATION
272 273.922/923/924 /960/961/962/963/965/967/968

Filling capacity
Liters - -
without oil filter
Filling capacity
Liters 8.0 8.5
with oil filter
BB00.40-
BF18.00- Sheet P-0229-01 BB00.40-P-0229-0 1A
Engine
P-1001- A
oil
01M Specifications BB00.40-
for service Sheet P-0229-03 BB00.40-P-0229-0 3A
products A
BB00.40-
Sheet P-0229-05 BB00.40-P-0229-0 5A
A
Tightening diagram of crankshaft bearing caps - AR03.20-P-4351-02SX

BA03.20-P- Bolt for M8 Stage 1 Nm 20
1001-01D crankshaft
bearing cap Stage 2 Angle° 90
BA03.20-P- Side bolt for M8 Nm 30
1002-01D crankshaft
bearing cap
BA03.20-P- Bolt for M10 Stage 1 Nm 5
1003-01D crankshaft Stage 2 Nm 30
bearing cap Stage 3 Angle° 90
Lubricate bolts (1 to 30) of crankshaft bearing cap and the crankshaft fitted bearing cap on thread and
bolt head contact surface.
1. Tighten bolts (1 to 30) in the numbering sequence.
If no torquing angle wrench is available at the final tightening stage, the bolts can be turned
further using a socket wrench and locking handle all in a single operation. Do not use a flexirod torque
wrench for tightening in order to avoid any angle errors.
To loosen the bolts (1 to 30), proceed in reverse order.

Fig. 120: Tightening Sequence Of Crankshaft Head Contact Bolts

Tightening diagram of crankshaft bearing caps - AR03.20-P-4351-02VA

BA03.20-P-1001- Screw of M8 1st stage Nm 20
01D crankshaft bearing
cap 2nd stage Angle ° 90
BA03.20-P-1002- Side bolt for M8 Nm 30
01D crankshaft bearing
cap
BA03.20-P-1003- Bolt for M10 1st stage Nm 5
01D crankshaft bearing 2nd stage Nm 30
cap Step 3 Angle ° 90
Tightening sequence for the crankshaft bearing cap and the crankshaft fitted bearing cap
Tighten the crankshaft bearing cap (2, 3, 4) and the crankshaft fitted bearing cap (1) individually in the
numerical sequence. Arrow identifies direction of travel.
Fig. 121: Tightening Sequence For Crankshaft Bearing Cap & Crankshaft Fitted Bearing Cap
Tightening sequence for the crankshaft bearing bolts and the crankshaft fitted bearing cap
1. Oil bolts of bearing cap on thread and bolt head contact surfaces.
2. Fully tighten bolts on bearing cap in the specified sequence.
If no angle tightener is available at the end tightening point, tighten bolts further by the specified
angle in a single operation using a wrench and tommy bar. Do not use a flexi-rod torque wrench for
tightening in order to avoid any angle errors.
3. Tighten bolts:
 Tighten bolt 1 (M10) with the 1st stage.
 Tighten bolt (5) (end tightening point).
 Tighten bolt (6) (end tightening point).
 Tighten bolt 1 (M10) with the 2nd stage.
 Tighten bolt 2 (M10) with the 2nd stage.
 Tighten bolt 3 (M8) with the 2nd stage rotation angle (end tightening point).
 Tighten bolt 4 (M8) with the 2nd stage rotation angle (end tightening point).
 Tighten bolt 1 (M10) with the 3rd stage rotation angle (end tightening point).
 Tighten bolt 2 (M10) with the 3rd stage rotation angle (end tightening point).
Fig. 122: Identifying Crankshaft Bearing Caps Bolt Tightening Sequence

ASSIGN CRANKSHAFT BEARING SHELLS - AR03.20-P-4360
Assign crankshaft bearing shells - AR03.20-P-4360-01SX

Assignment of crankshaft bearing shell upper halves (crankcase)

Diameter of crankshaft
bearing hole in Color coding for Crankshaft bearing
crankcase Number on crankcase bearing shell play (mm)
68.500...68.506 1 blue 0.022...0.046
above 68.506...68.513 2 yellow 0.022...0.046
above 68.513...68.519 3 red 0.022...0.046
Assignment of crankshaft bearing shell lower halves (bearing cap)

Diameter of crankshaft Laser labeling on front Color marking for Crankshaft bearing
journal crankshaft journal bearing shell play (mm)
63.945...63.949 v purple 0.022...0.046

above 63.949...63.953 w white 0.022...0.046
above 63.953...63.957 r red 0.022...0.046
above 63.957...63.961 g yellow 0.022...0.046
above 63.961...63.965 b blue 0.022...0.046
1. Clean crankshaft bearing points in crankcase, crankshaft bearing cap and crankshaft journal for crankshaft
with a chamois leather.
rod bores, the crankshaft and crankcase oil galleries as well as the crankcase!
Do not use any hard objects for cleaning.
Blow through oil galleries in direction of flow oil with compressed air.
The top crankshaft bearing shells are assigned to the crankcase by means of color codings (on the
reverse side of the crankshaft bearing shells) and numbers which are stamped on the crankcase (see
arrows).
Fig. 123: Locating Crankshaft Bearing Shell Indication Number Or Color

Assignment of the bottom crankshaft bearing shells to the crankshaft journal is by means of
letters (initial letter of the particular color).
The initial letters of the particular colors are engraved on the front journal of the crankshaft (arrow).
The color coding on the lower crankshaft bearing shell is located on its rear side.
When installing the crankshaft bearing shells, it is important to keep to the order of the
colors which is engraved on the crankshaft journal!
Fig. 124: Locating Initial Letter On Front Of Crankshaft

Example:
 First letter "b ": A crankshaft bearing shell with the color coding blue must be inserted in the
crankshaft bearing cap (1).
 Second letter "g ": A crankshaft bearing shell with the color coding yellow must be inserted in the
 Third letter "r ": A crankshaft bearing shell with the color coding red must be inserted in the
 Fourth letter "w ": A crankshaft bearing shell with the color coding white must be inserted in the
 Fifth letter "r ": A crankshaft bearing shell with the color coding red must be inserted in the
Fig. 125: Identifying Crankshaft Bearing Cap

2. Lubricate top crankshaft bearing shells (1) with the oil holes (2) and the oil grooves (3) and insert in the
crankcase.
When doing this ensure that the anti-twist locks (4)for the bearing shell halves (1) are located in
3. Lubricate lower crankshaft bearing shell (7) and insert in the crankshaft bearing cap (6).
located in the recesses of the crankshaft bearing cap (6).
Crankshaft Bearing Cap

4. Lay crankshaft (7) in the crankcase.

5. Lubricate upper thrust plate (8) and install.
There is only one fitted bearing width therefore only one washer disc thickness is used.
The oil grooves of the thrust washers (8) must point toward the crankshaft webs (10).
Fig. 127: Installing Upper Thrust Plate

6. Install the crankshaft bearing cap (2) as per its identification.
When installing the fit bearing cap (3)hold both thrust plates (8) tight. The anti-twist locks (11)
of the lower thrust plates (8) must be located in the slots (12) of the fit bearing cap (3).
The oil grooves (9) of the lower thrust plates (8) must point toward the crank webs (10).
Fig. 128: Identifying Crankshaft Bearing Cap, Anti-Twist Locks, Lower Thrust Plates, Slot And
Oil Grooves
Assign crankshaft bearing shells - AR03.20-P-4360-01VA

Assignment of crankshaft bearing shell upper half (crankcase)

Diameter crankshaft Number or center Color coding for Bearing clearance (mm)
bearing in crankcase punch marks on bearing shell
crankcase
68.500-68.506 1 blue 0.022-0.046
over 68.506-68.513 2 Yellow 0,022-0,046
over 68.513-68.519 3 Red 0.022-0.046
Assignment of crankshaft bearing shell lower half (bearing cap)

Diameter crankshaft Laser inscription on Color coding for Bearing clearance (mm)
bearing journal front crankshaft journal bearing shell
63.945-63.949 v purple 0.022-0.046
over 63.949-63.953 w white 0,022-0.046
over 63.953-63.957 r red 0.022-0.046
over 63.957-63.961 g yellow 0.022-0.046
over 63.961-63.965 b blue 0.022-0.046
1. Clean crankshaft bearing points in crankcase, crankshaft bearing caps and crankshaft journal for
crankshaft using a chamois leather.
After bearing damage has occurred, it may be necessary to remove swarf from the conrod bores
and from the crankshaft and crankcase oil galleries as well as from the crankcase!
 Do not use a hard object for cleaning.

 Blow through oil galleries in direction of flow oil with compressed air.
The top main bearing halves are assigned to the crankshaft journal by means of a colored coding
(on the rear of the main bearing shells) and numbers or chisel punches, which are stamped on the
crankcase (see arrows).
Fig. 129: Locating Bearing Shell Numbers Stamped On Crankcase

 The bottom crankshaft bearing shells are assigned to the crankshaft journal of the
crankshaft by means of letters (initial letter of the particular color).
 The colored coding of the lower crankshaft journal is located at its rear.
 The initial letters of the particular colors are engraved on the crankshaft journal.
When installing the crankshaft bearing shells it is important to keep to the order of the
colors which is engraved on the crankshaft journal!
Fig. 130: Identifying Initial Letters Of Particular Colors Engraved On Journal Of Crankshaft
 First letter r : A crankshaft bearing shell must be inserted in the crankshaft bearing cap (1) with the
colored coding red .
 Second letter b: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (2) with
the colored coding blue.
 Third letter v: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (3) with the
colored coding violet.
 Fourth letter w : A crankshaft bearing shell must be inserted in the crankshaft bearing cap (4) with
the colored coding white .
Fig. 131: Identifying Bearing Caps And Direction Of Travel

2. Insert top crankshaft bearing shell halves (1) with the oil drill holes (2) and the oil grooves (3) into the
crankcase.
When doing this, ensure that the anti-twist locks (4) of the crankshaft bearing shell halves (1) are
located in the recesses of the crankcase.
3. Insert bottom bearing shell halves (7) into the bearing caps (6).
When doing this, ensure that the anti-twist locks (5) of the bottom crankshaft bearing shell halves (7)
are located in the recesses of the crankshaft bearing caps (6).
Fig. 132: Identifying Crankshaft Bearing Components

4. Insert crankshaft (7) in the crankcase.

5. Install top thrust washers (8).
There is only one fitted bearing width and therefore only one washer disc width is used.
The oil grooves of the thrust washers (8) must point toward the crankshaft webs (10).
Fig. 133: Identifying Crankshaft, Thrust Washers And Crankshaft Webs

6. Install crankshaft bearing caps (2) according to their identification.
Installation: The anti-twist locks (11) of the lower thrust washers (8) must be located in the slots
(12) of the fit bearing cap (3).
The oil grooves (9) of the lower thrust washers (8) must point toward the crankshaft webs (10).
When installing the crankshaft fit bearing cap (3), hold both repair thrust washers (8) tight.
Fig. 134: Identifying Crankshaft Bearing Components

REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-P-1600
Remove/install belt pulley/vibration damper - AR03.30-P-1600GZ
Fig. 135: Identifying Belt Pulley/Vibration Damper Components

MODIFICATION NOTES
9.1.06 Central bolt to vibration damper *BA03.30-P-1001-01D
Remove/install

manufacturer.
AR01.10-P-
2405GZ
AR20.40-P-
5000GZ
AR13.22-P-
3 Remove poly-V-belt (3)
1202GZ
Installation: The center
bolt (2) should always be replaced.
4 Remove the center bolt (2) Installation: Make two
markings on counterholder to aid
applying tightening angle.
Use extension.
*BA03.30-
P-1001-01D
Counterholder Fig. 137
Installation: The groove on
Detach the belt pulley/vibration damper (1) belt pulley/vibration damper (1)
5
from the crankshaft must engage in the feather key of
crankshaft.
Checking
Check belt pulley/vibration damper (1) for
6
faults
AF03.30-P-
Noises from belt drive * Not for USA, Japan
1001AG
Check for scoring and galling; if
Check tread of crankshaft radial sealing ring necessary:?
7
at hub of belt pulley/vibration damper (1) Replace belt pulley/vibration damper
(1)
Only when replacing belt
pulley/vibration damper (1) or in the AR03.20-P-
8 Replace front crankshaft radial sealing ring
event of a leak at crankshaft radial 3000GZ
sealing ring.
Check engine oil level and replenish oil if AR18.00-P-
10
necessary 3035-01GZ
AS00.00-Z-
0005-01A
Conduct engine test run and check engine and eliminate cause, otherwise
for leaks
may occur.

Number Designation Engine 113.94/96/ 97/98
Stage 1 Nm 200
BA03.30-P-1001-01D Central bolt to vibration damper
Stage 2 Angle° 90

Fig. 137: Identifying Counterholder (112 589 00 40 00)

Remove/install belt pulley/vibration damper - AR03.30-P-1600GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 138: Identifying Belt Pulley/Vibration Damper Components

Remove/install

Vehicles with Keyless Go,
code 889:
1 Turn key in ignition lock to position "0"
AR13.20-P-
0001GZA
3 Position engine at top dead center
Install retaining lock for crankshaft/starter AR03.30-P-
4
ring gear 5000GZA
*BA03.30-
5 Remove center bolt (3) P-1001-
01M
Installation: Place belt
pulley/vibration damper (2) on
Detach belt pulley/vibration damper (2) crankshaft, and rotate to ensure that
6
from crankshaft groove of belt pulley/vibration damper
(2) is engaged in feather key (4) of
crankshaft.
Checking
Check for scoring and galling;

Check contact surface of crankshaft radial
if necessary:-->
7 sealing ring (5) at hub of belt
Replace belt pulley/vibration damper
pulley/vibration damper (2)
(2)
When replacing belt
pulley /vibration damper (2) or in the AR03.20-P-
8 Replace front crankshaft radial seal (5)
event of leaks on crankshaft radial 3000GZA
sealing ring (5).
Checking
moving by itself.
clothes.
10
engine for leaks

Stage 1 Nm 200 200
BA03.30-P-1001-01M Center bolt for belt pulley on crankshaft
Remove/install belt pulley/vibration damper - AR03.30-P-1600GZS

Fig. 139: Identifying Belt Pulley/Vibration Damper, Center Bolt, Poly-V-Belt And Counterholder
MODIFICATION NOTES
22.3.06 Bolt, starter ring gear/drive plate to crankshaft *BA03.30-P-1001-01Q
Remove/install

manufacturer.
AR20.40-P-
5000GZS
AR13.22-P-
3 Remove poly V-belt (3)
1202GZS
Installation: The center
bolt (2) should always be replaced.
4 Remove the center bolt (2) Installation: Make two
markings on counterholder (4) to aid
applying tightening angle.
Use extension.
*BA03.30-
P-1001-01Q
Counterholder Fig. 137
Installation: The groove on
Detach belt pulley/vibration damper (1) from belt pulley/vibration damper (1)
5
crankshaft must engage in feather key of
crankshaft.
Checking
Check for scoring and
Check tread of crankshaft radial sealing ring galling; if necessary:?
6
at hub of belt pulley/vibration damper (1) Replace belt pulley/vibration damper
(1)
Only when replacing belt
pulley/vibration damper (1) or in the AR03.20-P-
7 Replace front crankshaft radial sealing ring
event of a leak at crankshaft radial 3000GZS
sealing ring.
Check engine oil level and replenish oil if

9
necessary
off by itself when engine is running. Risk ofmoving by itself.
AS00.00-Z-
0005-01A
Conduct engine test run and check engine for
leaks
may occur.

Stage 1 Nm 200
BA03.30-P-1001-01Q Vibration damper on crankshaft
Stage 2 Angle° 90

Fig. 141: Identifying Counterholder (112 589 00 40 00)

REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT/RING GEAR - AR03.30-P-5000
Removing/installing retaining lock for crankshaft / ring gear - AR03.30-P-5000GZ

ENGINE 113.964 in MODEL 164.175 with TRANSMISSION 722.901
Fig. 142: Identifying Retaining Lock For Crankshaft / Ring Gear Components
Removing/installing
Align vehicle between the four

pillars of the hoist and position the
four support plates at the hoist
or toppling off the lifting platform. 0010-01A
mounting points specified by the
No parts of the body or limbs should
Risk of injury. Moving parts can pinch,
be within the operating range of the AS00.00-Z-
crush or , in extreme cases even sever
mechanism when moving 0009-01A
extremities.
components.
Switch ignition off, remove ignition key Go, Code 889: Press keyless go
1
(transmitter key). start/stop button repeatedly until
caused by swallowing battery acid. Risk of AS54.10-Z-
clothing and safety glasses. Only
injury caused by burns to skin and eyes 0001-01A
from battery acid or when handling damaged
lead-acid batteries
Insulate clamping device of the

ground line in order to prevent
2 Disconnect ground cable from battery inadvertent contact with the ground AR54.10-P-
point of the battery. 0003GZ
code 889: Switch off engine, remove
Keyless Go cards from the vehicle

and keep outside the range of the
transmitter.
AH54.10-P-
0001-01A
AR00.60-P-
1000GZ
AR15.30-P-
4 Remove starter
7100GZ
*BA15.30-P-
1001-01A
*BA15.30-P-
1002-01A
*BA15.30-P-
1003-01A
Slide the retaining lock into
the starter opening (see arrow) and
allow to latch into the ring gear. If
5 Insert retaining lock (1) into starter opening required, continue turning the engine
at the center Bolt for the crankshaft
in the direction of rotation of the
engine.
Retaining lock Fig. 143
6 Install in reverse order
7 Read out fault memory and erase simulation during test operations,
must be erased in the fault memory
after completing the work.
Connect up STAR DIAGNOSIS and read AD00.00-P-
system Z-1048-13A
STARTER
BA15.30-P-1001-01A Nut for connection for circuit 30 Nm 14
BA15.30-P-1002-01A Nut for connection for circuit 50 Nm 6
BA15.30-P-1003-01A Bolt for starter on crankcase Nm 40
Fig. 143: Identifying Retaining Lock (112 589 03 40 00)


Number Designation
Remove/install retaining lock for crankshaft/ring gear - AR03.30-P-5000GZA
ENGINES 272, 273 in MODEL 164, 251 with TRANSMISSION 722.9
Fig. 144: Identifying Retaining Lock For Crankshaft And Ring Gear Components
Remove/install

lifting platform.
manufacturer.
moving parts that can pinch, No parts of the body or limbs should be within AS00.00-Z-
crush or, in extreme cases, even the operating range of the mechanism when 0009-01A
sever extremities moving components.
AR49.10-P-
1 Remove left catalytic converter
7100GZA
Remove heat shield (5) of the
2 propeller shaft at the front axle
transmission
Remove bolts (3) on the
3 Counterhold nuts (1) from the rear.
transmission bell
*BA27.40-P-
1001-01E
Unclip cover on "Starter opening
4
on the left"
Checking
Check toothing for wear and damage,
Check splines of ring gear for by continuing to rotate engine at center bolt on
5
drive plate crankshaft in direction of rotation of engine. If
necessary:?
AR03.30-P-
Replace drive plate.
8001GZA
Fig. 42
Push the retaining lock (01) into the
opening and let it latch in the ring gear. If
Insert retaining lock (01) in
6 required, continue turning engine at center bolt
opening
on the crankshaft in direction of rotation of the
engine.
Fig. 143
HOUSING
Number Designation Transmission 722.9 in Transmission 722.9 in
model 164 model 251
BA27.40-P- Bolt, automatic transmission
Nm 39 39
1001-01E to crankcase

Fig. 146: Identifying Retaining Lock (112 589 03 40 00)

Remove/install retaining lock for crankshaft / ring gear - AR03.30-P-5000GZS
ENGINE 156 in MODEL 164, 251 with TRANSMISSION 722
Fig. 147: Identifying Retaining Lock For Crankshaft And Ring Gear Components
Remove/install

lifting platform and position four AS00.00-
Risk of death caused by vehicle slipping or
support plates at lifting platform Z-0010-
toppling off the lifting platform.
support points specified by vehicle 01A
manufacturer.
Risk of injury caused by moving parts AS00.00-
Keep body parts and limbs well clear
that can pinch, crush or , in extreme cases Z-0009-
of moving parts.
even sever extremities. 01A
On vehicles with code 889,

Switch ignition off, remove ignition key Keyless Go: Press keyless go start/stop
1
(transmitter key). button repeatedly until ignition is
switched off
smoking. Wear acid-resistant gloves, AS54.10-
caused by swallowing battery acid. Risk of
clothing and glasses. Only pour battery Z-0001-
injury caused by burns to skin and eyes
acid into suitable and appropriately 01A
from battery acid or when handling
marked containers.
Insulate clamping device of ground
2 Disconnect ground line from battery line in order to prevent inadvertent
contact with ground point of battery.
AR54.10-
Model 164
P-0003GZ
AR54.10-
Model 251
P-0003RT
AH54.10-
Notes on battery All models P-0001-
01A
AR00.60-
P-1000GZ
AR00.60-
Model 251
P-1000RT
AR15.30-
4 Remove starter P-
7100GZS
Slide the retaining lock into
the starter opening (see arrow) and
5 Insert retaining lock (1) into starter opening allow to latch into the ring gear. If
required, continue turning engine at the
center bolt for crankshaft in the
direction of rotation of the engine.
Retaining lock Fig. 143
AR00.19-
P-0200GZ
AR00.19-
P-0200RT
Fig. 148: Identifying Retaining Lock (64 112 589 03 40 00)

REMOVE/INSTALL FLYWHEEL / DRIVE PLATE - AR03.30-P-8001
Remove/install flywheel / drive plate - AR03.30-P-8001GZ
ENGINE 113.964 in MODEL 164.175 with TRANSMISSION 722.901
Fig. 149: Identifying Flywheel And Drive Plate Components (Model 164.175)
Remove/install

platform and position the four support plates AS00.00-Z-
below the lifting platform support points specified 0010-01A
by the vehicle manufacturer.
1
transmission 0500GZ
Install retaining lock for

AR03.30-P-
2 crankshaft (5) and starter ring
5000GZ
gear
Remove bolts (3) from drive Installation: Replace bolts, because if they are
3 used again, the connection may loosen and the
plate (1)
bolts may shear off.
*BA03.30-P-
1002-01D
Installation: The flex plate must be installed
4 Remove flex plate (2) back into the same position as the bulging caused
by the bolts may generate an incorrect torque.
Installation: The cylinder pin (4) determines the
If a new drive plate is installed, perform
initialization in the ME control unit with STAR
7 Carry out initialization
Diagnosis in the menu point "Control unit
adaptation".
*WH58.30-Z-
1048-13A

Number Designation Engine 113.94/96/
97/98
Stage
Nm 45
BA03.30-P-1002- Bolt connecting two-mass flywheel/drive plate 1
01D to crankshaft Stage
Angle° 90
2

Number Designation
Remove, install flywheel / drive plate - AR03.30-P-8001GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 150: Identifying Flywheel And Drive Plate Components (Model 164, 251)
Remove/install

slipping or toppling off the
lifting platform.
manufacturer.
AR27.10-P-
1 Remove automatic transmission Model 164
0500GZA
AR27.10-P-
Model 251
0500RTA
AR03.30-P-
5000GZA
gear
Installation: Replace bolts, because if
Remove bolts (3) from drive
3 they are used again, the connection may loosen
plate (1)
and the bolts may shear off.
*BA03.30-P-
1003-01M
Installation: The flex plate must be
installed back into the same position as bulging
4 Remove flex plate (2)
caused by bolts may generate an incorrect
torque.
Installation: The straight pin (4)
determines the installation position.
Only when replacing.

Menu guidance:
Carry out first initialization and  Engine control module

7 then sensor rotor adaptation  Adaptations
using STAR DIAGNOSIS  Learning processes

272 273
Stage
Nm 45 45
BA03.30-P-1003- Bolt, flywheel or two-mass flywheel / driven 1
01M plate to crankshaft Stage
Angle° 90 90
2
Remove, install flywheel / drive plate - AR03.30-P-8001GZS
ENGINE 156 in MODEL 164, 251 with TRANSMISSION 722
Fig. 151: Identifying Flywheel And Drive Plate Components (Model 164, 251)
MODIFICATION NOTES
22.3.06 Bolt, starter ring gear/drive plate to crankshaft *BA03.30-P-1002-01Q
Remove/install
Align vehicle between columns of lifting

platform and position four support plates at AS00.00-Z-
lifting platform support points specified by 0010-01A
the lifting platform.
1
transmission 0500GZS
AR03.30-P-
5000GZS
gear
Installation: Replace bolts, because if used
Remove bolts (3) from drive
3 again, the connection may loosen and the bolts
plate (1)
may shear off.
*BA03.30-P-
1002-01Q
Installation: The flex plate must be installed
4 Remove flex plate (2) back into the same position as bulging caused by
the bolts may generate an incorrect torque.
Installation: The straight pin (4)
determines the installation position.
If a new drive plate is installed, perform
initialization in the ME control unit with STAR
7 Carry out initialization
Diagnosis in the menu point "Control unit
adaptation".
*WH58.30-Z-
1048-13A

Stage 1 Nm 20
BA03.30-P-1002-01Q Bolt, starter ring gear/drive plate to crankshaft Stage 2 Nm 45
Stage 3 Angle° 90

Number Designation
TEST & ADJUSTMENT VALUES

TEST AND ADJUSTMENT VALUES: PASSENGER CARS: CRANK ASSEMBLY - BE03.00-Z-

9999AZ
MODEL all
TDC sensor ENGINE 604, 605, 606 / BE03

bracket P-100
01A
Inspection data ENGINE 601.943, 602.980 /982 /983 /984 /985 BE03
of connecting N-10
rod 01D
Test ENGINE 601.943, 602.980 /982 /983 /984 /985 BE03
dimensions for N-10
pistons 02E
Inspection data ENGINE 111, 166, 668... BE03
of connecting P-100
rod 01A
Inspection data ENGINE 120 BE03
of connecting P-100
rod 01B
Check values ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 646, 647, 648... BE03
for connecting P-100
rod 01C
Inspection data ENGINE 112, 113, 155... BE03
of connecting P-100
rod 01D
Check values ENGINE 137.970 BE03
for connecting P-100
rod 01E
of connecting P-100
rod 01F
Test values for ENGINE 629, 642 / BE03
connecting rod P-100
01G
Test values for ENGINE BE03
pistons 111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977 P-100
02A
Test values for ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 629, 642... BE03
pistons P-100
02B
Test values for ENGINE 120 with CODE (473) ENGINE with low compression BE03
pistons P-100
02C
Check values ENGINE 112, 113, 155, 272, 273... BE03
for pistons P-10

02D
Test values for ENGINE 137.970 BE03
pistons P-100
02E
Check values ENGINE 271, 275, 285... BE03
for pistons P-100
02F
Test values for ENGINE 642 BE03
pistons P-100
02G
pistons P-100
02H
Check values ENGINE 646.951 /8 /961 /962 /963 /966, 647, 648 BE03
for pistons P-100
02I
Test data for ENGINE 111, 112, 113, 137, 155, 156, 271, 272, 273, 275, 285, 604, 605, 606... BE03
conrod bolts P-10
03A
Inspection data ENGINE 103 /, 104 /, 119, 120 BE03
of conrod bolts P-100
03B
Test values for ENGINE 601, 602 /, 603 / (except, 602.98 /98) BE03
connecting rod P-100
bolts 03C
Test values for ENGINE 611, 612, 613, 628, 629, 642, 646, 647, 648, 668... BE03
conrod bolts P-100
03D
Inspection data ENGINE 166.940 /960 /961 /990 /991 /995 BE03
03E
Inspection data ENGINE 266.920 /940 /960 /980 BE03
for conrod bolts P-100
03F
03G
piston rings P-100
05A
Check values ENGINE 112, 113, 137, 155, 275, 285 BE03
for piston rings P-10
05B
Inspection data ENGINE 271.940 /941 /942 /943 /944 /946 /948 BE03
of piston rings P-100

05C
Check values ENGINE 156, 272.91 /92 /94 /96 /97 /98 /99, 273.92 /96 BE03
05D
piston rings P-100
05E
Inspection data ENGINE 266.920 /940 /960 /980 BE03
05F
05I
Check values ENGINE 646.951 /8 /961 /962 /963 /966, 647, 648 BE03
05J
Inspection data ENGINE 601, 602 /982 /983 BE03
of bolts for N-10
crankshaft 01B
bearing caps
Crankshaft test ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 BE03
data N-10
02D
Test values for ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 BE03
crankshaft N-10
main bearing 03A
shells
Test values for ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 BE03
crankshaft N-10
bearing play 04A
Test values for ENGINE 111, 604, 605, 606, 611, 612, 613, 628, 646, 647, 648... BE03
crankshaft P-100
bearing cap 01A
bolts
Test values for ENGINE 601, 602, 603 BE03
crankshaft P-100
bearing cap 01B
bolts
Inspection data ENGINE 137, 275, 285 BE03
of crankshaft P-100
bearing cap 01C
bolts
of bolts of P-100
crankshaft 01D
bearing caps
of bolts of P-100
crankshaft 01E
bearing caps
Crankshaft test ENGINE 111, 112.951 /976, 166.940 /960 /990, 668.940 /941 /942 BE03
data P-100
02A
Crankshaft test ENGINE 120 BE03
data P-100
02B
Crankshaft test ENGINE 601, 602 /, 603 / (except, 602.98 /98) BE03
data P-100
02C
Crankshaft test ENGINE 604, 605, 606 /, 611, 612.961 /962 /963 /990, 613 BE03
data P-100
02D
crankshaft P-100
02E
Crankshaft test ENGINE 640 BE03
data P-100
02F
Check values ENGINE 604, 605, 606, 611, 612, 613, 646, 647, 648... BE03
for crankshaft P-100
main bearing 03A
shells
crankshaft P-100
main bearing 03B
shells
crankshaft P-100
main bearing 03C
shells
Inspection data ENGINE 628.960 /961 /962 /963, 629, 642 BE03
of crankshaft P-100
main bearing 03D
shells
Test values of ENGINE 137, 275.950 /951 /953 /954 /980 /981 /982, 285.950 /980 BE03
crankshaft P-100
main bearing 03E
shells
Inspection data ENGINE 612.967 in MODEL 209 BE03
of crankshaft P-100
main bearing 03F
shells
of crankshaft P-100
main bearing 03H
shells
Check values ENGINE 604, 605, 606, 611, 612, 613, 628, 629, 642, 646, 647, 648... BE03
for crankshaft P-100
bearing 04A
clearance
crankshaft P-100
bearing play 04B
Test values for ENGINE 601, 602 /, 603 / (except, 602.982) BE03
crankshaft P-100
bearing play 04C
Inspection data ENGINE 111, 166.940 /960 /990, 668.940 /941 /942 BE03
of crankshaft P-100
bearing play 04D
Check values ENGINE 112, 113, 137, 155, 156, 271, 272, 273, 275, 285... BE03
for crankshaft P-10
bearing 04E
clearance
of crankshaft P-100
bearing 04F
clearance
Lanchester ENGINE 646.961 /962 /963 /966 /8 BE03
balancer P-100
05A
Flywheel, ENGINE 111, 271, 604, 605, 606, 611.96 /981 /983 /987, 612.981 /96 /99, 613 BE03
driven plate P-100
01A
Flywheel, ENGINE 103 /, 104 /, 119, 120 BE03
driven plate P-100
01B
Flywheel, ENGINE 601, 602 /, 603 / (except, 602.98 /98) BE03
driven plate P-100
01C
Belt ENGINE 111, 112 /, 113 /, 137, 155.980 BE03
pulley/vibration P-10
damper 02A
Belt ENGINE 120 BE03
damper 02B
Belt ENGINE 271, 275, 285 BE03
damper 02C
Belt pulley / ENGINE 642 / BE03
vibration P-100
damper 02D
Flywheel ENGINE 601, 602 /, 604, 605, 606 / BE03
P-100
03A
Flywheel ENGINE 103 /, 104 /, 111 BE03
P-100
03B
Flywheel ENGINE 601, 603 / BE03
P-100
03C
Starter ring ENGINE 602 /, 604, 605, 606 /, 611, 612.961 /962 /963 /965 /966 /967 /990 BE03
gear P-100
04A
Starter ring ENGINE 120 BE03
gear P-100
04B
CHECK VALUES FOR PISTON RINGS - BE03.10-P-1000
Check values for pistons - BE03.10-P-1000-02D
Engines 112, 113, 155, 272, 273

Number Designation Engines Engine 112.912 Engine 112.913
112.910/911
BE03.10-P- Piston Standard mm 83.175...83.195 83.175...83.195 89.875...89.895
1001-02D diameter identification X
Auxiliary mm 83.225...83.245 83.225...83.245 89.922...89.952
Repair size mm 83.425...83.445 83.425...83.445 90.125...90.145
BE03.10-P- Piston Standard mm < or = 0.040 < or = 0.040 < or = 0.043
1002-02D clearance identification
X
Auxiliary mm < or = 0.040 < or = 0.040 < or = 0.043
Repair size mm < or = 0.040 < or = 0.040 < or = 0.043

Number Designation Engines Engines Engine
112.920/921/940/941/942/943/944/945, 112.946/946/947/949/960 113.960

113.940/941/942/944
BE03.10- Piston Standard mm 89.872...89.902 89.872...89.902 96.972.
P-1001- diameter identification
02D X
Auxiliary mm 89.872...89.902 89.872...89.902 97.022.
Repair size mm 90.122...90.152 90.122...90.152 97.222.
BE03.10- Piston Standard mm < or = 0.043 < or = 0.043 < or = 0
P-1002- clearance identification
02D X
Auxiliary mm < or = 0.043 < or = 0.043 < or = 0
Repair size mm < or = 0.043 < or = 0.043 < or = 0

Number Designation Engine Engines Engine
112.960/960/961 113.987/988/989/990/991/992/993/995 155
961 AMG
BE03.10- Piston Standard mm 89.875...89.895 96.975...96.995 -
P-1001- diameter identification
02D X
Auxiliary mm 89.925...89.945 97.025...97.045 -
Repair size mm 90.125...90.145 97.225...97.245 -
BE03.10- Piston Standard mm < or = 0.04 0.005...0.040 -
P-1002- clearance identification
02D X
Auxiliary mm < or = 0.04 0.005...0.040 -
identification
Repair size mm < or = 0.04 0.005...0.040 -

Number Designation Engine Engine Engine 273.92
272.91/92/94 272.96/97/98/99
1001-02D diameter identification X
Auxiliary mm 88.073...88.103 92.963...92.997 92.963...92.997
Repair size mm 88.223...88.253 93.113...93.147 93.113...93.147
1002-02D clearance identification
X
Auxiliary mm 0.003...0.042 0.003...0.052 0.003...0.052
Repair size mm 0.003...0.042 0.003...0.052 0.003...0.052

Number Designation Engine 273.96

BE03.10-P-1001- Piston diameter Standard mm 97.973...98.007
02D identification X
Auxiliary mm 98.073...98.107
Repair size mm 92.223...92.257
BE03.10-P-1002- Piston clearance Standard mm 0.007...0.042
02D identification X
Auxiliary mm 0.007...0.042
Repair size mm 0.007...0.042
Test data for conrod bolts - BE03.10-P-1000-03A
Engine 111, 112, 113, 137, 155, 156, 271, 272, 273, 275, 285, 604, 605, 606

Number Designation Engine 111 Engine 112 except 112.951/976,
Engine
113.94/96/971/980/981/982/984/986
BE03.10-P- Conrod Thread diameter M 9x1 8x1
1001-03A bolts Shank When mm 51.7...52.3 47
length new
max. mm 52.9 47.6
Part no. 111 038 00 -
71

112.951/976 113.987/988/989/990/991/993
BE03.10-P- Conrod Thread diameter M 8x1 8x1
1001-03A bolts Shank When new mm 46.7...47.3 41.7...42.3
length
max. mm 47.6 42.5
Part no. - HWA 113 038 01 71

Number Designation Engine Engine 137,
113.992/995 275, 285
BE03.10-P- Conrod bolts Thread diameter M 8x1 7x1
1001-03A Shank length When new mm 42 38
max. mm 42.6 38.4
Part no. - -


BE03.10-P- Conrod bolts Thread diameter M- 9x1
1001-03A Shank length When new mm - 40
max. mm - 42.8
Part no. - -

1001-03A Shank length When new mm 38 39.5
max. mm 38.4 40.5
Part no. - -

Number Designation Engine 273 Engine 604,
605, 606
1001-03A Shank length When new mm 39.5 51.7...52.3
max. mm 40.5 52.9
Part no. - 111 038 00 71
Check values for piston rings - BE03.10-P-1000-05B
Engines 112, 113, 137, 155, 275, 285

Number Designation Engine Engine Engines
112.910/911/912 112.913 112.920/921/922/923/940/941/942/943/9
engine 113.940/941/942/943
BE03.10- Piston ring Groove 1 mm 0.012...0.060 0.033...0.075 0.012...0.060
P-1001- vertical
05B clearance Groove 2 mm 0.010...0.030 0.015...0.05 0.010...0.030
P-1002- end gap
05B Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400
BE03.10- Dimension Plain mm 83.2x1.5x3.1 89.9x1.5x3.1 89.9x1.5x3.1
P-1003- compression
05B ring
Taper-faced mm 83.2x3.5x3.5 89.9x1.75x3.5 89.9x3.5x3.5
hook
scraper ring

Number Designation ENGINE Engine 112.949 Engine 112.976

112.951
1001-05B vertical
BE03.10-P- Dimension Plain mm 89.9x1.5x3.05 89.9x1.5x3.1 97.00x1.5x3.3
1003-05B compression
ring
hook scraper
ring

Number Designation Engine Engines Engines
112.960/960/961 113.944/980/981/982/984 113.960/961/962/963/964/965
961 AMG
P-1001- vertical
05B clearance Groove 2 mm 0.005...0.020 0.010...0.030 0.010...0.030
P-1002- end gap
05B Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400
BE03.10- Dimension Plain mm 89.9x1.5x3.05 97.0x1.2x3.5 97.0x1.5x3.1
P-1003- compression
05B ring
hook
scraper ring

113.967 113.987/988/989 113.990/991/992/995
1001-05B vertical
1003-05B compression
ring
Taper-faced mm 97.0x1.75x3.5 97.0x1.5x4 97.0x1.75x3.5
hook scraper
ring

BE03.10-P- Piston ring Groove 1 mm - 0.012...0.060
1001-05B vertical clearance Groove 2 mm - 0.010...0.030
BE03.10-P- Piston ring end Groove 1 mm - 0.250...0.350
1002-05B gap Groove 2 mm - 0.250...0.500
BE03.10-P- Dimension Plain compression mm - 84.0x1.2x3.1
1003-05B ring
Taper-faced hook mm - 84.0x1.5x3.5
scraper ring

Number Designation Engines 275.95, Engines 275.98,
285.95 285.98
BE03.10-P- Piston ring Groove 1 mm 0.03...0.08 0.03...0.07
1001-05B vertical clearance Groove 2 mm 0.015...0.055 0.03...0.07
BE03.10-P- Piston ring end Groove 1 mm 0.200...0.400 0.20...0.35
1002-05B gap Groove 2 mm 0.200...0.400 0.35...0.55
BE03.10-P- Dimension Plain compression mm 82.0x1.2x2.9 82.6x1.2x2.9
1003-05B ring
Taper-faced hook mm 82.0x1.5x3.4 82.6x1.0x3.1
scraper ring
Check values for piston rings - BE03.10-P-1000-05D
Engines 156, 272, 273
MODIFICATION NOTES
25.1.06 Piston ring vertical Engines 272.967, 273.96
clearance
Dimensions of plain
compression ring, taper-
faced hook scraper ring, oil
scraper ring

Number Designation Engine 156 Engine Engine
272.91/92/94 272.96/97/98/99
BE03.10-P- Piston ring Groove 1 mm 0.02 to 0.065 0.03...0.08 0.02 to 0.07
1001-05D vertical Groove 2 mm 0.015...0.045 0.02...0.06 0.015 to 0.05
clearance Groove 3 mm 0.01 to 0.013 - -
BE03.10-P- Piston ring Groove 1 mm 0.2 to 0.35 0.2 to 0.35 0.2 to 0.35
1002-05D end gap Groove 2 mm 0.35...0.55 0.3...0.5 0.3...0.5
Groove 3 mm 0.2 to 0.7 0.2...0.9 0.2...0.9
1003-05D compression
ring
hook scraper
ring
Oil scraper mm 102.2x2.0x2.7 88.0x2.5x3.03 92.9x2.5x3.03
ring

BE03.10-P- Piston ring Groove 1 mm 0.02 to 0.07 0.02 to 0.07
1001-05D vertical Groove 2 mm 0.015 to 0.05 0.002 to 0.06
1002-05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9
BE03.10-P- Dimension Plain mm 92.9x1.5x3.1 98.0x1.2x3.1
1003-05D compression ring
Taper-faced hook mm 92.9x1.75x3.7 98.0x1.5x3.7
scraper ring
Oil scraper ring mm 92.9x2.5x3.03 98.0x2.5x3.03
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE - BE03.20-P-1000-04E
Engines 112, 113, 137, 155, 156, 271, 272, 273, 275, 285

Number Designation Engine 112 except 112.951/976, Engines
113.940/941/942/943/944/948/960/961/963/964/965/966/967/968/971/980/981/
BE03.20- Main radial mm 0.026...0.050
P-1001- bearing when
04E play new
axial mm 0.10...0.266
when
new
BE03.20- Connecting radial mm 0.022...0.067
P-1002- rod bearing when
04E play new


113.987/988/989/990/991/993 113.992/995
BE03.20-P- Main bearing radial when mm 0.026...0.050 0.026...0.050
1001-04E play new
axial when mm 0.10...0.266 0.10...0.266
new
BE03.20-P- Connecting rod radial when mm 0.022...0.067 0.022...0.067

Number Designation Engine 156 Engine 155 Engine 271
BE03.20-P- Main bearing radial when mm 0.024...0.044 - 0.021...0.045
1001-04E play new
axial when mm 0.10...0.266 - 0.10...0.30
new
BE03.20-P- Connecting rod radial when mm 0.022...0.062 - -

BE03.20-P- Main bearing play radial when mm 0.022...0.046 0.022...0.046
1001-04E new
axial when mm 0.100...0.266 0.100...0.266
new
BE03.20-P- Connecting rod radial when mm 0.022...0.066 0.022...0.066

Number Designation Engine 137 Engines 275.95, Engines
285.95 275.98, 285.98
BE03.20-P- Main bearing radial when mm 0.028...0.052 0.022...0.047 0.018...0.058
1001-04E play new
axial when mm 0.10...0.260 0.100...0.254 0.100...0.254
new
BE03.20-P- Connecting rod radial when mm 0.017...0.052 0.026...0.059 0.019...0.048
BELT PULLEY/VIBRATION DAMPER - BE03.30-P-1000-02A
Engine 111, 112, 113, 137, 155
BELT PULLEY/VIBRATION DAMPER

Number Designation Engine Engine 112, Engine Engine Engine
111 113.94/96/98 113.990/991 113.992 137
BE03.30- Permissible Radial mm 0.6 0.5 0.4 0.4 -

P-1001- difference at runout
02A vibration Axial mm 0.6 0.3 0.4 0.2 0.3
damper runout
BELT PULLEY/VIBRATION DAMPER

BE03.30-P-1001- Permissible difference Radial runout mm -
02A at vibration damper Axial runout mm -
TIGHTENING TORQUES: PASSENGER CARS: CRANK ASSEMBLY - BA03.00-Z-9999AZ
MODEL all
diameters ENGINE 111, 601 /943, BA03.10-N-1000-01A

602.980 /982 /983 /984 /985
Connecting rods ENGINE 103 /, 104 /, 120 BA03.10-P-1000-01A
Connecting rods ENGINE 604, 605, 606 / BA03.10-P-1000-01B
Connecting rods ENGINE 601, 602 /, 603 / (except, BA03.10-P-1000-01C
602.98 /98)
Connecting rods ENGINE 119 BA03.10-P-1000-01D
Connecting rods ENGINE 112 /, 113 /, 137, BA03.10-P-1000-01E
155.980, 271, 272, 273, 275, 285
Connecting rods ENGINE BA03.10-P-1000-01F
166.940 /960 /961 /990 /991 /995
Connecting rods ENGINE 668.914 /940 /941 /942 BA03.10-P-1000-01G
Connecting rods ENGINE 111 BA03.10-P-1000-01H
Connecting rod ENGINE 611, 612, 613, 628, 629 BA03.10-P-1000-01I
Connecting rods ENGINE 266.920 /940 /960 /980 BA03.10-P-1000-01J
Connecting rod ENGINE 642 / BA03.10-P-1000-01L
Connecting rods ENGINE 640 BA03.10-P-1000-01M
Connecting rod ENGINE 646, 647, 648 BA03.10-P-1000-01P
Connecting rod ENGINE 156 BA03.10-P-1000-01Q
Crankshaft ENGINE 111, 601 /943, BA03.20-N-1000-01A
602.980 /982 /983 /984 /985
Crankshaft ENGINE 601, 602, 603, 604, 605, BA03.20-P-1000-01A
606, 611, 612, 613, 646, 647, 648...
Crankshaft ENGINE 103 /, 104 /, 111, 271 BA03.20-P-1000-01B
Crankshaft ENGINE 119, 120 BA03.20-P-1000-01C
Crankshaft ENGINE 112 / /, 113 /, 155.980, BA03.20-P-1000-01D
272, 273
Crankshaft ENGINE 642 / BA03.20-P-1000-01E
Crankshaft ENGINE 640 BA03.20-P-1000-01F
Crankshaft ENGINE 156 BA03.20-P-1000-01J
Balancing shaft ENGINE 112 / /, 272 BA03.20-P-1000-02A
Balance shaft ENGINE 628.960 /961 /962 /963, BA03.20-P-1000-02B
629
Balancing shaft ENGINE 271 BA03.20-P-1000-02C
Balancing shaft ENGINE 642 / BA03.20-P-1000-02D
Balance shaft ENGINE 155 BA03.20-P-1000-02G
Lanchester balancer ENGINE BA03.20-P-1000-03A
646.8 /961 /962 /963 /966
Flywheel, driven plate, ENGINE 601, 602, 603, 604, 605, BA03.30-P-1000-01A
vibration damper, starter 606, 611, 612, 613, 647...
ring gear
Flywheel, driven plate, ENGINE 103 /, 104 /, 111 BA03.30-P-1000-01B
vibration damper, starter
ring gear
Flywheel, driven plate, ENGINE 119, 120 BA03.30-P-1000-01C
ring gear
Flywheel, driven plate, ENGINE 112 /, 113 /, 137, 155 BA03.30-P-1000-01D
ring gear
Flywheel, driven plate, ENGINE BA03.30-P-1000-01E
vibration damper, starter 166.940 /960 /961 /990 /991 /995
ring gear
Flywheel, driven plate, ENGINE 668.914 /940 /941 /942 BA03.30-P-1000-01F
ring gear
Flywheel, driven plate, ENGINE 628.960 /961 /962 /963, BA03.30-P-1000-01G
vibration damper, starter 629, 642 /
ring gear
Flywheel, driven plate, ENGINE BA03.30-P-1000-01H
vibration damper, starter 646.8 /951 /961 /962 /963 /966,
ring gear 647, 648
Flywheel, driven plate, ENGINE 271, 275, 285 BA03.30-P-1000-01I
ring gear
Flywheel, drive plate, ENGINE 272, 273 BA03.30-P-1000-01M
ring gear
Flywheel, drive plate, ENGINE 266.920 /940 /960 /980 BA03.30-P-1000-01N
ring gear
Flywheel, driven plate, ENGINE 640 BA03.30-P-1000-01O
ring gear
Flywheel, driven plate, ENGINE 156 BA03.30-P-1000-01Q
ring gear
CONNECTING RODS - BA03.10-P-1000
Connecting rods - BA03.10-P-1000-01E
Engines 112, 113, 137, 155, 271, 272, 273, 275, 285
CONNECTING ROD
Number Designation Engines 112, Engine 137 Engine 155
113
BA03.10-P- Connecting rod Stage 1 Nm 5 5 -
1001-01E bolt Stage 2 Nm 25 15 -
Stage 3 Angle ° 90 90 -
CONNECTING ROD
CONNECTING ROD
Number Designation Engine 273 Engine 275, 285
Connecting rod - BA03.10-P-1000-01Q
Engine 156
CONNECTING ROD
01Q bearing cap on Stage 2 Angle° 90
CRANKSHAFT/BALANCING SHAFT - BA03.20-P-1000
Crankshaft - BA03.20-P-1000-01D
Engines 112, 113, 155, 272, 273

Number Designation Engines Engine 155 Engine 272
112, 113
BA03.20-P- Crankshaft M8 Stage 1 Nm 20 - 20
1001-01D bearing cap
bolt Stage 2 Angle° 90 - 90
BA03.20-P- Side M8 Nm 30 - 30
1002-01D crankshaft
bearing cap
bolt
BA03.20-P- Crankshaft M10 Stage 1 Nm 5 - 5
1003-01D bearing cap Stage 2 Nm 30 - 30
bolt Stage 3 Angle° 90 - 90

BA03.20-P-1001- Crankshaft M8 Stage 1 Nm 20
01D bearing cap bolt Stage 2 Angle° 90
BA03.20-P-1002- Side crankshaft M8 Nm 30
01D bearing cap bolt
BA03.20-P-1003- Crankshaft M10 Stage 1 Nm 5
01D bearing cap bolt Stage 2 Nm 30
Stage 3 Angle° 90
Crankshaft - BA03.20-P-1000-01J
Engine 156

1001-01J cap bolt (crankcase Stage 2 Nm 32
bottom section/main Stage 3 Angle° 90
bearing screw
Stage 4 Angle° 5
connection)
Stage 5 Angle° 90
Stage 6 Angle° 5
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 5
Stage 5 Angle° 90
Stage 6 Angle° 5
BA03.20-P- Crankcase bottom M6 Nm 8.5
1002-01J section on
crankcase top M8 Nm 20
section
BA03.20-P- Bearing bolt on crankcase at the front for chain drive Nm 20
1003-01J
BA03.20-P- Axle journal on crankcase at the front for chain drive Nm 30
1004-01J
BA03.20-P- Fastening for cover M6 Nm 8.5
1005-01J plate for oil
thermostat on
crankcase top
section
BA03.20-P- Oil line (oil cooler) M8 Nm 20
1006-01J with bracket
BA03.20-P- Knock sensor shield M8 Nm 20
1007-01J
BA03.20-P- Bolt for oil dipstick M6 Nm 8.5
1008-01J guide tube on
camshaft adjuster
cover
BA03.20-P- Drain plug for coolant Nm 15
1009-01J
Balancing shaft - BA03.20-P-1000-02A
Engine 112, 272
BALANCING SHAFT
Number Designation Motor 112 Engine 272
BA03.20-P-1001- Bolt of locking M7 x 16.5 Nm 15 -
02A plate to crankcase
BA03.20-P-1002- Bolt of balancing 1st stage Nm 20 15
02A weight to 2nd stage Angle° 90 90
balancing shaft Length mm ±50,7 -
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000
Flywheel, driven plate, vibration damper, starter ring gear - BA03.30-P-1000-01D

Engine 112, 113, 137, 155
MODIFICATION NOTES
9.1.06 Central bolt to vibration
damper

Number Designation Engine 112 Engine
113.94/96/97/98
BA03.30-P- Central bolt to Stage 1 Nm 200 200
1001-01D vibration damper Stage 2 Angle° 90 90
BA03.30-P- Bolt of two-mass Stage 1 Nm 45 45
1002-01D flywheel/drive
plate to crankshaft Stage 2 Angle° 90 90

Number Designation Engine Engine 137 Engine 155
113.990/991/992/993/995
BA03.30-P- Central bolt to Stage 1 Nm 200 200 200
1001-01D vibration
damper Stage 2 Angle° 90 90 90
BA03.30-P- Bolt of two- Stage 1 Nm 45 45 45
1002-01D mass
flywheel/drive
plate to Stage 2 Angle° 90 90 90
crankshaft
Flywheel, drive plate, vibration damper, starter ring gear - BA03.30-P-1000-01M
Engine 272, 273
FLYWHEEL, DRIVE PLATE, VIBRATION DAMPER, STARTER RING GEAR

BA03.30-P-1001- Center bolt for 1st stage Nm 200 200
01M belt pulley on
crankshaft 2nd stage Angle ° 90 90
BA03.30-P-1002- Bolt of starter 1st stage Nm 20 20
01M ring gear/drive 2nd stage Nm 45 45
plate to crankshaft 3rd stage Angle ° 90 90
BA03.30-P-1003- Bolt for flywheel 1st stage Nm 45 45
01M or two-mass
flywheel / drive 2nd stage Angle ° 90 90
plate to crankshaft
Flywheel, driven plate, vibration damper, starter ring gear - BA03.30-P-1000-01Q
Engine 156
MODIFICATION NOTES
22.3.06 Vibration damper on
crankshaft Bolt, starter
ring gear/drive plate to
crankshaft

BA03.30-P-1001- Vibration damper on Stage 1 Nm 200
01Q crankshaft Stage 2 Angle° 90
BA03.30-P-1002- Bolt, starter ring Stage 1 Nm 20
01Q gear/drive plate to Stage 2 Nm 45
crankshaft Stage 3 Angle° 90
BA03.30-P-1003- Guide wheel on M10 Nm 58
01Q crankcase
2006-2008 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 164 Chassis
2006-2008 ACCESSORIES & BODY CAB
Throttle Control, Speed Control Systems - 164 Chassis
BASIC KNOWLEDGE
COMPONENT DESCRIPTION FOR THE ACCELERATOR PEDAL SENSOR - GF30.20-P-2010AMG
Location on model 164, 251
Fig. 1: Identifying Accelerator Pedal Sensor - Model 164, 251

The accelerator pedal sensor is located at top right of accelerator pedal module.
Location for model 209, 211, 216, 219, 221
Fig. 2: Identifying Accelerator Pedal Sensor - Model 209, 211, 216, 219, 221
The accelerator pedal sensor is located at top right of accelerator pedal module.
The accelerator pedal sensor converts the mechanical operation input by accelerator pedal into an electrical
voltage corresponding to the accelerator pedal position.
Design of accelerator pedal module for model 164, 251
Fig. 3: Identifying Kickdown Simulator And Desolator Pedal Sensor Model 164, 251
The kickdown simulator is not an electrical component. It is designed to enable the driver to sense with his foot
the point at which the accelerator pedal is fully depressed (full load position).
The accelerator pedal sensor can only be replaced completely by an accelerator pedal module.
Design of accelerator pedal module, model 209, 211, 216, 219, 221
Fig. 4: Identifying Accelerator Pedal Sensor And Kickdown Simulator Model 209, 211, 216, 219, 221
The kickdown simulator is not an electrical component. It is designed to enable the driver to sense with his foot
the point at which the accelerator pedal is fully depressed (full load position).
The accelerator pedal sensor can only be replaced completely by an accelerator pedal module.
Body (internal circuit)
Fig. 5: Identifying Internal Circuitry Of Pedal Value Sensor

Function
The accelerator pedal sensor consists of a shaft with a ring magnet. The ring magnet rotates in a printed circuit
board with stator in the two fixed Hall elements. This produces a change in the voltage. The supply voltage of 5
V is performed by the ME-SFI [ME] control unit.N3/10 The supply voltage in the accelerator pedal sensor is
halved for sensor 2.
Information from the accelerator pedal position is fed in the form of two signal voltages to the ME-SFI [ME]
control unit.
If there is a fault on Signal 1 (sensor 1) the system switches over to Signal 2 (sensor 2) and limp-home is
activated.
Signal 1 ranges are defined as percentages of the supply voltage (approx. 5 V) as follows:
 <4.0% is the signal caused by short circuit to ground - too small

 4.0 to 9.4% - idle range
 9.4 to 81.0% - partial load range
 81.0 to 96.0% - full load range
 >96.0% the signal is too high due to a short-circuit to positive.
Kickdown recognition takes place by the ME-SFI [ME] control unit if the accelerator pedal sensor prescribes
full load for a certain time.
ACCELERATOR PEDAL SENSOR COMPONENT DESCRIPTION - GF30.20-P-2010BK

Location
The accelerator pedal sensor is located at the top of the accelerator pedal module.
Task
Detecting the accelerator pedal position and relaying corresponding voltage signals to the motor electronics
control unit.
Fig. 6: Identifying Accelerator Pedal Sensor Components

Shown: the internal circuit in the accelerator pedal sensor (Hall principle)
Fig. 7: Internal Circuit In Accelerator Pedal Sensor (Hall Principle)

Fig. 8: Design - Accelerator Pedal Sensor Component

Design
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical
The accelerator pedal sensor operating on the Hall principle is integrated in the pedal lever shaft and consists of
a shaft with a ring magnet. This rotates in a printed circuit board with stator in the fixed Hall elements. This
produces a change in the voltage.
Function
The accelerator pedal sensor is supplied via pin 1 from the ME control unit
with 5 V. Pin 3 and 6 are ground connections.
The information of the accelerator pedal position is transmitted to the motor electronics control unit in the form
of two signals (pin 5 with signal 1 has maximum approximately 4.8 V and pin 4 with signal 2 maximum
approximately 2.4 V).
In the accelerator pedal sensor, the supply voltage for sensor 2 is split in half.
 up to 4 % the signal is too small via short-circuit to ground or via line interruption
 4 to 9.4 % idle range
 9.4 to 81 % partial load range
 81 to 96 % full-load range
 above 96 % the signal is too high via short-circuit to positive.
In the event of an error at signal 1, a switchover to signal 2 takes place and emergency mode is activated.
Kick-down detection takes place via the accelerator pedal sensor, is signals 1 and 2 fall within full load range
for a certain period.
If the brake pedal is operated, only idle values will now be accepted by the accelerator pedal sensor. If required,
the engine control unit generates the substitute values. The signals from the accelerator pedal sensor are rejected
over this time
COMPONENT DESCRIPTION FOR THE ACCELERATOR PEDAL SENSOR - GF30.20-P-2010GZ
ENGINE 642 in MODEL 164.1 /8
ENGINE 642.970 in MODEL 463.303 /340 /341
Fig. 9: Identifying Accelerator Pedal Sensor (Illustrated On Model 164.1)

Location
The accelerator pedal sensor is located in the driver footwell at the right front.
Task
The accelerator pedal sensor detects the accelerator pedal position and supplies a matching voltage signal to the
CDI control unit (N3/9).
Design
The accelerator pedal sensor consists of a Hall sensor with an integrated Hall IC.
Function
The Hall sensor integrated in the accelerator pedal sensor detects the current position of the accelerator pedal by
means of the permanent magnets fitted on the pedal axis.
ACCELERATOR PEDAL SENSOR COMPONENT DESCRIPTION - GF30.20-P-2010V

View of accelerator pedal module
Fig. 10: Identifying Accelerator Pedal Sensor And Kickdown Simulator - Engines 272.920/940/941
Location
The accelerator pedal sensor is located at the top of the accelerator pedal module.
Task
Detects the accelerator pedal position and relays the corresponding voltage signals to the motor electronics
control unit.
Fig. 11: Exploded View Of Accelerator Pedal Sensor Components

Replace accelerator pedal module always complete!
Shown: the internal circuit in the accelerator pedal sensor (Hall principle)
Fig. 12: Internal Circuit Of Accelerator Pedal Sensor (Hall Principle)

Function
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical
The accelerator pedal sensor operating on the Hall principle is integrated in the pedal lever shaft and consists of
a shaft with a ring magnet. This rotates in a printed circuit board with stator in the fixed Hall elements. This
produces a change in the voltage.
The accelerator pedal sensor is supplied via pin 1 from the ME control unit with 5 V. Pin 3 and 6 are ground
connections.
The information of the accelerator pedal position is transmitted to the motor electronics control unit in the form
of two signals (pin 5 with signal 1 has maximum approximately 4.8 V and pin 4 with signal 2 maximum
approximately 2.4 V).
The supply voltage in the accelerator pedal sensor is halved for sensor 2.
 up to 4 % the signal is too small via short-circuit to ground or via line interruption
 4 to 9.4 % idle range
 9.4 to 81 % partial-load range
 81 to 96 % full load range
 above 96 % the signal is too high via short-circuit to positive.
Kick-down detection takes place via the accelerator pedal sensor, is signals 1 and 2 fall within full load range
for a certain period.
If the brake pedal is operated, only the idle speed values from the accelerator pedal sensor are accepted. If
necessary, the engine control unit will generate substitute values. The signals from the accelerator pedal sensor
are rejected over this time In the event of an error at signal 1, a switchover to signal 2 takes place and
emergency mode is activated.
COMPONENT DESCRIPTION FOR THE THROTTLE VALVE ACTUATOR - GF30.20-P-2020AMG

Location
Fig. 13: Identifying Variable Intake Manifold, Front And Rear Throttle Valve Actuator
The throttle valve actuator is located under housing bottom section in the variable intake manifold.
Task
The throttle valve actuator regulates the functions:
 Idle speed
 Driving mode (according to accelerator pedal position and engine load)
 Cruise control mode
 Electronic accelerator emergency mode
Function
Actuator motors (M16/3m1, M16/4m1) in the throttle valve actuator adjust the opening angle of the throttle
valve continuously from about 0 to 90° according to specifications from the ME-SFI [ME] control unit (N3/10).
Both throttle valves are always actuated at the same time (same opening angle for both throttle valves).
The ME-SFI [ME] control unit is informed about the current positions of the throttle valves by two actual value
potentiometers respectively operating in the opposite direction. In idle the signal from actual value
potentiometer sliding contact 1 (M16/3r3, M16/4r3) is at about 0.5 V and the signal from actual value
potentiometer sliding contact 2 (M16/3r4, M16/4r4) is at about 5 V.
In a deenergized state, the opening angle of the throttle valve (from 4°) is determined by a spring capsule (limp-
home position).
For "ignition ON" the ME-SFI [ME] control unit is always checking the limp-home position of the throttle
valves. Prerequisites for checking the limp-home position are:
 Ignition ON
 Drive position P or N
 Vehicle at rest
 Engine OFF
 Coolant temperature 5 to 100°C
 Accelerator not operated
For first time connection of a throttle valve actuator to the vehicle the ME-SFI [ME] control unit automatically
execution adaptation of the actuator. These include:
 Determining the limp-home position of the throttle valve

 Determining the lower mechanical stop of the throttle valve
 Adaptation of the actual value amplifier (from signal 1 and 2) in the ME-SFI [ME] control unit
COMPONENT DESCRIPTION OF THROTTLE VALVE ACTUATOR - GF30.20-P-2020BK
Location
The throttle valve actuator is flanged to the intake manifold at the rear.
Fig. 14: Identifying Throttle Valve Actuator Components

Task
 Idle speed
 Driving mode, corresponding with the accelerator pedal position and load

 Emergency electronic accelerator pedal
Design
Fig. 15: Design - Throttle Valve Actuator Components

Fig. 16: Identifying Throttle Valve Actuator, Actual Value Potentiometer And Actuator Motor
Function
The actuator motor in the throttle valve actuator continuously adjusts the throttle valve from around 0 to 90°
according to the specified value in the ME control unit.
The typical power consumption of the pulse width modulation signal is
approx. 1 A, however it is possible up to approx. 9 A. For output stage protection the power is limited to 6 A
after approx.
30 seconds.
The actual value potentiometers advise the current position of the throttle valve to the ME control unit.
The signals of both actual value potentiometer are opposed.
A. Ignition "Off"
In deenergized status, the throttle valve position is determined by the spring capsule (8 to 10° opening
angle).
B. Ignition "On"
When the ignition is switched on, the actuator motor in the throttle valve actuator is operated by the ME
control unit.
The throttle valve adopts a position which depends on the coolant temperature.
C. Idle speed
Depending upon the coolant temperature and engine load, the actuator motor changes the rpm in the idle
speed range by opening the throttle valve further (increased mixture) or closing it further.
(less mixture).
Here, the throttle valve can be closed further by the actuator motor against force of the spring capsule.
D. Driving mode
In the driving mode (full / partial load), the actuator motor changes the throttle valve position depending
on the different load states and / or according to the input signals from the accelerator pedal sensor
dependent on the performance maps.
E. Emergency running
If the actuator is deenergized, the throttle valve is set to approx. 8 to 10° opening angle by the spring
capsule.
In the idle speed range, this results in an engine speed of approx. 1200 to 1400/min.
For first time connection of the throttle valve actuator to circuit 30 or 87, the ME control unit carries out
automatically within approx. 60 seconds the following actions:
 Determining the emergency running position

 Determining the lower mechanical stop
 matches actual value amplifier (signal 1 and 2) in the ME control unit.
 Inspection of return spring (always performed with ignition ON)
Requirement: Drive position P or N, vehicle is stationary, engine OFF, ignition ON, coolant temperature 5°C up
to 100°C and accelerator pedal not operated.
The procedure must be activated using STAR DIAGNOSIS, if the throttle valve actuator or the ME control unit
have been replaced, otherwise the engine may surge.
THROTTLE VALVE ACTUATOR, COMPONENT DESCRIPTION - GF30.20-P-2020P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
ENGINE 642.970 in MODEL 463.303 /340 /341
Fig. 17: Locating Throttle Valve Actuator

Location
The throttle valve actuator is located on the engine at the right front.
Task
The throttle valve actuator regulates the fresh air quantity and mixes the recirculated exhaust with fresh air.
Function
The throttle valve actuator is actuated by the CDI control unit (N3/9) over a pulse width modulation signal and
controls the fresh air quantity via the installed throttle valve.
Through connection of the exhaust gas recirculation with the mixing throttle, the suctioned fresh air is mixed
with the recirculated exhaust.
COMPONENT DESCRIPTION FOR THE THROTTLE VALVE ACTUATOR - GF30.20-P-2020V

Fig. 18: Identifying Throttle Valve Actuator

Location
The throttle valve actuator is flanged to the intake manifold at the rear.
Task
 Idle speed
 Drive mode, according to accelerator pedal position, load and requests of momentary interface
 Engine 272.985: In stratified charge operation with excess air, open the throttle valve as far as possible
according to the performance map.

 Emergency electronic accelerator pedal
Design
Fig. 19: Throttle Valve Actuator Design

Fig. 20: Identifying Throttle Valve Actuator Circuit Diagram

Function
The actuator motor (M16/6m1) in the throttle valve actuator (M16/6) adjusts the opening angle of the throttle
valve (1) continuously from approx. 0 to 90° according to presets from the ME-SFI [ME] control unit.
The typical power consumption of the pulse width modulation signal is approx. 1 A, however it is possible up to
approx. 9 A. For output stage protection the power is limited to 6 A after approx. 30 seconds. The actual value
potentiometers (M16/6r3, M16/6r4) advise the current position of the throttle valve to the ME-SFI [ME] control
unit. The signals of both actual value potentiometer are opposed.
A. Ignition "Off"
In a de-energized state, the throttle valve position is determined by the spring capsule (3) (8 up to 10°
opening angle).
B. Ignition "On"
When the ignition is switched on, the actuator motor in the throttle valve actuator is operated by the ME-
SFI [ME] control unit.
The throttle valve adopts a position which depends on the coolant temperature.
C. No-load speed
Depending upon the coolant temperature and engine load, the actuator motor changes the rpm in the idle
speed range by opening the throttle valve further (increased mixture) or closing it further. (less mixture).
Here, the throttle valve can be closed further by the actuator motor against the force of the spring capsule.
D. Driving mode
In the driving mode (full / partial load), the actuator motor changes the throttle valve position depending
on the different load states and / or according to the input signals from the accelerator pedal sensor
dependent on the performance maps.
E. Emergency running
If the actuator is de-energized, the throttle valve is set by the spring capsule to approx. 8 to 10° opening
angle.
In the idle speed range, this results in an engine speed of approx. 1200 to 1400/min.
For first time connection of the throttle valve actuator to circuit 30 or 87, the ME-SFI [ME] control unit
carries out automatically within approx. 60 seconds the following actions:
 Determines the emergency running position

 Determines lower mechanical stop
 Matches the actual value amplifier (signal 1 and 2) in the ME-SFI [ME] control unit.
 Checks the return spring (always takes place when ignition ON) Prerequisite: gear P or N, vehicle
stationary, engine OFF, ignition ON, coolant temperature 5°C to 100°C and accelerator pedal not
operated.
The procedure must be activated with STAR DIAGNOSIS, if the throttle valve actuator or the ME-SFI [ME]
control unit was replaced, otherwise engine surges can occur.
CRUISE CONTROL PUSH-BUTTON SWITCH COMPONENT DESCRIPTION - GF30.20-P-2100BK
Location
The CC push-button switch is located at the top of the steering column module.
Fig. 21: Identifying Cruise Control Push-button Switch Components

Task
Set by
 Cruise control/Distronic (special equipment)

 Variable speed limitation (except
 Downhill Speed Regulation (model 164.1).
Function
When the cruise control push-button switch is operated, two switching contacts are always activated
simultaneously.
The actual input is performed by one switch contact closing, e.g. for storing the speed. The safety contact must
close simultaneously so that the input is accepted.
The switching signals are detected by the steering column module and transmitted to the CAN databus.
COMPONENT DESCRIPTION FOR THE CC [TPM] SWITCH - GF30.20-P-2100GR
ENGINE 113, 156, 272, 629, 642 in MODEL 164.1 with CODE (219) Distronic (DTR) with CODE (491)
USA version
ENGINE 273, 629, 642 in MODEL 164.8 with CODE (219) Distronic (DTR) with CODE (491) USA
version
ENGINE 113, 156, 272, 642 in MODEL 251 with CODE (219) Distronic (DTR) with CODE (491) USA
version
Location
The CC [TPM] switch is located at the top left of the steering column.
Fig. 22: Identifying CC [TPM] Switch

Task
The CC [TPM] switch has the following tasks:
 Activate/deactivate the function DISTRONIC PLUS

 Increase or decrease setting/nominal speed in 1 mph or in 10 mph steps (two settings) for DISTRONIC
and Downhill Speed Regulation
 Set target proximity for DISTRONIC
Design
Fig. 23: Design - CC [TPM] Switch

Function
Fig. 24: Function - CC [TPM] Switch

When the CC [TPM] switch is operated, two switching contacts are always activated simultaneously. The actual
input takes place by closing the switching contacts (storing the target speed). The safety contact (S40s5) must
close simultaneously so that the entry is accepted.
The DISTRONIC distance potentiometer allows the driver to adjust the target distance to the preceding vehicle
to suit his/her own personal taste.
The setting range of the target distance is divided into six increments and is approx. 1.0 s to 2.0 s depending on
vehicle speed.
Within this setting range the legally prescribed minimum distance is always guaranteed.
The CC [TPM] switch signals are read in by the steering column module (N80) and transmitted via the drive
CAN to the ESP control unit (N47-5) for evaluation.
COMPONENT DESCRIPTION FOR THE CC [TPM] SWITCH - GF30.20-P-2100GZ
ENGINE 113, 156, 272, 629, 642 in MODEL 164.1
ENGINE 273, 629, 642 in MODEL 164.8
ENGINE 642.970 in MODEL 463.303 /340 /341
Shown on model 164 except code (494) USA version
Fig. 25: Function - CC [TPM] Switch (Shown On Model 164 Except Code (494) USA Version)
Shown on model 164 with code (494) USA version

Fig. 26: Function - CC [TPM] Switch (Shown On Model 164 With Code (494) USA Version)
Task
The Cruise control switch detects the CC [TPM] switch functions operated by the driver, the Variable Speed
Limiter (except code (494) USA version) and Downhill Speed Regulation.
Function
When the CC [TPM] switch is operated, two switching contacts are always activated simultaneously. The actual
input takes place by closing the switching contacts (storing the target speed). The control contact must close
simultaneously so that the input is accepted. Signals from the Cruise control switch are read in by the steering
column module (N80) and transmitted for evaluation via the Controller Area Network (data bus/CAN bus)
(CAN) to the ESP control unit (N47-5), for model 164, or to the ESP and BAS control unit (N47-5), for model
463.
COMPONENT DESCRIPTION FOR THE CC [TPM] SWITCH. - GF30.20-P-2100V

Location
Fig. 27: Locating Components For CC [TPM] Switch - Engines 272.920/940/941

The CC [TPM] switch is located at the top left of the steering column module (N80).
Task
The CC push-button switch switches the cruise control functions, Distronic (with Distronic) and variable speed
limitation (except ) on and off.
Function
When the cruise control push-button switch is operated, two switching contacts are always activated
simultaneously. The actual input takes place by closing the switching contacts (storing the speed). The safety
contact must close simultaneously so that the input is accepted. The shift signals from the CC push-button
switch are detected by the steering column module and transmitted to the CAN data bus.
For Distronic (DTR)
The Distronic control unit (N63/1 up to 06/2004 and A89n1 as of 07/2004) evaluates shift signals for operation
of Distronic and sends corresponding signals for speed limitation to the ME-SFI [ME] control unit (N3/10).
Up to 05/2005
The ME-SFI [ME] control unit evaluates shift signals for operation of cruise control and variable speed
limitation (except ).
From 06/2005
The ESP control unit, ESP and BAS control unit or ESP, SPS [PML] and BAS control unit (N47-5) evaluate the
shift signals for operation of cruise control and variable speed limitation (except ) and send corresponding
signals for the purpose of speed limitation to the ME-SFI [ME] control unit.
ME-SFI ELECTRONIC ACCELERATOR, FUNCTION - GF30.20-P-3012AMG

Fig. 28: ME-SFI Electronic Accelerator Function Diagram

The electronic accelerator function (EFP) is integrated in the ME-SFI [ME] control unit and controls the
opening angle of the throttle valves depending on driver input and the operating condition.
Input signals for the electronic accelerator pedal:
 Accelerator pedal position (from accelerator pedal sensor)

 Air mass (from hot film mass air flow sensor)
 Brake actuation (via the ESP control unit)
 Cruise control operation (from ESP control unit)
 Request from torque interface (e.g. from ESP control unit and electric controller unit (VGS))
 Selector lever position (from electronic selector lever module control unit for model 209, 211, 219 or
from intelligent servo module for DIRECT SELECT for model 164, 216, 221, 251)
 Drive positions (from electric controller unit (VGS))
If the brake pedal is operated, this always means idle speed input.
The position of the accelerator pedal and speed at which the position of the accelerator pedal changes are
transmitted to the sensor located on the accelerator pedal mechanically.
The Hall sensor in the accelerator pedal sensor sends an appropriate voltage signal to the motor electronics
control unit. The ME-SFI [ME] control unit analyzes the voltage signal and actuates the throttle valve actuators
in parallel according to the performance map.
The opening angles of throttle valves are altered by the actuator motors in the actuators according to actuation
by the ME-SFI [ME] control unit.
The opening angles of throttle valves are only determined by the accelerator pedal request if no limiting
function are active (e.g. idle request or a torque reduction).
The actual value potentiometer in actuators report the current throttle valves to the ME-SFI [ME] control unit.
The second potentiometer in the throttle valve actuators and the second Hall sensor in the accelerator pedal
sensor deliver reference values for plausibility checking of input signals to the ME-SFI [ME] control unit.
Ignition "On"
Upon switching on the ignition, throttle valve actuators are actuated by the ME-SFI [ME] control unit and take
on a throttle valve position dependent on the coolant temperature.
Reverse travel
If reverse travel (selector lever position "R") is recognized by the ME-SFI [ME] control unit, the throttle valve
are opened more slowly and the maximum opening angle of the throttle valves is limited to about 50%.
This function has the task of optimizing ride comfort and safety when reversing.
Adaptive accelerator pedal
The ME-SFI [ME] control unit recognizes how rapidly the accelerator pedal is being actuated and switches
between characteristic curves.
After approx. 50% pedal travel by a sporty driver, around 80% of engine load is released and by a smooth
driver, around 40%. From a pedal travel of about 90% the full load request takes place for both characteristic
and there no difference noticeable anymore.
If, for example, the characteristic curve for a quiet driver is active after a long drive on the freeway then the
accelerator pedal must be pressed down unusually hard to obtain a higher acceleration level.
Additional functions of the electronic accelerator pedal:
 Idle speed control

 Cruise control (CC [TPM])
 Variable/Permanent Speed Limiter
 Torque interface
 Emergency running
 Fault storage
 Data transfer over CAN
Component description B70 GF07.04-P-6220AMG

for crankshaft Hall sensor
Component description B2/6, B2/7 GF07.07-P-6000AMG
for the hot film mass air

flow sensor
Component description N3/10 GF07.61-P-6000AMG
for the ME-SFI [ME]
control unit
for the accelerator pedal
sensor
Component description M16/3, M16/4 GF30.20-P-2020AMG
for the throttle valve
actuator
ME-SFI ELECTRONIC ACCELERATOR, FUNCTION - GF30.20-P-3012BK
Fig. 29: Function - ME-SFI Electronic Accelerator

The function of the electronic accelerator (EA) N3/10 the ME-SFI control unit determines the opening angle of
the air recirculation flap in line with the accelerator pedal input.
The position of the accelerator pedal and the speed at which the position of the accelerator pedal changes are
transmitted to the sensor (B37) located on the accelerator pedal mechanically.
The Hall sensor in the accelerator pedal sensor sends an appropriate voltage signal to the motor electronics
control unit. The motor electronics control unit analyzes the voltage signal and depending upon the performance
map, activates the throttle valve actuator motor.
The opening angle of the throttle valve will only be determined by the accelerator pedal specification when no
limiting functions are active.
The actual value potentiometer 1 in the throttle valve actuator reports the current position of the throttle valve to
the motor electronics control unit.
The second potentiometer in the throttle valve actuator and the second signal from the pedal value sensor supply
a reference value for a plausibility check. Furthermore, a switchover to the additional sensor takes place if the
first signal fails (emergency mode).
Further functions are:

 Variable speed limiter, except
 Requests of momentary interface, such as:
 Reducing or increasing the engine torque for ESP operation
 Load limitation when coolant temperature is too high
 Reducing engine torque during gear-shift operation
 Reduces engine torque at maximum speed
 Fault storage
 Data exchanger via CAN
The input signals for the EA function are:
 Accelerator pedal sensor

 Stop lamp switch (CAN message "Driver applies brakes")
 Hot film mass air flow sensor
 CC [TPM] switch
 Requirement of torque interface
 Information selector lever position P/N and drive position engaged from transmission control unit.
When braking is detected, the idle speed is always controlled.
Reversing
If reversing is detected by the ME control unit through a CAN message from the transmission control unit, the
throttle valve is opened more slowly. The maximum opening angle of the throttle valve is limited to around 50
%.
This function has the task of optimization of ride comfort and safety when reversing.
The ME control unit recognizes how the accelerator pedal is being actuated and switches between characteristic
curves. Eighty percent of the engine load is released for a pedal travel of about 50 % for a sporty driver and
about 40 % for a quiet driver. There no further difference to be felt after about 90 % of the full pedal travel.
If, for example, the characteristic curve for a quiet driver is active after a long drive on the motor-way then
the accelerator pedal must be pressed down unusually hard to obtain a higher acceleration level.
Motor electronics control unit component description GF07.61-P-6000BK

Accelerator pedal sensor component description GF30.20-P-2010BK
Component description of throttle valve actuator GF30.20-P-2020BK
Component description of hot film MAF sensor GF07.07-P-6000BK
ME-SFI ELECTRONIC ACCELERATOR, FUNCTION - GF30.20-P-3012V

Shown on engine 272 in model 171

Fig. 30: ME-SFI Electronic Accelerator Function Diagram - Shown On Engine 272 In Model 171
The electronic accelerator function is integrated and controlled in the motor electronics control unit depending
on the driver input and the operating condition, the opening angle of the throttle valve.
Input signals for the electronic accelerator pedal:
 Accelerator pedal position

 Brake actuation (from ESP control unit)
 Cruise control operation (from ESP control unit)
 Engine torque requirements (via CAN)
 Gear ranges (over electronic selector lever module control unit (N15/5)) (for automatic transmission
722.9)
 Clutch operating system (for manual transmission 716.6)
 Reverse travel (for manual transmission 716.6)
The position of the accelerator pedal and speed at which the position of the accelerator pedal changes are
transmitted to the sensor located on the accelerator pedal mechanically. The Hall sensor in the accelerator pedal
sensor sends an appropriate voltage signal to the ME-SFI [ME] control unit. The ME-SFI [ME] control unit
analyzes the voltage signal and, depending on the performance map, activates the throttle valve actuator. The
opening angle of the throttle valve is altered appropriately by the actuator motor (M16/6m1) in the throttle valve
actuator.
The opening angle is only determined by the accelerator pedal request if no limiting functions are active (e.g.
idle request or a torque reduction).
The throttle valve actual value potentiometer (M16/6r1) reports the current throttle valve position back to the
ME-SFI [ME] control unit.
Throttle valve damping
The throttle valve damping function closes the throttle valve up to the idle speed range with a time delay if the
accelerator pedal is suddenly released. In this way, the engine torque goes down slowly and the vehicle does not
slow down with jerks.
Following input signals are processed:
 Change in the speed of the accelerator pedal position.

 Engine speed
 Throttle valve position
 Vehicle speed
Reversing
If the ME-SFI [ME] control unit recognizes a reverse travel, the throttle valve will be opened more slowly and
the maximum opening angle limited to about 50%. This function has the task of optimizing ride comfort and
safety when reversing.
The ME-SFI [ME] control unit evaluates how the accelerator pedal is being actuated and switches between
characteristic curves. After a 50% pedal travel, about 80% of the engine load is released for a sporty driver and
40% of the engine load is released for a quiet driver.
There is no further difference felt above a pedal travel of about 90%.
If, for example, the characteristic curve for a quiet driver is active after a long drive on the freeway then the
accelerator pedal must be pressed down unusually hard to obtain a higher acceleration level.
Additional functions of the electronic accelerator pedal:

 Cruise control (CC [TPM])
 Torque interface
Component description GF07.04-P-6220V

for the crankshaft Hall
sensor

flow sensor
for the ME-SFI [ME]
control unit
Component description With manual GF29.10-P-2200V
for the clutch pedal transmission (716.6)
switch
sensor
actuator
for the CC [TPM] switch
ELECTRONIC ACCELERATOR PEDAL EMERGENCY RUNNING MODE, FUNCTION - GF30.20-

P-4026AMG

Fig. 31: Electronic Accelerator Pedal Emergency Running Mode Function Diagram
The task of the electronic accelerator emergency mode consists in ensuring that the vehicle can continue to be
driven safely even in case of faults in the electronic accelerator system (EA).
Accelerator pedal sensor emergency running
If a Hall sensor fails, the system switches over to the second Hall sensor. Throttle valve openings are limited to
about 60% of the maximum opening. Furthermore the speed at which the throttle valve opens is dynamically
limited (throttle valve opens with a delay).
If the plausibility check is negative or if both Hall sensors fail, only idle speed is then still controlled.
Emergency mode in the event of failure of the throttle valve potentiometer
If one potentiometer fails, the system switches over to the second, intact potentiometer. The air mass value of
the sequential multiport fuel injection system is used as an additional comparative parameter. If both
potentiometers of a throttle valve actuator are defective then every two throttle valve actuators will be de-
energized and the throttle valve brought into the limp-home position of a 4° opening angle by the spring
capsules.
Emergency mode in the event of failure of the throttle valve actuator
The throttle valve actuators are switched to a denergized state and the throttle valve is brought to the limp-home
position of a 4° opening angle by the spring capsules.
Engine speed control with throttle valve in emergency mode position

In the idle speed range, engine speed is regulated to approx. 1200 rpm up to 1400 rpm by shutting off and
switching on cylinders on fuel side.
While driving, depending on the engine load, engine speed is controlled to about 1800 rpm by switching the
cylinders on and off on the fuel side. In doing so, the maximum engine speed is determined by the limp-home
position of the throttle valves.
Limp-home is recognizable from a significantly surging engine running characteristic.
Faults detected by the accelerator pedal sensor and throttle valve actuators are stored in the fault memory and
can be read out and deleted with the STAR DIAGNOSIS.
The input signals for switching the cylinder on and off (fuel injection valves) are:
 Engine speed
 Brake detection (via the ESP control unit)
 Drive position recognition (via the electric controller unit (VGS))
Component description Y62y1-Y62y8 GF07.03-P-6010AMG

for fuel injection valves
sensor
Component description B2/6, B2/7 GF07.07-P-6000AMG
flow sensor
for the ME-SFI [ME]
control unit
sensor
Component description M16/3, M16/4 GF30.20-P-2020AMG
actuator

P-4026BK

Fig. 32: Function - Electronic Accelerator Pedal Emergency Running Mode

The task of the emergency running consists of enabling a safe continuation of journey if interference occurs at
the electronic accelerator.
Accelerator pedal sensor, emergency mode
If a Hall sensor fails, the system switches over to the second Hall sensor. The throttle valve opening is limited to
approx. 60%. In addition, the throttle valve opening rate is dynamically limited, in other words the throttle valve
opens with a time delay.
If the result of the plausibility check is negative, or if both potentiometers are faulty, only the idle speed is then
controlled.
Throttle valve actuator, emergency mode (electrical)
If a potentiometer fails, the system switches over to the second potentiometer. The signal from the hot film
MAF sensor is used as an additional comparative size.
If the plausibility check is negative or if both potentiometers are faulty, the throttle valve adopts a mechanical
emergency running position (approx. 8 to 10°) which is fixed by the spring capsule in the throttle valve actuator
(EPC malfunction indicator lamp comes on).
Throttle valve actuator, emergency mode (mechanical)
If the actuator motor is defective or there are other mechanical faults present, the power supply to the throttle
valve actuator will be shut off.
The throttle valve is resting against the mechanical stop (spring capsule) as a result of which the throttle valve
opening is maintained constantly at approx. 8 to 10°.
In neutral at engine speeds of > 1400 rpm, the fuel injection valves are deactivated and then reactuated at engine
speeds < 1200 rpm.
While driving, depending on the engine load, engine speed is controlled by switching the cylinders on and off
on the fuel side.
The maximum engine speed is approx. 1800 rpm and is fixed by the mechanical stop.
Faults detected by the accelerator pedal sensor and the throttle valve actuator are stored in the diagnostic
trouble code memory and can be read out and deleted with the STAR DIAGNOSIS.
Emergency mode can be identified by the obviously surging engine.

Accelerator pedal sensor component description GF30.20-P-2010BK
Component description of throttle valve actuator GF30.20-P-2020BK
Component description of hot film MAF sensor GF07.07-P-6000BK
Crankshaft position sensor component description GF07.04-P-6010BK
Fuel injection valves, component description GF07.03-P-6010BK

P-4026V

Shown on Engine 272.963 in Model 171

Fig. 33: Electronic Accelerator Pedal Emergency Running Mode Function Diagram - Shown On Engine
272.963 In Model 171
The task of the emergency running consists of enabling a safe continuation of journey if interference occurs at
the electronic accelerator.
Accelerator pedal sensor, emergency mode
If a Hall sensor fails, the system switches over to the second Hall sensor. The throttle valve opening is limited to
approx. 60%. In addition, the throttle valve opening rate is dynamically limited, in other words the throttle valve
opens with a time delay.
If the result of the plausibility check is negative, or if both potentiometers are faulty, only the idle speed is then
controlled.
Throttle valve actuator, emergency mode (electrical)
If a potentiometer fails, the system switches over to the second potentiometer. The signal from the hot film
MAF sensor is used as an additional comparative size.
If the plausibility check is negative or if both potentiometers are faulty, the throttle valve adopts a mechanical
emergency running position (approx. 8 10°) which is fixed by the spring capsule in the throttle valve actuator
(EPC malfunction indicator lamp comes on).
Throttle valve actuator, emergency mode (mechanical)

If the actuator motor is defective or there are other faults present the power supply to the throttle valve actuator
will be shut off. The throttle valve is resting against the mechanical stop (spring capsule) as a result of which
the throttle valve opening is maintained constantly at approx. 8 to 10°.
In neutral at engine speeds of > 1400/min, the fuel injection valves are deactivated and at engine speeds of <
1200 rpm actuated again.
While driving, depending on the engine load, engine speed is controlled by switching the cylinders on and off
on the fuel side. The maximum engine speed is approx. 1800 rpm and is fixed by the mechanical stop.
Faults detected by the accelerator pedal sensor and the throttle valve actuator are stored in the diagnostic
trouble code memory and can be read out and deleted with the STAR DIAGNOSIS.
Emergency mode is recognizable on a clearly surging engine running.
ME-SFI [ME] control GF07.61-P-6000V

unit component
description
Accelerator pedal sensor GF30.20-P-2010V
Component description of GF30.20-P-2020V
throttle valve actuator
Crankshaft Hall sensor, GF07.04-P-6220V
Hot film MAF sensor, GF07.07-P-6000V
ME-SFI IDLE SPEED CONTROL, FUNCTION - GF30.22-P-0003V

Shown on engine 272.963 in model 171

Fig. 34: ME-SFI Idle Speed Control Function Diagram - Shown On Engine 272.963 In Model 171
The throttle valve actuator controls the idle speed by altering the position of the throttle valve. It is actuated by
the ME-SFI control unit.
To assist the idle speed control, the ignition angle can be retarded by as much as 36° crank angle and advanced
by as much as a 20° crank angle.
The ME control unit actuates the throttle valve motor in line with the input signals received at the ME control
unit.
The throttle valve actuator controls the idle speed:
 At different engine loads, e.g. steering turned to full lock (power steering pump), drive position engaged,
clutch pedal actuated, refrigerant compressor engaged
 In the warming-up phase
 At undervoltage
 At different mixture composition e.g. through lambda control or fuel evaporation control system.
Heating-up speed
In order to warm up the catalytic converters more rapidly to operating temperature, the engine speed is
increased in the idle speed range to 1100 up to 1300 rpm for about 20 seconds after each starting procedure at
coolant temperatures of < 40°C. Following this period, the idle speed is increased at a coolant temperature < 70°
C for around 50 seconds by approx. 50 to 100/rpm. When a drive position is selected, this is immediately
reduced.
Automatic transmission (AT)
When a drive position is engaged, a lower engine speed is controlled in order to reduce the creeping tendency of
the vehicle.
The information "Drive position engaged/not engaged" is transmitted by the transmission control unit via the
CAN data bus to the ME control unit.
AC compressor
To avoid engine speed dropping in the idle speed range when the AC compressor is engaged, the automatic air
conditioning control system issues a signal to the ME control unit via the CAN data bus which is adapted
appropriately to the idle speed (increased).
When the air conditioning unit is switched on and the external temperature exceeds 35°C, the idling speed is
increased for the driving mode selected by about 100 rpm when the switch-on threshold of about 900 rpm is
exceeded. This increase is canceled again when the external temperature drops below 32° C.
Undervoltage
If the engine control unit detects an undervoltage the idling speed is increased until the ignition is switched off
for the driving mode selected by about 100 rpm.

for the ME-SFI [ME]
control unit
sensor
for the coolant
temperature sensor
actuator
for the intake manifold
for the ignition coil
Component description with manual transmission GF29.10-P-2200V
for the clutch pedal
switch

sensor
CRUISE CONTROL (CC) FUNCTION - GF30.30-P-0001BK
Fig. 35: Function - Cruise Control (CC)

The cruise control must maintain the preselected speed constant irrespective of the load condition, without the
accelerator pedal being operated.
The cruise control function can be actuated from > 40 km/hour using the Cruise control push-button switch. The
engine control unit operates the throttle valve actuator for the cruise control function with the aid of the input
signals and the position of the cruise control switch.
The cruise control mode is switched off by:
 Moving the cruise control switch into OFF position

 Actuation of the service brake (CAN message)
 Moving selector lever into position "N"
 Operation of the clutch pedal
 Control intervention function of the traction system.
The signals from the push-button switch for the cruise control are detected by the steering column module and
transmitted to the CAN data bus.
The speed signal is transmitted by the traction system control unit (ESP) via the CAN to the engine control unit.
The software for the Cruise control is stored according to model and equipment either in the ESP control unit
or in the City Assist System control unit.
Variable speed limiter (VSL), except
Switching in the variable speed limit takes place through pressing the Cruise control push-button switch (yellow
light emitting diode lights up).
The vehicle speed limit is set by means of the variable cruise control switch.
If the braking effect in overrun mode is not sufficient to maintain the speed at a high gradient, a chime will
request the driver to brake. Vehicles with Distronic (DTR) are braked.
Deviating functions compared to cruise control:
 Variable speed-governor function (VGB) adjustable from 30 km/h (20 mph) to the top speed of the
vehicle.
 The accelerator pedal must be actuated further.
 When the brakes are applied the variable speed limit is not switched off.
 When the ignition is switched OFF the preset speed data remain stored in the variable cruise control
system.
Component description for the ME-SFI [ME] control unit GF07.61-P-6000BK

Component description for the Cruise control push-button switch GF30.20-P-2100BK
Component description for the accelerator pedal sensor GF30.20-P-2010BK
Component description for the stop lamp switch GF42.10-P-2010BK
Component description for the throttle valve actuator GF30.20-P-2020BK
CRUISE CONTROL (CC) FUNCTION - GF30.30-P-0001V

Fig. 36: Cruise Control (CC) Function Diagram - Shown On Engine 272.963 In Model 171
The cruise control must maintain the preselected speed constant irrespective of the load condition, without the
accelerator pedal being operated.
The Cruise control function can be actuated using the Cruise control push-button switch. The engine control
position of the cruise control push-button switch.
The cruise control mode is switched off by:
 Moving the cruise control switch into OFF position

 Actuation of the service brake (CAN message)
 Moving selector lever into position "N"
 Operation of the clutch pedal
 Control intervention function of the traction system.
The signals from the push-button switch on the cruise control are detected by the steering column module and
transmitted over the CAN data bus to the engine control unit.
The speed signal is transmitted by the traction system control unit (ESP) via the CAN to the engine control unit.
Variable speed limiter (VSL), except
Switching in the variable speed limit takes place through pressing the Cruise control push-button switch (yellow
light emitting diode lights up). The vehicle speed limit is set by means of the variable cruise control switch.
If the braking effect in overrun mode is not sufficient to maintain the speed at a high gradient, a chime will
request the driver to brake.
Vehicles with Distronic (DTR) are braked.
Deviating functions compared to cruise control:
 Variable speed-governor function (VGB) adjustable from 30 km/h (20 mph) to the top speed of the
vehicle.
 The accelerator pedal must be actuated further.
 When the brakes are applied the variable speed limit is not switched off.
 When the ignition is switched OFF the preset speed data remain stored in the variable cruise control
system.

for the ME-SFI [ME]
control unit
for the Cruise control
push-button switch
actuator
DISTRONIC, LOCATION OF COMPONENTS - GF30.30-P-0005-01GZ
Fig. 37: Location Of DISTRONIC Components

DISTRONIC, DISPLAY AND OPERATING ELEMENTS - GF30.30-P-0005-02GZ
Without Offroad package, code 430
Fig. 38: Identifying DISTRONIC, Display And Operating Elements (Without Offroad Package, Code
430)
With Offroad package, code 430
Fig. 39: Identifying DISTRONIC, Display And Operating Elements (With Offroad Package, Code 430)
DISTRONIC FUNCTION DIAGRAM - GF30.30-P-0005-03GZ
Fig. 40: DISTRONIC Function Diagram

DISTRONIC RADAR SENSOR GROUP - GF30.30-P-0005-04GZ

Fig. 41: Identifying DISTRONIC Radar Sensor Range

Detection range of radar sensor (schematic)
With a low radar beam divergence 9° (sharp focussing), the radar sensor covers a very narrow area in front of
the vehicle. For this reason, it is only used above a speed of 30 km/h (at greater safe distances).
Its detection range measures up to 150 m.
The radar sensor, which functions according to the "Pulse Doppler Principle", can measure the distance and the
speed of individual objects (vehicles) independently of each other.
DISTRONIC, OVERALL FUNCTION - GF30.30-P-0005GZ
ENGINE 113, 156, 272, 629, 642 in MODEL 164.1 with CODE (219) Distronic (DTR)
ENGINE 273, 629, 642 in MODEL 164.8 with code (219) Distronic (DTR)
ENGINE 113, 156, 272, 642 in MODEL 251 with CODE (219) Distronic (DTR)
Fig. 42: DISTRONIC, Overall Function Diagram

DISTRONIC, operation
The systems described below belong to the driving assistance systems and are offered as special equipment
(SA) under the designation "DISTRONIC" with Code 219.
The DISTRONIC special equipment includes the following functionality:
 DISTRONIC (DTR)
 Distance warning system (AWS)
 Variable Speed Limiter (except )
 Permanent Speed Limiter
DISTRONIC
Using a radar sensor, DISTRONIC maintains the vehicle at a target distance from the vehicle ahead, set by the
driver, and alerts the driver via visual and audible signals before dangerous situations arise.
The electronics activates the brakes automatically when the target distance falls short and reaccelerates back up
to the target speed as soon as the traffic situation permits.
Distance warning system
The distance warning system is an additional function of DISTRONIC.
Independently of the DISTRONIC distance control, the driver can activate or deactivate the distance warning
system in the instrument cluster (A1) via a menu in the instrument cluster.
DISTRONIC, location of components GF30.30-P-0005-01GZ

DISTRONIC, display and operating elements GF30.30-P-0005-02GZ
DISTRONIC function diagram GF30.30-P-0005-03GZ
DISTRONIC radar sensor group GF30.30-P-0005-04GZ
Downhill Speed Regulation, function GF28.19-P-3600GR
Variable Speed Limiter, function GF30.30-P-3001GZ
Permanent speed limiter, function GF30.30-P-3002GZ
DISTRONIC, function GF30.30-P-3200GZ
Distance warning system, function GF54.70-P-2000GZ
DISTRONIC, TABLE OF CONTENTS FOR FUNCTION DESCRIPTION - GF30.30-P-0995GZ
DISTRONIC, overall function GF30.30-P-0005GZ

Downhill Speed Regulation, function GF28.19-P-3600GR
Variable Speed Limiter, function GF30.30-P-3001GZ
Permanent speed limiter, function GF30.30-P-3002GZ
DISTRONIC, function GF30.30-P-3200GZ
Distance warning system, function GF54.70-P-2000GZ
Overview of system components for DISTRONIC GF30.30-P-9995GZ
VARIABLE SPEED LIMITER, FUNCTION - GF30.30-P-3001GZ
Variable Speed Limiter activated

Fig. 43: Variable Speed Limiter, Function Diagram

The Variable Speed Limiter (also known as the Limiter) is an additional function of DISTRONIC and is
integrated in the ESP control unit (N47-5).
The variable speed limiter enables the driver to set a maximum speed himself ranging from 30 km/h up to the
maximum vehicle speed. If the vehicle approaches the set maximum speed, the set maximum speed is
maintained by engine intervention and if necessary by intervention by the brake system.
The CC [TPM] switch can be moved up or down (S40/4 or S40 for ) to increase or decrease the maximum
speed in 1 km/h or 10 km/h increments (two settings).
 "Circuit 61 ON" (engine running)

 By pressing the CC [TPM] switch, a switchover must place from the DISTRONIC position to the
Variable Speed Limiter position.
The LIM indicator lamp in the CC [TPM] switch lights up.
By pressing the CC [TPM] switch, a switchover to the Variable Speed Limiter takes place and DISTRONIC
is deactivated simultaneously.
Activation
Pulling or moving the CC [TPM] switch up or down will activate the Variable Speed Limiter.
1. By up the CC [TPM] switch, the Variable Speed Limiter is activated with the last saved target speed
provided that a target speed has already been saved since the last engine start (set). If no target speed is
stored, the current vehicle speed is set as the target speed.
2. By moving the CC [TPM] switch up or down, the Variable Speed Limiter is activated with the current
vehicle speed as the target speed.
3. By moving the Cruise control switch upwards with the vehicle at a standstill the Variable Speed Limiter
is activated at the minimum settable nominal speed of 30 km/h.
If the Variable Speed Limiter is activated then the segment in the tachometer annulus is lit from the beginning
of the scale until the set maximum speed and the LIM indicator lamp lights up in the Cruise control switch.
Deactivation
The Variable Speed Limiter is deactivated if:
 The CC [TPM] switch is pushed forwards

 By pressing the CC [TPM] switch, a switchover to the DISTRONIC position takes place (LIM indicator
lamp off)
 Kickdown is triggered (accelerator pedal depression >90 %) and the driven speed is more than 20 km/h
from the set maximum speed
The Variable Speed Limiter and Permanent Speed Limiter have the sales designation "SPEEDTRONIC".
Component description for the CC [TPM] switch S40 at GF30.20-P-2100GR

Component description for the CC [TPM] switch S40/4 except GF30.20-P-2100GT
PERMANENT SPEED LIMITER, FUNCTION - GF30.30-P-3002GZ
Indicator in the multifunction display (A1p13) of the instrument cluster (A1)
Fig. 44: Identifying Indicator In Multifunction Display (A1P13) Of Instrument Cluster (A1)
The Permanent Speed Limiter allows the driver to limit the maximum speed of the vehicle (e.g. for winter tires
with a lower permissible maximum speed).
The function of the Permanent Speed Limiter is integrated in the ESP control unit (N47-5).
If the vehicle comes close to the set maximum speed the set maximum speed is maintained by means of an
engine intervention.
If the set maximum speed is exceeded a warning message is shown in the multifunction display (A1p13) of the
When the Permanent Speed Limiter is activated, DISTRONIC or the Variable Speed Limiter can be used
(activated) up to the set permanent maximum speed.
Activation/deactivation
The Permanent Speed Limiter is switched on and off via the left or right switch group in the multifunction
steering wheel (S110 and S111).
Here the maximum speed can be set in a menu item of the instrument cluster in 10 km/h steps from 160 km/h to
240 km/h.
The Variable Speed Limiter and Permanent Speed Limiter have the sales designation "SPEEDTRONIC".
CC [TPM] switch, component description S40 At GF30.20-P-2100GR

DISTRONIC, FUNCTION - GF30.30-P-3200GZ
Fig. 45: DISTRONIC, Function Diagram

Detection of a vehicle traveling ahead with DISTRONIC activated
The DISTRONIC regulates the speed and the distance to the next vehicle ahead according to the driver's
commands (nominal speed and nominal distance to the next vehicle ahead) in the speed range from 30 km/h to
180 km/h.
In doing so, DISTRONIC regulates the set target speed in an empty lane (no vehicle moving ahead) as per
conventional cruise control. As the car approaches a preceding vehicle, the speed is reduced in order to maintain
the target distance set by the driver by:
 Reducing the engine output

 Activating the brakes
 Shifting the gear
If the traffic situation allows an increase in speed as the vehicle immediately ahead has accelerated or left the
lane, for example, Distronic increases the speed back up to the set target speed.
 "Circuit 61 ON" (engine running)

 ESP not deactivated
 Parking brake not applied
 DIRECT SELECT gear selector switch (S16/13) in "D" position
 By pressing the CC [TPM] switch (S40/4) a switchover to the DISTRONIC position must take place
(LIM indicator lamp off)
 Dirt/function test of DTR radar sensor (A89b1) completed successfully
 Brake pedal not pressed
 Speed of the vehicle <30 km/h
Dirt/function test
To guarantee smooth functioning of the radar system after each engine start, the DTR control unit (A89n1)
performs a dirt/function test of the radar sensor. If a malfunction is established or no objects (for the function
test) are available in the radar sensor detection range, DISTRONIC cannot be activated and the message
'DISTRONIC not available appears in the multifunction display (A1p13) of the instrument cluster (A1).
The DTR control unit actuates the radar sensor, evaluates the radar sensor data and then transmits this data via
the drive dynamic CAN to the ESP control unit (N47-5).
Following evaluation of all sensor data and input signals, the ESP control unit takes over control of the entire
longitudinal movement of the vehicle in DISTRONIC operation. For this purpose, it sends signals (for shifting
gear, accelerating or decelerating) via the drive CAN to the corresponding control units.
The ESP control unit also actuates warning chimes and displays in the instrument cluster.
Automatic acceleration
The automatic maximum acceleration by DISTRONIC is limited to around 1 m/s2 for reasons of safety and
comfort.
Automatic braking
Intervention by the brake system is restricted to 20% (approx. 2 m/s2 ) of the maximum possible deceleration
capacity for reasons of safety and comfort. Driving situations requiring more than 20% braking power are
signaled to the driver visually by the DTR warning lamp (A1e59) in the instrument cluster and acoustically by a
tone. This takeover tone is an intermittent tone and signals to the driver to observe the traffic situation carefully
and to intervene if necessary and to reassume full control of the vehicle. The tone is shut off automatically when
the situation becomes less critical; it cannot be deactivated manually.
Target speed
The minimum target speed that can be set is 30 km/h and the maximum target speed 180 km/h.
The CC [TPM] switch can be moved up or down (S40/4 or S40 for ) to increase or decrease the nominal
speed in 1 km/h or 10 km/h increments (two settings).
Activation
DISTRONIC can be activated from 30 km/h up to a speed of 180 km/h.
Pulling or moving the CC [TPM] switch up or down will activate DISTRONIC
1st By pulling the CC [TPM] switch, DISTRONIC is activated with the last saved target speed provided that a
target speed has already been saved since the last engine start (set). If no target speed is stored, the current
vehicle speed is set as the target speed.
2. By moving the CC [TPM] switch up or down, DISTRONIC is activated with the current vehicle speed as the
target speed.
The message "DISTRONIC not available" is displayed, for example, when the radar plate in the radiator grill
is soiled or iced up, operation is not possible due to weathering or the transmitter/receiver signals are restricted
by external influences (e.g. EMC interference).
DISTRONIC activated
Fig. 46: Display - DISTRONIC Activated

In the Electronic Speedometer (A1p8) of the instrument cluster, when DISTRONIC is activated, the segments
between the measured speed of the vehicle moving ahead and the set target speed are illuminated.
The vehicle immediately ahead is shown with the current distance from it in meters in the multifunction display
of the instrument cluster.
If no vehicle is detected immediately ahead then segments of the electronic speedometer between 0 km/h and
the set nominal speed are lit up (Cruise control mode).
Target distance
Using the DTR distance potentiometer (S40/4r1 or S40r1 for ), which is integrated in the CC [TPM]
switch, the target distance to the vehicle ahead can be set in six increments between approx. 1.0 s and 2.0 s
depending on the speed.
At setting three and at a speed of 100 km/h, this corresponds to a target distance of around 42 m.
The target distance is converted from seconds to meters depending on the speed of the vehicle, and is displayed
in the form of a white line on the range indicator in the multifunction display of the instrument cluster.
The target distance in the distance indicator matches the current vehicle speed without the driver having to
adjust the DTR distance potentiometer.
The legally required minimum distance is thus always guaranteed in the setting range for the target distance.
Target distance falls short

Fig. 47: Display - Target Distance Falls Short

If the set target speed to the vehicle ahead falls short, DISTRONIC reduces the speed.
In driving situations requiring more than 20 % braking power, the DTR warning lamp in the instrument cluster
is lit and the takeover tone signals to the driver to carefully observe driving situation and to intervene himself by
measured heavy braking or steering if necessary.
Special driving situations
 If the driver accelerates the vehicle independently higher than the acceleration set by DISTRONIC or
accelerates up to over 180 km/h, DISTRONIC is not deactivated, but switches to passive. In the
multifunction display of the instrument cluster, the message "DISTRONIC passive" appears and distance
control from the vehicle ahead does not take place for this acceleration procedure.
If the driver once more releases the accelerator (vehicle speed decreases), DISTRONIC once again
regulates the set target speed and distance control is reactivated.
 No regulation takes place relative to stationary objects.

 If a vehicle cuts in between the host vehicle and the vehicle ahead (target vehicle), the system switches
over to the new target vehicle.
 If, during the journey, the vehicle ahead pulls out of the lane and another vehicle is now moving ahead of
the host vehicle, then the system will only control the distance to this new vehicle if it is moving. In the
event that a stationary obstruction is encountered, an intermittent takeover tone and the DTR warning
lamp warn the driver about the impending collision.
Deactivation
 The CC [TPM] switch is pushed forwards

 The brake pedal is operated.
 By pressing the CC [TPM] switch, a switchover to the Variable Speed Limiter takes place (LIM indicator
lamp lights up)
 DIRECT SELECT gear selector switch in position "N"
 Vehicle moving at a speed of <30 km/h is "lost"
 Function requirements for the DISTRONIC function are no longer provided
Component description for the CC [TPM] switch S40 At GF30.20-P-2100GR

Component description for the DTR controller unit A89 GF30.30-P-3210GZ
COMPONENT DESCRIPTION FOR THE DTR CONTROLLER UNIT - GF30.30-P-3210GZ
Location
The DTR controller unit is located in the center behind the radiator grille.
Fig. 48: Identifying DTR Controller Unit Location

Task
The DTR controller unit has the following tasks:
 Actuation, supply and evaluation of the signals received by the integrated DTR radar sensor (A89b1)
 Computation of the road geometry
 Control of target evaluation
 Transmission of data for control of longitudinal movement of the vehicle to the ESP control unit (N47-5)
Design
The DTR radar sensor and the DTR control unit are integrated within the DTR controller unit
Fig. 49: Design - DTR Controller Unit Components

Function
The DTR control unit actuates the radar sensor and evaluates the target data. The radar data is transmitted from
the DTR control unit via the drive dynamic CAN to the ESP control unit (for control of longitudinal movement
of the vehicle by DISTRONIC).
Radar characteristics
 Detection range of the radar sensor from 10 m to 150 m

 Divergence of radar beam 9° (sharp focussing)
 77 GHz radar sensor according to the "Pulse Doppler Principle" for independent measurement of distance
and speed
 Fully-integrated electronic implementation (the DTR controller unit contains high-frequency circuits)
The radar plate is a radar transparent cover in the radiator grille which is necessary for correct functioning of the
DISTRONIC.
Its tasks are as follows:
 Shielding against external effects (such as dirt, ice or insects)

 Ensuring optimal transmission and reception properties of the radar sensor
Fig. 50: Identifying Radar Plate

OVERVIEW OF SYSTEM COMPONENTS FOR DISTRONIC - GF30.30-P-9995GZ
Component description for the CC [TPM] switch S40 At GF30.20-P-2100GR

Component description for the DTR controller unit A89 GF30.30-P-3210GZ
SAFETY PRECAUTIONS
RISK OF INJURY TO SKIN AND EYES FROM LASER BEAMS - AS30.30-Z-0001-01A
Never look directly into the laser beam.
Do not attempt to suppress the natural reflex of the eyelids.
Avoid direct skin contact with the laser beam.
If eye damage is suspected, consult an eye specialist without delay.

Risk of injury!
Class 2 lasers emit a visible radiation. Looking directly into the laser beam can result in damage to the eye.
The reflected laser beam can likewise cause damage to the eye.
For this reason, avoid reflections of the laser beam by using mirrors and similar aids. Laser beams may also
cause skin damage.
 Never look directly into the laser beam.

 Do not attempt to suppress the natural reflex of the eyelids.
The eye is normally protected by defensive reactions including the reflex of the eyelid closing.
 Avoid direct skin contact with the laser beam.

 If damage to the eye is suspected, consult an eye specialist immediately.
 It is prohibited to further bundle the laser beam and thus to concentrate the energy (increasing the laser
class).
 Only properly instructed personnel may be entrusted with the work on this equipment.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: THROTTLE CONTROL, CRUISE
CONTROL SYSTEM - AR30.00-Z-9113AB
ENGINE 113
Adjusting throttle control ENGINE 112, 113... AR30.10-P-1010BA

Adjusting throttle control ENGINE 111, 112, 113... AR30.10-P-1010CA
Adjust throttle control ENGINE 112, 113... AR30.10-P-1010GJ
Removing and installing ENGINE 111, 112, 113, AR30.10-P-3400EA
throttle control cable 119, 120, 606...
Removing and installing ENGINE 112, 113, 612, AR30.10-P-3400GI
throttle control cable 628...
Removing and installing ENGINE 111, 112, 113... AR30.12-P-1321GH
accelerator pedal
Removing/installing ENGINE 113, 156, 272, AR30.12-P-1321GZ
accelerator pedal 273, 629, 642 in MODEL
164
Removing/installing the ENGINE 113.971, AR30.12-P-1321RT
accelerator pedal 272.967, 642.950 in
MODEL 251
Remove/install ENGINE 113, 271, 272... AR30.12-P-1321V

accelerator pedal
Removing/installing the ENGINE 113.964 in AR30.20-P-1262GZ
electronic accelerator MODEL 164.1
actuator with flap
connection
Removing/installing the ENGINE 113 in MODEL AR30.20-P-1262RT
electronic accelerator 251
actuator with flap
connection

CONTROL SYSTEM - AR30.00-Z-9164AA
MODEL 164
AR30.12-P-
Removing/installing accelerator pedal MODEL 164
1321GZ
Check / adjust the sensor setting of MODEL 164, 209, 211, 215, 216, 219, 220, AR30.30-P-
Distronic (DTR) 221, 230, 240, 251 ... 1000R
Remove/install Distronic sensor (DTR)
Distronic (DTR) 1010GZ

ENGINE 272
Remove/install accelerator pedal ENGINE 113, 271, 272 ... AR30.12-P-1321V

Remove/install the electronic accelerator actuator with ENGINE 272, 273 in AR30.20-P-
flap connection MODEL 164 1262GZA
Remove/install electronic accelerator actuator with ENGINE 272, 273 in AR30.20-P-
valve fitting MODEL 251 1262RTA

ENGINE 273
Remove/install the electronic accelerator actuator with ENGINE 272, 273 in AR30.20-P-
flap connection MODEL 164 1262GZA
Remove/install electronic accelerator actuator with ENGINE 272, 273 in AR30.20-P-
valve fitting MODEL 251 1262RTA
REMOVING/INSTALLING ACCELERATOR PEDAL - AR30.12-P-1321GZ

MODEL 164
Fig. 51: Identifying Accelerator Pedal Remove/Install Components

Remove/install

Keyless Go start/stop button repeatedly until the
remove transmitter key
1 ignition is switched off. Remove transmitter key from
from EIS [EZS] control
vehicle and store it in a location beyond its
unit
Remove cover below
AR68.10-
2 instrument panel on
P-1500GZ
driver's side
3 Unscrew nuts (1)
Remove accelerator pedal Pull out the upper part of the accelerator pedal (2)
4
(2) slightly and then push upwards to release the lug (3).
5
connector (4)
REMOVING/INSTALLING THE ELECTRONIC ACCELERATOR ACTUATOR WITH FLAP

CONNECTION - AR30.20-P-1262GZ
Symbolic representation
Fig. 52: Identifying Electronic Accelerator Actuator With Flap Connection Remove/Install Components
Remove/install

fingers being jammed or
When moving components, ensure that no body parts
pinched when removing, AS00.00-Z-
or limbs are within the operating range of moving
installing or aligning hoods, 0011-01A
parts.
doors, trunk lid/rear-end
door or sliding roof.
Open engine hood and raise AR88.40-P-
1
to vertical position 1000GZ
AR09.10-P-
1150GZ
Remove hot film mass air AR07.07-P-
3
flow sensor (B2/5) 1454GZ
Do not disconnect the plug from the throttle valve
actuator as it is bonded. The electrical connections
from the throttle valve actuator and from the air
Disconnect electrical recirculation flap actuator are identical and are
connector in feed line interchangeable. The wiring harness of the throttle
4
throttle valve actuator valve actuator is marked with a blue insulating tape
(M16/6) (arrow). Mark wiring harness before disconnecting
the electrical connector if this is not the case.
Installation: Coat the electrical connector with
contact fluid.
*BR00.45-
Contact fluid
Z-1001-14A
Unscrew bolts (10) of

*BA07.61-
5 throttle valve actuator
P-1001-01A
(M16/6)
Take out throttle valve
6 Installation: Install new gasket
actuator (M16/6)
Read out fault memory and
8
erase if required
Connect up STAR
AD00.00-P-
2000-04A
fault memory
*WH58.30-
Z-1048-13A
ME-SFI FUEL INJECTION AND IGNITION SYSTEM

BA07.61-P-1001-01A Bolt on throttle valve actuator Nm 10

Number Designation
REPAIR MATERIALS
BR00.45-Z-1001-14A Contact fluid A 008 989 55 71
REMOVE/INSTALL THE ELECTRONIC ACCELERATOR ACTUATOR WITH FLAP

CONNECTION - AR30.20-P-1262GZA
ENGINE 272, 273 in MODEL 164
Fig. 53: Identifying Electronic Accelerator Actuator With Flap Connection Remove/Install Components
Remove/install

1
position 1000GZ
AR62.30-P-
2.1 Remove strut brace Only model 164.8. 2500GY
AR09.10-P-
1150GZA
AR07.07-P-
4 Remove hot film mass air flow sensor
1453GZA
AR09.20-P-
5 Remove air duct housing
0080GZA
Detach vent line (1) from throttle valve
6
actuator (M16/6)
Installation: Coat the
Disconnect plug (3) from plug shoe on
7 electrical connector with contact
throttle valve actuator (M16/6)
fluid.
*BR00.45-Z-
Contact fluid
1001-14A
*BA07.61-P-
8 Unscrew bolt (2)
1001-01D
9 Remove throttle valve actuator (M16/6)
gasket
11 Read out fault memory and erase if required
system 1048-13A
Connect up STAR DIAGNOSIS and read out AD00.00-P-
ME-SFI FUEL INJECTION AND IGNITION SYSTEM

272 273
BA07.61-P-1001- Bolt, throttle valve actuator to resonance intake
Nm 9 9
01D manifold

Number Designation
REPAIR MATERIALS

BR00.45-Z-1001-14A Contact fluid A 008 989 55 71
CHECK / ADJUST THE SENSOR SETTING OF DISTRONIC (DTR) - AR30.30-P-1000R
MODEL 164, 209, 211, 215, 216, 219, 220, 221, 230, 240, 251 with CODE (219) Distronic (DTR)
MODEL 216, 221 with CODE (233) Distronic Plus
Shown on model 230 with an arched radar sensor
Fig. 54: Identifying Distronic Sensors - Shown On Model 230 With Arched Radar Sensor
Fig. 55: Identifying Distronic Sensor Adjustment - Shown On Model 230

shown on model 230
Vehicle with an arched radar sensor

Fig. 56: Checking Distronic Sensor Setting For Vehicle With Arched Radar Sensor
Vehicle with a radar sensor that is not arched (flat)
Fig. 57: Checking Distronic Sensor Setting For Vehicle With Radar Sensor
Fig. 58: Identifying Reticule Center

Measuring, adjusting
Risk of injury to skin Never look directly into the AS30.30-Z-0001-01A
and eyes from laser laser beam. Do not attempt
beams to suppress natural reflex of
eyelids.
Avoid direct skin contact
with the laser beam. If
damage to the eye is
suspected, consult an eye
specialist immediately.
1 Conduct quick test with *WH58.30-Z-1048-13A
STAR DIAGNOSIS
DIAGNOSIS and read
out fault memory
Risk of injury caused Keep body parts and limbs AS00.00-Z-0011-01A
by fingers being well clear of moving parts.
pinched or crushed
when removing,
2 Open engine hood Model 164 AR88.40-P-1000GZ
Model 209 AR88.40-P-1000Q
Model 211 AR88.40-P-1000T
Model 219 AR88.40-P-1000TX
Model 215, 220 AR88.40-P-1000M
Model 216, 221
Model 230 AR88.40-P-1000R
Model 240 except 240.179 AR88.40-P-1000H

Model 240.179
Model 251 AR88.40-P-1000RT
3.1 Remove radiator trim Model 164 AR88.40-P-4001GZ
Model 216
Model 219 AR88.40-P-4001TX
Model 230 AR88.40-P-4001R
Model 251 AR88.40-P-4001RT
3.2 Remove bumper Model 240 except 240.179 AR88.20-P-2000H
Model 240.179
4 Check DTR radar sensor Only conduct visual
(A89b1, B29) test on mechanical damages.
Check if:
 DTR radar sensor

(A89b1, B29) is
damaged or dirty
 Connectors (9) are
loose
On the DTR radar

sensor (A89b1) only
one connector is
available.
 Clips (10) for

mounting adjusting
bolts (3a, 3b, 3c) are
loose or defective
 Spacers between clips
(10) for mounting
adjusting bolts (3a,
3b, 3c) and the DTR
radar sensor (A89b1,
B29) are available.
5 Align front wheels to the The front wheels must be
geometric driving axle aligned to the geometric
driving axle. Measure
chassis if necessary.
6 Remove front measuring
heads from the quick
tensioning holders
7 Fit the measuring rods
(1) onto the quick
tensioning holders in
place of measuring
heads
8 Attach the spacer ring Only for vehicles with
(8) to the DTR radar non-arched (flat) DTR radar
sensor (A89b1) sensor (A89b1).
*WH58.30-Z-1053-12A
9 Align headlamp Observe operating
adjustment testing unit instructions of headlamp
(2) to vehicle and carry adjustment testing unit (2).
out height adjustment to Headlamp adjustment
position of DTR radar testing unit (2) must stand
sensor (A89b1, B29) on even surface, parallel to
contact patch.
Set headlamp range
adjustment at headlamp
adjustment testing unit (2)
to "0".
Headlamp adjustment *WE58.40-Z-1006-19A
testing unit
10 Fit optical adjusting In order to secure
device (5) with distance the optical adjusting device
pins (5b) onto DTR (5) from falling down, hang
radar sensor (A89b1, up fastening strap (4) at
B29) and firmly suction vehicle.
using the hand In order to guarantee a
vacuum pump (6) secure seating of optical
adjusting device (5) on DTR
radar sensor (A89b1, B29),
petroleum jelly should be
applied to the rubber lip of
suction bell and the hand
vacuum pump (6) should be
evacuated from 600 to 700
mbar.
DISTRONIC adjusting *WE58.40-Z-1004-19A
device
Hand vacuum pump Fig. 59
11 Align headlamp For alignment look into
adjustment testing unit overhead mirror (2/1). Align
(2) to vehicle headlamp adjustment testing
unit (2) by rotating (arrow)
around the vertical axis, in
such a way, that the right
and the left sounding rods
(1) overlap with mirror
reticule (2/1a) in the

overhead mirror (2/1).
12 Connect optical On vehicles with Keyless
adjusting device (5) to Go Code 889: press the
cigarette lighter Keyless Go start and stop
push-button once without
depressing the brake pedal -
the laser in the optical
adjusting device (5) is
activated.
On vehicles without
Keyless Go: turn ignition
key to position "1" - the
laser in the optical adjusting
device (5) is activated.
13 Connect STAR Only for vehicles with
DIAGNOSIS and AIRmatic, code 489 or with
starting off automatic Active Body Control
calibration level (ABC), code 487.
14 Read off point of impact Point of impact and
of laser beam in graticule center (7) must
headlight adjustment match.
testing unit (2)
15 Adjust horizontal In case of a correction,
adjustment of DTR radar ensure that the adjustment
sensor (A89b1, B29), for screw (3a) is turned
this step bring point of counterclockwise by one
impact to height of piece first (eliminate
reticule center (7) by threaded play).
twisting adjusting bolt The adjusting bolt (3b) is
(3a) at DTR radar sensor only to be twisted in the
(A89b1, B29) in the case that the range of
headlamp adjustment adjustment of adjusting
testing unit (2) bolts (3a, 3c), would not be
adequate for a correction.
16 Set vertical adjustment For vertical alignment of
of DTR radar sensor optical adjusting device (5),
(A89b1, B29); for this observe bubble level (5a). In
step point of impact case of a correction, ensure
must overlap with the that adjustment screw (3c) is
reticule center (7) in the turned counterclockwise by
headlamp adjustment one piece first (eliminate
testing unit (2) through threaded play).
twisting of the adjusting The adjusting bolt (3b) is
bolt (3a) at the DTR only to be twisted in the
radar sensor (A89b1, case, that range of
B29) adjustment of the adjusting

bolts (3a, 3c), would not be
adequate for a correction.
17 Remove optical Remove petroleum jelly
adjusting device (5) from the DTR radar sensor
(A89b1, B29).
18 Remove the spacer ring Only for vehicles with
(8) of the DTR radar non-arched (flat) DTR radar
sensor (A89b1) sensor (A89b1).
The spacer ring (8)
must be removed to ensure
that DTR radar sensor
(A89b1) functions correctly.
19 Reset the learning values
with STAR
DIAGNOSIS
20.1 Install radiator trim Model 164 AR88.40-P-4001GZ
Model 216
Model 219 AR88.40-P-4001TX
Model 230 AR88.40-P-4001R
Model 251 AR88.40-P-4001RT
20.2 Install bumper Model 240 except 240.179 AR88.20-P-2000H
Model 240.179
21 Close engine hood Model 164 AR88.40-P-1000GZ
Model 209 AR88.40-P-1000Q
Model 211 AR88.40-P-1000T
Model 219 AR88.40-P-1000TX
Model 215, 220 AR88.40-P-1000M
Model 216, 221
Model 230 AR88.40-P-1000R
Model 240 except 240.179 AR88.40-P-1000H
Model 240.179
Model 251 AR88.40-P-1000RT
Fig. 59: Identifying Hand Vacuum Pump (001 589 73 21 00)


Number Designation
WH58.30-Z-1053-12A Spacer ring and compressed air connection, Company Polytec GmbH
D-76337 Waldbronn
WORKSHOP EQUIPMENT
WE58.40-Z-1004-19A DISTRONIC adjusting device
WE58.40-Z-1006-19A Headlamp adjustment testing unit
REMOVE/INSTALL DISTRONIC SENSOR (DTR) - AR30.30-P-1010GZ
MODEL 164, 251 with CODE (219) Distronic (DTR)

Fig. 60: Identifying Distronic Sensor (DTR) Remove/Install Components

Remove/install

AH54.00-P-
0001-01A
position "0".
2 Model 164
AR88.40-P-
Model 251
1000RT
AR88.40-P-
3 Remove radiator trim Model 164
4001GZ
AR88.40-P-
Model 251
4001RT
Unlock and disconnect electrical
4 connector (1) from DTR radar
sensor (4)
Remove fixing bolts (3b), remove
5 Do not turn on adjustment screws (3a).
DTR radar sensor (4)
Checking
Check setting of DTR radar sensor AR30.30-P-
7
(A89b1) and correct if necessary 1000R
*WH58.30-Z-
8 Read out and erase fault memory STAR DIAGNOSIS diagnosis system
1048-13A

Number Designation
2006-2008 ACCESSORIES & BODY, CAB Detachable Body Components - 164 Chassis
Detachable Body Components - 164 Chassis
BASIC KNOWLEDGE
ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, LOCATION OF COMPONENTS - GF88.79-
P-0005-01GZ
Fig. 1: Identifying Electrically Adjustable Outside Mirrors, Location Of Components - Shown On Model
164.1
ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR, BLOCK DIAGRAM - GF88.79-P-0005-02GZ

Fig. 2: Electrically Adjustable Outside Mirror - Block Diagram

ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, FUNCTION - GF88.79-P-0005GZ
MODEL 164.1/8
Entire function
With the left outside mirror adjustment selection switch (S20/1s10) or right outside mirror adjustment selection
switch (S20/1s11), the left electrically adjustable and heated outside mirror (M21/1) or right electrically
adjustable and heated outside mirror (M21/2) can be selected for manual adjustment. The mirror lens can be
moved to the desired position with the outside mirror adjustment rocker switch (S20/1s12) An LED in the
corresponding right/left outside mirror preselection switch indicates which outside mirror can be adjusted at this
moment.
The mirror heater is automatically regulated when the vehicle engine is running depending on the outdoor
temperature and dewpoint.
The left outside mirror and right outside mirror can be folded in and out via the outside mirror fold-in/fold-out
switch (S20/1s9) (with folding left/right outside mirror, code 500).
Partial functions
 Horizontal and vertical mirror lens adjustment

 Mirror selection between left outside mirror and right outside mirror
 Automatically dimming driver's side outside mirror and inside rearview mirror
 Move left outside mirror and right outside mirror to garage position
(with folding left/right outside mirror, code 500)
 Store, call and automatically adjust position of left outside mirror and right outside mirror with the
memory function
(with memory package (driver seat, steering column, mirror), code 275)
 Move right outside mirror to park position
(with memory package (driver seat, steering column, mirror), code 275)
Electrically adjustable outside mirrors, GF88.79-P-

Electrically adjustable outside mirror, GF88.79-P-
block diagram 0005-02GZ
Mirror lens adjustment left/right outside GF88.79-P-
mirror, function 2008GZ
Automatic dimming outside mirror and GF88.79-P-
inside rearview mirror, function 2010GZ
With folding left/right outside mirror, GF88.79-P-
Fold left/right outside mirror, function
code 500 2002GZ
With memory package (driver seat, GF88.79-P-
Store outside mirror position, function
steering column, mirror), code 275 2004GZ
Retrieve stored outside mirror position, With memory package (driver seat, GF88.79-P-
function steering column, mirror), code 275 2005GZ
Passenger-side outside mirror park With memory package (driver seat, GF88.79-P-
position, function steering column, mirror), code 275 2006GZ
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR ELECTRICALLY ADJUSTABLE

OUTSIDE MIRROR - GF88.79-P-0999GZ
MODEL 164.1/8

function 0005GZ
Electrically adjustable outside mirror, block GF88.79-P-
diagram 0005-02GZ
Mirror lens adjustment left/right outside GF88.79-P-

mirror, function 2008GZ
Automatic dimming outside mirror and GF88.79-P-
inside rearview mirror, function 2010GZ
With folding left/right outside mirror, GF88.79-P-
Fold left/right outside mirrors, function
code 500 2002GZ
With memory package (driver seat, GF88.79-P-
Store outside mirror position, function
steering column, mirror), code 275 2004GZ
Retrieve stored outside mirror position, With memory package (driver seat, GF88.79-P-
Passenger-side outside mirror park position, With memory package (driver seat, GF88.79-P-
Outside mirror position measurement, With memory package (driver seat, GF88.79-P-
Overview of system components for GF88.79-P-
electrically adjustable outside mirror 9998GZ
FOLD LEFT/RIGHT OUTSIDE MIRROR, FUNCTION - GF88.79-P-2002GZ
MODEL 164.1/8 with CODE (500) Folding left/right outside mirrors
Shown manual fold in/out
Fig. 3: Identifying Fold Left/Right Outside Mirror Function

Manually folding-in/out, function
 Circuit 15R ON or circuit 15 ON

 No overvoltage/undervoltage
 No mirror lens adjustment active
 Speed signal < 47 km/h for folding in mirror housing
Function
The housing of the left and right outside mirror can be folded in and out electrically. The housings of the left
and right outside mirrors can be moved to the garage position (mirror housing folded in) or the driving position
(mirror housing folded out) via the outside mirror fold-in/out switch which is located in the driver power
window and outside mirror adjustment switch.
For this purpose, it is only necessary to momentarily press the outside mirror fold-in/out switch and the
housings of the left and right outside mirror are automatically adjusted to the selected position
The adjustment request of the outside mirror fold-in/out switch is read in via the LIN-BUS by the left front door
control unit The left front door control unit has the master function during adjustment and relays the signals to
the right front door control unit via the CAN B bus.
The left front door control unit actuates the mirror fold-in motor in the left outside mirror and the right front
door control unit actuates the mirror fold-in motor in the right outside mirror.
If the function prerequisite circuit 15R ON is not present after starting to fold in or out, the adjustment is
continued until the end position is reached.
The left front door control unit receives the speed signal by the instrument cluster via the CAN B bus.
The mirror housings can only be folded in up to a maximum speed of 47 km/h.
Abort conditions
Electrical movement to the position is interrupted if:
 the outside mirror lens adjustment is activated by a switch

 a memory request is present from the driver
 overvoltage or undervoltage is present
After interruption the outside mirror fold-in/out function is continued
Automatically folding in/out, function
When folding in
 Circuit 15C OFF

 Mirror housing last actuated in the fold out direction
When folding out
Circuit 15R ON or
 Circuit 15R ON or
 Driver and passenger door open
 Mirror has automatically folded in previously
Function
When the vehicle is locked with the central locking (CL) from outside with the transmitter key (A8/1), both
mirror housings are folded in automatically (garage position). The next time the vehicle is unlocked with the CL
and the driver or passenger door are opened, the mirror housings are returned to the previous position If the
mirror housings are still folded in with circuit 15R ON, with a previous automatic folding-in procedure, the
mirror housings are folded out immediately.
If the mirror housings were manually adjusted to the garage position, the mirror housings are not adjusted via
the automatic adjustment
The automatic fold-in/out function can interrupted any time by adjusting the mirror in the outside mirror switch.
The master for this function is the left front door control, responsible for actuating the left outside mirror as well
as for transmission of the corresponding signals to the right front door control unit via the CAN B bus to actuate
the right outside mirror
Abort conditions
Electrical movement to the position is interrupted if:
 the outside mirror lens adjustment is activated by a switch

 fold in/out is activated by a switch actuation
 a memory request is present
 a function prerequisite is eliminated
After interruption the outside mirror fold-in/out function is continued

Outside mirror adjustment motor, component description GF88.79-P-4111GZ

Outside mirror adjustment switch, component description GF88.79-P-4110GZ
STORE OUTSIDE MIRROR POSITION, FUNCTION - GF88.79-P-2004GZ
Fig. 4: Identifying Store Outside Mirror Position Function

 C. 15R "ON" or c. 15 "ON"

Function
Per transmitter key (A8/1), three positions of the left and right outside mirror can be stored manually and one
position automatically with the memory function.
For storing a position, the left front seat adjustment switch group has switches for memory location 1, 2, 3 as
well as the memory switch required to start the storage procedure. The signal for storing the position is read in
discretely by the front seat adjustment control unit with memory, driver.
Before storing, move left outside mirror and right outside mirror to the desired position via the outside mirror
adjustment switch.
There are two possibilities for manual storage.
 Press and hold memory switch and simultaneously actuate the desired memory position button in memory
location switch 1, 2, 3 for min. 40 ms.
 Actuate memory location switch for min. 40 s and press desired memory position button in memory
location switch 1, 2, 3 within 3 s.
Automatically storing position:
 The last position of the driver seat, steering column and outside mirror is stored automatically in relation
to the key, when changing from c. 15 to c. 15R.
The position of the left outside mirror is stored in the left front door control unit and the position of the right
outside mirror in the right front door control unit.
Master of the function is the driver front seat adjustment control unit with memory. Here also the
positions of the steering column and the driver seat are stored and called.
GF88.79-P-
Outside mirror position measurement, function
4000GZ
Outside mirror adjustment motor, component GF88.79-P-
description 4111GZ
Driver-side front seat adjustment control unit GF91.29-P-
with memory, component description 5223GZ
description 4141GZ
description 4142GZ
Electronic ignition switch control unit (EIS), GF80.57-P-
Outside mirror adjustment switch, component GF88.79-P-
description 4110GZ
Front seat adjustment switch group, component With electrically adjustable front GF91.29-P-
description passenger seat with memory, code 242 5220GZ
CALL STORED OUTSIDE MIRROR POSITION, FUNCTION - GF88.79-P-2005GZ
Fig. 5: Identifying Call Stored Outside Mirror Position Function

 C. 15R ON or c. 15 ON or
 Driver door open
 No manual seat, mirror or steering column adjustment actuated
 Position measurement supplies valid readings
 EIS control unit transmits valid memory block numbers
Function
The position of the left and right outside mirror stored in the left front door control unit and right front door
control unit can be called with the driver seat adjustment switch group with memory.
For this purpose, press and hold down one of the memory position buttons in the memory button 1, 2, 3 switch.
The driver front seat adjustment control unit with memory receives the memory request via the front door
control unit via CAN B bus and relays it to the left front door control unit and right front door control unit via
CAN B bus.
The left front door control unit actuates the left outside mirror and right front door control unit actuates the right
outside mirror as long as the memory button 1, 2, 3 switch is pressed or the position for the memory location
selected is reached.
The steering column and driver seat are moved to the associated memory positions for the selected memory
location at the same time when the outside mirror positions are retrieved.
The last position of the driver seat, steering column and outside mirror is adjusted in relation to the key
as of c. 15C ON.
GF88.79-P-
Outside mirror position measurement, function
4000GZ
Outside mirror adjustment motor, component GF88.79-P-
description 4111GZ
GF54.21-P-
7030GZ
Driver-side front seat adjustment control unit GF91.29-P-
with memory, component description 5223GZ
description 4141GZ
description 4142GZ
Electronic ignition switch control unit (EIS), GF80.57-P-
Front seat adjustment switch group, component With electrically adjustable passenger GF91.29-P-
description seat with memory, code 242 5220GZ
PASSENGER OUTSIDE MIRROR PARK POSITION, FUNCTION - GF88.79-P-2006GZ
Fig. 6: Identifying Passenger Outside Mirror Park Position Function

 Circuit 15 ON
 Reverse gear engaged for longer than 0.6 s
 Left/right outside mirror adjustment switch in passenger-side mirror position
 Position measurement supplies valid readings
 No manual mirror lens adjustment actuated or memory request active.
 Function activated via diagnosis
Function
If the right front door control unit receives the message "Reverse gear engaged" via CAN B bus by the central
gateway control unit, the right outside mirror is moved to park position stored for the transmitter key (A8/1).
Aborting the function

The right outside mirror is automatically returned to the original position, when:
 the reverse gear signal is not recognized after 10 s or

 the vehicle speed is greater than 10 km/h or
 the left/right outside mirror adjustment switch is switched to driver's mirror position
It is also then returned to the original position if the right outside mirror is adjusted manually in the park
position via the outside mirror adjustment switch. If the right outside mirror is located in the park position with
circuit 15 OFF, it is returned after 10 s when c. 15 is switched back on and the transmission no longer shifted to
reverse. If reverse gear is recognized with circuit 15 ON, the mirror moves to the associated park position for
the transmitter key in use after 0.6 s.
Store park position
 Circuit 15 ON or circuit 15R ON

 Valid memory block number recognized
In order to store the park position of the passenger mirror, select right outside mirror adjustment selection
switch with LED function in the driver power window and outside mirror adjustment switch group
Then it is necessary to adjust the desired park position for the right outside mirror manually with the outside
mirror adjustment raise/ lower, in/out rocker switch on the driver power window switch and outside mirror
adjustment.
The park position is stored by the left front seat adjustment switch group.
After shortly pressing the memory switch for min. 40 ms, the momentary outside mirror position in the right
door control unit is stored as park position.
The storage request is transmitted to the left front door control unit by the driver power window and outside
mirror adjustment switch group and from there, relayed to the right front door control unit via the CAN B bus
The position and storage data is stored in the right front door control unit.
If the desired park position is not yet correct, it can be corrected afterwards by adjusting the rearview mirror
manually even when the "park position" function is activated.
Outside mirror position measurement, GF88.79-P-

function 4000GZ
Outside mirror adjustment motor, GF88.79-P-
description 4141GZ

description 4142GZ
Electronic ignition switch (EIS) control unit, GF80.57-P-
Central gateway control unit, component GF54.21-P-
description 4170GZ
Outside mirror adjustment switch, GF88.79-P-
Front seat adjustment switch group, With electrically adjustable passenger seat GF91.29-P-
component description with memory, code 242 5220GZ
LEFT/RIGHT OUTSIDE MIRROR LENS ADJUSTMENT, FUNCTION - GF88.79-P-2008GZ
MODEL 164.1 /8
Fig. 7: Identifying Left/Right Outside Mirror Lens Adjustment Function

 Term. 115R or 15 ON
 No mirror lens position storage presently activated
Function
The left outside mirror and right outside mirror are adjusted by the driver power window and outside mirror
adjustment switch group. Each adjustment request is read in by the left front door control unit via LIN-bus
The left outside mirror or right outside mirror to be selected is accomplished via the left and right outside mirror
adjustment switch.
The following adjustments are possible via the outside mirror adjustment raise/lower, in/out rocker switch :
 Horizontal mirror lens adjustment

 Vertical mirror lens adjustment
The adjustment requests are transmitted to the left front door control unit by the outside mirror adjustment
rocker switch via the LIN bus, which relays the information for the right outside mirror via CAN B bus to the
right front door control unit
The left front door control unit actuates the mirror adjustment motors in the left outside mirror
The right front door control unit actuates the mirror adjustment motors in the right outside mirror

Outside mirror adjustment switch, component description GF88.79-P-4110GZ
AUTOMATIC DIMMING OUTSIDE MIRROR AND INSIDE REARVIEW MIRROR, FUNCTION -

GF88.79-P-2010GZ
MODEL 164.1 /8
Fig. 8: Identifying Automatic Dimming Outside Mirror And Inside Rearview Mirror Function
 Circuit 15R On or circuit 15 ON

Function
The mirror glass of the inside rearview mirror and left outside mirror can be dimmed electro-chromatically.
This is realized by a layer of electrolyte gel in the mirror which controls the light permeability in increments
depending on the voltage applied.
The inside rearview mirror senses the ambient light via the front mirror dimming sensor and the light hitting the
surface of the mirror glass via the rear mirror dimming sensor.
The inside rearview mirror evaluates these input variables and supplies dimming information to the overhead
control panel control unit which transmits the message for mirror dimming tot he CAN-B bus.
The left front door control unit relays the dimming information and supplies the corresponding actuation
voltage to the mirror dimming of the left outside mirror. The dimming information for the inside rearview
mirror is taken over by the overhead control panel control unit, which supplies the voltage to the mirror
dimming of the inside rearview mirror.
If an interior lamp is switched on during mirror dimming or the reverse gear is engaged, the dimming is
interrupted.
Inside rearview mirror component description GF68.49-P-2105GZ


Overhead control panel control unit, component description GF82.20-P-5216GZ
OUTSIDE MIRROR POSITION MEASUREMENT, FUNCTION - GF88.79-P-4000GZ
Position measurement
The left electrically adjustable and heated outside mirror (M21/1) has a potentiometer on the mirror up/down
adjustment motor (M21/1m1) and on the mirror in/out adjustment motor (M21/1m2) for position recognition.
The right electrically adjustable and heated outside mirror (M21/2) has a potentiometer on the mirror up/down
adjustment motor (M21/2m1) and on the mirror in/out adjustment motor (M21/2m2) for position recognition.
The position of the left outside mirror is transmitted by the front left door control unit (N69/1) and the position
of the right outside mirror is transmitted to the right front door control unit (N69/2) via the voltage change on
the mirror adjustment motor potentiometers.
Lockup recognition
If a voltage of less than 50 mV per 2 s is recognized on the mirror adjustment motor potentiometers during
mirror lens adjustment, the adjustment operation is interrupted.
The lock-up recognition is only performed on a programmed adjustment.

OUTSIDE MIRROR ADJUSTMENT SWITCH, COMPONENT DESCRIPTION - GF88.79-P-4110GZ
MODEL 164.1/ 8

Fig. 9: Identifying Outside Mirror Adjustment Switch Component Location - Shown On Model 164.1
Location
The outside mirror adjustment switch is located in the driver door panel
Task
All adjustment possibilities on the outside mirror adjustment rocker switch in the driver power window and
outside mirror adjustment switch group are read in by the left front door control unit (N69/1) and then
transmitted to the right front door control unit (N69/2) via LIN-BUS.
The outside mirror adjustment raise/lower, in/out rocket switch serves for adjusting the mirror lenses of the left
electrically adjustable and heated outside mirror (M21/1) and right electrically adjustable and heated outside
mirror (M21/2).
The corresponding left or right outside mirror is selected via the left outside mirror adjustment selection witch
or right outside mirror adjustment selection switch.
The outside mirror fold-in/out switch (S20/1s9) is installed as a button and allows the left and right outside
mirror housings to be folded when pressed momentarily.
Design
The following control elements are integrated into the outside mirror adjustment driver power window switch
group:
 Outside mirror adjustment rocker switch

 Left outside mirror adjustment selection switch or right
outside mirror adjustment selection switch
 Outside mirror fold-in/out switch (with code (500) Folding left/right outside mirrors)
OUTSIDE MIRROR ADJUSTMENT MOTOR, COMPONENT DESCRIPTION - GF88.79-P-4111GZ
MODEL 164.1/ 8
Fig. 10: Identifying Outside Mirror Adjustment Motor Component Location - Shown On Model 164.1
Location
The mirror adjustment motors are installed in the mirror housing of the left outside mirror and right outside
mirror to adjust the mirror lens as well as the mirror fold-in motors and to fold out and in the mirror
Task
The outside mirror lens is adjusted vertically and horizontally by the mirror adjustment motors in the in the left
outside mirror and right outside mirror.
The housing of the left and right outside mirror can be folded in (garage position) and folded out (driving
position) with the mirror fold-in motors.
On vehicles with memory package (driver seat, steering column, mirror), code 275, one potentiometer each is
installed on the mirror adjustment motors for position recognition of the mirror lens in the left and right outside
mirrors.
OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRICALLY ADJUSTABLE OUTSIDE

MIRROR - GF88.79-P-9998GZ
MODEL 164.1 /8
Inside rearview mirror unit, GF68.49-P-

Outside mirror adjustment motor, GF88.79-P-
description 7030GZ
Driver-side front seat adjustment
With memory package (driver seat, steering column, GF91.29-P-
control unit with memory,
mirrors), code 275 5223GZ
Electronic ignition switch control GF80.57-P-
unit (EIS), component description 6000GZ
Outside mirror adjustment switch, GF88.79-P-
With memory package (driver seat, steering column,
Front seat adjustment switch group, GF91.29-P-
mirror), code 275 and electrically adjustable
passenger seat with memory, code 242
Table of contents, function
GF88.79-P-
description for electrically
0999GZ
adjustable outside mirror
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - AR88.00-Z-9164AA
MODEL 164
AR88.10-P-
Remove/install front fenders MODEL 164
1000GZ
Remove/install fender liner in front AR88.10-P-
MODEL 164
fender 1300GZ
Remove/install fender liner front AR88.10-P-

MODEL 164
section in front fender 1310GZ
Remove/install fender liner in rear AR88.10-P-
MODEL 164
fender 1400GZ
AR88.20-P-
Remove/install front bumper MODEL 164
2000GZ
AR88.20-P-
Disassemble/assemble front bumper MODEL 164.8
2050GY
MODEL 164.1 with CODE (220) Parktronic AR88.20-P-
Disassemble/assemble front bumper
system (PTS) 2050GZ
AR88.20-P-
Disassemble/assemble rear bumper MODEL 164
2100GZ
AR88.20-P-
Remove/install rear bumper reflector MODEL 164.8
2110GY
AR88.20-P-
Replace mount on bumper MODEL 164
2150GZ
AR88.20-P-
Remove/install rear bumper MODEL 164
2200GZ
AR88.20-P-
Remove/install carrier for rear bumper MODEL 164
2250GZ
MODEL 164 with CODE (430) Offroad AR88.30-P-
Remove/install underride guard
package 0010GZ
MODEL 164.1 with CODE (990) AMG AR88.30-P-
Remove/install styling package
vehicles with CODE (U49) Styling package 0200GZ
MODEL 164 with CODE (846) Running AR88.30-P-
Remove/install side step
boards 2400GY
Open engine hood, move to upright AR88.40-P-
MODEL 164
position and close 1000GZ
AR88.40-P-
Remove/install engine hood MODEL 164
3000GZ
Remove/install air inlet grille on AR88.40-P-
MODEL 164
engine hood 3001GZ
Remove/install gas-operated strut on AR88.40-P-
MODEL 164
engine hood 3010GZ
AR88.40-P-
Adjust engine hood MODEL 164
3020GZ
AR88.40-P-
Remove/install hood hinge MODEL 164
3060GZ
Remove/install rebound for engine AR88.40-P-
MODEL 164
hood 3100GZ
AR88.40-P-
Remove/install engine hood catch MODEL 164.1/ 8
3200GZ
AR88.40-P-
Remove/install radiator grille MODEL 164
4001GZ
AR88.40-P-
Remove/install Mercedes star MODEL 164
4050GZ
AR88.50-P-
Install model plate on trunk lid MODEL 164
5050GZ
AR88.60-P-
Remove/install tank recess MODEL 164
2000GZ
AR88.60-P-
Remove/install tank flap MODEL 164
6023GZ
Remove/install complete outside AR88.70-P-
MODEL 164
mirror 9000GZ
AR88.70-P-
Remove/install mirror lens MODEL 164
9020GZ
AR88.70-P-
Remove/install outside mirror paneling MODEL 164
9040GZ
AR88.70-P-
Remove/install glass adjustment drive MODEL 164
9060GZ
Remove/install covers on rear-end AR88.80-P-
MODEL 164 Right rear-end door cover
door frame seal 0003GZ
Remove/install covers on rear-end AR88.80-P-
MODEL 164 Left rear-end door cover
door frame seal 0003GZA
Remove/install rear door protective AR88.80-P-
MODEL 164
strip 1030GZ
Remove/install longitudinal member MODEL 164.1 /8 except CODE (846) Running AR88.80-P-
paneling boards 6000GZ
AR88.80-P-
Remove/install front door molding MODEL 164
6600GZ
Remove/install seal section at roof AR88.85-P-
MODEL 164
frame 2000GZ
REMOVE/INSTALL FRONT FENDERS - AR88.10-P-1000GZ
MODEL 164
Fig. 11: Identifying Front Fenders Remove/Install Components

Remove/install
AR88.40-P-
1 Open engine hood and move to vertical position
1000GZ
AR88.10-P-
2 Remove fender liner in front fender (1)
1300GZ
Remove connecting clamp between front fender (1)
3
and bumper
Unscrew nut at bottom on longitudinal member On model 164.1
4.1 paneling end cap (6), remove longitudinal member without running boards,
paneling end cap (6) code 846.
*BA88.10-P-
1001-01E
On model 164.8 AR88.80-P-
4.2 Remove longitudinal member paneling without running boards, 6000GZ
code 846.
On vehicles with AR88.30-P-
4.3 Remove step plate
running boards, code 846. 2400GY
*BA88.10-P-
5 Unscrew bolt (2)
1001-01E
*BA88.10-P-
6 Undo bolts (3) on inside of A-pillar
1001-01E
*BA88.10-P-
7 Unscrew nuts (7).
1001-01E
8 Remove front fender (1)
Only when
Remove expansion clips (4), remove fender cover
9 installing a new front
(5) together with insulating material located below.
fender (1).
Check gaps and
adjust, see: ?
AR60.00-P-
0700-01GZ
*BE60.00-P-
Gap dimensions on hoods, 1001-01P
doors and lids *BE60.00-P-
1003-01P
*BE60.00-P-
1005-01P
Feeler gauge Fig. 12
AR97.20-P-
11 Complete cavity preservation in repair area.
1500GZ

Front fender to A- Dimension
mm 4.5 (±0.5) 3.5 (±1.0)
pillar "A"
Dimension
Fuel filler flap mm 3 (±0.5) 3.0 (±0.5)
"A1"
Fender to engine Dimension
mm 3.5 (±0.5) 3.5 (±1.0)
BE60.00-P- Gap hood "B"
1001-01P dimension Rear door to side Dimension
mm 4.5 (±0.5) 4.5 (±1.0)
roof frame "B1"
mm 4.5 (±0.5) 4.5 (±1.0)
door "C"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Door sill molding to Dimension
mm 6 (±1) 6.0 (±1.0)
front door "G"
Rear door to rear Dimension
mm 4.5 (±0.5) 4.5 (±1.0)
fender "H"
Front door to A- Dimension
mm 4.5 (±0.5) 4.5 (±1.0)
BE60.00-P- Gap pillar "I"
mm 4 (±1) 4.0 (±1.0)
headlamps "J"
mm 6 (±1.5) 6.0 (±1.0)
grille "K"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Front bumper to Dimension
fender "Q" mm - 0.0 (±1.0)

mm 5 (±0.5) 5.0 (±1.0)
door "R"
Dimension
Bumper to taillamp mm 3 (±0.5) 3.0 (±1.0)
"S"
BE60.00-P- Gap
1005-01P dimension Top of taillamp to D- Dimension
mm 3 (±0.5) 3.0 (±1.0)
pillar "T"
Bottom of taillamp Dimension
mm 5 (±0.5) 3.0 (±1.0)
to D-pillar "T1"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
FENDER SPECIFICATIONS
Number Designation Model 1641/8
BA88.10-P-1001-01E Mount, fender to body Nm 10

REMOVE/INSTALL FENDER LINER IN FRONT FENDER - AR88.10-P-1300GZ
MODEL 164

Fig. 13: Identifying Fender Liner In Front Fender Remove/Install Components - Shown On Model 164.1
Remove/install

AR00.60-P-
1000GZ
Remove fender liner front AR88.10-P-
2
section in front fender (1) 1310GZ
3 Unscrew nuts (2).
4 Remove expansion rivets (3)
Remove fender liner in front Installation: Ensure that fender liner is
5
fender (1). seated correctly in front fender.
REMOVE/INSTALL FENDER LINER FRONT SECTION IN FRONT FENDER - AR88.10-P-1310GZ
MODEL 164

Fig. 14: Identifying Fender Liner Front Section In Front Fender Remove/Install Components - Shown
On Model 164.1
Remove/install

AR00.60-P-
1000GZ
Unscrew bolts of fender liner
2
front section (2) on bumper.
3 Unscrew nuts (1).
5 Remove screws (4)
Lift rear section of fender liner Lift rear section of fender liner at top
6 overlap with mounting wedge until front section of
in fender.
fender liner (2) can be removed from fender.
Remove front section of
7
fender liner (2) from fender

REMOVE/INSTALL FENDER LINER IN REAR FENDER - AR88.10-P-1400GZ
MODEL 164
Fig. 16: Identifying Fender Liner In Rear Fender Remove/Install Components - Shown On Model 164.1
Remove/install

AR00.60-P-
1000GZ
On model 164.1 unscrew three nuts (2).

2 Unscrew nuts (2).
On model 164.8 unscrew two nuts (2).
On model 164.1 remove three expansion
rivets (3) at rear.
On model 164.8 remove six expansion
rivets (3) at rear.
Loosen fender liner in rear
Installation: Ensure that fender liner is
4 fender (1) from rear fender
seated correctly in rear fender.
with mounting wedge.

REMOVE/INSTALL FRONT BUMPER - AR88.20-P-2000GZ
MODEL 164
Fig. 18: Identifying Front Bumper Remove/Install Components - Shown On Model 164.1

Shown on model 164.1 with Parktronic system (PTS), code 220

Fig. 21: Identifying Front Bumper Remove/Install Components - Shown On Model 164.1 With
Parktronic System (PTS), Code 220
Remove/install
Align the vehicle between the lifting

Risk of death caused by vehicle platform pillars and position the four
AS00.00-Z-
slipping or toppling off of the lifting support plates at the lifting platform
0010-01A
manufacturer.
AR00.60-P-
1000GZ
*WH58.30-Z-
2 Remove bolts (1) Handymaster cordless drill/driver 1007-20A
3 Unclip clips (2)
Remove front section of fender liner AR88.10-P-
4
in right and left front fender 1310GZ
On model 164.8 additional bolts in
5 Remove bolts (3)
vehicle center.
*WH58.30-Z-
Handymaster cordless drill/driver 1007-20A
Remove expansion rivet on Only on vehicles with Offroad
6
underride guard. package, code 430.
Unscrew bolt (4), pivot bracket (5)
7 On left and right.
to vehicle and remove toward rear.
from left engine
8
compartment/bumper connector
(X26/32)
from right front engine On vehicles with Parktronic system
9
compartment/bumper connector (PTS) code 220.
(X26/36)
Use helper
10 Remove bumper toward front.
Installation: Adjust gap if required
*BE60.00-P-
1004-01P
*BE60.00-P-
1005-01P


Rear door to C- Dimension
mm 4.5 (±0.5) 4.5 (±1.0)
pillar "L"
mm 4 (±1) 4.0 (±1.0)
headlamp "M"
Bumper to Dimension
mm 4 (±1) 4.0 (±1.0)
BE60.00-P- Gap headlamp "N"
1004-01P dimension Front grille to Dimension
mm 6 (±1.5) -
bumper "O"
mm 5 (±0.5) 5.0 (±1.0)
door "P"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Front bumper to Dimension
mm - 0.0 (±1.0)
fender "Q"
mm 5 (±0.5) 5.0 (±1.0)
door "R"
Dimension
BE60.00-P- Gap "S"
1005-01P dimension Top of taillamp to Dimension
mm 3 (±0.5) 3.0 (±1.0)
D-pillar "T"
Bottom of taillamp Dimension
mm 5 (±0.5) 3.0 (±1.0)
to D-pillar "T1"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ


Number Designation
DISASSEMBLE/ASSEMBLE FRONT BUMPER - AR88.20-P-2050GY

MODEL 164.8
Fig. 23: Identifying Front Bumper Disassemble/Assemble Components - Model 164.8 (1 Of 3)



Remove
AR88.20-
P-2000GZ
Lay bumper down on suitable
subsurface to prevent damaging paint.
Remove license plate and license plate
2
bracket from bumper
Unclip impact absorber (1) (arrows A) Installation: First arrest impact
3
and remove absorber (1) at bottom.
Disconnect outside temperature sensor
4
(2) from cable set and remove.
Disconnect front fog lamp connector (4)
5
on left and right
Unclip cable set connector (3) from
6
bumper
Remove bumper wiring harness from Installation: Route wiring
7
bumper inner section (9) harness in corresponding recesses.
AR82.10-
8 Remove front fog lamps
P-5103GY
Remove expansion rivets (5) on left and Installation: Check expansion
9
right rivets (5), replace if necessary.
Installation: Ensure that bottom
Unclip bottom catch lugs (7) from
10 catch lugs (7) are seated correctly on
bottom section (6).
bumper inner section (9).
Remove upper catch lugs (8) and Installation: Ensure that upper
11 catch lugs (8) are seated correctly on
remove bottom section (6).
bumper inner section (9).
Remove expansion rivets (10) and Installation: Check expansion
12 expansion rivets (11) from bumper rivets (10) and expansion rivets (11),
paneling (15) on left and right. replace if necessary.
13 Remove bumper inner section (9).
Pry tow eye cover (12) out of
14 Remove tow eye cover (12). bumper paneling (15) with suitable tool,
press barb on retaining strap together and
guide through retaining bracket.
Only on vehicles with headlamp
cleaning system, code 600.

Remove retaining clips (14) and remove
15.1 left and right telescopic nozzle cover Installation: Ensure that
telescopic nozzle cover (13) is seated
(13) from bumper paneling (15)
correctly in bumper paneling (15).
Unclip air inlet grille (16) on arrests (17)
16 Mounting wedge Fig. 15
from bumper paneling (15) and remove
Install
AR88.20-
18 Install front bumper
P-2000GZ

DISASSEMBLE/ASSEMBLE FRONT BUMPER - AR88.20-P-2050GZ
MODEL 164.1 with CODE (220) Parktronic system (PTS)
Fig. 27: Identifying Front Bumper Disassemble/Assemble Components - Model 164.1 With Code (220)
Parktronic System (PTS) (1 Of 6)
Remove
AR82.10-P-
1 Remove front fog lamps
5103GZ
AR88.20-P-
2000GZ
Unclip front bumper PTS sensors (1) from
3 Release tool Fig. 34
bumper paneling
Installation: Lay
Remove Parktronic wiring harness (2) from
4 Parktronic wiring harness (2) in
inner section of bumper (5)
corresponding recesses
Unclip clips for inner connection section (6)
5
from bumper paneling
Unclip clips for outer inner connection section
6
(7) from bumper paneling
Remove expansion rivets (8, 9) from bumper
7
paneling
Lift lugs (11) and remove center impact
8
absorber (10)
Unclip clips for center inner connection
9
section (12) from bumper paneling
Unclip clips for bottom inner connection
10
section (13) from bumper paneling
11 Remove inner bumper section (5)
Remove left and right impact absorber (14) The impact absorber (14) is
12
from bumper paneling arrested with a retaining lug
Remove clips (15) and remove left and right Installation: Ensure that
13 telescopic nozzle cover (17) from bumper retaining lugs (16) are seated
paneling correctly in bumper paneling
Unclip air inlet grate (9) from latching hooks
(18) on bumper paneling and remove
Lift clips for bottom section connection (20)
15 and remove bumper bottom section (21) from
bumper paneling
16 Assemble in reverse order
Install
AR88.20-P-
2000GZ
AR82.10-P-
18 Install front fog lamps
5103GZ

Fig. 34: Identifying Unlocking Tool (168 589 02 31 00)

DISASSEMBLE/ASSEMBLE REAR BUMPER - AR88.20-P-2100GZ
MODEL 164
Shown on bumper on model 164.1
Fig. 35: Identifying Rear Bumper Disassemble/Assemble Components - Shown On Bumper On Model
164.1

164.1
Illustrated on bumper on model 164.1
164.1

164.1
164.1
AR88.20-P-
1 Remove rear bumper
2200GZ
Only on model 164.8. AR88.20-P-
2.1 Remove rear bumper reflector
On left and right. 2110GY
Only on vehicles with
Remove Parktronic system sensors (PTS) in AR54.65-P-
3.1 Parktronic system (PTS), code
rear bumper 0002GZ
220.

Parktronic system (PTS), code
220.
4.1 Remove cable strap (1) and wiring harness (2). Installation: Use new
cable strap (1).
Remove clips (3) for impact absorber (4) on Number and position of
5 left and right and remove impact absorber (4) clips (3) can vary depending on
from bumper vehicle model.
Remove clips (5) for center impact absorber Number and position of
6 (6) and remove center impact absorber (6) clips (5) can vary depending on
from bumper vehicle model.
Number and position of
Loosen retaining lugs (7) and separate bumper
7 retaining lugs (7) can vary
halves
depending on vehicle model.
Number and position of
8 Remove clips (8) and remove bumper insert clips (8) can vary depending on
vehicle model.
REMOVE/INSTALL REAR BUMPER REFLECTOR - AR88.20-P-2110GY
MODEL 164.8
Fig. 40: Identifying Rear Bumper Reflector Remove/Install Components

Remove/install
Position long wedge on inner narrow side of Fig.

1 Long wedge
reflector (1), unclip reflector (1). 41
Work carefully, otherwise the lugs (2)
Pivot reflector (1) toward outside and can break off easily.
2
remove Installation: First position lugs (2)
in mounts (3), then clip in reflector (1).

REPLACE MOUNT ON BUMPER - AR88.20-P-2150GZ
MODEL 164
Fig. 42: Identifying Replace Mount On Bumper Components - Shown On Model 164.1
MODIFICATION NOTES
Bolt connecting exhaust rubber mount bracket Engines 272, 273 in *BA49.10-P-1008-
11.5.07
(outer) to bumper bracket model 164 01W
Remove/install
AR88.20-P-
2200GZ
Unscrew bolts (1) from outer exhaust *BA49.10-P-
2 Engine 113, 156
rubber bearing (2) 1008-01S
*BA49.10-P-
Engine 272, 273 1008-01W
Engine 629, 642 *BA49.10-P-
1008-01U
Remove outer exhaust rubber bearing Installation: Coat rubber
3
(2) from rear muffler mounts with lubricant.
*BR00.45-Z-
Lubricating paste
1002-06A
Unscrew nuts (4) from rear bumper *BA88.20-P-
4
mount (3) 1002-01E
5 Remove rear bumper mount (3)
EXHAUST SYSTEM
Number Designation Engine 113.964 in Engine 156.980 in
model 164.1 model 164.1
BA49.10-P- Bolt connecting exhaust rubber mount
Nm 12 12
1008-01S bracket (outer) to bumper bracket
EXHAUST SYSTEM CHART

Number Designation Engines 272, 273 in
model 164
BA49.10-P-1008- Bolt connecting exhaust rubber mount bracket (outer)
Nm 18
01W to bumper bracket

model 164 model 164
Nm 12 12
1008-01U bracket (outer) to bumper bracket
BUMPER CHART
BA88.20-P-1002-01E Nut bumper mount on body Nm 18

BR00.45-Z-1002-06A Lubricating paste A 000 989 01 60
REMOVE/INSTALL REAR BUMPER - AR88.20-P-2200GZ
MODEL 164
Fig. 43: Identifying Rear Bumper Remove/Install Components - Model 164

Fig. 44: Identifying Rear Bumper Remove/Install Components - Shown On Model 164.1

Fig. 45: Identifying Rear Bumper Remove/Install Components - Shown On Model 164.1
Remove/install
Loosen fender liner (1) in area

1 Do not remove tires.
of rear bumper (7)
2 Unscrew bolt (2) on both sides.
3 Open rear-end door
Open side paneling (3) in load
4
compartment and remove
5 Remove screws (4)
The long nut (5) on left and right can
Unscrew long nut (5) on left and
6 be reached from the service opening on left or
right in rear crossmember.
right.
Disconnect PTS connector, rear Vehicles with Parktronic system
7.1
bumper (X35/28) (PTS), code 220.
Unscrew bolt (6) at bottom on
8
rear bumper (7)
Remove rear bumper (7) toward Use aid of helper
9
rear. Installation: If required, adjust gap.
*BE60.00-P-
1002-01P
*BE60.00-P-
1005-01P
*BE60.00-P-
1006-01P

Dimension
Rear bumper to fender mm - 0.0 (±0.5)
"C1"
Dimension
Front door to rear door mm 5 (±0.5) 5.0 (±1.0)
"D"
mm 5 (±1) 5.0 (±1.0)
BE60.00-P- Gap pillar "D1"
1002-01P dimension Front door to rear door Dimension
mm 5 (±0.5) 5.0 (±1.0)
mm 6 (±1) 6.0 (±1.0)
rear door "F"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
Front bumper to fender mm - 0.0 (±1.0)
"Q"
mm 5 (±0.5) 5.0 (±1.0)
door "R"
Dimension
BE60.00-P- Gap "S"
1005-01P dimension Taillamp to upper D- Dimension
mm 3 (±0.5) 3.0 (±1.0)
pillar "T"
Taillamp to lower D- Dimension
mm 5 (±0.5) 3.0 (±1.0)
pillar "T1"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
mm - 5.0 (±1.0)
pillar "D1"
Dimension
for glass mm 5 (±1) 5.0 (±1.0)
"U"
mm 8 (±1.5) 8.0 (± 1.5)
bumper "V"
BE60.00-P- Gap
Antenna cover
1006-01P dimension
Dimension
on roof mm 5 (±2) 6.0 (±2.5)
"W"
Dimension
mm 8 (±0.5) 6.0 (±1.0)
"W"
On rear-end door
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ

REMOVE/INSTALL CARRIER FOR REAR BUMPER - AR88.20-P-2250GZ
MODEL 164
Shown model 164.1 with TIREFIT
Fig. 47: Identifying Carrier For Rear Bumper Remove/Install Components - Shown Model 164.1 With
TIREFIT
Picture only valid for model 164.1.
Shown on vehicle with TIREFIT

Fig. 48: Identifying Carrier For Rear Bumper Remove/Install Components - Shown On Vehicle With
TIREFIT

With Engine 113

MODIFICATION NOTES
11.5.07
(inner) to body model 164 01W
11.5.07
(outer) to bumper bracket model 164 01W
Remove/install

lifting platform.
manufacturer.
AR00.60-P-
1 Raise vehicle
1000GZ
AR88.20-P-
2200GZ
AR68.30-P-
3 Remove rear door sill molding
4100GZA
Unclip clips (1), remove
4.1 On vehicles with Tirefit.
stowage compartment paneling.
AR68.30-P-
4.2 Remove spare tire well paneling On vehicles with spare tire. 4620GZ
Remove plastic caps from nuts *BA88.20-P-
5
(2), unscrew nuts (2). 1001-01E
6.1 Remove right ventilation (3) Only on model 164.1.
Remove rear SAM control AR54.21-P-
module (N10/8) 1269GZ
Unscrew nuts (4) and lay SAM
8.1 control module bracket down to Only on model 164.1.
side
Remove right plastic caps from *BA88.20-P-
9
nuts (5), unscrew right nuts (5). 1001-01E
If nuts (9) are not accessible, remove
10.1 Secure rear muffler
without heat shields.
Unscrew bolts (6, 7) from rear If nuts (9) are not accessible, remove
11.1
muffler mount. without heat shields.
*BA49.10-P-
Engine 113, 156 1007-01S
*BA49.10-P-
Engine 113, 156 1008-01S
*BA49.10-P-
Engine 272, 273 1007-01W

*BA49.10-P-
Engine 272, 273 1008-01W
*BA49.10-P-
Engine 629, 642 1008-01U
*BA49.10-P-
Engine 629, 642 1011-01U
Unscrew nuts (8) on heat shield If nuts (9) are not accessible, remove
12.1
on both sides. without heat shields.
If nuts (9) are not accessible, remove
13.1 Remove heat shields
without heat shields.
*BA88.20-P-
14 Unscrew nuts (9) on both sides.
1001-01E
15 Remove carrier (10) With aid of helper.

model 164.1 model 164.1
Nm 20 20
1007-01S bracket (inner) to body
Nm 12 12
1008-01S bracket (outer) to bumper bracket

Number Designation Engines 272, 273 in
model 164
BA49.10-P-1007- Bolt connecting exhaust rubber mount bracket (inner)
Nm 18
01W to body
BA49.10-P-1008- Bolt connecting exhaust rubber mount bracket (outer)
Nm 18
01W to bumper bracket

model 164 model 164
Nm 12 12
1008-01U bracket (outer) to bumper bracket
Nm 20 20
1011-01U bracket (inner) to body
BUMPER CHART
BA88.20-P-1001-01E Nut, rear crossmember to rear center section Nm 50
REMOVE/INSTALL UNDERRIDE GUARD - AR88.30-P-0010GZ
MODEL 164 with CODE (430) Offroad package
Fig. 50: Identifying Underride Guard Remove/Install Components - Shown On Model 164.8 With Engine
629
Remove/install

platform.
Always wear protective gloves when working
Risk of injury caused by scraping
on or near sharp and non-deburred vehicle AS00.00-Z-
or cutting body parts on sharp
parts. 0017-01A
vehicle parts
AR00.60-P-
1 Raise vehicle
1000GZ
Use aid of helper because underride

guard is extremely heavy.
Installation: It is necessary to slide

lugs (6) below counter elements (arrows) on
Unscrew bolts on underride guard
bumper.
2 front section (3), remove underride
guard front section (3). Installation on engine 629 : Align
plastic tube (4b) and plastic fitting (4a) with
one another.
Use aid of helper because underride
guard are extremely heavy.
Unscrew bolts from underride guard
Installation: Insert hooks (7) into
rear section (2), pivot underride
3 holes (arrows B) on front axle carrier.
guard rear section (2) toward front
and remove. Installation on engine 629 : Align
plastic tube (5b) and plastic fitting (5a) with
one another
Unscrew rear bolts from plastic
4 bridge (1), remove plastic bridge
(1).
If applicable, transfer plastic fittings
5 Only for engine 629.
(4a, 5a)
REMOVE/INSTALL STYLING PACKAGE - AR88.30-P-0200GZ
MODEL 164.1 with CODE (990) AMG vehicles with CODE (U49) Styling package
Shown on model 164.1 on rear left fender

Fig. 51: Identifying Styling Package Remove/Install Components - Shown On Model 164.1 On Rear Left
Fender
Remove
Fender flare (3) and fender flare bracket
(1) are not planned to be reinstalled.
Dispose of parts after removal.
1 Unscrew bolts (6) from fender flare (3).
Fender flare (3) is fastened to fender with
2 Loosen fender flare (3) from fender
adhesive strips.
Pull mounting wedges (4) on fender flare
3
bracket (1) out of fender edge.
Loosen fender flare bracket (1) from Fender flare bracket (1) is fastened to
4
fender fender with adhesive strips.
5 Remove adhesive residues from fender Using suitable solvent
Install
Fender flares are delivered preinstalled on
front and rear bumpers.
Installation location is indicated on each
detachable part: "LR LR (left rear, right
rear), RH FRT (right rear, front section)",
etc.
Carefully clean bonding surfaces: The
Clean fender and fender edge in inner and bonding surfaces must be free of dust and grease
6
outer wheelhouse and should be absolutely dry to ensure proper
adhesion.
Align fender flare bracket (1) in Fastener (arrow A) must be positioned on
7 fender flare bracket (1) between fender and
installation position on fender
rocker panel.
Remove protective foil (2) from fender While doing this, press fender flare
8 flare bracket (1) in direction of arrow bracket (1) to fender and fender edge in
(arrows B). wheelhouse.
Press fender flare bracket (1) on with
9 Pressing pressure should be 10 N.
uniform pressure (arrows C).
Fig.
Roller 53
Slide mounting wedges (4) behind fender
10
edge in wheelhouse
Position fender flare (3) in installation
11
position on fender.
Align fender flare (3) with fender flare on
12 Dimension (F) is 5 mm.
bumper
Fig.
Feeler gauge 12
Remove protective foil (5) on inside of Ensure that fender flare (3) is in the
13 fender flare (3) in direction of arrow correct installation position.
(arrows D). Press fender flare (3) against fender
Screw bolts (6) into fender flare (3) and

14 CAUTION:
fender flare bracket (1)
Only slightly tighten bolts (6) to prevent
stripping
Press fender flare (3) on with uniform
15 Pressing pressure should be 10 N.
pressure.
Fig.
Roller 53

Fig. 53: Identifying Roller (168 589 05 63 00)

REMOVE/INSTALL SIDE STEP - AR88.30-P-2400GY
MODEL 164 with CODE (846) Running boards

Fig. 54: Identifying Side Step Remove/Install Components - Shown On Model 164.8
Fig. 55: Identifying Side Step Remove/Install Components - Shown On Model 164.8
Remove/install
1 Move vehicle onto drive-on platform When using lifting platform, bolts
(6) cannot be removed.
Remove rear rubber mounts for lifting platform
2 So that bolts (6) can be removed.
plate
3 Unscrew bolt (2)
4 Remove threaded sleeves (3).
Installation: Replace expansion

5 Remove expansion clips (4, 5)
clips.
6 Open front and rear door
Insert mounting wedge between longitudinal
7 member and running board (1) and unclip metal
clips (arrows A) from subconstruction (9).
When removing and installing, pay
8 Remove running board (1) particular attention to lower edge of front
and rear door to prevent paint damage.
9 Close front and rear door
10 Unscrew nuts (8). Installation: Install new nuts.
11 Remove bolts (6, 7) Installation: Align subconstruction
(9) (raise slightly), then tighten bolts.
12 Remove subconstruction (9) The subconstruction is sharp edged.
Danger of paint damage.
OPEN ENGINE HOOD, MOVE TO UPRIGHT POSITION AND CLOSE - AR88.40-P-1000GZ
MODEL 164
Fig. 56: Identifying Open Engine Hood, Move To Upright Position And Close - Shown On Model 164.1
Risk of injury caused by fingers being jammed

or pinched when removing, installing or AS00.00-Z-
aligning hoods, doors, trunk lid/ rear-end door or 0011-01A
sliding roof.
Open engine hood
Pull lever (1) in left side of footwell to unlock Engine hood (2) pops open, if
1
the engine hood (2) necessary slight lift engine hood.
Do not lift on handle (3).The
Pull handle (3) out of radiator grille as far as the
2 windshield wiper arms must not be
stop and open engine hood
folded forward.
Move to upright position
Press red release button (4) on gas-operated strut
3
and position engine hood (2) upright.
Close engine hood
Press red release button (4) on gas-operated strut
4 and lower engine hood (2) until it is positioned at
an angle.
Place hands only on front
5 Close engine hood (2)
edges of engine hood (2).
Pull engine hood (2) upward with a jerk to check
6
locking function of engine hood lock.
REMOVE/INSTALL ENGINE HOOD - AR88.40-P-3000GZ
MODEL 164
Fig. 57: Identifying Engine Hood Remove/Install Components - Shown On Model 164.1
Remove/install
Risk of injury caused by fingers being When moving components, ensure AS00.00-Z-
jammed or pinched when removing, that no body parts or limbs are 0011-01A
installing or aligning hoods, doors, trunk lid/ within the operating range of
rear-end door or sliding roof. moving parts.

1
position 1000GZ
AR83.25-P-
2 Remove air intake duct (4) below engine hood
1407GZ
Carefully unclip washer fluid
nozzles from below, risk of cracks
and fracture!
3 Unlock wash water nozzles and unclip
Installation: The washer
fluid nozzles must be mounted
into the guides.
Long wedge Fig. 41
AR88.40-P-
4 Remove gas-operated struts from engine hood
3010GZ
5 Mark position of hood hinges on engine hood To facilitate installation.
6 Undo screw (1, 2) Installation: Paint screws.
*BA88.40-P-
1001-01K
Use aid of helper to avoid
7 Remove engine hood (3) damage. Set down on suitable
surface.
AR88.40-P-
9 Adjust engine hood (3)
3020GZ
ENGINE HOOD SPECIFICATIONS

BA88.40-P-1001-01K Bolt, hood hinge to engine hood Nm 20

REMOVE/INSTALL AIR INLET GRILLE ON ENGINE HOOD - AR88.40-P-3001GZ
MODEL 164
Fig. 59: Identifying Air Inlet Grille On Engine Hood Remove/Install Components
Remove/install
Remove air inlet duct under the AR83.25-P-

1
hood 1407GZ
Carefully unclip washer fluid nozzles (1)
from below, risk of cracks and fracture!
2 Unclip washer fluid nozzles (1)
Installation: The washer fluid
nozzles must be mounted into the guides.
Long wedge Fig. 41
4 Remove bolts (3)
Remove left air inlet grating (4)
5
and right air inlet grating (5)

REMOVE/INSTALL GAS-OPERATED STRUT ON ENGINE HOOD - AR88.40-P-3010GZ
MODEL 164
Fig. 61: Identifying Gas-Operated Strut On Engine Hood Remove/Install Components

Remove/install

jammed or pinched when removing, installing that no body parts or limbs are AS00.00-Z-
or aligning hoods, doors, trunk lid/ rear-end within the operating range of 0011-01A
door or sliding roof. moving parts.
AR88.40-P-
1 Open engine hood
1000GZ
2 Secure engine hood
Lift retainer (2) on top of gas-operated strut (1),
3
unhook gas-operated strut (1) at top.
Risk of injury caused by drilling gas-filled
Wear safety glasses and a face AS00.00-Z-
assemblies or components (noncombustible
mask. 0006-01A
gases)
If required, replace gas-
Lift retainer (2) at bottom of gas-operated strut
4 operated strut (1) and dispose of
(1), unhook gas-operated strut (1) at bottom
old gas-operated strut (1).
OS00.00-P-
Degas and drain gas pressure strut
1001-01A
ADJUST ENGINE HOOD - AR88.40-P-3020GZ
MODEL 164

Fig. 62: Adjusting Engine Hood - Shown On Model 164.1

Remove
being jammed or pinched when When moving components, ensure that no
AS00.00-Z-
removing, installing or aligning body parts or limbs are within the operating
0011-01A
hoods, doors, trunk lid/rear-end range of moving parts.
1
Remove both engine hood catch top
2
sections (1)
Adjust in lateral direction
Undo bolts (2) and adjust engine Check gap dimension between fender
3 and engine hood. Adjust if necessary, see:
hood in transverse direction
?
AR60.00-P-
Gap around hoods, doors, and lids
0700-01GZ
Gap dimension between fender and engine *BE60.00-
hood, dimension "B" P-1001-01P
*BA88.40-
4 Tighten screws (2)
P-1001-01K
Adjust in longitudinal direction
AR88.40-P-
5 Remove gas-operated strut for hood
3010GZ
Check gap dimension between fender
Undo bolts (2) and adjust engine and engine hood. Adjust if necessary, see:
6
hood in longitudinal direction ?
AR60.00-P-
0700-01GZ
*BA88.40-
P-1001-01K
Adjust height
Close engine hood and place onto
8
stop buffers (3).
Adjust stop buffers (3) such that the engine
hood and radiator paneling cannot distort.
Check gap dimension for fender to
9 Adjust gap dimensions engine hood, gap dimension for engine hood
to front grille and gap dimension for engine
hood to headlamp. If necessary, undo nuts and
set height of stop buffers (3), see:-->
AR60.00-P-
0700-01GZ
Gap dimension between engine hood and front *BE60.00-
grille, dimension "K" P-1003-01P
Gap dimension between engine hood and *BE60.00-
headlamp, dimension "M" P-1004-01P
10 Open engine hood
Install
Install engine hood catch upper
11
sections (1)
Only if necessary.
Adjust height of striker (4) on upper The locked engine hood should not
12.1 part of engine hood lock using the exhibit any play in the upper part of the engine
adjusting nut (5) hood lock (1) or should have only a slight
tension downwards.
To do so pull engine hood up abruptly.
Close engine hood and then check Engine hood should drop and arrest
13 that the engine hood catches are automatically in engine hood locks from a
locked into place. height of 100 to 130 (measure above fender
tip).
14 Unlock engine hood and check

arrest of safety hook (6) on radiator
crossmember (7)
Install gas-operated strut on engine AR88.40-P-
15
hood 3010GZ
Repair paint damage on bolts (2)
16 and adjustment nuts (5) using
touch-up paint pen

Dim.
Front fender to A-pillar mm 4.5 (±0.5) 3.5 (±1.0)
"A"
Dim.
"A1"
Dim.
Fender/engine hood mm 3.5 (±0.5) 3.5 (±1.0)
BE60.00-P- Gap "B"
1001-01P dimension Rear door to side roof Dim.
mm 4.5 (±0.5) 4.5 (±1.0)
frame "B1"
Dim.
Front fender to front door mm 4.5 (±0.5) 4.5 (±1.0)
"C"
See AR60.00-P- AR60.00-P-
picture 0700-01GZ 0700-01GZ
Door sill molding to Dim.
mm 6 (±1) 6.0 (±1.0)
front door "G"
Dim.
Rear door to rear fender mm 4.5 (±0.5) 4.5 (±1.0)
"H"
BE60.00-P- Gap Front door to A-pillar Dim. "I" mm 4.5 (±0.5) 4.5 (±1.0)
1003-01P dimension Fender/side headlamps Dim. "J" mm 4 (±1) 4.0 (±1.0)
Dim.
Engine hood to front grill mm 6 (±1.5) 6.0 (±1.0)
"K"
See AR60.00-P- AR60.00-P-
Dim.
Rear door to C-pillar mm 4.5 (±0.5) 4.5 (±1.0)
"L"
Dim.
Engine hood to headlamp mm 4 (±1) 4.0 (±1.0)
"M"
Dim.
Bumper/headlamps mm 4 (±1) 4.0 (±1.0)
BE60.00-P- Gap "N"
1004-01P dimension Dim.
Front grill to bumper mm 6 (±1.5) -
"O"
Taillamp to rear-end
Dim. "P" mm 5 (±0.5) 5.0 (±1.0)
door
See AR60.00-P- AR60.00-P-

BA88.40-P-1001-01K Bolt, hood hinge to engine hood Nm 20

REMOVE/INSTALL HOOD HINGE - AR88.40-P-3060GZ
MODEL 164
Fig. 64: Identifying Hood Hinge Remove/Install Components

Remove/install

Only remove and install gas-operated
Risk of injury caused by body parts being
struts when they are not under AS00.00-Z-
pinched or crushed when working on gas
tension and when the components are 0012-01A
operated struts under tension
properly secured.
1
position 1000GZ
Installation: Install new tie

2 Remove tie straps (1)
straps.
Mark installation of engine hood hinge (4) Facilitates assembly when
3
on engine hood and on body. installing
Secure engine hood with aid of
4 Unscrew bolt (2)
second person to prevent damage.
*BA88.40-P-
1001-01K
Lay engine hood down on suitable
subsurface with aid of second person
to prevent damaging hood, fenders
5 Lay engine hood down on engine block.
and radiator grille.
Do not remove gas-operated
struts.
*BA88.40-P-
6 Remove bolts (3)
1002-01K
7 Remove engine hood hinge (4) plastic lug on cover below
windshield is seated correctly.
Check gap dimension AR88.40-P-
9 Adjust engine hood between fender and engine hood.
3020GZ
Adjust if necessary, see:?
AR60.00-P-
0700-01GZ
Gap dimension between fender and *BE60.00-P-
engine hood, dimension "B" 1001-01P
Gap dimension between engine hood *BE60.00-P-
and front grille, dimension "K" 1003-01P
Gap dimension between engine hood *BE60.00-P-
and headlamp, dimension "M" 1004-01P
Repair paint damage on bolts (2, 3), on
10 inner engine hood and upper longitudinal
member with touch-up paint pen.

Front fender to A- Dimension
mm 4.5 (±0.5) 3.5 (±1.0)
pillar "A"
Dimension
"A1"
Fender to engine Dimension
mm 3.5 (±0.5) 3.5 (±1.0)
BE60.00-P- Gap hood "B"
1001-01P dimension Rear door to side Dimension

mm 4.5 (±0.5) 4.5 (±1.0)
roof frame "B1"
mm 4.5 (±0.5) 4.5 (±1.0)
door "C"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
mm 6 (±1) 6.0 (±1.0)
front door "G"
mm 4.5 (±0.5) 4.5 (±1.0)
fender "H"
mm 4.5 (±0.5) 4.5 (±1.0)
mm 4 (±1) 4.0 (±1.0)
headlamps "J"
mm 6 (±1.5) 6.0 (±1.0)
grille "K"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
"L"
mm 4 (±1) 4.0 (±1.0)
headlamp "M"
Dimension
Bumper to headlamp mm 4 (±1) 4.0 (±1.0)
BE60.00-P- Gap "N"
1004-01P dimension Front grille to Dimension
mm 6 (±1.5) -
bumper "O"
mm 5 (±0.5) 5.0 (±1.0)
door "P"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ

BA88.40-P-1001-01K Bolt for engine hood hinge on engine hood Nm 20
BA88.40-P-1002-01K Screw for engine hood hinge on body Nm 20

REMOVE/INSTALL REBOUND FOR ENGINE HOOD - AR88.40-P-3100GZ
MODEL 164
Fig. 66: Identifying Rebound For Engine Hood Remove/Install Components

Remove/install
Rear engine hood release

cable
Installation: Before closing the engine hood

Open engine hood and check for proper function: When the engine hood is AR88.40-P-
raise to vertical position open lock engine hood locks with screwdriver and 1000GZ
1 then unlock engine hood locks with engine hood
release lever.
2 Remove bolt (1)
Remove engine hood
release lever (2) from
3
cover below instrument
panel
Unhook rear release cable
4 (8) from engine hood
release lever (2)
Remove seal (3) and lay
5
down to side
6 Unscrew bolt (4)
7 Remove cover (5).
8 Open connector (6)
Unhook front release cable
9
nipple (7)
Installation: Apply lubricant to passage
grommet (9) and pull rear release cable into vehicle
Pull rear release cable (8) interior with aid of second person. Ensure that passage
10 through firewall on engine grommet (9) is seated correctly in firewall!
side and remove. Installation: If necessary, remove cover below
instrument panel, if the rear release cable cannot be
reached, see:?
AR68.10-P-
Remove/install cover below instrument panel (left)
1500GZ
*BR00.45-
Anti-friction agent
Z-1010-06A
Front engine hood
release cable
AR88.40-P-
11 Remove engine hood locks
3200GZ
12 Open connector (6)
Unhook front release cable
13
nipple (7)
Unclip front release cable
14 (11) from clips (10) on
radiator crossmember
Remove front release
15 cable (11) with connector
(12).
REPAIR MATERIALS
BR00.45-Z-1010-06A Anti-friction agent A 000 989 03 67
REMOVE/INSTALL ENGINE HOOD CATCH - AR88.40-P-3200GZ
MODEL 164.1/8
Shown on vehicle with anti-theft alarm system (ATA), code 551
Fig. 67: Identifying Engine Hood Catch Remove/Install Components - Shown On Vehicle With Anti-
Theft Alarm System (ATA), Code 551
Remove/install

AR88.40-P-
1 Open engine hood
1000GZ
Unscrew bolts (1) and remove left engine *BA88.40-P-
2
hood lock (2) upward 1003-01K
Unclip outer sleeve mount (7) from engine

3
hood cable (3) on left engine hood lock.
Disconnect electrical connector (4) from ATA Vehicles with anti-theft
4.1
hood switch (S62) alarm system (ATA), code 551.
Unscrew bolts (5) and remove right engine *BA88.40-P-
5
hood lock (6). 1003-01K
Unclip outer sleeve mount (7) from engine
6
hood cable (3) on right engine hood lock (6).

BA88.40-P-1003-01K Screw, engine hood lock to radiator crossmember Nm 12
REMOVE/INSTALL RADIATOR GRILLE - AR88.40-P-4001GZ
MODEL 164
Fig. 68: Identifying Radiator Grille Remove/Install Components - Shown On Model 164.1
Remove
AR88.40-P-
1 Open engine hood
1000GZ
Press catch lugs (3) on inside
3 Release radiator grille (1) of radiator grille (1) downward with
suitable tool.
Push lower area of radiator grille (1) toward
4
rear and remove
Install
Put on radiator grille (1) and push toward The catch lugs (3) should
5
front catch audibly in radiator grille (1).
Installation: Adjust gap if
6 Install expansion rivets (2).
required.
*BE60.00-P-
1004-01P
AR88.40-P-
7 Close engine hood
1000GZ
Installation: Adjust gap if
required.
*BE60.00-P-
1003-01P

mm 6 (±1) 6.0 (±1.0)
front door "G"
mm 4.5 (±0.5) 4.5 (±1.0)
fender "H"
mm 4.5 (±0.5) 4.5 (±1.0)
mm 4 (±1) 4.0 (±1.0)
headlamps "J"
mm 6 (±1.5) 6.0 (±1.0)
grille "K"
AR60.00-P- AR60.00-P-
See picture
0700-01GZ 0700-01GZ
Dimension
"L"
Engine hood to Dimension mm 4 (±1) 4.0 (±1.0)
headlamp "M"
Bumper to Dimension
mm 4 (±1) 4.0 (±1.0)
headlamps "N"
Dimension
BE60.00-P- Gap Front grill to bumper mm 6 (±1.5) -
"O"
1004-01P dimension
mm 5 (±0.5) 5.0 (±1.0)
door "P"
R60.00-P-0700- AR60.00-P-
See picture
01GZ 0700-01GZ

REMOVE/INSTALL MERCEDES STAR - AR88.40-P-4050GZ
MODEL 164
Fig. 70: Identifying Mercedes Star Remove/Install Components

Remove/install
Work carefully to avoid damaging paint

Remove Mercedes star (1) upward Installation: Observe installation

1
using long wedge position of Mercedes star (1)
Fig.
Long wedge 41
Check grommets (2), and replace if
2 Remove grommets (2)
required.

INSTALL MODEL PLATE ON TRUNK LID - AR88.50-P-5050GZ
MODEL 164
Fig. 72: Identifying Model Plate On Trunk Lid - Shown On Model 164.1 With Engine 113
Install
Check position of individual letters and numbers of
1
model plate (1) on carrier foil (2) and correct, if necessary
2 Clean and degrease assembly point on rear-end door (5)
Align template (4) on exterior
3 Install template (4) on rear-end door (5) and align contour (A) of rear-end door (5)
Model 164.1:
Fig.
Template 73
Model 164.8:
Fig.
Template 74
Model plate (1) should remain
4 Remove protective foil (3)
fastened on carrier foil (2)
5 Align model designation (1) on template (4) and press on.
6 Remove carrier foil (2).
Fig. 73: Identifying Template (164 589 06 23 00)

Fig. 74: Identifying Template (164 589 02 23 00)

REMOVE/INSTALL TANK RECESS - AR88.60-P-2000GZ
MODEL 164

Fig. 75: Identifying Tank Recess Remove/Install Components - Shown On Model 164.1
Removing
igniting, risk of poisoning caused by Pour fuels only into suitable and
AS47.00-Z-
inhaling and swallowing fuel as well as appropriately marked containers.
0001-01A
risk of injury to eyes and skin caused Wear protective clothing when handling
by contact with fuel. fuel.
1 Open fuel filler flap (4) Vehicles should not be locked.
Unlock lock button (5) with suitable
tool, slide fuel filler flap (4) in
2
direction of arrow and remove from
fuel filler flap inner section (7)
Remove retaining strap from fuel filler
3
inner section (7)
Unscrew fuel filler flap (2) and remove
4
with retaining tape
5 Remove screws (8)
Loosen tank recess (1) and remove tank
6
filler neck
Install
Carefully install lip (3) of tank recess
(1) over tank filler neck, otherwise it can
Install lip (3) of tank recess (1) over
7 tear.
tank filler neck.
Coat lip (3) on tank recess (1) with
lubricant.
*BR00.45-
Anti-friction agent
Z-1010-06A
Align tank recess (1) and screw in bolts
8
(8)
Check fuel filler flap (2), seal in
fuel filler flap (2) and retaining strap for
9 Screw fuel filler flap (2) to filler neck damage. Replace fuel filler flap (2)
completely, if only one of the components
mentioned is damaged.
Install retaining strap on fuel filler

10
inner section (7)
Position fuel filler flap (4) with guides
(6) on fuel filler inner section (7), slide
Check fuel filler flap (4) for
11 fuel filler flap (4) in opposite direction
damage, replace if required
of arrow until lock button (5) arrests
perceptibly.
12 Close fuel filler flap (4)
REPAIR MATERIALS
BR00.45-Z-1010-06A Anti-friction agent A 000 989 03 67
REMOVE/INSTALL TANK FLAP - AR88.60-P-6023GZ
MODEL 164
Fig. 76: Identifying Tank Flap Remove/Install Components - Shown On Model 164.1
Removing
Vehicles should not
1 Open fuel filler flap (4)
be locked.
Unlock lock button (5) with suitable tool, slide fuel filler flap (4) in
2
direction of arrow and remove from fuel filler flap inner section (7)
Install
Position fuel filler flap (4) with guides (6) on fuel filler inner Check fuel filler
3 section (7), slide fuel filler flap (4) in opposite direction of arrow flap (4) for damage, replace
until lock button (5) arrests perceptibly. if required
4 Close fuel filler flap (4)
REMOVE/INSTALL COMPLETE OUTSIDE MIRROR - AR88.70-P-9000GZ
MODEL 164
Fig. 77: Identifying Complete Outside Mirror Remove/Install Components

Remove/Install
AR72.10-P-
1 Remove door lining on front door
1000GZ
Disconnect electrical connector (1) from left front door control unit (N69/1)
2
or right front door control unit (N69/2)
3 Unscrew bolts (2)
4 Remove outside mirror (3) with electrical line
REMOVE/INSTALL MIRROR LENS - AR88.70-P-9020GZ
MODEL 164
Shown on vehicle with dimming inside rearview mirror and outside mirror (driver), code 249
Fig. 78: Identifying Mirror Lens Remove/Install Components - Shown On Vehicle With Dimming Inside
Rearview Mirror And Outside Mirror (Driver), Code 249
Remove/install
Risk of injury. Skin, eye and

respiratory system irritation may AS60.00-
occur through contact or inhalation Wear protective gloves and safety glasses. Z-0008-
of substances contained in the 01R
mirror lens.
1 transmitter key from EIS [EZS] until ignition is switched off. Remove
control unit transmitter key from vehicle and store it in a
2 m).
2 Tilt mirror lens (1) out upward
Installation: Clip mirror lens (1) into
Press retaining spring (2) upward
mirror adjustment drive from bottom upward.
with suitable screwdriver and press
3 Observe retaining spring (2), fasteners on
mirror lens (1) off of mirror
mirror lens as well as fasteners on mirror
adjustment drive.
adjustment drive.
4
from mirror heater
Disconnect electrical connector On vehicles with automatic dimming
5.1
from mirror dimming (4) inside and outside mirror (driver), code 249.
7 Clean mirror lens
REMOVE/INSTALL OUTSIDE MIRROR PANELING - AR88.70-P-9040GZ
MODEL 164
Fig. 79: Identifying Outside Mirror Paneling Remove/Install Components

Remove/install
Risk of injury. Skin, eye and respiratory system

Wear protective gloves and AS60.00-Z-
irritation may occur through contact or inhalation of
safety glasses. 0008-01R
substances contained in the mirror lens.
1 Adjust mirror lens (1) toward inside.
Work carefully with
2 Release retaining lug (2) in housing long wedge to prevent
breaking mirror lens (1)
Long wedge Fig. 41
Remove outside mirror paneling (3) toward outside
3
while disconnecting turn signal lamp connector.

REMOVE/INSTALL GLASS ADJUSTMENT DRIVE - AR88.70-P-9060GZ
MODEL 164

Fig. 81: Identifying Glass Adjustment Drive Remove/Install Components - Shown On Model 164.1
Remove/install
AR88.70-P-
1 Remove mirror lens
9020GZ
2 Remove bolts (1)
Remove glass adjustment drive (3) and disconnect electrical connector
3
(2).
4 Remove glass adjustment drive (3).
REMOVE/INSTALL COVERS ON REAR-END DOOR FRAME SEAL - AR88.80-P-0003GZ
MODEL 164
Right rear-end door cover
Shown on vehicle with automatic rear-end door, code 890

Fig. 82: Covers On Rear-End Door Frame Seal Remove/Install Components - Right rear-end door cover
(1 Of 2)
Fig. 83: Covers On Rear-End Door Frame Seal Remove/Install Components - Right rear-end door cover
(2 Of 2)
MODIFICATION NOTES
26.7.06 "Disconnect/connect battery ground line" removed 3rd stage
Remove/install

being pinched or crushed when

removing, installing or aligning hoods, Keep body parts and limbs well clear of AS00.00-Z-
doors, trunk lids, tailgates or sliding moving parts. 0011-01A
roof.
1 Open tailgate
Turn key in ignition switch to position 889:
2
"0". Press keyless go start/stop button
3 Install support for rear-end door Support Fig. 85
AR72.20-P-
4 Partially remove frame seal (1) In area of cover (2). 3540GZ
Long wedge Fig. 41
5 Remove bolts (3)
6 Remove cover (5)
Installation: Replace expansion
7 Remove expansion clips (4)
clips.
On vehicles with automatic rear- AR72.20-P-
8 Remove gas strut (7)
end door, code 890. 3600GZ
On vehicles without automatic
Remove gas-operated strut (7) from rear-end door, code 890.
9
lower attachment point on body Do not bend clip on lower
attachment point on gas-operated strut.
Unscrew bolts (8) from lever arm on Only on vehicles with automatic
10
hydraulic cylinder. rear-end door, code 890.
*BA72.20-
P-1001-02J
Open side paneling maintenance flap
and disconnect right rear-end door Only on vehicles with automatic
11
closing obstruction sensor strip rear-end door, code 890.
connector (B86/2x1)
On vehicles with automatic rear-
end door, code 890, thread obstruction
sensor strip (6) through body.
On vehicles with automatic rear-
end door, code 890: If applicable, lower
12 Remove cover (2). rear-end door slightly and open again to
remove lever arm on hydraulic cylinder
from the cover (2).
Installation: On vehicles with
automatic rear-end door, code 890, ensure
that obstruction sensor strip is seated
correctly.
Only on vehicles with automatic

rear-end door, code 890.
Check air gap between rear-end door An air gap must be present to ensure
and obstruction sensor strips over proper function of the automatic rear-end
14
entire length of obstruction sensor door.
strip. Check air gap: Pull thick sheet of
paper between obstruction sensor strip and
rear-end door over entire length.
TAILGATE CHART
BA72.20-P-1001-02J Bolt, hydraulic cylinder bracket to body Nm 34

Fig. 85: Identifying Support (170 589 04 63 00)

REMOVE/INSTALL COVERS ON REAR-END DOOR FRAME SEAL - AR88.80-P-0003GZA
MODEL 164
Left rear-end door cover

Fig. 86: Covers On Rear-End Door Frame Seal Remove/Install Components - Left Rear-End Door Cover
(1 Of 2)
Fig. 87: Covers On Rear-End Door Frame Seal Remove/Install Components - Left Rear-End Door Cover
(2 Of 2)
MODIFICATION NOTES
26.7.06 "Disconnect/connect battery ground line" removed 3rd stage
Remove/install

pinched or crushed when removing,

Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk
of moving parts. 0011-01A
1 Open tailgate
2 Turn key in ignition switch to position "0". code 889: Press keyless go start/stop
switched off
AR72.20-P-
4 Partially remove frame seal (1) In area of cover (2). 3540GZ
Long wedge Fig. 41
5 Remove bolts (3)
7 Remove expansion clips (4)
expansion clips.
Do not bend clip on lower
Remove gas-operated strut (7) from lower
8 attachment point on gas-operated
attachment point on body
strut.
Open side paneling maintenance flap and
9 disconnect left rear-end door closing
obstruction sensor strip connector (B86/1x1) automatic rear-end door, code 890.
On vehicles with automatic
rear-end door, code 890, thread
obstruction sensor strip (6) through
body.
10 Remove rear-end door cover (2).
Installation: On vehicles with
automatic rear-end door, code 890,
ensure that obstruction sensor strip is
seated correctly.
automatic rear-end door, code 890.
An air gap must be present to
Check air gap between rear-end door and ensure proper function of the
12 obstruction sensor strips over entire length automatic rear-end door.
of obstruction sensor strip. Check air gap: Pull thick sheet
of paper between obstruction sensor
strip and rear-end door over entire
length.


REMOVE/INSTALL REAR DOOR PROTECTIVE STRIP - AR88.80-P-1030GZ
MODEL 164
Fig. 90: Identifying Rear Door Protective Strip Remove/Install Components

Remove/Install

or aligning hoods, doors, trunk lid/ rear-end within the operating range of 0011-01A
1 Open rear door

2 Remove bolt (1)
3 Close rear door
4 Open front door
Slide rear door protective strip (2) toward front
5 Do not damage paint!
and remove from rear door
REMOVE/INSTALL LONGITUDINAL MEMBER PANELING - AR88.80-P-6000GZ
MODEL 164.1 /8 except CODE (846) Running boards
Fig. 91: Identifying Longitudinal Member Paneling Remove/Install Components - Shown On Model 164.1
(1 Of 2)

Fig. 92: Identifying Longitudinal Member Paneling Remove/Install Components - Shown On Model 164.1
(2 Of 2)
Removing
AR00.60-P-
1 Raise vehicle Ensure that all nuts (10) are exposed. 1000GZ
Remove expansion clips (1,
2
8), unscrew nuts (10)
Remove front end cap (2) and
3 Only on model 164.1
rear end cap (9)
AR00.60-P-
4 Lower vehicle
1000GZ
Do not press catches too far in with long wedge,
otherwise, they can break off.
Slide long wedge between longitudinal
member and longitudinal member paneling. Press in
Remove longitudinal member
5 paneling (3) with long wedge catches (5) one after the other using long wedge
(11) (arrow A) and disengage longitudinal member
paneling (arrow B).
Start at rear, prevent part already detached
from longitudinal member paneling from arresting
again, with additional mounting wedge.
Long wedge Fig. 41
6 Unscrew nuts (7).
Remove front retaining rail (4)
7
and rear retaining rail (6)
Install
Install front retaining rail (4)
8 and rear retaining rail (6)

9 Install nuts (7)
Press longitudinal member
paneling (3) to
10
subconstruction until notches
(5) arrest perceptibly
AR00.60-P-
11 Close doors, raise vehicle. Ensure that all nuts (10) can be installed. 1000GZ
Install front end cap (2) and
12 Only on model 164.1.
rear end cap (9)
Install expansion clips (1, 8)
13 Replace damaged expansion clips.
and nuts (10).
AR00.60-P-
14 Lower vehicle
1000GZ


REMOVE/INSTALL FRONT DOOR MOLDING - AR88.80-P-6600GZ
MODEL 164

Fig. 95: Identifying Front Door Molding Remove/Install Components - Shown On Model 164.1
Remove/install
1 Open front door
2 Unscrew bolt (1)
3 Slide protective molding (2) toward rear and remove Do not damage paint!
REMOVE/INSTALL SEAL SECTION AT ROOF FRAME - AR88.85-P-2000GZ
MODEL 164
Fig. 96: Identifying Seal Section At Roof Frame Remove/Install Components

Removing
1 Unclip clips (2)
Remove from front
2 Remove sealing profile (1) toward rear (arrow).

Clean
Bonding surface must be
3 Remove adhesive residues from roof frame
free of grease and dust
Dia. 100 mm eraser disc with *WH58.30-Z-
mounting shaft 1037-04A
*WE58.40-Z-
Drill (electric/pneumatic)
1001-03A
*BR00.45-Z-
Cleaner
1025-04A
Install
Remove protective foil from adhesive strips
4 in area of clips (2), align sealing channel (1), Replace clips.
install clips (2).
Remove protective foil on adhesive strips in
5 Start at front.
sections, lightly press on sealing channel (1)
6 Check alignment for sealing channel (1). Correct, if necessary.
7 Completely press on sealing channel (1). Roller Fig. 53


Number Designation
Removal disk, 100 mm dia. with fixing shank,
WH58.30-Z-1037-04A
Firma 3M Deutschland GmbH D-41453 Neuss
WORKSHOP EQUIPMENT
WE58.40-Z-1001-03A Drill (electric/pneumatic)
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
MAINTENANCE
CHECK ENGINE HOOD LOCK AND SAFETY HOOK - AP88.40-P-8851GZ
MODEL 164.1/ 8
Fig. 98: Identifying Engine Hood Lock And Safety Hook - Shown On Model 164.1
Checking
The locking system of the engine hood should
not be oiled or greased. The engine hood hinges
are maintenance free. Replace system if hard to
move or defective, do not attempt to free up or
repair.
1 Open engine hood
Opening engine hood, moving to upright AR88.40-
position and closing P-1000GZ
The components must be
Check all elements of the locking system for
2 replaced even in the event of slight
wear, cracks, deformation and damage.
defects.
Both notches (1a) must latch
Allow engine hood to fall freely into engine securely in the engine hood catches
3
hood locks from a max. height of 150 mm (1) (1) in order to guarantee faultless
locking.
Grasp the engine hood with

your hand from the front and pull
with a firm jerk to check the engine
4 Check engine hood lock hood is locked properly.
In the event of function
impairments, replace the engine
hood catches (1) with notches (1a):?
AR88.40-
Remove/install hood lock
P-3200GZ
For this purpose grip engine
hood at front and check whether
retaining hook (2) arrests properly
Unlock engine hood and check retaining hooks
5 by pulling with a firm jerk.
(2) for proper function
Do not actuate release lever (3) for
retaining hook (2) or change its
position
When the engine hood is put
down gently, the retaining hook (2)
Check retaining hook (2) and its flexible should arrest automatically in the
6 elements as well as the locking pawl (4) for locking pawl (4).
wear, cracks, deformation and damage Components must be
replaced in the event of slight defects
or function impairments:?
AR88.40-
Remove/install hood lock
P-3200GZ
7 Close engine hood
Opening engine hood, moving to upright AR88.40-
position and closing P-1000GZ
RETROFITTING & CONVERSION

RETROFIT RUNNING BOARDS - AN88.30-P-0005GZ
MODEL 164 without mud guards (accessory), without side step bar
Fig. 99: Identifying Running Boards Cover

Fig. 100: Identifying Jack Tubes, Step Platform, Nuts, Bracket, Bolt And Cover
Fig. 101: Identifying Running Boards Cover, Expansion Clips, Bolt Inserts And Bolts
Removal
1 Move vehicle to ramp platform
Dispose of longitudinal
2 Remove longitudinal member paneling
member paneling and retaining rails
Remove/install longitudinal member AR88.80-P-
paneling 6000GZ
Remove seam sealing in
3 Remove jack tubes (1) from body
mounts for jack tubes.
Install
4 Install stop plugs in body Instead of jack tubes.
Install running board (2) with nuts (3) in If necessary, adjust bracket (4)
5
correct installation position. at end of running board (2).
6 Tighten bracket (4) with bolts (5).
Install cover (6) with nuts (7) at bottom Tighten 2 nuts (7) at end of
7
of longitudinal member. bracket (4).
8 Install jack tubes (1) on bracket (4).
Clip running board cover (8) into running
9
board (2).
10 Install expansion clips (9)
11 Install bolt inserts (10) with bolts (11).

KG99 (see EPC) Running boards 1
MODIFY BUMPER LOWER SECTION - AN88.30-P-0007-01GY
Model 164.8 except offroad appearance package, code U89
Front bumper
1. Route front optical underride guard (1) on front bumper lower section to correct installation position.
2. Mark position of holes (3) on front bumper lower section (2).
3. Remove front optical underride guard (1).
4. Drill dia. 8 mm holes on markings.
5. Debur holes.
Fig. 102: Identifying Front Optical Underride Guard And Front Bumper Lower Section
Rear bumper
6. Route rear optical underride guard (4) on rear bumper lower section (5) to correct installation position.
7. Mark position of holes (6) on rear bumper lower section (5).
Only with trailer hitch, code 550
8. Mark hole for lug (7).

9. Remove rear optical underride guard (4).
Fig. 103: Identifying Rear Optical Underride Guard And Rear Bumper Lower Section
Only with trailer hitch, code 550
11. Cut out hole for lug (7) in corresponding size.

12. Debur holes.
Rear bumper
13. Route reinforcement (8) on rear bumper lower section (5) to correct installation position.
14. Mark positions of holes (9) on rear bumper lower section (5).
15. Remove reinforcement (8).
17. Debur holes.
Fig. 104: Identifying Reinforcement, Rear Bumper Lower Section And Holes
RETROFIT OFFROAD APPEARANCE PACKAGE - AN88.30-P-0007GY
MODEL 164.8 except CODE (U89) Offroad appearance package

Rear bumper
Fig. 105: Identifying Expansion Rivets, Rear Bumper, Bolts And Clips - Rear Bumper
Front bumper
Fig. 106: Identifying Threaded Clips And Front Bumper

Front bumper
Fig. 107: Identifying Front Bumper Lower Section And Bolts

Front bumper
Fig. 108: Identifying Front Bumper Lower Section, Front Bumper And Nuts
Rear bumper
Fig. 109: Identifying Rear Bumper Lower Section, Reinforcement And Nuts
Rear bumper
Fig. 110: Identifying Rear Bumper Lower Section, Rear Optical Underride Guard And Bolts
Removal

platform and position the four support plates at AS00.00-Z-
the lifting platform support points specified by 0010-01A
lifting platform.
Remove front bumper lower
1 Do not disassemble entire front bumper.
section
Disassembling and assembling AR88.20-P-
front bumper 2050GY
Remove expansion rivet (1) from
2 bottom of fender liner and rear
bumper (2).
Unclip clips (16) from inside of
3
rear bumper (2).
Unscrew bolts (3) from rear
4
bumper lower section (4).
Remove rear bumper lower Press down at each clip starting at front
5
section (4) (arrows). corners of rear bumper (2) (arrows)
Modify
Remove front and rear bumper AN88.30-P-
6
lower section. 0007-01GY
Install
Risk of injury caused by scraping Always wear protective gloves when working
AS00.00-Z-
or cutting body parts on sharp on or near sharp and non-deburred vehicle parts.
0017-01A
vehicle parts Deburr repair panels.
Install threaded clips (5) on front
7
bumper (6).
Assemble front bumper (6) with
8 Do not install front bumper.
front bumper lower section (7).
Disassemble and assemble front AR88.20-P-
bumper 2050GY
Fasten front optical underride
guard (8) to front bumper lower Insert shims between nuts and lower
9
section (7) with bolts (9) and nuts section.
(10).
10 Install front bumper (6).
AR88.20-P-
Remove/install front bumper
2000GZ
Fasten reinforcement (11) to rear
11 bumper lower section (4) with
expansion rivets (17).
Fasten rear optical underride Only with trailer hitch, code 550: Use
guard (12) to rear bumper lower lug (15) to align appearance underride guard.
section (4) with bolts (13) and Insert shims between nuts and lower
12
nuts (14). section.
Install rear bumper lower section
13
(4) on rear bumper (2).
Install expansion rivets (1) on
14
fender liner and rear bumper (2).
Install clips (16) on inner side of
15
rear bumper.
Install bolts (3) on rear bumper
16
lower section (4)


B6 688 0164 Appearance underride guard, set, front, except model 164.828 1
B6 688 0165 Appearance underride guard, set, rear, except trailer hitch, code 550 1
B6 688 0166 Appearance underride guard, set, front, model 164.828 1
B6 688 0167 Appearance underride guard, set, rear, with trailer hitch, code 550 1
RETROFIT OFFROAD APPEARANCE PACKAGE - AN88.30-P-0007GZ
MODEL 164.1 except CODE (U89) Offroad appearance package except CODE (772) AMG styling
package - front spoiler, side skirts and rear apron
Fig. 112: Identifying Cover And Front Bumper

Fig. 113: Identifying Clips, Bolts, Bottom Rear Bumper Paneling And Cover
Fig. 114: Identifying Spring Nuts And Front Bumper

Fig. 115: Identifying Bolt, Front Optical Underride Guard And Front Bumper
Fig. 116: Identifying Bottom Rear Bumper Paneling, Reinforcement And Nuts
Fig. 117: Identifying Bottom Rear Bumper Paneling, Cover, Bolts And Tow Eye Cover
Removal
1 Remove front bumper (2).
AR88.20-P-
2000GZ
Unclip cover (1) from front bumper (2)
2 Dispose of cover (1)
(arrows)
Long wedge Fig. 41
Unclip clips (3) from bottom side of fender
3
liner and rear bumper (6)
Unscrew bolts (4) from bottom side of rear
4
bumper (6)
Remove rear bottom bumper paneling (5) Press down at each clip
5 starting at front corners of rear
from rear bumper (6)
bumper (6) (arrows)
Long wedge Fig. 41
Remove cover (7) from bottom rear bumper Dispose of bottom rear
6
paneling (5). bumper paneling (5).
Install
Risk of injury caused by scraping or cutting Always wear protective gloves when AS00.00-Z-
body parts on sharp vehicle parts working on or near sharp and non- 0017-01A
deburred vehicle parts.

Install spring nuts (8) in correct installation
7
position on inside of front bumper (2).
Fasten front optical underride guard (9) to
8
front bumper (2) with bolts (10)
AR88.20-P-
2000GZ
Install reinforcement (11) in correct
10 installation position on inside of new rear
bottom bumper paneling (5).
Fasten rear visual underride guard (12) to
Use lugs (arrows) for
11 rear bumper paneling (5) with bolts (13) and
aligning optical underride guard.
nuts (14)
Install cover (7) on new bottom rear bumper
12
paneling (5)
Install tow eye cover (15) to rear optical
13
underride guard (12)
Install new bottom rear bumper paneling (5)
14
to rear bumper (6)
Install clips (3) to fender liner and rear
15
bumper (6)
Screw in bolts (4) at bottom side of rear
16
bumper (6).


B6 688 0162 Appearance underride guard, set, front 1
B6 688 0163 Optical underride guard, set, rear 1

CONVERTING FRONT BUMPER - AZ88.00-P-0001-02GZ
Fig. 119: Identifying Front Bumper Components

Only with Parktronic system (PTS) (CODE 220)
1.1 Clip outer left front PTS ultrasonic sensor (B8/1), center left front PTS ultrasonic sensor (B8/2), inner
left front PTS ultrasonic sensor (B8/3), inner right front PTS ultrasonic sensor (B8/4), center right front
center ultrasonic sensor (B8/5) and outer right front PTS ultrasonic sensor (B8/6) into brackets on AMG
front apron (1) as shown in picture at top.
Previously check whether a decoupling ring (transparent silicon ring) is installed on all PTS
ultrasonic sensors.
Only with headlamp cleaning system (code 600)
2.1 Clip HCS frame (headlamp cleaning system) (3) into AMG front apron (1) with spring (4), left and
right (see arrows in magnified section at right bottom).
Ensure that HCS frame (3) is seated correctly in left and right cutouts on AMG front apron (1).
3.1 Install HCS carrier (6) on axles in internal component and hook in spring (4) as shown in picture
(arrows in magnified section at top right).
4.1 Fasten HCS frame (3) to AMG front apron (1) with retaining clips (5).
HCS carrier (6) is different for left and right side
5 Clip clips (24 each) for fastening vent grille into AMG front apron (1) (see circles).
Openings of clips should point in direction of travel.
6 Insert left reinforcement (8), center reinforcement (9) and right reinforcement (10) into AMG front
apron (1) as shown on picture.
Fig. 120: Identifying Left Reinforcement, Center Reinforcement And Right Reinforcement
7 Fasten left reinforcement (8) and right reinforcement in AMG front apron with three expansion rivets
(11) each and with two retaining clips (5) each.
Shown on left reinforcement (8)
Fig. 121: Identifying Left Reinforcement, Right Reinforcement And Expansion Rivets
8 Fasten center reinforcement (9) in AMG front apron with four expansion rivets (11) and three retaining
clips (5) as shown in picture.
Fig. 122: Identifying Center Reinforcement, Expansion Rivets And Retaining Clips
9 Insert right impact absorber (12) and left impact absorber into AMG front apron as shown in figure.
Shown on right impact absorber (12).
Fig. 123: Identifying Right Impact Absorber

10 Clip plastic nuts (15) from bottom into brackets (17) on left and right in basic carrier (14).
11 Screw adjusting screws (16) into plastic nuts (15) on left and right.
Do not screw adjusting screws (16) completely into plastic nuts (15); allow adjusting screws (16)
to extend approx. 3 threads.
12 Slide clip nuts (18) (6 each) onto basic carrier as shown in magnified section at bottom.
Fig. 124: Identifying Clip Plastic Nuts, Brackets, Adjusting Screws And Right In Basic Carrier
Fig. 125: Identifying Clip Plastic Nuts, Brackets, Adjusting Screws And Right In Basic Carrier
Only with wheelhouse covers
13.1 Fasten wheelhouse covers to AMG front apron (1) on left and right with three bolts (20) each.
Only with wheelhouse covers
14.1 Fasten wheelhouse covers to AMG front apron (1) at bottom with one expansion rivet (19) on left
and right.
15 Carefully install basic carrier (14) on catch lugs on AMG front apron (1) and arrest.
First arrest basic carrier (14) in upper area of AMG front apron
and then in lower area in left reinforcement (8), center reinforcement (9) and right reinforcement (10).
16 Fasten basic carrier (14) in AMG front apron (1) with two expansion rivets (11) each.
17 Fasten basic carrier (14) in AMG front apron (1) with two blind rivets (13) each.
18 Position bolt covers (21) on AMG front apron (1).
Bolt covers (21) should be fastened precisely when positioned initially. The holes for the bolts M6 20
mm (22) should match the bolt cover (21) and the AMG front apron (1).It is not possible to use the
double-sided adhesive tape more than once.
The shape of the bolt covers (21) varies, thus preventing mixup.
19 Fasten AMG front apron (1) to base carrier (14) with four bolts M6 20 mm (22).
Fig. 126: Identifying AMG Front Apron, Base Carrier And Bolt Covers
20 Fasten AMG front apron (1) in air inlets on left and right to basic carrier (14) with one expansion rivet
(11) each.
Fig. 127: Identifying AMG Front Apron, Left And Right To Basic Carrier And Expansion Rivet (1
Of 2)
Fig. 128: Identifying AMG Front Apron, Left And Right To Basic Carrier And Expansion Rivet (2
Of 2)
21.1 Only with Parktronic system (PTS) (CODE 220)

 Route PTS wiring harness (23) in present cutouts in basic carrier (14) as shown on figure and fasten
to fastening shackle (circles) in basic carrier (14) as shown in picture.
 Connect PTS wiring harness (23) to the four outer PTS sensors.
 Fasten right front engine compartment/bumper connector (X26/36) to basic carrier (14) on right
(see arrow in magnified section at top right).
22.1 Only cornering illumination (code 619) or front fog lamp
 Route cornering illumination/front fog lamp and temperature sensor wiring harness (24) in present
cutouts in basic carrier (14) and fastening shackles (circles) in basic carrier (14).
 Guide cornering illumination/front fog lamp connector (25) to cornering illumination/front fog
lamp cutouts according to magnified sections on top left and right.
 Fasten left front engine compartment/bumper connector (X26/32) to basic carrier (14) on left with
present clip as shown in picture (picture at top left).
23 Clip outside temperature display temperature sensor (B14) into basic carrier and connect to cornering
illumination/front fog lamp wiring harness and temperature sensor (24).
Fig. 129: Identifying Clip Outside Temperature Display Temperature Sensor And Temperature
Sensor
24 Insert center impact absorber (26) into basic carrier.
Ensure that center impact absorber (26) is seated correctly in right and left impact absorbers.
Center impact absorber (26) is arrested in left and right impact absorbers using two lugs.
Only with Parktronic system (PTS) (code 220)
25.1 Connect PTS wiring harness (23) to inner left front PTS ultrasonic sensor (B8/3) and inner right
front PTS ultrasonic sensor (B8/4).
Fig. 130: Identifying PTS Wiring Harness And Inner Left Front PTS Ultrasonic Sensor
26 Check whether seal (28) is seated correctly on left front fog lamp (E5/1) and right front fog lamp
(E5/2), seal if necessary and install cable strap around seal (28).
27 Connect AMG wiring harness (27) for front fog lamp each to left front fog lamp (E5/1) and right front
fog lamp (E5/2).
The left front fog lamp (E5/1) and right front fog lamp (E5/2) differ and are marked according to
the vehicle side (arrows), the AMG wiring harness (27) for the front fog lamp should point toward the
outside in the installed state.
Fig. 131: Identifying Whether Seal, Left Front Fog Lamp And Right Front Fog Lamp
28 Install four each sheet metal nuts (29) on cutout for left front fog lamp (E5/1) and right front fog lamp
(E5/2) in AMG front apron.
29 Position left front fog lamp (E5/1) and right front fog lamp (E5/2) each from front on AMG front
apron and connect AMG wiring harness (27) with cornering illumination/front fog lamp connector (25).
Left front fog lamp (E5/1) and right front fog lamp (E5/2) are marked according to the side of the
vehicle (arrow).
Illustrated on left fog lamp (E5/1)
Fig. 132: Identifying Left Front Fog Lamp And Right Front Fog Lamp
30 Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) from front into AMG front apron (1),
align and fasten with bolts (31).
The adjusting screw (30) should be positioned at bottom.
Fig. 133: Identifying Left Front Fog Lamp And Right Front Fog Lamp And AMG Front Apron
31 Install chrome rings (32) on left front fog lamp (E5/1) and right front fog lamp (E5/2).
Fig. 134: Identifying Chrome Rings, Left Front Fog Lamp And Right Front Fog Lamp
32 Hook tow eye cover (33) with check strap (34) into AMG front apron (1) and clip in tow eye cover
(33).
Fig. 135: Identifying Tow Eye Cover, Check Strap, AMG Front Apron And Clip In Tow Eye Cover
Only with headlamp cleaning system (CODE 600)
33.1 Clip both HCS covers (35) into HCS carrier and align in center of AMG front apron (1).
The HCS covers (35) should be flush with the paneling and have a uniform gap all-round. Proper
opening and closing must be ensured. The HCS covers (35) are different for the left and right side.
Fig. 136: Identifying HCS Covers And AMG Front Apron

34 Clean contact surface on left horn cover (36) and right horn cover (37) on AMG front apron (1).
The area to be glued on the AMG front apron (1) should be free of dust and grease. To clean use a
50 : 50 mixture of IPA (iso-propanol alcohol) and water.
Fig. 137: Identifying Left Horn Cover, Right Horn Cover And AMG Front Apron
35 Remove protective foil from bonding surfaces on left horn cover (36) and right horn cover (37).
36 Position left horn cover (36) and right horn cover (37) in corresponding recesses in AMG front apron
(1) and press on firmly.
The left horn cover (36) and right horn cover (37) are different for the left and right side.
When initially positioning the left horn cover (36) and right horn cover (37), the cover must be seated
correctly on the AMG front apron (1). It is not possible to readjust the left horn cover (36) and right horn
cover (37)! Detaching the left horn cover (36) or right horn cover (37) again would destroy them!
Clip grille of upper center air inlet (38) and lower center air inlet (39) into AMG front apron (1)
on vehicle after installing, adjusting and aligning AMG front apron (1).
Clip grille of left air inlet (40) and right air inlet (41) into AMG front apron (1) only after
adjusting left front fog lamp (E5/1) and right front fog lamp (E5/2).
37 Fasten license plate molding to AMG front apron (1) with 4 bolts.
RETROFIT AMG TRIM PARTS - AZ88.00-P-0001GZ
MODEL 164.1
On vehicles with AMG wide tire cover, drill holes on front and
rear bumper before painting parts.
On vehicles without code (900) Exterior chrome package and
without code (952) Sport package, the cutouts for the upper
chrome-plated strips in the standard bumper upper section are
not present. If, in this case, the customer desires chrome-plated
strips, it is also necessary to order the bumper top section in
addition to the AMG modification kit in these vehicles.
The trim parts in the accessories and replacement part scope of
delivery are primed and should be painted to match the color
of the car before installation.

Front AMG license plate molding is not included in scope of
delivery!
Must be ordered separately depending on specific national
version.
After conversion, have proper installation confirmed by
authorized workshop on form sheet "Excerpt from EU Type
Approval". The form sheet is to be kept in the vehicle and to
be handed over to the responsible persons, if required.
Model 164. OF88.00-P-
Body kit, certificate
* For Germany only 1000-01TA
Removal
Remove front
1
bumper
Remove internal component as well as impact absorber. With
code (220) Parktronic system (PTS), remove wiring harness
and PTS sensors (required for AMG front apron).
Remove wiring harness for cornering illumination and front AR88.20-
fog lamp and outside temperature sensor (B14). P-2000GZ
With code (600) Headlamp cleaning system, remove HCS
cover (headlamp cleaning system) and HCS carrier.
For this purpose, see:?
AR88.20-
Disassemble front bumper
P-2050GZ
AR88.20-
P-2200GZ
Installation
AZ88.00-
Modify front
3 P-0001-
bumper
02GZ
Install wide tire AZ88.80-
4.1 cover on front On vehicles with wide tire cover. P-0004-
bumper 01GZ
AR88.20-
P-2000GZ
Replace bumper
bottom section with
6 AMG bottom For this purpose, see:?
section on rear
bumper
AR88.20-
Disassemble rear bumper.
P-2100GZ
Install wide tire AZ88.80-
cover on rear P-0004-

7.1 On vehicles with wide tire cover.
bumper 01GZ
8 Install rear bumper
AR88.20-
P-2200GZ
Install wide tire AZ88.80-P-
9.1 On vehicles with wide tire cover.
cover on wheelhouse 0004-02GZ

Complete front bumper (without Parktronic system (PTS); without
B6 603 62 21 1
cornering illumination)
A164 817 00
AMG license plate molding ECE (not included in bumper kit) 1
78
A164 817 01
AMG license plate molding USA (not included in bumper kit) 1
78
A164 817 02
AMG license plate molding Japan (not included in bumper kit) 1
78
A164 885 19
Cover (chrome ring, not included in bumper set) 2
23
B6 603 62 22 Complete front bumper (with cornering illumination) 1
A164 817 00
78
A164 817 01
78
A164 817 02
78
A164 885 27
Cover (left cornering illumination chrome ring, not included in bumper kit) 1
23
A164 885 28
Cover (right cornering illumination chrome ring, not included in bumper kit) 1
23
B6 603 62 23 Complete front bumper (with PTS) 1
A164 817 00
78
A164 817 01
78
A164 817 02
78
A164 885 19
Cover (chrome ring, not included in bumper set) 2
23
B6 603 62 24 Complete front bumper (with PTS; with cornering illumination) 1
A164 817 00
78
A164 817 01
78
A164 817 02
78
A164 885 27
Cover (left cornering illumination chrome ring, not included in bumper kit) 1
23
A164 885 28
Cover (right cornering illumination chrome ring, not included in bumper kit) 1
23
Complete rear bumper (without AMG muffler system; without trailer
B6 603 62 25 1
hitch (AHV))
B6 603 62 26 Complete rear bumper (with AMG muffler system) 1
B6 603 62 27 Complete rear bumper (with trailer hitch (AHV)) 1
B6 603 62 28 Complete rear bumper (with AMG muffler system; with AHV) 1
B6 603 62 29 Wheelhouse extension 1
A164 884 35
Left lower section front wheelhouse cover (color code 7C45) 1
22
A164 884 36
Right lower section front wheelhouse cover (color code 7C45) 1
22
A000 990 75
Expansion rivet 2
92
N000 000 000
Round head hex. bolts, 4.8 19 6
529
A164 884 37
Left lower section rear wheelhouse cover (color code 7C45) 1
22
A164 884 38
Right lower section rear wheelhouse cover (color code 7C45) 1
22
N000 000 000
Round head hex. bolts, 4.8 19 4
529
A164 884 27
Left upper section front wheelhouse cover (color code 7C45) 1
22
A164 884 31
Inner left upper section front wheelhouse cover 1
22
A164 884 28
Right upper section front wheelhouse cover (color code 7C45) 1
22
A164 884 32
Inner right upper section front wheelhouse cover 1
22
A001 984 62
Screw 8
29
A164 884 29
Left upper section rear wheelhouse cover (color code 7C45) 1
22
A164 884 33
Inner left upper section rear wheelhouse cover 1
22
A164 884 30
Right upper section rear wheelhouse cover (color code 7C45) 1
22
A164 884 34
Inner right upper section wheelhouse cover 1
22
A001 984 62
Screw 8
29
SUBSEQUENT CONDITIONING OF BUMPERS - AZ88.30-P-0001-01GZ
Model 164 with USA version, code 494, except Parktronic system (PTS), code 220, except styling package,
code U49
REPAIR MATERIALS
BR00.45-Z-1011-05A Preservation agent A 000 986 72 70 10
1. Place bumper (1) on workbench.
Model 164.8 with offroad appearance package, code U89
2. Attach adhesive tape on outer cutouts (3).

3. Mark center (2) at outer cutouts (3).
4. Drill dia. 54 mm passage holes at marks in bumper.
Fig. 138: Marking Center At Outer Cutouts


5. Remove adhesive tape.

6. Deburr passage holes.
7. Apply primer pin and wax preservative to passage holes in visual front underride guard.
Template, model 164.1
Determine ACTUAL dimension (a) from drawing
Divide NOMINAL dimension (a) by determined ACTUAL dimension (a) and copy template to original
size with corresponding factor.
Check dimensions for both axes.
Left template
Fig. 139: Identifying Left Template Dimension

Divide NOMINAL dimension (a) by determined ACTUAL dimension (a) and copy template to original
Right template
Fig. 140: Identifying Right Template Dimension

Divide NOMINAL dimension (c) by determined ACTUAL dimension (c) and copy template to original
Left template
Fig. 141: Identifying Left Template Dimension


Divide NOMINAL dimension (c) by determined ACTUAL dimension (c) and copy template to original
Right template
Fig. 142: Identifying Right Template Dimension

8. Print out left template (4) and right template (5) and adapt size to correct dimensions (a, b, c, d)
9. Cut templates to size.
10. Position left template (4) and right template (5) on bumper grate and mark passage holes.
11. Remove templates and cut out passage holes and deburr.
RETROFIT BRUSH GUARD - AZ88.30-P-0001GZ
MODEL 164 with CODE (494) USA version except CODE (220) Parktronic system (PTS) except CODE
(U49) Styling package

Fig. 143: Identifying Brush Guard - Shown On Model 164.1

Fig. 144: Identifying Nuts, Crossmember, Bolts And Cable Strap - Shown On Model 164.1

Fig. 145: Identifying Bracket, Crossmember, Bolts And Wiring Harness - Shown On Model 164.1
Fig. 146: Identifying Brush Guard, Rubber Grommets, Bolts And Nuts - Shown On Model 164.1
Removal
AR88.20-P-
2000GZ
Unscrew nuts (1) from crossmember
2 Dispose of bolts (3) and nuts (1).
(2).
3 Remove cable strap (4) and clip (5). Dispose of clip.
Modify
Always wear protective gloves when AS00.00-Z-
Risk of injury caused by scraping or working on or near sharp and non- 0017-01A
cutting body parts on sharp vehicle deburred vehicle parts.
parts Deburr repair panels.

AZ88.30-P-
4 Modify front bumper
0001-01GZ
*BR00.45-Z-
Wax preservative
1011-05A
Install
Do not tighten screws.
Fasten bracket with weld nut on
left.
Install bracket (6) on crossmember (2) Weld nut should point toward outside .
5
with new bolts (7) and nuts (8). Vehicles without underride
guard: Insert washer on left between
crossmember and lower bracket on inner
bolt.
Position brush guard (9) on bracket in
6
correct installation position.
*BA88.30-P-
7 Fully tighten bolts (7)
1003-01D
8 Remove brush guard
Install new clip with cable strap (10)
9 on bracket and fully tighten wiring
harness (11)
AR88.20-P-
2000GZ
Install rubber grommets (12) on upper
11
bracket of brush guard (9)
Install brush guard (9) with bolts (13) *BA88.30-P-
12
and nuts (14) 1004-01D
*BA88.30-P-
1005-01D
Install rubber grommets (12) in
bumper grate (15) in correct
13
installation position through passage
holes.
Install mount for license plate on brush
14 Only if necessary.
guard.
DETACHABLE PARTS, UNDERRIDE GUARD

BA88.30-P-1003-01D Nut/bolt, brush guard bracket to crossmember Nm 18
BA88.30-P-1004-01D Nut, brush guard to bracket Nm 25
BA88.30-P-1005-01D Bolt, brush guard to bracket Nm 49
REPAIR MATERIALS

B6 688 0160 Parts kit, brush guard, model 164.1 1
B6 688 0170 Parts kit, brush guard, model 164.8 1
163 885 00 56 Bracket 1
163 885 03 81 License plate molding 1
000 986 06 50 Primer stick 1
RETROFIT MUD GUARDS - AZ88.30-P-0003GY
MODEL 164.8
Fig. 147: Identifying Mud Guards Components (1 Of 2)

Fig. 148: Identifying Mud Guards Components (2 Of 2)

Removal
Only on vehicles
Remove expansion rivet (1) for front inner without running board, code
2
fender (2) 846.
Reuse larger expansion
Remove larger expansion rivet (3) and rivets (3)
3
expansion rivets (12) for inner rear fender (4) Dispose of other expansion
rivets (12).
Only on vehicles
Installation of front fender flap without running board, code
846
*BR00.45-Z-
4 Clean all surfaces in installation area Cleaner
1025-04A
Detach protective foil (5) over a length of 20
5 mm at the end of the bonding surface of the
front mud guard (6).
Install front mud guard (6) with expansion rivets
6
(1)
It is not possible to align
Remove protective foil (5) from bonding surface
7 the front mud guard again after
and press on front mud guard (6)
sticking on.
After installing the vehicle may not be driven
for 24 h. Do not carry out any high pressure
wash or machine wash for 48 h
Installation of rear fender flaps
*BR00.45-Z-
8 Clean all surfaces in installation area Cleaner
1025-04A
Install sheet metal clips (7) and threaded clips
9
(8) on inner side of bumper and mount (9)
Detach protective foil (13) over a length of 20
10 mm at the end of the bonding surface of the rear
mud guard (10).
11 Install rear mud guard (10) with bolts (11)
It is not possible to align
Remove protective foil (13) from bonding
12 the rear mud guard again after
surface and press on rear mud guard (10)
sticking on.
13 Install larger expansion rivets (3)
After installing the vehicle may not be driven
for 24 h. Do not carry out any high pressure
wash or machine wash for 48 h
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71


B6 652 8236 Parts kit, front mud guard, only on vehicles without running board, code 846 1
B6 652 8237 Parts kit, rear mud guard 1
TRANSFER LONGITUDINAL MEMBER PANELING - AZ88.30-P-0006-02GZ
Model 164 except styling package, code U49
1. Position longitudinal member paneling (1) on work bench

2. Drill dia. 54 mm passage holes on markings (2) in longitudinal member paneling.
3. Deburr passage holes.
Fig. 149: Identifying Longitudinal Member Paneling And Hole Mark

RETROFIT SIDE STEP BAR - AZ88.30-P-0006GZ
MODEL 164 except CODE (U49) Styling package

Fig. 150: Identifying Side Step Bar

Fig. 151: Identifying Side Step Bar, Drain Bore, Flange And Edge Guard Bracket
Fig. 152: Identifying Nuts, Bolts, Rear Retaining Rail And Edge Guard Bracket
Fig. 153: Identifying Side Step Bar, Rubber Seal And Bolts
Removal
2 Remove longitudinal member paneling Dispose of retaining rails.
paneling 6000GZ
Convert
AZ88.30-P-
3 Transfer longitudinal member paneling
0006-02GZ
Install
Position new front retaining rail (7) in
4
correct installation position
Position edge guard bracket (2) with 3 nuts Position edge guard bracket
5
in correct installation position. only; do not tighten nuts.
Tighten nuts. Clamp lower
Position side step bar (3) on edge guard
6 area of edge guard bracket to
bracket (2) in correct installation position.
flange.
Mark positions of drain holes (4) on flange
7
(5).
8 Remove side step bar (3).
Drill dia. 5.5 mm holes at markings in Do not damage plastic
9
flange. reservoir.
10 Remove side step bar (2).
*BR00.45-Z-
11 Clean, prime, paint and wax holes. Preservation wax
1011-05A
12 Install new front retaining rail (7)

Position edge guard bracket in correct
13
14 Install new rear retaining rail (10)
Tighten edge guard bracket (2) and bracket
15 Use new nuts.
with nuts (8) and bolts (9).
*BA88.30-P-
1001-01D
16 Install longitudinal member paneling
paneling 6000GZ
17 Install rubber seal (11) on side step bar (3).
*BA88.30-P-
18 Install side step bar (3) with bolts (12).
1002-01D
*BR00.45-Z-
Quick glue
1011-02A
Enclose modified instructions for raising/
19 jacking up vehicle with owner's manual and
jack
DETACHABLE COMPONENTS, UNDERRIDE GUARD

BA88.30-P-1001-01D Nut, side step bar bracket to body mount Nm 10
BA88.30-P-1002-01D Bolt, side step bar to mounting plate Nm 14
REPAIR MATERIALS
BR00.45-Z-1011-02A Quick glue A 003 989 31 71

B6 688 0600 Parts kit, side step bar with running board, model 164.1 1
B6 688 0620 Parts kit, side step bar with running board, model 164.8 1
000 986 06 50 Primer stick 1
RETROFIT VISUAL UNDERRIDE GUARD - AZ88.30-P-0009GZ
MODEL 164.1 except CODE (U89) Offroad appearance package except CODE (772) AMG styling
package - front spoiler, side skirts and rear apron
Fig. 154: Identifying Cover And Front Bumper

Fig. 155: Identifying Expanding Rivets, Bolts, Bottom Rear Bumper Paneling, Rear Bumper And Cover
Fig. 156: Identifying Front Bumper And Threaded Clips

Fig. 157: Identifying Front Bumper, Front Optical Underride Guard And Bolts
Fig. 158: Identifying Bottom Rear Bumper Paneling, Reinforcement And Nuts
Fig. 159: Identifying Bottom Rear Bumper Paneling, Cover, Rear Optical Underride Guard, Bolts And
Towing Eye Cover
Remove
AR88.20-P-
2000GZ
Unclip 2 expansion rivet at
Unclip cover (1) from front bumper (2) bottom.
2
(arrows) Dispose of cover and expansion
rivets.
Long wedge Fig. 41
Unclip expansion rivets (3) at bottom of

3
inner fender and rear bumper.
4 Unscrew bolts (4) at bottom rear bumper.
Press down at each clip
Remove bottom rear bumper paneling (5)
5 (arrows) starting at front corners of
from rear bumper (6).
rear bumper.
Long wedge Fig. 41
Remove cover (7) from bottom rear Dispose of bottom rear
6
bumper paneling (5). bumper paneling (5).
Install
Always wear protective gloves when
Risk of injury caused by scraping or working on or near sharp and non- AS00.00-Z-
cutting body parts on sharp vehicle parts deburred vehicle parts. 0017-01A
Install threaded nuts (8) in correct
7 installation position on inside of front
bumper (2)
Fasten front optical underride guard (9) to
8
front bumper (2) with bolts (10)
AR88.20-P-
2000GZ
Install reinforcement (11) in correct
10 installation position on inside of new
bottom rear bumper paneling.
Fasten rear visual underride guard (12) to
Use lugs (arrows) for aligning
11 rear bumper paneling (5) with bolts (13)
and nuts (14) optical underride guard.
Install cover (7) to new bottom rear bumper
12
paneling (5).
Install tow eye cover (15) to rear optical
13
underride guard (12)
Install new bottom rear bumper paneling
14
(5) to rear bumper (6).
Remove expansion rivets (3) on fender
15
liner and rear bumper
Screw bolts (4) into bottom side of rear
16
bumper.


B6 688 0162 Appearance underride guard, set, front 1
B6 688 0163 Optical underride guard, set, rear 1
RETROFIT CHROME-PLATED RADIATOR GRILLE - AZ88.40-P-0001GZ
MODEL 164.1
Fig. 161: Identifying Chrome-Plated Radiator Grille

Remove/Install
Part discontinued.
1 Remove radiator grille Installation: Replaced by new chrome-
plated radiator grille (1).
Remove/install radiator AR88.40-P-
grille 4001GZ
2 order

B6 688 0354 Chrome-plated radiator grille (observe color of equipment) 1
INSTALL WIDE TIRE COVER - AZ88.80-P-0001-01GZ
MODEL 164.1 except CODE (772) AMG styling package - front spoiler, side skirts and rear apron
without rear mud guard.
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Shown on vehicle with primed wide tire cover
1. Clean the installation area of wide tire cover (1) in area of rear bumper.
2. Detach protective foil (2) over a length of 10 mm at end of inside bonding surface of wide tire cover (1).
Fig. 162: Identifying Protective Foil And Wide Tire Cover

3. Position wide tire cover (1) on rear bumper in correct installation position and remove protective foil (2)
from bonding surface and thoroughly press on wide tire cover (1).
It is not possible to align the wide tire cover again after gluing on.
INSTALL WIDE TIRE COVER ON BUMPER - AZ88.80-P-0004-01GZ
Model 164.1
Installation of the wheelhouse cover bottom section on the front and rear bumper cover is explained on
one side in each case. Installation is identical on both sides.
Installation to front bumper
1. Lay drilling template on front bumper cover (1), align and fasten with adhesive tape.
Center drilling template so that each of the opposite sides have the same distance to the edges of
front bumper cover.
Drilling template is included in parts kit.
Fig. 163: Identifying Front Bumper Cover

2. Drill three holes (dia. 7 mm) at marked points and remove drilling template.
Rework holes with suitable tool to adapt wheelhouse cover front bottom section.
Fig. 164: Identifying Front Bumper Cover

Fig. 165: Identifying Upper Expansion Rivets And Outer Bottom Expansion Rivets
3. Remove upper expansion rivets (8) and the two outer bottom expansion rivets (9).
Remove bumper internal component (5) from front bumper cover when positioning the
wheelhouse cover front bottom section until it is possible to position and tighten the retaining bolts
without problems.
4. Thoroughly clean contact surface (2) for wheelhouse cover front bottom section.
The area to be glued on the front bumper cover must be free of dust and grease. To clean use a
Fig. 166: Identifying Contact Surface And Bumper Cover

5. Remove covering foil from double-sided adhesive tape 30 mm in upper area of wheelhouse cover front
bottom section.
Clean covering foil remaining on the double-sided adhesive tape with a mixture of isopropanol
alcohol and water mixed 50:50 to prevent soiling the contact surface.
Fig. 167: Identifying Double-Sided Adhesive Tape

6. Position wheelhouse cover front bottom section (3) on front bumper cover (1) and align.
Position wheelhouse cover front bottom section (3) 1 mm below top edge of front bumper cover
(1).Rework holes for mounting bolts with suitable tool, if required.
Fig. 168: Identifying Wheelhouse Cover Front Bottom Section And Front Bumper Cover
7. Position mounting bolts on inside of front bumper cover (1) and tighten with tightening torque of 1 Nm
after aligning wheelhouse cover front bottom section (3).
When positioning and tightening mounting bolts, have second mechanic remove bumper internal
component (5).
Fig. 169: Positioning Mounting Bolts On Inside Of Front Bumper Cover

8. Remove covering foil in increments and firmly press on wheelhouse cover front bottom section (3).
9. Fasten bumper internal component in front bumper cover (1) with expansion rivets.
To increase process safety, press wheelhouse cover front bottom section (3) onto front bumper
cover (1) with a 3M load roller, starting at one side.
10. Drill dia. 5 mm hole at bottom edge of wheelhouse cover front bottom section (3) into front bumper cover
(1) and fasten wheelhouse cover front bottom section (3) with expansion rivet (6).
The wheelhouse cover front bottom section (3) serves as drilling template.
Fig. 170: Identifying Bottom Edge Of Wheelhouse Cover Front Bottom Section And Front Bumper
Cover
Installation to rear bumper cover
11. Lay drilling template on rear bumper cover (10), align and fasten with adhesive tape.
Center drilling template so that each opposite sides have the same distance to the edges of the rear
bumper cover (10).
Drilling template is included in parts kit.
Fig. 171: Identifying Template On Rear Bumper Cover

12. Drill two holes (dia. 7 mm) at marked points and remove drilling template.
Rework holes with suitable tool to adapt wheelhouse cover rear bottom section.
Fig. 172: Identifying Template On Rear Bumper Cover

13. Remove clip (11) from bracket (12).
The clip (11) serves for fastening the wheelhouse cover rear bottom section after installation.
Fig. 173: Identifying Clip And Bracket

14. Thoroughly clean contact surface (13) for wheelhouse cover rear bottom section.
The area to be glued on the rear bumper cover (10) must be free of dust and grease. To clean use a
Fig. 174: Identifying Contact Surface And Rear Bumper Cover

15. Remove covering foil from double-sided adhesive tape 30 mm in upper area of wheelhouse cover rear
bottom section (14).
Clean covering foil remaining on double-sided adhesive tape with a mixture of isopropanol
Fig. 175: Identifying Double-Sided Adhesive Tape

16. Position wheelhouse cover rear bottom section (14) on rear bumper cover (10) and align.
Position wheelhouse cover rear bottom section (14) 1 mm below top edge of rear bumper cover
(10). Rework holes for mounting bolts with suitable tool, if required.
Fig. 176: Identifying Wheelhouse Cover Rear Bottom Section And Rear Bumper Cover
17. Position mounting bolts (15) on inside of rear bumper cover (10) and tighten with tightening torque of 1
Nm after aligning wheelhouse cover rear bottom section (14).
Fig. 177: Identifying Mounting Bolts, Rear Bumper Cover And Wheelhouse Cover Rear Bottom
Section
18. Remove covering foil in increments and firmly press on wheelhouse cover rear bottom section (14).
To increase process safety, press wheelhouse cover rear bottom section (14) onto rear bumper
cover (10) with a 3M load roller starting at one side.
19. Position wheelhouse cover rear bottom section with clip (11) on rear bumper cover (10) and align.
Fig. 178: Identifying Wheelhouse Cover Rear Bottom Section With Clip And Rear Bumper Cover
INSTALL WIDE TIRE COVER ON WHEELHOUSE. RISK OF INJURY CAUSED BY SCRAPING

OR CUTTING BODY PARTS ON SHARP VEHICLE PARTS - AZ88.80-P-0004-02GZ
Model 164.1
Always wear protective gloves when working on or near sharp and nondeburred vehicle parts.

The operation steps for installing the wheelhouse cover bottom section are the same for all wheelhouses.
For this reason, installation of left rear wheelhouse cover bottom section is described as an example.
1. Check whether clips (2) on locks for inner left rear wheelhouse (1) are seated correctly; correct if
necessary.
The angled section should point downward to facilitate pushing the clips onto the wheelhouse
(locking).
Before installing inner left rear wheelhouse covers (1) check whether it is possible to lock the
clips (2) properly. If required, remove excessive sealant or preservative from lock points (see bottom
picture).
Fig. 180: Identifying Whether Clips And Inner Left Rear Wheelhouse
2. Thoroughly clean contact surface (3) on inner left rear wheelhouse cover on left rear side section.
The area on the left rear side section to be glued must be free of dust and grease. To clean use a
Fig. 181: Identifying Contact Surface On Inner Left Rear Wheelhouse Cover
3. Remove covering foil 30 mm from double-sided adhesive tape at both ends.
Also clean covering foil remaining on double-sided adhesive tape using a mixture of isopropanol
Fig. 182: Identifying Double-Sided Adhesive Tape Dimension

4. Position inner left rear wheelhouse cover (1).
The stop on the inner left rear wheelhouse cover (1) should be positioned behind the wheelhouse
bead (see bottom picture).
Fig. 183: Identifying Inner Left Rear Wheelhouse Cover

5. Align inner left rear wheelhouse cover (1) and lock clips (2).
Properly arrest clips (2).

Fig. 184: Identifying Inner Left Rear Wheelhouse Cover And Lock Clips
6. Remove covering foil in increments and firmly press on inner left rear wheelhouse cover.
To increase process safety, press inner left rear wheelhouse cover to left rear side section with a
3M load roller starting at one side.
7. Remove covering foil on left rear wheelhouse cover top section 50 mm from double-sided adhesive tape
in area of butt joint to rear bumper.
Also clean covering foil remaining on double-sided adhesive tape using a mixture of iso-propanol
alcohol and water at a mixing ratio of 50:50 to prevent soiling the contact surface.
8. Position left rear wheelhouse cover top section (4) starting at rear bumper.
Adjust gap with feeler gauge to 5 mm.

Fig. 185: Identifying Left Rear Wheelhouse Cover Top Section

9. Remove covering foil in increments and firmly press on wheelhouse cover left rear top section (4).
When positioning left rear wheelhouse cover top section (4) in direction of wheelhouse over entire
length.
Fig. 186: Pressing Wheelhouse Cover Left Rear Top Section

To increase process safety, press left rear wheelhouse cover top section (4) to left rear side
section, with a 3M load roller, starting at one side.
10. Fasten left rear wheelhouse cover top section (4) to inner left rear wheelhouse cover with four bolts (6)
(tightening torque 1 Nm).
Install remaining wheelhouse cover top sections in the same manner.

Fig. 187: Identifying Left Rear Wheelhouse Cover Top Section And Inner Left Rear Wheelhouse
Cover With Four Bolts
RETROFIT AMG WIDE TIRE COVER - AZ88.80-P-0004GZ
MODEL 164.1
Inform customer that the following two versions are

available for retrofitting wheelhouse covers :
 Wheelhouse covers in B6 scope of delivery (painted

deep dark gray with texture).
 Wheelhouse covers in parts department (primed and
painted to match vehicle color before installation).
Retrofitting wheelhouse covers with standard bumpers
(recommended).
Wheelhouse covers in B6 scope of delivery painted deep
dark gray with texture
Individual parts of B6 scope of delivery are available only
from AMG directly indicating part number and color
code 7C45. The complete B6-scope of delivery is available
as usual from any Mercedes-Benz Partner or any
Mercedes-Benz company-owned sales and service outlet.
Retrofitting wheelhouse covers with AMG trim parts
(recommended).
When simultaneously retrofitting AMG trim parts (front and
rear bumper) order primed wheelhouse covers with color
code 9999 from parts department and painted to match
vehicle color before installation.
After conversion, have proper installation confirmed by
authorized workshop on form sheet "Excerpt from EU Type
Approval". The form sheet is to be kept in the vehicle and to
be handed over to the responsible persons if required.
Body kit, certificate Model 164. OF88.00-P-
* for Germany only 1000-01TA

Removal
AR88.20-
P-2000GZ
AR88.20-
P-2200GZ
Installation
AZ88.80-
Install wheelhouse
3 P-0004-
cover on bumper
01GZ
AR88.20-
P-2000GZ
5 Install rear bumper
AR88.20-
P-2200GZ
Risk of injury caused
Always wear protective gloves when working on or near
by scraping or cutting AS00.00-Z-
sharp and non-deburred vehicle parts.
body parts on sharp 0017-01A
vehicle parts
Install wheelhouse
AZ88.80-P-
6 covers on
0004-02GZ
wheelhouses


B6 603 62 29 Wheelhouse extension 1
A164 884 35 22 Left lower section front wheelhouse cover (color code 7 C45) 1
A164 884 36 22 Right lower section front wheelhouse cover (color code 7 C45) 1
A000 990 75 92 Expansion rivet 2

N000 000 000 529 Round head hex. bolts, 4.8 19 6
A164 884 37 22 Left lower section rear wheelhouse cover (color code 7C45) 1
A164 884 38 22 Right lower section rear wheelhouse cover (color code 7 C45) 1
N000 000 000 529 Round head hex. bolts, 4.8 19 4
A164 884 27 22 Left upper section front wheelhouse cover (color code 7C45) 1
A164 884 31 22 Inner left upper section front wheelhouse cover 1
A164 884 28 22 Right upper section front wheelhouse cover (color code 7C45) 1
A164 884 32 22 Inner right upper section front wheelhouse cover 1
A001 984 62 29 Bolt 8
A164 884 29 22 Left upper section rear wheelhouse cover (color code 7C45) 1
A164 884 33 22 Inner left upper section rear wheelhouse cover 1
A164 884 30 22 Right upper section rear wheelhouse cover (color code 7C45) 1
A164 884 34 22 Inner right upper section wheelhouse cover 1
A001 984 62 29 Bolt 8
PAINT WIRE TIRE COVER RISK OF EXPLOSION CAUSED BY PAINT VAPORS IGNITING.
RISK OF POISONING CAUSED BY INHALING PAINT VAPORS - AZ88.80-P-0005-01GZ
without rear mud guard.
No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and
skin cream. Ensure that the area is well ventilated.
Use only paint materials and paint systems approved by DC.
1. Mask off inside of wire tire cover (1).
Ensure that no paint or paint fog reaches the inside of the wide tire cover
2. Pre-treat wide tire cover (1) according to DC painting guidelines and paint outside of wide tire cover to
match color of car.
The outside of the new wide tire cover is already primed with transparent primer.
Fig. 189: Identifying Wire Tire Cover

3. Remove masking material from wide tire cover after paint has cured.
4. Cut off lugs (2), deburr area and paint.
RETROFIT WIDE TIRE COVER - AZ88.80-P-0005GZ
without rear mud guard
Fig. 190: Identifying Wide Tire Cover

Install
After installing the vehicle may not be
driven for 24 h. Do not carry out any

high pressure wash or machine wash for
48 h.
No smoking! No open flames! Use
Risk of explosion caused by paint respiratory protection, protective
AS98.00-Z-
vapors igniting. Risk of poisoning clothing, gloves, safety goggles and
0002-01A
caused by inhaling paint vapors. skin cream.
Ensure that the area is well ventilated.
AZ88.80-P-
1 Paint wide tire cover (1).
0005-01GZ
AZ88.80-P-
2 Install wide tire cover (1).
0001-01GZ
*WH58.30-Z-
1001-28A
*WH58.30-Z-
1003-28A
*BR00.45-Z-
Cleaner
1025-04A

Number Designation
WH58.30-Z-1001-28A Recirculated air warming cabinet
WH58.30-Z-1003-28A Heating oven
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71

KG99 (see EPC) Parts kit, wide tire cover 1
TIGHTENING TORQUES: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - BA88.00-Z-9999AZ
MODEL all
Fender MODEL 163 BA88.10-P-1000-01A

Fenders MODEL 171, 210, 211, BA88.10-P-1000-01B
220, 230, 240
Fenders MODEL 169.0 /3, 245.2 BA88.10-P-1000-01C
Fenders MODEL 216, 219, 221 BA88.10-P-1000-01D

Fenders MODEL 164.1 /8 BA88.10-P-1000-01E
Fenders MODEL 251 BA88.10-P-1000-01F
Fenders MODEL 204 BA88.10-P-1000-01G
Bumper MODEL 168, 170, 202, BA88.20-P-1000-01A
203, 208.3 /4, 209, 210,
215, 220
Bumper MODEL 163 BA88.20-P-1000-01B
Bumper MODEL 169, 245 BA88.20-P-1000-01C
Bumper MODEL 219, 221 BA88.20-P-1000-01D
Bumper MODEL 164.1 /8 BA88.20-P-1000-01E
Bumper MODEL 251 BA88.20-P-1000-01F
Detachable body MODEL 163 BA88.30-P-1000-01A
components, underride
guard
Detachable body MODEL 164.1 /8 BA88.30-P-1000-01D
components, underride
guard
Engine hood MODEL 170, 171, 202, BA88.40-P-1000-01A
203, 208.3 /4, 209, 211,
210
Engine hood MODEL 168, 414.700 BA88.40-P-1000-01B
Engine hood MODEL 163 BA88.40-P-1000-01C
Engine hood MODEL 199, 215, 220, BA88.40-P-1000-01D
230, 461, 463 ...
Engine hood MODEL 240.078 /079/178 BA88.40-P-1000-01E
Engine hood MODEL 169, 245 BA88.40-P-1000-01I
Engine hood MODEL 219 BA88.40-P-1000-01J
Engine hood MODEL 164.1 /8 BA88.40-P-1000-01K
Engine hood MODEL 251 BA88.40-P-1000-01L
Engine hood MODEL 216, 221 BA88.40-P-1000-01M
Engine hood MODEL 204 BA88.40-P-1000-01N
Trunk lid MODEL 170, 171, BA88.50-P-1000-01A
199.376, 202, 203,
208.3 /4, 209, 210, 211,
215, 220, 230
Trunk lid MODEL 240 BA88.50-P-1000-01B
Trunk lid MODEL 216, 219, 221 BA88.50-P-1000-01D
Trunk lid MODEL 204 BA88.50-P-1000-01E
Outside flaps MODEL 208.4, 209.4 BA88.60-P-1000-01A
Outside flaps MODEL 169.0 /3, 245.2 BA88.60-P-1000-01B
Outside flaps MODEL 219.3 BA88.60-P-1000-01C
Outside mirrors MODEL 171, 211, 230 BA88.70-P-1000-01A

Outside mirrors MODEL 216, 219, 221 BA88.70-P-1000-01B
Exterior rearview mirrors MODEL 221 BA88.70-P-1000-01C
Cover strips MODEL 219 BA88.80-P-1000-01A
FENDERS - BA88.10-P-1000-01E
Model 164
FENDER SPECIFICATIONS
Number Designation Model 1641/8
BA88.10-P-1001-01E Mount, fender to body Nm 10
BUMPER - BA88.20-P-1000-01E
Model 164
BUMPER SPECIFICATIONS
BA88.20-P-1001-01E Nut, rear crossmember to rear center section Nm 50
BA88.20-P-1002-01E Nut, bumper bracket to body Nm 18
DETACHABLE BODY COMPONENTS, UNDERRIDE GUARD - BA88.30-P-1000-01D
Model 164
DETACHABLE COMPONENTS, UNDERRIDE GUARD

BA88.30-P-1001-01D Nut, side step bar bracket to body mount Nm 10
BA88.30-P-1002-01D Bolt, side step bar to mounting plate Nm 14
BA88.30-P-1003-01D Nut/bolt, brush guard bracket to crossmember Nm 18
BA88.30-P-1004-01D Nut, brush guard to bracket Nm 25
BA88.30-P-1005-01D Bolt, brush guard to bracket Nm 49
ENGINE HOOD - BA88.40-P-1000-01K
Model 164
ENGINE HOOD CHART

BA88.40-P-1001-01K Bolt for engine hood hinge on engine hood Nm 20
BA88.40-P-1002-01K Screw for engine hood hinge on body Nm 20
BA88.40-P-1003-01K Screw for engine hood catch on radiator crossmember Nm 12
BA88.40-P-1004-01K Bolt, upper frame crossmember to engine hood catch hook Nm 10

2006-2008 ACCESSORIES & BODY, CAB Doors - 164 Chassis
Doors - 164 Chassis
BASIC KNOWLEDGE
POWER WINDOWS (PW [EFH]), FUNCTION - GF72.29-P-0003GZ
MODEL 164.1/8
The power window system (PW) allows opening and closing the front and rear window. In addition, on model
164.8, the right/left rear vent window can be opened and closed manually via the driver power window and
outside mirror adjustment switch group (S20/1).
Functions
 Manual and automatic raising and lowering, opening and closing via:
 driver power window and outside mirror adjustment switch group
 Front passenger power window switch (S21/2)
 Left rear power window switch (S21/3)
 Right rear power window switch (S21/4)
 Vent window open switch (S20/1s15) (model 164.8)
 Close vent window switch (S20/1s16) (model 164.8)
 Desmodromic valve control for opening and closing doors (short stroke)
The convenience features are additional operating functions for opening and closing the side windows as well as
the vent windows (model 164.8) allowing them to be opened and closed centrally from one control point:
 Convenience closing/opening via:

 Recirculated air function
 Transmitter key (A8/1)
 Convenience closing via:

 Keyless go (KG)
(with keyless go code 889)
The convenience functions are described in the convenience feature (CF) function
Obstruction sensor
The excess force limiter (indirect obstructoin sensor) is active while the windows are being closed.
Normalization
The power window must be normalized (upper mechanical window stop learned in) for the automatic raising
and lowering function and the obstruction sensor.
PRE-SAFE (model 164.8)
The PRE-SAFE function is intended to prevent objects penetrating into the passenger cell when the vehicle
skids as well as body or body parts of the vehicle occupants from swinging out of the vehicle. The open side
windows and the open tilting/sliding roof are closed leaving a gap of approx. 50 mm. This closing procedure
can only be interrupted by actuating the driver power window and outside mirror adjustment switch group.
The power window must be normalized for the PRE-SAFE function.
The PRE-SAFE functions are described under foresighted vehicle occupant protection
Power windows (PW), location GF72.29-P-

Model 164.1
of components 0003-01GZ
GF72.29-P-
Model 164.8
0003-01GY
Power window (PW), GF72.29-P-
Model 164.1
interlinkage of components 0003-02GZ
GF72.29-P-
Model 164.8
0003-02GY
Power window raising/lowering, GF72.29-P-
function 3013GZ
Power window excess force GF72.29-P-
limiter, function 3014GZ
Normalization of power GF72.29-P-
windows, function 4003GZ
With PRE-SAFE, code 299 and electrically
Foresighted vehicle occupant GF91.60-P-
adjustable front passenger seat with memory, code
protection, function 2010GZ
242
Power windows (PW), location of components - GF72.29-P-0003-01GY
Fig. 1: Identifying Power Windows (PW) Components Location

Power windows (PW), location of components - GF72.29-P-0003-01GZ
Fig. 2: Identifying Power Windows (PW) Components Location

Power window (PW), interlinkage of components - GF72.29-P-0003-02GY

Fig. 3: Identifying Interlinkage Components Of Power Windows (PW)

Power windows (PW), interlinkage of components - GF72.29-P-0003-02GZ
Fig. 4: Identifying Interlinkage Components Of Power Windows (PW)

TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR POWER WINDOWS (PW) - GF72.29-P-

0998GZ
MODEL 164.1/8
Power windows (PW [EFH]), GF72.29-P-

function 0003GZ
Power windows (PW), location of GF72.29-P-

Model 164.1
components 0003-01GZ
GF72.29-P-
Model 164.8
0003-01GY
Power window (PW), interlinkage GF72.29-P-
Model 164.1
of components 0003-02GZ
GF72.29-P-
Model 164.8
0003-02GY
Power window raising/lowering, GF72.29-P-
function 3013GZ
Power window excess force limiter, GF72.29-P-
function 3014GZ
Normalization of power windows, GF72.29-P-
function 4003GZ
With PRE-SAFE, code 299 and electrically
Foresighted vehicle occupant GF91.60-P-
adjustable front passenger seat with memory, code
protection, function 2010GZ
242
Overview of system components GF72.29-P-
for power windows (PW) 9997GZ
POWER WINDOW RAISING/LOWERING, FUNCTION - GF72.29-P-3013GZ
MODEL 164.1/8
Fig. 5: Power Window Raising/Lowering Function Diagram - Shown On Model 164.1

Shown on model 164.1 without electrically heated left and right rear seats, code 872
Fig. 6: Power Window Raising/Lowering Function Diagram - Shown On Model 164.8

Shown on model 164.8 without electrically heated left and right rear seats, code 872
 Circuit 15 ON or circuit 15R ON

 Not active for rear power window child safety lock switch
 For automatic raising or lowering additionally normalized power windows.
Up to 5 min. after circuit 15R or circuit 15 OFF, the power window can be actuated if the front doors are not
open.
Driver control point
All windows in the front and rear doors and vent windows (model 164.8) can be opened or closed from the
driver power window and outside mirror adjustment switch group.
Press corresponding switch on driver power window switch group to catch point in the opening or closing
direction for manual raising or lowering.
Momentarily press corresponding switch on driver power window and outside mirror adjustment switch group
to catch point in the opening or closing direction for automatic raising or lowering. Actuation is performed until
the position recognition detects that the windows are opened or closed.
Actuation of the driver power window and outside mirror adjustment switch group is read in by the left front
door control unit via the LIN BUS and the corresponding message is relayed to the right front door control unit
and the front SAM control unit via CAN BUS. Both door control units then actuate the left front power window
motor and right front power window motor. The front SAM control unit actuates the left rear power window
and right rear power window motor as well as the left and right vent window motors on model 164.8.
Passenger control points and rear control points

Only the associated window can be opened or closed by the passenger power window switch or the rear power
window switch. Press passenger power window switch or corresponding rear power window switch in the
opening or closing direction for manual raising or lowering.
Momentarily actuate passenger power window switch or corresponding rear power window switch beyond the
catch point in the opening or closing direction for automatic raising or lowering until the position recognition
detects complete opening or closing the window
Actuation of the front passenger power window switch or the corresponding rear power window switch is read
in voltage-coded by the left front door control unit and front SAM control unit which directly actuates the
corresponding power window motor windows is realized via the left/right vent window obstruction sensor
strips.
Function abort
 If the corresponding operating switch is actuated again

 I the excess force limiter is actuated during automatic raising
 If function prerequisites are not fulfilled
 Recognition of Hall sensor defective
 Release corresponding vent window switch
The excess force limiter on the side windows is only active during automatic raising. The excess force limiter of
the vent the window
On vehicles with electrically heated left and right rear seats, code 872, the rear power window switch as well as
the driver power window switch group are read in by the switching bus
Child safety lock function
The function of the rear control points can be disabled with the child safety lock switch located in the driver
power window and outside mirror adjustment switch group. Already performed actions are interrupted
immediately by the rear power window switch when the child safety lock is activated The current status is
recognized by the child safety lock indicator lamp and the current position of the child safety lock switch in the
driver power and outside mirror adjustment switch group.
Vent window play protection
If the vent window motor is actuated more than 10 times after switching on the ignition, the play protection is
activated. However, the vent windows can still be closed.
Sequence of priority
The driver power window and outside mirror adjustment switch group has the master function. An adjustment
request via the front passenger control point or rear control points is interrupted by a corresponding actuation of
the driver power and outside mirror adjustment switch group.
Power window motor, component description GF72.29-P-6030GZ

Vent window motor, component description Model 164.8 GF72.29-P-6035GY
Power window switch, component description GF72.29-P-6040GZ
POWER WINDOW EXCESS FORCE LIMITER, FUNCTION - GF72.29-P-3014GZ
MODEL 164.1/8
Excess force limiter (indirect obstruction sensor)
 Windows normalized
 Function in range of 230 mm to approx. 3 mm of window opening
 The switches for the power window are in the rest position.
Function
If the left front door control unit (N69/1), right front door control unit (N69/2) and front SAM control unit
(N10) recognize pinching while automatically raising a window, the drive is reversed and the window opens
approx. 70 mm.
An excess force limiter for the vent window (model 164.8) is realized via the left vent window obstruction
sensor strip (B51/5) and right vent window obstruction sensor strip (B51/6) which is read in directly by the rear
SAM control unit (N10/8).When pinching is recognized, the corresponding vent window reverses direction and
is automatically and completely opened.
The vent window drive is not normalized or denormalized.
If a request is received by the front left power window motor (M10/3) for another automatic closing operation
within 5 t 10 s, this operation is performed without obstruction sensor.
Adaptive excess force limiter for power window
 Windows normalized
 Function in range of 230 mm to approx. 3 mm of window opening
Function
The adaptive excess force limiter serves for recognition of sluggishness when the window rolls up and takes this
into consideration the next time it is actuated. The adapted values are not erased by normalization nor by
voltage loss.

NORMALIZATION OF POWER WINDOWS, FUNCTION - GF72.29-P-4003GZ
MODEL 164.1/8
Normalization
Normalization is learning in the left front door control unit (N69/1), right front door control unit (N69/2) and
front SAM control unit (N10) to the upper mechanical window stop (zero point).
For this purpose, it is necessary to completely close and then continue to actuate or hold down the
corresponding window via the driver power window and outside mirror adjustment switch group (S20/1) or the
corresponding switch on the other window. The corresponding door control unit or the front SAM control unit
sets the position counter for the Hall signals to zero if it recognizes a lock-up of the left front power window
motor (M10/3), right front power window motor (M10/4), left rear power window motor (M10/5) or right rear
power window motor (M10/6) for approx. 0.5 s.
Denormalization
Denormalization occurs when:
 the position counter status exceeds the maximum window travel.

 an incorrect rotation direction of the Hall sensors is recognized
 the Hall sensor signal is not present
 Circuit 30 is "OFF"
A prerequisite for this function is a normalization of the power window:
 Automatic closing with excess force limitation

Vent window motor, component description GF72.29-P-6035GY
LEFT FRONT DOOR CONTROL UNIT, COMPONENT DESCRIPTION - GF72.29-P-4141GZ
MODEL 164.1/8
Location
The left front door control unit is located in the upper area of the left door inside.
Fig. 7: Identifying Left Front Door Control Unit

Task
The left front door control unit is connected with the controller area network bus, class B (interior compartment)
(CAN B) to exchange data and has the following purposes:
Reading in switches:
 Driver power window and outside mirror adjustment switch group (S20/1)
 Rear side windows child safety lock switch (S20/1s5)
 Outside mirror fold-in/out switch S20/1s9
 Outside mirror adjustment rocker switch S20/1s12
 Open vent window switch (S20/1s15)
 Close vent window switch (S20/1s16)

Outside mirror adjustment switch S50
 Open and close switch for rear-end door, driver (S15/3)

 Left interior CL [ZV] switch S85/5
Reading in sensors:
 Left front IR receiver (A26/1)

 Left front power window motor Hall sensor (M10/3)
 Mirror up/down adjustment potentiometer (M21/1r2)
 Mirror in/out adjustment potentiometer (M21/1r3)
Switching loads via internal semi-conductor switches:
 Left outside mirror turn signal lamp (E6/5)

 Left front door entrance/exit lamp (E17/3)
 Left front door inside handle illumination (E17/11)
 Left front power window motor (M10/3)
 Left front door CL [ZV] motor (M14/6)
 Left electrically adjustable and heated outside mirror (M21/1)
 Left outside mirror ambient lamp (M21/1e1)
 Automatic mirror dimming (M21/1h1)
 Mirror fold-in motor (M21/1m3)
 Mirror heater (M21/1r1)
 Illumination of driver power window and outside mirror adjustment switch group
The left front door control unit is connected with the CAN interior bus to exchange data.
The driver power window and outside mirror adjustment switch group is read in by the left front door control
unit via a LIN BUS
Task in combination with air conditioning
The left front door control unit senses the window position in the left front door of the vehicle and stores this
information on the CAN B.
The AAC control and operating unit (N22) or the comfort AAC control and operating unit (N22/7) reads in the
signals for the "Driver door ON" window position, to achieve better control quality in the open position
Recirculated air convenience closing, task
When the air recirculation switch (N22s2 or N22/7s2) is pressed for longer than 1.5 s, the convenience closing
function is activated. The left front door control unit stores the momentary window position and closes the
window if it is open in the automatic mode. When the convenience closing function is completed, the window is
returned to the stored position when the air recirculation switch is pressed again for longer than 1.5 s.
RIGHT FRONT DOOR CONTROL UNIT, COMPONENT DESCRIPTION - GF72.29-P-4142GZ
MODEL 164.1/8
Location
The right front door control unit is located in the upper area of the right door inside.
Fig. 8: Identifying Right Front Door Control Unit

Task
The right front door control unit is connected with the controller area network bus, class B (interior
compartment) (CAN B) to exchange data and has the following tasks:
Reading the following switches:
 Front passenger power window switch (S21/2)
Reading the following sensors:
 Right front power window motor Hall sensor (M10/4)

 Mirror up/down adjustment potentiometer (M21/2r2)
 Mirror in/out adjustment potentiometer(M21/2r3)
Switching loads via internal semi-conductor switches:
 Right outside mirror turn signal lamp (E6/6)

 Right front door entrance/exit lamp (E17/4)
 Right front door inside handle illumination (E17/12)
 Right front power window motor (M10/4)
 Right front door CL [ZV] motor (M14/5)
 Mirror up/down adjustment motor (M21/2m1)

 Mirror in/out adjustment motor (M21/2m2)
 Right outside mirror ambient lamp (M21/2e1)
 Automatic dimming mirror (M21/2h1)
 Mirror fold-in motor (M21/2m3)
 Mirror heater (M21/2r1)
 Illumination for front passenger power window switch
The right front door control unit is connected with the CAN interior bus to exchange data.
The front passenger power window switch is read in by the right front door control unit via a LIN BUS
Task in combination with air conditioning
The right front door control unit senses the window position in the right front door of the vehicle and stores this
information on the CAN interior.
The AAC control and operating unit (N22) or the comfort AAC control and operating unit (N22/7) reads in the
signals for the "Driver door ON" window position, to achieve better control quality in the open position
Recirculated air convenience closing, task
When the air recirculation switch (N22s2 or N22/7s2) is pressed for longer than 1.5 s, the convenience closing
function is activated. The right front door control unit stores the momentary window position and closes the
window - if open - in the automatic function. When the convenience closing function is completed, the window
is returned to the stored position when the air recirculation switch is pressed again for longer than 1.5 s.
POWER WINDOW MOTOR, COMPONENT DESCRIPTION - GF72.29-P-6030GZ
MODEL 164.1/8
Fig. 9: Identifying Power Window Motor Component Locations

Location
The power window motors are located in the corresponding doors below the door paneling
Design
The power window motors are DC motors which turn to the right or left depending on the actuation. Each motor
has a thermal safety switch and two halls sensors each for position recognition.
Position recognition
The position counter in the corresponding left front door control unit (N69/1), right front door control unit
(N69/2) and front SAM control unit (N10) evaluates the signals of the corresponding Hall sensors of the power
window motors. Depending the actuation direction the counter is increased when "opening" and
correspondingly decreased when "closing". The zero position is set by normalization. The position recognition
is always active except in the sleep mode
Direction recognition
The rotation direction is recognized by evaluating both Hall sensor signals located offset 90° on each shaft of
the power window motors. Each edge of the Hall sensors is evaluated for rotation recognition.
Overload protection
The power window motors are switched off by a thermal switch to protect against overheating. After a waiting
time of 5 to 10 s the power window motor switched off can be actuated again.
VENT WINDOW MOTOR, COMPONENT DESCRIPTION - GF72.29-P-6035GY
MODEL 164.8
Fig. 10: Identifying Vent Window Motor Component Locations

Location
The left and right vent window motors are located on the side in the trunk.
Design
The vent window motors are DC motors which turn to the right or left, depending on the actuation.
Task
Drive for left and right vent window
Function
The function is actuated by pressing the switch on the driver power window and outside mirror adjustment
switch group (S20/1) in the "Opening" or "Closing" direction. The switch position is read in by the left front
door control unit (N69/1) via LIN BUS and the corresponding message is relayed to the rear SAM control unit
(N10/8) via CAN B
An excess force limiter for the vent window is realized via the left vent window obstruction sensor strip (B51/5)
and right vent window obstruction sensor strip (B51/6) which is read in directly by the rear SAM control unit.
The vent window drive is not normalized or denormalized.
POWER WINDOW SWITCH, COMPONENT DESCRIPTION - GF72.29-P-6040GZ
MODEL 164.1/8
Fig. 11: Identifying Power Window Switch Component Locations - Shown On Model 164.1
Location
The power window switches are installed in the corresponding armrest in the door paneling
Function
All windows can be operated from the driver via the driver power window and outside mirror adjustment switch
group. The operation of the rear driver window can be interrupted by the child safety lock switch. This is
indicated by the child safety lock indicator lamp. In addition, the rear vent window (model 164.8) can be
opened and closed via the driver power and outside mirror adjustment switch group
Only the associated window can be operated via the front passenger and rear passenger power window switch
The manual and automatic raising/lowering feature can be operated from all control points
The driver power window and outside mirror adjustment switch group is read in via switching bus.
On vehicles with code (872) Electrically heated left and right rear seats, the rear power window switches are
also read in by the switching bus
SURVEY OF SYSTEM COMPONENTS FOR ELECTRIC POWER WINDOWS (PW) - GF72.29-P-

9997GZ
MODEL 164.1/8

Table of contents, function description for power windows (PW) GF72.29-P-0998GZ
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: DOORS - AR72.00-Z-9164AA
MODEL 164
AR72.10-P-
Remove/install front door MODEL 164
0500GZ
AR72.10-P-
Adjust front door MODEL 164.1/ 8
0550GZ
AR72.10-P-
Remove/install door module MODEL 164
0900GZ
AR72.10-P-
Remove/install front door lining MODEL 164
1000GZ
AR72.10-P-
Disassemble/assemble front door lining MODEL 164
1030GZ
AR72.10-P-
Remove/install speaker cover MODEL 164
1032GZ
AR72.10-P-
Remove/install armrest on front door MODEL 164
1033GZ
AR72.10-P-
Remove/install door pocket MODEL 164
1040GZ
AR72.10-P-
Remove/install trim strip on front door lining MODEL 164
1050GZ
AR72.10-P-
Remove/install window guide rail MODEL 164 Front door 1500GZ

AR72.10-P-
Remove/install inner sealing rail MODEL 164
1600GZ
AR72.10-P-
Remove/install outer sealing rail MODEL 164
1700GZ
AR72.10-P-
Remove/install crank window in front door MODEL 164
1900GZ
Remove/install seal for crank window on AR72.10-P-
MODEL 164
front door 1905GZ
AR72.10-P-
Remove/install door sealing frame MODEL 164
2120GZ
Remove/install outside door handle on front AR72.10-P-
MODEL 164
door 2400GZ
Remove/install inside door opener on front AR72.10-P-
MODEL 164
door 2420GZ
AR72.10-P-
Remove/install front door hinge MODEL 164
2660GZ
AR72.10-P-
Remove/install front door lock MODEL 164
4011GZ
Removing and installing front door lock AR72.10-P-
MODEL 164
cylinder 4015GZ
Remove/install inner paneling at window AR72.10-P-
MODEL 164
frame of front door 6580GZ
AR72.12-P-
Remove/install rear door module MODEL 164 (except 164.177)
0103GZ
AR72.12-P-
Remove/install rear door MODEL 164
0600GZ
AR72.12-P-
Adjust rear door MODEL 164
0650GZ
AR72.12-P-
Remove/install rear door lining MODEL 164
1010GZ
Remove/install inner paneling on rear door AR72.12-P-
MODEL 164
window frame 1012GZ
AR72.12-P-
Remove/install inner sealing rail on rear door MODEL 164
1013GZ
AR72.12-P-
Remove/install outer sealing rail on rear door MODEL 164
1014GZ
Remove/install door sealing frame on rear AR72.12-P-
MODEL 164
door 1015GZ
AR72.12-P-
Remove/install armrest on rear door MODEL 164
1020GZ
AR72.12-P-
Remove/install door pocket on rear door MODEL 164
1021GZ
Assemble/disassemble door lining in rear AR72.12-P-
door MODEL 164 1040GZ

AR72.12-P-
Remove/install trim strip on front door lining MODEL 164
1050GZ
Remove/install window guide rail for rear AR72.12-P-
MODEL 164
door 1500GZ
AR72.12-P-
Remove/install crank window in rear door MODEL 164
1910GZ
Remove/install sealing for crank window on AR72.12-P-
MODEL 164
rear door 1911GZ
AR72.12-P-
Remove/install fixed window in rear door MODEL 164
1970GZ
Remove/install inside door opener on rear AR72.12-P-
MODEL 164
door 2310GZ
AR72.12-P-
Remove/install outer rear door handle MODEL 164
2410GZ
AR72.20-P-
Remove/install rear-end door lock MODEL 164
2550GZ
AR72.20-P-
Remove/install rear-end door hinge MODEL 164
2560GZ
AR72.20-P-
Remove/install rear-end door MODEL 164
3500GZ
AR72.20-P-
Adjust rear-end door MODEL 164
3510GZ
AR72.20-P-
Remove/install rear-end door lining MODEL 164
3520GZ
Remove/install rear-end door AR72.20-P-
MODEL 164
weatherstripping 3540GZ
Remove/install gas-operated strut to rear-end AR72.20-P-
MODEL 164
door 3600GZ
Remove/install position sensor for automatic MODEL 164 with CODE (890) AR72.20-P-
rear-end door Automatic tailgate 3602GZ
Remove/install automatic rear-end door MODEL 164 with CODE (890) AR72.20-P-
hydraulic unit Automatic tailgate 3604GZ
Remove/install rear door closing system MODEL 164 with CODE (890) AR72.20-P-
switch Automatic rear-end door 3605GZ
MODEL 164 Outer rear-end door AR72.20-P-
Remove/install rear-end door handle strip
handle strip 3650GZ
AR72.20-P-
Remove/install tailgate handle molding MODEL 164 Inner tailgate handle
3650GZA
Remove/install rear door closing control MODEL 164 with CODE (890) AR72.20-P-
module Automatic tailgate 7551GZ
Remove/install switches for rear door power AR72.29-P-
MODEL 164
windows 0002GZ
Remove/install front door power window MODEL 164 Switch in front passenger AR72.29-P-
switch door 0100GZ

Remove/install front door power window AR72.29-P-
MODEL 164
switch group 0110GZ
Remove/install automatic rear-end door MODEL 164 with CODE (890) AR72.29-P-
switch Automatic rear-end door 0130GZ
AR72.29-P-
Remove/install front door control unit MODEL 164
1000GZ
Remove/installing front door power window AR72.29-P-
MODEL 164
motor 1860GZ
Remove/install power window motor in rear AR72.29-P-
MODEL 164
door 1880GZ
REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500GZ
MODEL 164
Fig. 12: Identifying Front Door Components - Shown On Model 164.1

MODIFICATION NOTES
"Disconnect/connect ground lines for battery" and "Perform basic programming" Steps 1 and
26.7.06
eliminated 9
Remove/install

Unlock locking tongue (2) of electrical
1 connector (1) with suitable screwdriver and
lift catch hook (3)
Press caps (4) off of screws (5) with
3
suitable screwdriver
Helper is required for securing front door (6)
since front door (6) can detach from vehicle
4 Remove screws (5) in uncontrolled manner and be damaged
Installation: Repair paint damage on bolt
(5) with touch-up pencil.
*BA72.10-P-
1005-01O
Carefully remove front door (6) from door
Detach front door (6) upward from the door hinges with aid of helper and lay down on
5
hinge assemblies and lay on a suitable base suitable subsurface, otherwise the paint on
the front door (6) can be damaged.
Check gaps of front door (6), adjust front AR72.10-P-
7
door (6) if necessary. 0550GZ
FRONT DOOR
BA72.10-P-1005-01O Bolt on door hinge half connection Nm 10
ADJUST FRONT DOOR - AR72.10-P-0550GZ
MODEL 164.1/8
Fig. 13: Identifying Front Door Adjusting Components - Shown On Model 164.1
Inspect, set
jammed or pinched when removing, installing AS00.00-Z-
or aligning hoods, doors, trunk lid/rear-end 0011-01A
1 Remove locking eye (1)
Check gap between front fender and front door *BE60.00-P-
2
(C) on door 1001-01P
Check gap between front door and rear door
*BE60.00-P-
3 (D) and gap between front door and rear door
1002-01P
in area of B-pillar (E) on door
Check gap between door sill molding and front
*BE60.00-P-
4 door (G) and gap between front door and A-
1003-01P
pillar (I) on door
Loosen bolts for door hinge on A-pillar (3) and
*BE60.00-P-
5 adjust by moving gap between front fender and
1001-01P
front door (C)
Adjust gap between front door and rear door
*BE60.00-P-
6 (D) and gap between front door and rear door
1002-01P
in area of B-pillar (E)

Adjust gap between door sill molding and front
*BE60.00-P-
7 door (G) and gap between front door and A-
1003-01P
pillar (I)
*BA72.10-P-
8 Tighten bolts on door hinge on A-pillar (3)
1003-01O
Loosen bolts on door hinge on front door (4) The contour of the front fender must be
9 and adjust transition between front fender and flush with the door paneling or should
front door by moving front door not be protrude more than 1 mm.
*BA72.10-P-
10 Tighten bolts for door hinge on front door (4)
1002-01O
11 Install locking eye (1) Do not tighten screws (2).
Completely close front door and adjust Contour of front door should be flush
transition between front door and rear door or with contour of rear door or B-pillar
12
in relation to B-pillar by moving locking eye and should not protrude more than 1
(1) mm.
*BA72.10-P-
1004-01O

Dimension
"A"
Dimension
"A1"
Dimension
Fender to engine hood mm 3.5 (±0.5) 3.5 (±1.0)
"B"
BE60.00-P- Gap
Rear door to side roof Dimension
1001-01P dimension mm 4.5 (±0.5) 4.5 (±1.0)
frame "B1"
mm 4.5 (±0.5) 4.5 (±1.0)
door "C"
See picture AR60.00-P- AR60.00-P-

0700-01GZ 0700-01GZ
Dimension
"C1"
Dimension
"D"
BE60.00-P- Gap Rear-end door to D- Dimension
1002-01P dimension mm 5 (±1) 5.0 (±1.0)
pillar "D1"
Front door to rear door Dimension
mm 5 (±0.5) 5.0 (±1.0)
Door sill molding to rear Dimension
door "F" mm 6 (±1) 6.0 (±1.0)

0700-01GZ 0700-01GZ
mm 6 (±1) 6.0 (±1.0)
front door "G"
Dimension
"H"
Dimension
Front door to A-pillar mm 4.5 (±0.5) 4.5 (±1.0)
"I"
BE60.00-P- Gap
Fender to side Dimension
1003-01P dimension mm 4 (±1) 4.0 (±1.0)
headlamps "J"
mm 6 (±1.5) 6.0 (±1.0)
grill "K"

0700-01GZ 0700-01GZ
FRONT DOOR
BA72.10-P-1002-01O Bolt, door hinge to front door Nm 32
BA72.10-P-1003-01O Bolt, door hinge to A-pillar Nm 32
BA72.10-P-1004-01O Bolt, locking eye to B-pillar Nm 28

REMOVE/INSTALL DOOR MODULE - AR72.10-P-0900GZ
MODEL 164
Fig. 15: Identifying Door Module Components - Illustrated On Model 164.1

Fig. 16: Identifying Door Module

Remove/install
Risk of injury due to hands being crushed Secure window to prevent it from falling AS67.00-Z-
when window glass is not secure down. 0002-01A
AR72.10-P-
1 Remove front door lining
1000GZ
AR72.10-P-
2 Remove outside door handle on front door
2400GZ
3 Open access opening covers (1)
The bonding surfaces must be free of
dust and grease, otherwise the crank

window could fall down and be
damaged.
Place a rag underneath to prevent
Close crank window (dimension A) and
4 adhesive residue from falling on the
secure with fabric adhesive tape (2)
paintwork.
Dimension A approx. 80 mm; the screws
(3) in the access openings must be
accessible.
*BA72.10-P-
5 Loosen screws (3)
1001-01O
6 Loosen screw (4)
7 Slide door lock (7) toward front and unhook
8 Remove screws (5)
Disconnect electrical connectors (6) from left
9 door control module (N69/1) or right front
door control module (N69/2)
10 front door speaker (H4/5) or right front door
speaker (H4/6)
11 front power window motor (M10/3) or right
front power window motor (M10/4)
12 Unclip clips (10) from door module (15)
Disconnect electrical connector (12, 13) from
14 Pull door module (15).
door lock (7)
Guide wiring harness through rubber
15
grommet (14).
Installation: Coat seal (arrows) with
16 Remove door module (15)
lubricant
*BR00.45-Z-
Antifriction agent
1010-06A
Front door
BA72.10-P-1001-01O Bolt, crank window to window lift Nm 7
REPAIR MATERIALS
REMOVE/INSTALL FRONT DOOR LINING - AR72.10-P-1000GZ

MODEL 164
Fig. 17: Identifying Front Door Lining Components - Shown On Model 164.1 With Automatic Rear-End
Door
Shown on model 164.1 with automatic rear-end door, code 890
Remove/install
On vehicles with Keyless Go, code 889: Press Keyless Go
start/stop button repeatedly until ignition is switched off.
1 transmitter key from the EIS [EZS]
Remove transmitter key from vehicle and store it in a
control unit
Fig.
2 Pry trim strip (1) off door lining (9) Mounting wedge
18
3 Unclip mirror triangle cover (2) Unclip the mirror triangle cover (2) at the top (arrow).
Fig.
Mounting wedge
18
4
from left front door tweeter (H4/33)
5 Remove screws (4)
Press both central locking buttons
Pull the tab visible between the central locking buttons. Do
simultaneously; remove central
6 not disconnect the electrical connector (7) from the central
locking switch (6) from door lining
locking switch (6).
(9)
7 Remove screw (8)
Unclip the clips at the bottom and side of the door lining in
8 Pry off door lining (9) order to prevent the clip holder from breaking off.
Installation: Replace damaged clips.
Fig.
Mounting wedge
18
Lift door lining (9) upwards and
9 In order to provide access to the Bowden cable (10).
inwards
Detach Bowden cable (10) from
10
inside of door opener
11 Separate electrical connectors (11) Handle the ribbon cable with care to prevent damage.
12 Remove door liner (9)

DISASSEMBLE/ASSEMBLE FRONT DOOR LINING - AR72.10-P-1030GZ
MODEL 164
Fig. 19: Identifying Front Door Lining Components - Shown On Driver Door
Remove/Install
AR72.10-P-
1 Remove front door lining (1)
1000GZ
Remove sound deadening mat from front door Installation: Position glue points and
2
lining (1) fasten sound deadening mat
Disconnect connector (7) from left interior CL Treat ribbon cable carefully to
3
switch (S85/5) prevent damage
AR72.10-P-
4 Remove trim strip (2)
1050GZ
AR72.10-P-
5 Remove inside door opener (3)
2420GZ
Remove driver power window and outside AR72.29-P-
6
mirror adjustment switch group (S20/1) 0110GZ
Remove open and close switch for rear-end Only on vehicles with automatic rear- AR72.29-P-
7.1
door, driver (S15/3) end door, code 890. 0130GZ
AR72.10-P-
8 Remove armrest (4)
1033GZ
Unclip left front entrance/exit lamp (E17/3) Treat ribbon cable carefully to
9
and disconnect from connector prevent damage
AR72.10-P-
10 Remove speaker cover (5)
1032GZ
AR72.10-P-
11 Remove door pocket (6)
1040GZ

REMOVE/INSTALL SPEAKER COVER - AR72.10-P-1032GZ
MODEL 164
Fig. 21: Identifying Speaker Cover Components

Remove
Lay front door lining (1) down on AR72.10-P-
suitable subsurface to prevent damage. 1000GZ
Remove sound deadening mat (2) from
2 door lining and fold over until speaker
front door lining (1)
cover (3) is accessible
When initially removing speaker cover
(3).
Do not operate at excessive speed
Separate plastic bonds (arrows) on speaker
because the plastic becomes too hot,
3.1 cover (3) with suitable bit and remove
melts and galls the bit
plastic residues from front door lining (1)
Number of plastic spot welds can vary
according to model designation and
equipment.
*WH58.30-Z-
Rechargeable drill/screwdriver
1007-20A
Bend open clamping plates (4) with suitable When repeatedly removing speaker
3.2
screwdriver and remove from pins cover (3)
4 Remove speaker cover (3) Press clips (6) together
Install
5 Insert speaker cover (3) Ensure that clips (6) are seated correctly
Use 10 mm socket. The clamping plates
Press clamping plates (4) over pins (5) of (4) should make firm contact to the front
6
speaker cover (3) door lining (1)
Replace clamping plates.
Fasten sound deadening mat (2) to front Position gluing points and press on
7
door lining (1) sound deadening mat (2)
If required, cut off pins (5) on speaker AR72.10-P-
8 Install front door lining (1)
cover (3) with suitable tool 1000GZ

Number Designation
REMOVE/INSTALL ARMREST ON FRONT DOOR - AR72.10-P-1033GZ
MODEL 164
Fig. 22: Identifying Armrest Components On Front Door

Remove
Lay front door lining (1) down on AR72.10-P-
suitable subsurface to prevent damage. 1000GZ
2 door lining and fold back until armrest
(3) is accessible
When initially removing armrest (3).
Work carefully to prevent damage to flat
Drill plastic spot welds (arrows) out in
ribbon cables
3.1 armrest (3) with suitable bit and remove
plastic residues from front door lining (1)
*WH58.30-Z-
1007-20A
Bend open clamping plates (4) with When removing armrest (3) a second
3.2
suitable screwdriver and remove from pins time
Number of plastic spot welds and clips
4 Remove armrest (3) can vary according to model designation
and equipment.
Install
5 Install armrest (3)
Use 10 mm socket wrench. The clamping
Press clamping plates (4) over pins (5) of plates (4) should make firm contact to the
6
armrest (3) front door lining (1)
Replace clamping plates (4)
Fasten sound deadening mat (2) to front Position gluing points and press on sound
7
door lining (1) deadening mat (2)
If required, cut off pins (5) on armrest (3) AR72.10-P-
with suitable tool 1000GZ

Number Designation
REMOVE/INSTALL DOOR POCKET - AR72.10-P-1040GZ
MODEL 164
Fig. 23: Identifying Door Pocket Components

Remove
AR72.10-P-
1000GZ
Remove exit lamp from door pocket with
2 Disconnect electric connector.
suitable tool.
3 door lining until plastic spot welds in
door pocket (2) are accessible.
AR72.10-P-
4 Remove speaker cover (6)
1032GZ
When initially removing door pocket (2).
Drill out plastic spot welds (arrows) in
door pocket (2) with suitable bit and
5.1 melts and galls the bit
remove plastic residues from front door
Number of plastic spot welds can vary
lining (1)
according to model designation and
equipment.
*WH58.30-Z-
1007-20A
Bend open clamping plates (4) with When removing door pocket (2) a second
5.2
Install
7 Install door pocket (2)
Use 10 mm socket. The clamping plates
Press clamping plates (4) over pins (5) of (4) should make firm contact to the front
8
door pocket (2) door lining (1)
AR72.10-P-
9 Install speaker cover (6)
1032GZ
Fasten sound deadening mat (3) to front Position gluing points and press on sound
10
door lining (1) deadening mat (3),
11 Install exit lamp Connect electrical connector.
If required, cut pins (5) off of door pocket AR72.10-P-
(2) with suitable tool 1000GZ

Number Designation
REMOVE/INSTALL TRIM STRIP ON FRONT DOOR LINING - AR72.10-P-1050GZ
MODEL 164
Fig. 24: Identifying Trim Strip Components On Front Door Lining - Shown On Vehicle With Automatic
Rear-End Door
Remove
Lay door lining front side down on suitable AR72.10-P-
subsurface to prevent damage! 1000GZ
Bend open clamping plates (2) with
2 suitable screwdriver and remove
from pins (3)
Lift door lining (1) and remove trim
3
strip (4)
Install
Insert trim strip (4) in door lining Ensure that trim strip (4) is seated correctly on door
4
(1) lining (1).
Replace clamping plates (2) Use 11 mm socket with
Press clamping plates (2) over pins
5 suitable handle Clamping plates (2) should make
(3) of trim strip (4)
contact with door lining (1).
AR72.10-P-
6 Install door lining in front door
1000GZ
REMOVE/INSTALL WINDOW GUIDE RAIL - AR72.10-P-1500GZ
MODEL 164
Front door
Fig. 25: Identifying Window Guide Rail Components - Shown On Model 164.1
Remove/install
1 Completely roll down crank window
AR72.10-P-
2 Remove outer sealing rail
1700GZ
To facilitate removal and installation
Remove crank window seal (1) in working of window guide rail (3)
3
area and lay down to side Installation: Apply lubricant to
window guide rail (3).
*BR00.45-Z-
Antifriction agent
1010-06A
4 Unscrew bolt (2)
Pull window guide rail (3) toward front
5 Avoid paint damage.
(arrow A), then toward outside
Pull window guide rail (3) toward rear
6 Avoid paint damage.
(arrow B) and remove.
REPAIR MATERIALS
REMOVE/INSTALL INNER SEALING RAIL - AR72.10-P-1600GZ
MODEL 164

Fig. 26: Identifying Sealing Rail And Front Door - Shown On Model 164.1
Remove/install
1 Remove front door lining AR72.10-P-1000GZ
2 Pry sealing rail (1) off of front door (2). Mounting wedge Fig. 18

REMOVE/INSTALL OUTER SEALING RAIL - AR72.10-P-1700GZ
MODEL 164

Fig. 28: Identifying Sealing Rail And Clip - Shown On Model 164.1
Remove/install
Completely lower crank
1
window
Move mounting wedge to clip (arrow), carefully pry off to prevent
damage.
2 Pry off sealing rail (1).
Installation: Insert sealing rail (1) below outside mirror cover, align
and install on window channel.
Fig.
Mounting wedge
18
Check clip (2), replace if
3 Clip (2) is riveted. Remove sealing rail (1) first!
required.

REMOVE/INSTALL CRANK WINDOW IN FRONT DOOR - AR72.10-P-1900GZ
MODEL 164
Fig. 30: Identifying Crank Window Components In Front Door

Removing
Risk of injury due to hands
AS67.00-Z-
being crushed when window Secure window to prevent it from falling down.
0002-01A
glass is not secure
The bonding surfaces must be free of dust and grease,
Lower crank window (1) by otherwise the crank window (1) could fall down and be
1 80 mm (A) and secure with damaged.
fabric adhesive tape (2) Place a rag underneath to prevent adhesive residue from
falling on the paintwork.
Switch off ignition and On vehicles with Keyless Go, code 889: Press Keyless
remove the transmitter key Go start/stop button repeatedly until ignition is switched
2
from the EIS [EZS] control off. Remove transmitter key from vehicle and store it in
unit a location beyond its transmission range (at least 2 m).
AR72.10-P-
1000GZ
4 Remove rubber grommets (3)
Slacken screws (4) at window
5
mount
Connect power window

switch to door control unit;

6 lower window mount
completely
Disconnect power window
switch from door control unit;
7
place door lining outside of
working area
Remove fabric adhesive tape Secure the crank window (1) so that it cannot fall down
8
(2) and rag and be damaged.
Move crank window (1)
9 forwards, downwards,
backwards and upwards
Lift crank window (1) out of
10
window channel
Install
Insert crank window (1) into
11
window channel
Move crank window (1)
12
upwards completely
The bonding surfaces must be free of dust and grease,
otherwise the crank window (1) could fall down and be
Attach fabric adhesive tape
13 damaged.
(2)
Place a rag underneath to prevent adhesive residue from
falling on the paintwork.
Connect power window
switch to door control unit;
14
raise window mount
completely
Remove fabric adhesive tape
15
(2) and rag
Lower crank window (1) by
16 To provide access to the screws (4).
approx. 80 mm (A)
Disconnect power window
switch from door control unit;
17
place door lining outside of
working area
Tighten screws (4) at window *BA72.10-P-
18
mount 1001-01O
19 Install rubber grommet (3)
Install door lining in front AR72.10-P-
20
door 1000GZ
FRONT DOOR
BA72.10-P-1001-01O Bolt, crank window to window lift Nm 7
REMOVE/INSTALL SEAL FOR CRANK WINDOW ON FRONT DOOR - AR72.10-P-1905GZ
MODEL 164
Fig. 31: Identifying Sealing And Window Dimension

Remove
1 Open crank window by dimension (A) To facilitate installation.
2 Remove gasket (1). Do not damage sealing frame.
Install
3 Install sealing (1) Lubricate sealing (1) with lubricant
Antifriction agent *BR00.45-Z-1010-06A
4 Close crank window
REPAIR MATERIALS
REMOVE/INSTALL DOOR SEALING FRAME - AR72.10-P-2120GZ

Fig. 32: Identifying Door Sealing Frame Components

Remove
1 Wind crank window fully down
Remove mirror triangle cover (3) from front
door (1)
Loosen window frame paneling (2) from AR72.10-P-
3 Do not damage rubber seal and paint
window frame and rubber seal 6580GZ
Completely remove door sealing frame
4
(arrows) from front door (1)
Remove sealing and glue residues from front Dia. 100 mm eraser disc with mounting *WH58.30-Z-
5
door (1) with eraser disc shaft 1037-04A
*WE58.40-Z-
1001-03A
Remove sealing and glue residues from front At points on front door (1) which are not
6
door (1) with eraser disc accessible with erase disc
Gluing surface must be free of grease
7 Clean gluing surface on front door (1)
and dust
*BR00.45-Z-
Cleaner 1025-04A
Install
Glue door sealing frame (arrows) onto front
8 Roller Fig. 33
door (1)
Clip window frame paneling (2) into AR72.10-P-
Install mirror triangle cover (3) on front door
10
(1)
Remove dirt from front door (1) and in area
12
of entry



Number Designation
WH58.30-Z-1037- Removal disk, 100 mm dia. with fixing shank, Firma 3M Deutschland GmbH D-
04A 41453 Neuss
WORKSHOP EQUIPMENT
REPAIR MATERIALS

BR00.45-Z-1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL OUTSIDE DOOR HANDLE ON FRONT DOOR - AR72.10-P-2400GZ
MODEL 164
Shown on model 164.1 with Keyless Go, code 889
Fig. 35: Identifying Outside Door Handle Components On Front Door - Shown On Model 164.1 (1 Of 4)
Removing
Remove lock cylinder from front AR72.10-P-
1
door 4015GZ
Push door handle (4) slightly
2 toward rear (arrow A) and Do not damage paint!
remove from door (arrow B)
3.1 On vehicles with keyless go, code 889.
(2)
Install
Make sure that underlays are fitted correctly and in
good condition; install new underlays if necessary.
4 Insert underlay (1, 3) in door The underlays must be attached with their mounting
tabs correctly inserted in the recesses in the door
(arrows C and D).
5.1 Connect electrical connector (2) On vehicles with keyless go, code 889.
Ensure that door handle (4) is inserted properly
(arrows G), otherwise the door handle (4) cannot be
Insert door handle (4) (arrow E) moved toward front far enough for installation.
6
and slide toward front (arrow F). Do not damage paint!
Ensure that subsurfaces do not move when inserting
the door handle (4).
AR72.10-P-
7 Install front door lock cylinder
4015GZ
REMOVE/INSTALL INSIDE DOOR OPENER ON FRONT DOOR - AR72.10-P-2420GZ
MODEL 164
Fig. 39: Identifying Inside Door Opener Components On Front Door - Shown On Vehicle With
Automatic Rear-End Door
Remove
Lay door lining front side down on suitable AR72.10-P-
subsurface to prevent damage! 1000GZ
Bend open clamping plate (1) with
2
suitable screwdriver, remove
3 Remove screw (2)
4 Unclip clips (3)
Raise door lining and remove inside
5
door opener (4).
Install
Insert inside door opener (4) into door
6
lining
7 Clip in clips (3)
Replace clamping plate (1).Use 11 mm socket
8 Press clamping plate (1) over pin
with suitable handle for pressing in.
9 Tighten screw (2)
AR72.10-P-
10 Install door lining in front door
1000GZ
REMOVE/INSTALL FRONT DOOR HINGE - AR72.10-P-2660GZ
MODEL 164
Fig. 40: Identifying Front Door Hinge Components - Shown On Model 164.1
Remove/install
AR72.10-P-
1 Remove front door (3)
0500GZ
Mark installation position of front door hinge leaf (1)
2
and A-pillar hinge leaf (2)
Unscrew bolts for door hinge on A-pillar (4) and *BA72.10-P-
3
remove front door hinge half (1). 1002-01O
Unscrew bolts for door hinge on A-pillar (5) and Observe intermediate
4
remove A-pillar hinge half (2). layers (arrows).
*BA72.10-P-
1003-01O
AR72.10-P-
6 Check adjustment of front door (3), correct if necessary.
0550GZ
Repair paint damage on screw heads with suitable
7
touch-up paint pen
FRONT DOOR
BA72.10-P-1002-01O Bolt, door hinge on front door Nm 32
BA72.10-P-1003-01O Bolt, door hinge on A-pillar Nm 32
REMOVE/INSTALL FRONT DOOR LOCK - AR72.10-P-4011GZ
MODEL 164
Fig. 41: Identifying Front Door Lock Components

Remove
AR72.10-P-
1 Remove door module (2)
0900GZ
Press rubber grommets (1) out of
2
door module (2)
Punch plastic bolts (3) out in
3 direction of door inside with Support door module (2) to prevent from bending
suitable punch
Remove door lock (4) from door
module (2)
Install
5 When clipping in door lock (4), hold door module (2)

Position door lock (4) on door to prevent door module (2) from bending.
module (2) and clip in With aid of helper. Door lock (4) should catch audibly
on clamping sleeves in door module (2)
When pressing in plastic bolts (3), a helper should
Press plastic bolts (3) into
press against the door lock (4) with a hammer handle
6 clamping sleeves in direction of
or similar object to prevent door module (2) from
door inside with suitable punch.
bending.
Press rubber grommets (1) into
7
door module (2)
AR72.10-P-
8 Install door module (2)
0900GZ

REMOVING AND INSTALLING FRONT DOOR LOCK CYLINDER - AR72.10-P-4015GZ
MODEL 164
Fig. 43: Identifying Front Door Lock Cylinder Components - Illustrated On Model 164.1
Remove/install
Pry off rubber grommet (1) and Fig.

1 Long wedge
reflector (2) 44
Installation: Do not excessively tighten the screw (3), otherwise
2 Loosen screw (3)
the lock cylinder (4) will be damaged.
The electrical connector is disconnected when the lock cylinder
3 Remove lock cylinder (4)
(4) is pulled out.

REMOVE/INSTALL INNER PANELING AT WINDOW FRAME OF FRONT DOOR - AR72.10-P-

6580GZ
MODEL 164
Fig. 45: Identifying Inner Paneling

Remove/Install
1 Remove front door lining AR72.10-P-1000GZ
2 Remove inner paneling (1) from window frame
REMOVE/INSTALL REAR DOOR MODULE - AR72.12-P-0103GZ
MODEL 164 (except 164.177)

Fig. 46: Identifying Rear Door Module Components - Shown On Model 164.1 (1 Of 2)
Fig. 47: Identifying Rear Door Module Components - Shown On Model 164.1 (2 Of 2)
Remove/install
Risk of injury due to hands being crushed Secure window to prevent it from AS67.00-Z-
when window glass is not secure falling down. 0002-01A
AR72.12-P-
1 Remove door lining from rear door
1010GZ
AR72.12-P-
2 Remove door handle from rear door
2410GZ
3 Open access opening cover (1)
The bonding surfaces must be free of

dust and grease, otherwise the crank

window could fall down and be
damaged.
Place a rag underneath to prevent
Close crank window partially (dimension A)
4 adhesive residue from falling on the
and secure with fabric adhesive tape (3)
paintwork.
Dimension (A) approx. 115 mm. Open
the crank window until the screw (2) in
the access opening becomes accessible.
It is not necessary to unscrew the bolt
5 Remove screw (2)
completely.
6 Remove screws (4)
Release and disconnect electrical connector (5)
7 from left rear door speaker (H4/3) or right rear
door speaker (H4/4)
Release and disconnect electrical connector (6)
8 from left rear power window motor (M10/5) or
right rear power window motor (M10/6)
Unclip wiring harness from clips (7) of door
9
module
11 Remove door module screws (9)
Release and disconnect electrical connector
12
(10, 11) from door lock
Pull out wiring harness through cable duct (12)
13
of door module (13)
14 Remove door module (13) on rear door
REMOVE/INSTALL REAR DOOR - AR72.12-P-0600GZ
MODEL 164
Fig. 48: Identifying Rear Door Components - Shown On Model 164.1

MODIFICATION NOTES
"Disconnect/connect ground line for battery" and "Perform basic programming Steps 1 and
26.7.06
eliminated" 9
Remove/install
Unlock locking tongue (2) of electrical
1 connector (1) with suitable screwdriver and
lift catch hook (3)
Press caps (4) off of screws (5) with
3
suitable screwdriver
Aid of helper is required for securing rear
door (6); rear door (6) can detach from
vehicle in uncontrolled manner and be
4 Remove screws (5)
damaged.
Installation: Repair paint damage on bolt
(5) with touch-up pencil.
*BA72.12-P-
1005-01K
Carefully remove rear door (6) from door
Remove rear door (6) from door hinges hinges with aid of helper and lay down on
upward and lay down on suitable suitable subsurface, otherwise the paint on
5
subsurface the rear door (6) can be damaged.
Check gaps on rear door (6), adjust if AR72.12-P-
7
necessary. 0650GZ
REAR DOOR
BA72.12-P-1005-01K Bolt on door hinge half connection Nm 10
ADJUST REAR DOOR - AR72.12-P-0650GZ
MODEL 164
Fig. 49: Identifying Rear Door Adjusting Components - Shown On Model 164.1
Inspecting, setting
Risk of injury caused by fingers being jammed When moving components, ensure AS00.00-Z-
or pinched when removing, installing or that no body parts or limbs are within
0011-01A
aligning hoods, doors, trunk lid/rear-end door or the operating range of moving parts.
sliding roof.
Check gap dimension of rear door to side roof *BE60.00-P-
2
frame (B1) on rear door 1001-01P
Check gap dimension of front door to rear door
(D), gap dimension of front door to rear door in *BE60.00-P-
3
area of B-pillar (E) on rear door and gap 1002-01P
dimension of door sill molding to rear door (F).
Check gap dimension of rear door to rear fender *BE60.00-P-
4
(H) on rear door 1003-01P
Check gap dimension of rear door to C-pillar (L) *BE60.00-P-
5
on rear door 1004-01P
Loosen bolts for door hinge on B-pillar (4) and *BE60.00-P-
6
adjust by moving rear door toward roof frame. 1001-01P
Check gap dimension of front door to rear door
(D), gap dimension of front door to rear door in *BE60.00-P-
7
area of B-pillar (E) and gap dimension of door 1002-01P
sill molding to rear door (F).
Adjust gap dimension of rear door to rear fender *BE60.00-P-
8
(H) 1003-01P
*BE60.00-P-
9 Adjust gap dimension of rear door to C-pillar (L)
1004-01P
*BA72.12-P-
10 Tighten bolts for door hinge on B-pillar (4)
1003-01K
Loosen bolts for door hinge on rear door (3) and The contour of the front door should
11 adjust transition between front door and rear be flush with the rear door and should
door by moving rear door not protrude more than 1 mm.
*BA72.12-P-
12 Tighten bolts for door hinge on rear door (3)
1002-01K
13 Install locking eye (1) Do not tighten down the bolts (2).
The contour of the rear door should be
Close rear door completely and, by moving the
flush with the contour of the rear
14 locking eye (1), adjust the transition between
fender or C-pillar and should not
rear door and rear fender and C-pillar
protrude more than 1 mm.
*BA72.12-P-
15 Tighten bolts (2)
1004-01K

Dimension
"A"
Dimension
"A1"
Dimension
Fender/engine hood mm 3.5 (±0.5) 3.5 (±1.0)
"B"
BE60.00-P- Gap
Rear door to side roof Dimension
1001-01P dimension mm 4.5 (±0.5) 4.5 (±1.0)
frame "B1"
Dimension
Front fender to front door mm 4.5 (±0.5) 4.5 (±1.0)
"C"

0700-01GZ 0700-01GZ
Dimension
"C1"
Dimension
"D"
Dimension
Rear-end door to D-pillar mm 5 (±1) 5.0 (±1.0)
"D1"
BE60.00-P- Gap
Front door to rear door in Dimension
1002-01P dimension mm 5 (±0.5) 5.0 (±1.0)
area of B-pillar "E"
Door sill molding to rear Dimension
mm 6 (±1) 6.0 (±1.0)
door "F"

0700-01GZ 0700-01GZ
Door sill molding to front Dimension"
mm 6 (±1) 6.0 (±1.0)
door G"
Dimension
"H"
Dimension
Front door to A-pillar mm 4.5 (±0.5) 4.5 (±1.0)
"I"
BE60.00-P- Gap
Dimension
1003-01P dimension Fender/side headlamps mm 4 (±1) 4.0 (±1.0)
"J"
Dimension
Engine hood to front grill mm 6 (±1.5) 6.0 (±1.0)
"K"

0700-01GZ 0700-01GZ
Dimension
"L"
Dimension
Engine hood to headlamp "M" mm 4 (±1) 4.0 (±1.0)

Dimension
Bumper/headlamps mm 4 (±1) 4.0 (±1.0)
"N"
Dimension
Front grill to bumper mm 6 (±1.5) -
BE60.00-P- Gap "O"
Taillamp to rear-end door mm 5 (±0.5) 5.0 (±1.0)
"P"

0700-01GZ 0700-01GZ
REAR DOOR
BA72.12-P-1002-01K Bolt, door hinge to rear door Nm 32
BA72.12-P-1003-01K Bolt, door hinge to B-pillar Nm 32
BA72.12-P-1004-01K Screw for striker eye on C-pillar Nm 28

REMOVE/INSTALL REAR DOOR LINING - AR72.12-P-1010GZ
MODEL 164
Shown on 164.1
Fig. 51: Identifying Rear Door Lining Components - Shown On 164.1

Remove/install
Fig.
1 Unclip trim strip (1) Long wedge
44
Fig.
2 Unclip cover (2) Long wedge
44
3 Remove bolts (3)
Position mounting wedge immediately next to
clips (5) and carefully pry off door lining. Do
4 Unclip door lining (4) from rear door
not damage door lining and paint.
Installation: Replace damaged clips.
Fig.
Mounting wedge
18
5 Remove Bowden cable (6) from door lining. Do not kink Bowden cable.
Disconnect electrical connector from left rear
7 power window switch (S20/1s3) or right rear Do not damage ribbon cable!
power window switch (S20/1s4)
8 Remove door lining.


REMOVE/INSTALL INNER PANELING ON REAR DOOR WINDOW FRAME - AR72.12-P-1012GZ
MODEL 164
Shown on 164.1
Fig. 54: Identifying Window Frame Paneling And Rubber Seal - Shown On 164.1
Remove/install
AR72.12-P-
1010GZ
Completely move down window in rear
2
door
Do not damage rubber seal (2) and paint.
Loosen window frame paneling (1) Installation: Ensure that window frame
3
from window frame and rubber seal paneling (1) and rubber seal (2) are seated
correctly.

REMOVE/INSTALL INNER SEALING RAIL ON REAR DOOR - AR72.12-P-1013GZ
MODEL 164

Fig. 56: Identifying Inner Sealing Rail And Rear Door - Shown On Model 164.1
Remove/install
AR72.12-P-
1010GZ
Uniformly pry off inner sealing rail to prevent
Pry inner sealing rail (1) off of rear bending.
2
door with mounting wedge Installation: Inner sealing rail should make
completely contact with inner door panel.

REMOVE/INSTALL OUTER SEALING RAIL ON REAR DOOR - AR72.12-P-1014GZ

MODEL 164
Fig. 58: Identifying Outer Sealing Rail And Rear Door - Shown On Model 164.1
Remove/install
1 Completely move down window in rear door
Uniformly pry off outer sealing rail to prevent
bending.
Pry outer sealing rail (1) off of rear door with
2 Do not damage paint.
mounting wedge
Installation: Ensure that outer sealing rail is
seated correctly
Fig.
Mounting wedge
18

REMOVE/INSTALL DOOR SEALING FRAME ON REAR DOOR - AR72.12-P-1015GZ
MODEL 164
Fig. 60: Identifying Rear Door And Window Frame Paneling

Remove
Loosen window frame paneling (2) from AR72.12-P-
Completely remove door sealing frame
3
(arrows) form rear door (1)
Remove sealing and glue residues from rear Dia. 100 mm eraser disc with mounting *WH58.30-Z-
4
door (1) with eraser disc shaft 1037-04A
*WE58.40-Z-
1001-03A
Remove sealing and glue residues from rear At points on rear door (1) which are not
5
door (1) with plastic scraper accessible with erase disc
Gluing surface must be free of grease
6 Clean gluing surface on rear door (1)
and dust
*BR00.45-Z-
Cleaner
1025-04A
Install
Glue door sealing frame (arrows) onto rear
7 Roller Fig. 33
door (1)
Clip window frame paneling (2) into AR72.12-P-
Remove dirt from rear door (1) and in area
10
of entry



Number Designation
WH58.30-Z-1037- Removal disk, 100 mm dia. with fixing shank, Firma 3M Deutschland GmbH D-
04A 41453 Neuss
WORKSHOP EQUIPMENT
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL ARMREST ON REAR DOOR - AR72.12-P-1020GZ
MODEL 164
Fig. 63: Identifying Armrest Components On Rear Door - Shown On Model 164.1
Remove
Put down rear door lining (1) on suitable AR72.12-P-
1 Remove rear door lining (1)
subsurface to prevent damage 1010GZ
Loosen sound deadening mat (2) from
2 rear door lining (1) and fold over until
rear door lining (1)
armrest (3) is accessible.
When initially removing armrest (3).
Number of plastic spot welds (arrows)
can vary depending on model series.
Drill out plastic spot welds (arrows) in
Work carefully to prevent damage to flat
3.1 armrest (3) with suitable bit and remove
ribbon cables
plastic residues from rear door lining (1)
*WH58.30-Z-
1007-20A
Bend open clamping plates (4) with When removing armrest (3) a second
3.2
4 Remove armrest (3)
Install
5 Install armrest (3)
Use 10 mm socket. Clamping plates (4)
Press clamping plates (4) over pins (5) of should make firm contact with rear door
6
armrest (3) lining (1).
Fasten sound deadening mat (2) to rear Position gluing points and press on sound
7
If required, shorten pins (5) of armrest AR72.12-P-
8 Install rear door lining (1)
(3) with suitable tool 1010GZ

Number Designation
REMOVE/INSTALL DOOR POCKET ON REAR DOOR - AR72.12-P-1021GZ
MODEL 164
Fig. 64: Identifying Door Pocket Components On Rear Door

Remove
AR72.12-P-
1010GZ
Remove exit lamp from door pocket with
2
suitable tool.
Disconnect electrical connector from exit
3
lamp
Loosen sound deadening mat (2) from
4 rear door lining (1) until plastic spot
rear door lining (1)
welds in door pocket (4) are accessible
Loosen clips (7) and remove speaker cover AR72.10-P-
5
(3) 1032GZ
Drill out plastic spot welds (arrows) in When initially removing door pocket (4).
door pocket (4) with suitable bit and Do not operate at excessive speed
6.1
remove plastic residues from rear door because the plastic becomes too hot,
lining (1) melts and galls the bit
*WH58.30-Z-
1007-20A
Bend open clamping plates (6) with When removing door pocket (4) a second
6.2
Install
8 Install door pocket (4)
Use 10 mm socket wrench. The clamping
plates (6) should make firm contact with
Press clamping plates (6) over pins (5) of
9 rear door lining (1).
door pocket (4)
Installation: Replace clamping plates
(6).
AR72.10-P-
10 Install speaker cover (3) Ensure that clips (7) are seated correctly
1032GZ
Fasten sound deadening mat (2) to rear Position gluing points and press on sound
11
12 Connect electrical connector of exit lamp.
13 Install exit lamp
Shorten pins (5) with suitable tool, if AR72.12-P-
14 Install rear door lining (1)
required. 1010GZ

Number Designation
ASSEMBLE/DISASSEMBLE DOOR LINING IN REAR DOOR - AR72.12-P-1040GZ
MODEL 164
Shown on left rear door
Fig. 65: Identifying Door Lining Components - Shown On Left Rear Door
Remove/Install
Lay rear door lining (1) front side down on AR72.12-P-
suitable subsurface to prevent damage 1010GZ
Remove sound deadening mat from rear Installation: Position gluing points and
2
door lining (1) fasten sound deadening mat
AR72.12-P-
3 Remove trim strip (2).
1050GZ
AR72.12-P-
2310GZ
Remove left rear power window switch AR72.29-P-
5
(S21/3) 0002GZ
Unclip left rear door entrance/exit lamp Treat ribbon cable carefully to prevent
6
(E17/5) and disconnect from connector damage
When the door pocket (6) is removed, the
AR72.12-P-
7 Remove door pocket (6) speaker cover (5) should be removed as
1021GZ
well.

REMOVE/INSTALL TRIM STRIP ON FRONT DOOR LINING - AR72.12-P-1050GZ
MODEL 164
Shown on left rear door lining
Fig. 67: Identifying Trim Strip Components - Shown On Left Rear Door Lining
Remove/install
Remove door lining (1) from rear Lay door lining (1) front side down on suitable AR72.12-P-
1
door subsurface to prevent damage 1010GZ
Fold over sound deadening mat until sheet metal
2 Unscrew sheet metal nuts (2)
nuts (2) are accessible.
Lift door lining (1) and remove Installation: Ensure that trim strip (3) is seated
3
trim strip (3) correctly on door lining (1).
REMOVE/INSTALL WINDOW GUIDE RAIL FOR REAR DOOR - AR72.12-P-1500GZ
MODEL 164

Fig. 68: Identifying Window Guide Rail Components For Rear Door - Shown On Model 164.1
Remove/install
1 Completely lower crank window
Pull out of window guide rail only
2 Pull window guide seal (1) out of window frame Installation: Apply lubricant to
ends of window guide rail (1).
*BR00.45-Z-
Antifriction agent
1010-06A
AR72.12-P-
1010GZ
4 Remove screw (2)
5 Remove cover (3).
Work carefully to prevent bolt from
6 Unscrew bolt (4)
falling into inner door.
Avoid paint damage.
Carefully tilt window guide rail (5) in direction
7 Installation: Apply lubricant to
of B-pillar at top and remove upward
window guide rail (5).
*BR00.45-Z-
Antifriction agent
1010-06A
REPAIR MATERIALS
REMOVE/INSTALL CRANK WINDOW IN REAR DOOR - AR72.12-P-1910GZ
MODEL 164

Fig. 69: Identifying Crank Window Components In Rear Door - Shown On Model 164.1
Remove/install
Risk of injury due to hands being crushed Secure window to prevent it from falling AS67.00-Z-
when window glass is not secure down. 0002-01A
AR72.12-P-
1 Remove window guide seal
1911GZ
AR72.12-P-
1010GZ
AR72.12-P-
3 Remove window guide rail
1500GZ
4 Open access opening cover (3)
By actuating power window switch on front
door.
Dimension A approx. 115 mm (measured
5 Partially close crank window (1).
from top edge of window frame).
Open crank window (1) until bolt (4) in
access opening is accessible.
Unclip inner paneling on window frame
(2) from rear door with mounting wedge.
7 Unscrew bolt (4)
Carefully remove crank window (1) from
rear door to prevent damaging crank
8 Remove crank window (1) from rear door window (1)
Installation: The crank window (1) should
make contact in window mount (5).

REMOVE/INSTALL SEALING FOR CRANK WINDOW ON REAR DOOR - AR72.12-P-1911GZ
MODEL 164
Fig. 71: Identifying Window Guide Seal - Illustrated On Model 164.1

Remove/install
1 Completely lower crank window
Pull window guide seal (1) out of Installation: Apply lubricant to both ends
2
window frame (arrows) of window guide seal (1)
*BR00.45-Z-
Antifriction agent
1010-06A
REPAIR MATERIALS
REMOVE/INSTALL FIXED WINDOW IN REAR DOOR - AR72.12-P-1970GZ

MODEL 164
Fig. 72: Identifying Fixed Window - Shown On Model 164.1

Remove/install
AR72.12-P-
1010GZ
Remove outer window guide seal from Only in working area. AR72.12-P-
3
window guide rail. Installation: Use liquid lubricant. 1911GZ
*BR00.45-Z-
Antifriction agent
1010-06A
AR72.12-P-
4 Remove window guide rail
1500GZ
Model 164.1
Pull stationary window (1) toward front out of
5.1 Installation: Apply lubricant to seal
rear door.
(arrows) of stationary window (1).
*BR00.45-Z-
Antifriction agent
1010-06A
Model 164.8
Installation: Ensure that seal is
Pull stationary window (1) toward front out of seated correctly in stationary
5.2
rear door, tilt toward outside and remove. window.
Installation: Apply lubricant to seal
(arrows) of stationary window (1).
*BR00.45-Z-
Antifriction agent
1010-06A
REPAIR MATERIALS
REMOVE/INSTALL INSIDE DOOR OPENER ON REAR DOOR - AR72.12-P-2310GZ
MODEL 164
Fig. 73: Identifying Inside Door Opener - Shown On Model 164.1

Shown on vehicle with interior lights package, code 876
Fig. 74: Identifying Inside Door Opener Components On Rear Door - Shown On Vehicle With Interior
Lights Package
Fig. 75: Identifying Catch Lugs And Guides

Remove/install
1 Completely move down rear window to left or right side See Operator's Manual
AR72.12-P-
2 Remove trim strip from rear door lining
1050GZ
Loosen sound deadening mat (2) until inside door opener Installation: Glue on
3
is accessible sound deadening mat (2)
Disconnect electrical connector from left rear inside door Only on vehicles with
4.1 handle illumination (E17/13) or right rear inside door interior lights package,
handle illumination (E17/14) code 876
5 Remove screw (3)
6 Unclip clips (4)
7 Remove handle recess toward front
8 Loosen catch lugs (5) guides (6) are seated
correctly.
REMOVE/INSTALL OUTER REAR DOOR HANDLE - AR72.12-P-2410GZ
MODEL 164
Shown on vehicle with Keyless Go, code 889

Fig. 76: Identifying Outer Rear Door Handle Components - Shown On Vehicle With Keyless Go
Fig. 77: Identifying Outer Rear Door Handle Components


Fig. 78: Identifying Underlay - Shown On Model 164.1

Fig. 79: Identifying Door Handle

Remove
1 Remove cover (4).
It is not possible to unscrew the bolt completely (5)
when the guide (6) is installed; bolt serves as clamping
Loosen bolt (5) and pull out
2 bolt. It can only be turned a few turns!
guide (arrow C)
Loosen guide (6): When the bolt (5) is turned
counterclockwise (arrow), the guide (6) is loosened.
Slightly slide door handle (7)
3 toward rear (arrow D) and then Do not damage paint!
remove (arrow E).
4.1 On vehicles with Keyless Go, code 889.
(2)
Install
Ensure that subsurfaces (1, 3)
The subsurface (1, 3) should be fastened properly with
5 are seated correctly and in
fastening lugs (arrows F and G).
proper state
Connect electrical connector
6.1 On vehicles with Keyless Go, code 889.
(2)
Ensure that the door handle is inserted correctly
(arrow J), otherwise the door handle cannot be moved
Insert door handle (arrow H) toward front far enough for installation.
7
and slide toward front (arrow I) Do not damage paint!
Ensure that the subsurface (1, 3) does not move when
inserting the door handle.
Completely screw bolt (5) into
8 guide (6) and insert guide into
door handle.
Fasten guide (6) and tighten
Fastening guide (6): When the bolt (5) is turned
9 bolt (5) with correct tightening
clockwise (arrow B), the guide is tensioned (6).
torque.
*BA72.12-P-
1001-01K
10 Install cover (4) Ensure that the cover is positioned correctly.
REAR DOOR
BA72.12-P-1001-01K Bolt for clamping guide in door handle mechanism Nm 3
REMOVE/INSTALL REAR-END DOOR LOCK - AR72.20-P-2550GZ
MODEL 164
Fig. 80: Identifying Rear-End Door Lock Components - Shown On Model 164.1
Fig. 81: Identifying Rear-End Door Lock Components - Shown On Model 164.8
Remove/install
1 Remove door lining on rear-end door AR72.20-P-3520GZ
2 Unclip release cable (1) from inner lock (2).
3.1 Drill out rivets (3) with dia. 6 mm drill bit
Only on right side
*WH58.30-Z-1003-
Hand riveter
29A
Rechargeable drill / *WH58.30-Z-1007-
screwdriver 20A
Pivot inner lock (2) out of working area (arrow)
and secure.
*BA72.20-P-1007-
5 Unscrew bolts (4) from rear-end door lock (5).
02J
Disconnect electrical connector (6) from rear-end
6
door lock (5).
7 Remove rear-end door lock (5)
AR68.30-P-
8 Remove door sill molding (load compartment).
4100GZA
9 Unscrew bolts (7) from locking eye (8) Mark installed position.
*BA72.20-P-1006-
02J
Check
12 Check gaps on rear-end door If necessary: ?
Adjust rear-end door AR72.20-P-3510GZ
REAR-END DOOR
BA72.20-P-1006-02J Bolt, locking eye to body Nm 11
BA72.20-P-1007-02J Bolt, door lock to rear-end door Nm 11

Number Designation
REMOVE/INSTALL REAR-END DOOR HINGE - AR72.20-P-2560GZ
MODEL 164
Shown on model 164.1, left hinge, vehicles with automatic rear-end door, code 890
Fig. 82: Identifying Rear-End Door Hinge Components - Shown On Model 164.1
Remove/install
Risk of injury caused by fingers being jammed When moving components, ensure
or pinched when removing/installing or aligning that no body parts or limbs are AS00.00-Z-
hoods, doors, trunk lid/rear-end door or sliding within the operating range of 0011-01A
roof. moving parts.
AR68.30-P-
1 Remove headliner
4300GZ
3 Remove frame seal (2) from body flange

5 Press cover (4) to side
Install suitable protective layer
Mark installation position of hinge (1) on rear-end
6 between rear spoiler and roof to
door and roof frame.
prevent paint damage.
Unscrew bolts (6) and remove left rear surround
7
speaker (H4/54)
Support rear-end door with aid of
8 Unscrew nuts (7).
second mechanic.
*BA72.20-P-
1008-02J
Support rear-end door with aid of
second mechanic.
9 Unscrew bolts (5) and remove hinge (1). Installation: Repair paint damages
on screw heads with corresponding
touch-up paint pen
*BA72.20-P-
1005-02J
Check
11 Check gaps on rear-end door If necessary: ?
AR72.20-P-
Adjust rear-end door
3510GZ
REAR-END DOOR
BA72.20-P-1005-02J Bolt, door hinge to rear-end door Nm 34
BA72.20-P-1008-02J Nut, rear-end door hinge to body Nm 34

REMOVE/INSTALL REAR-END DOOR - AR72.20-P-3500GZ

MODEL 164
Shown on model 164.1 with Keyless Go, code 889 and automatic rear-end door, code 890
Fig. 84: Identifying Rear-End Door Components - Shown On Model 164.1 With Keyless Go
Remove/install
jammed or pinched when removing/installing AS00.00-Z-
Switch off ignition and remove transmitter key
1 off. Remove transmitter key from
from EIS control unit
vehicle and store it in a location
beyond its transmission range (at least
2 m).
AR72.20-P-
2 Remove liner on rear-end door
3520GZ
AR82.35-P-
3 Remove rear-end door spray nozzle
6920GZ
4 Unclip water drain hose (1) from clips (2).
5 Loosen nuts on ground, rear-end door (W8)
Disconnect electrical connector from rear
7
window antenna FM amplifier (A2/19)
Disconnect electrical connector from rear-end
9
door wiper motor (M6/4)
Disconnect electrical connector from rear-end
door handle switch (S88/9), rear-end door
Keyless Go button (S62/21), left rear-end door
10
license plate lamp (E19/3), right rear-end door
license plate lamp (E19/4) and electrical
connector (11).
11 Unclip wiring harness from metal clip (12).
12 Unclip plastic clip (13).
Guide water fluid hose through opening (14) at
13
left
Guide wiring harness through opening (14) at
14
left
Ensure that rubber grommets are not
Guide wiring harness through opening (15) at
15 damaged to prevent damage from
right
water entry.
Loosen gas-operated strut only at top. AR72.20-P-
16 Remove gas-operated strut for rear-end door
Secure rear-end door. 3600GZ
Only on vehicles with automatic rear-
17.1 Loosen bolts (16)
end door, code 890.
Repaint visible surfaces on bolts (17)
18 Loosen bolts (17)
to prevent damage.
*BA72.20-
P-1005-02J
19 Remove rear-end door With aid of helper!
AR72.20-P-
21 Adjust rear-end door
3510GZ
REAR-END DOOR
BA72.20-P-1005-02J Bolt, door hinge to rear door Nm 34
ADJUST REAR-END DOOR - AR72.20-P-3510GZ

MODEL 164
Fig. 85: Identifying Rear-End Door Adjusting Components - Shown On Model 164.1 With Automatic
Rear-End Door, Code 890
Adjust on door hinge

jammed or pinched when removing/installing AS00.00-Z-
the operating range of moving parts.
AR68.30-P-
4100GZA
2 Loosen bolts (1) from left and right door hinge
3 Loosen bolts (2) at locking eye (3)
4 Screw in stops (4)
Top edge of rear-end door should be
flush with outer skin of the roof (W).
5 Adjust rear-end door on hinges Simultaneously maintain gap
dimensions, see:
?
Gap dimensions on hoods, doors and AR60.00-P-
lids 0700-01GZ
*BE60.00-P-
Gap dimension 1006-01P

Repair paint damages on screw heads
6 Tighten bolts (1) on hinges
with suitable touch-up paint pen.
*BA72.20-P-
1005-02J
Adjust locking eye
Rear-end door should be flush with
fender edges (U). Simultaneously
7 Adjust rear-end door by moving locking eye (3)
maintain gap dimensions, see:
?
Gap dimensions on hoods, doors and AR60.00-P-
lids 0700-01GZ
*BE60.00-P-
Gap dimension
1006-01P
*BA72.20-P-
8 Tighten screws (2) on locking eye (3)
1006-02J
Slight deviations in the position of the
rear-end door relative to the rear
9 Adjust stops (4) by turning.
fender can be compensated by
adjusting the stop.
Only on vehicles with automatic rear-
end door, code 890.
An air gap must be present to ensure
proper function of the automatic rear-
Check air gap between rear-end door and
end door.
10.1 obstruction sensor strips over entire length of
Check air gap: Pull thick sheet of
obstruction sensor strip.
paper between obstruction sensor
strip and rear-end door over entire
length.
On both sides of vehicle.
AR68.30-P-
11 Install door sill molding (load compartment).
4100GZA

mm - 5.0 (±1.0)
D-pillar "D1"
Dimension
for glass mm 5 (±1) 5.0 (±1.0)
BE60.00-P- Gap "U"
1006-01P dimension Rear door to Dimension
mm 8 (±1.5) 8.0 (±1.5)
bumper "V"
Antenna cover
Dimension
on roof mm 5 (±2) 6.0 (±2.5)
"W"
Dimension
mm 8 (±0,5) 6.0 (±1.0)
"W"
on rear-end door
AR60.00-P-0700- AR60.00-P-0700-
See picture
01GZ 01GZ
REAR-END DOOR
BA72.20-P-1005-02J Bolt, door hinge to rear door Nm 34

REMOVE/INSTALL REAR-END DOOR LINING - AR72.20-P-3520GZ
MODEL 164

Fig. 87: Identifying Rear-End Door Lining Components - Shown On Model 164.1 (1 Of 2)
Fig. 88: Identifying Rear-End Door Lining Components - Shown On Model 164.1 (2 Of 2)
Remove/install
Danger of breakage or tearing off plastic trim
Removal
parts and associated mounting clips.
Unclip upper door lining paneling (1) from mounting Fig.
1 clips (2) and remove Mounting wedge 18

2 Remove screws (4)
Pull side door lining paneling (3)
downward (arrow A) and pull out of
3 Unclip side door lining paneling (3) and remove
rear-end door toward front (arrow
B).
Fig.
Mounting wedge
18
Start at right and left side with
4 Unclip bottom door lining paneling (5) mounting clips (6), then unclip
locking tabs (7).
Fig.
Mounting wedge
18
Disconnect electrical connector (8) and remove
5
bottom door lining paneling downward (5).
Unclip rear-end door ambient light (E40/1) from
center door lining paneling (9), disconnect electrical
6
connector (11) and remove rear-end door ambient
light (E40/1)
Start unclipping at right and left
7 Unclip center door lining paneling (9) side. Directly move mounting
wedge to mounting clips (12).
Fig.
Mounting wedge
18
Installation: Replace mounting
8 Remove center door lining paneling (9)
clips (12).

REMOVE/INSTALL REAR-END DOOR WEATHERSTRIPPING - AR72.20-P-3540GZ
MODEL 164

Fig. 90: Identifying Weatherstripping, Weatherstripping Seam And Locking Eye - Shown On Model
164.1 With Automatic Rear-End Door
Remove
AR68.30-P-
4100GZA
2 Remove weatherstripping (1) from body flange
Install
Do not use lubricant, otherwise
leaktightness cannot be
3 Install weatherstripping (1) on body flange guaranteed.
Align weatherstripping seam
(2) with locking eye (3).
Check whether weatherstripping (1) is seated correctly, if
4 necessary lift weatherstripping lip (1) over paneling on Long wedge Fig. 44
D-pillar and headliner with clean long wedge.
AR68.30-P-
5 Install door sill molding (load compartment).
4100GZA

REMOVE/INSTALL GAS-OPERATED STRUT TO REAR-END DOOR - AR72.20-P-3600GZ
MODEL 164
Fig. 92: Identifying Retainer, Upper Ball Head, Bottom Ball Head And Gas-Operated Strut - Shown On
Model 164.1
Remove/install
Injury hazard Gas-operated struts are Only remove and install gas-operated struts
AS00.00-Z-
under high pressure and can pinch and crush in the relaxed position and when the
0012-01A
body parts during work components are secured properly.
Installation : Check retainer and replace if
2 Lift retainer (1) on upper ball head (2).
damaged.
Installation : First insert retainer into ball
3 Pull off upper ball head (2).
head, then press on ball head.
Installation : Check retainer and replace if
4 Lift retainer (1) at lower ball head (3).
damaged.
Installation : First insert retainer into ball
5 Remove lower ball head (3).
head, then press on ball head
Risk of injury caused by drilling gas-filled
AS00.00-Z-
assemblies or components (noncombustible Wear safety glasses and a face mask.
0006-01A
gases)
When replacing gas-operated strut, dispose

6 Remove gas-operated strut (4)
of gas-operated strut (old part).
OS00.00-P-
Degas and drain gas-operated strut
1001-01A

REMOVE/INSTALL POSITION SENSOR FOR AUTOMATIC REAR-END DOOR - AR72.20-P-

3602GZ
MODEL 164 with CODE (890) Automatic tailgate

Fig. 94: Identifying Position Sensor Components For Automatic Rear-End Door - Shown On Model 164.1
Remove/install
or crushed when removing, installing or Keep body parts and limbs well clear AS00.00-Z-
aligning hoods, doors, trunk lids, tailgates or of moving parts. 0011-01A
sliding roof.
Model 164.1
1.1 Turn key in ignition switch to position "0". 889: Press keyless go start/stop button
off
AR54.10-P-
1.2 Disconnect battery ground line Model 164.8
0003GZ
AR68.30-P-
2 Remove headliner
4300GZ
AR72.20-P-
3 Remove right gas-operated strut Support rear-end door.
3600GZ
Support Fig. 83
*BA72.20-P-
4 Unscrew ball pivot (7)
1004-02J
5 Remove bolts (1) *BA72.20-P-
1002-02J
Unclip rescue line (2) for windowbag from clip
6.1 Model 164.1
(3).
AR91.60-P-
6.2 Remove right windowbag Model 164.8
0693GZ
7 Unscrew bolt (5), remove bracket (6). Only on model 164.1
*BA72.20-P-
1003-02J
8 Remove windowbag bracket from roof frame Only on model 164.8
10 Remove cable straps (9) Installation: Install new cable straps.
11 Remove foam material (10) If present.
12 Unclip line from clips (13).
*BA72.20-P-
13 Remove bolts (4)
1001-02J
Pull hydraulic cylinder through passage (11) in It is not necessary to remove the
14
roof grommet
Pry position sensor (12) off of hydraulic
cylinder and opening lever
16 Remove position sensor (12).
AR00.19-P-
18 Perform basic programming Only on model 164.8
0200GZ
Check pinch protection for proper
function to prevent personal injury.
TAILGATE
BA72.20-P-1002-02J Bolt for hydraulic cylinder to body Nm 23
BA72.20-P-1003-02J Bolt, luggage net bracket to body Nm 23
BA72.20-P-1004-02J Ball stud to body Nm 19


REMOVE/INSTALL AUTOMATIC REAR-END DOOR HYDRAULIC UNIT - AR72.20-P-3604GZ
Fig. 97: Identifying Automatic Rear-End Door Hydraulic Unit Components - Shown On Model 164.1 (1
Of 3)
Of 3)
Of 3)
Remove/install
pinched or crushed when removing, installing Keep body parts and limbs well clear AS00.00-Z-
or aligning hoods, doors, trunk lids, tailgates or of moving parts. 0011-01A
sliding roof.
Model 164.1
889: Press keyless go start/stop

1.1 Turn key in ignition switch to position "0". button repeatedly until ignition is
switched off
AR54.10-P-
1.2 Disconnect battery ground line Model 164.8
0003GZ
AR68.30-P-
2 Remove headliner
4300GZ
3.1 Remove bolts (10) Model 164.1
*BA91.60-P-
1006-01H
AR91.60-P-
3.2 Remove right windowbag Model 164.8
0693GZ
4.1 Unclip check strap (7) form clip (8) Model 164.1
Remove windowbag mount through side
4.2 Model 164.8
window
Remove gas-operated strut from rear-end door AR72.20-P-
5 Support rear-end door.
on right 3600GZ
Support Fig. 83
*BA72.20-P-
6 Unscrew ball pivot (9)
1004-02J
*BA72.20-P-
7 Remove bolts (1)
1002-02J
Only on model 164.1 with keyless
Remove keyless go control unit with bracket go, code 889 AR80.35-P-
8
and remove from working area Do not disconnect Keyless Go 0001GZ
control unit electrically.
9 Unscrew bolts (2), remove sheet metal cover Only on model 164.1
10 Unscrew bolt (4), remove bracket (5). Only on model 164.1
*BA72.20-P-
1003-02J
*BA91.60-P-
11 Unscrew bolt (6)
1005-01H
13 Unclip hydraulic lines from clips (13, 14)
*BA72.20-P-
14 Remove bolts (3)
1001-02J
It is not necessary to remove the
15 Guide hydraulic arm through opening (11)
grommet
Remove spare wheel, remove paneling for spare AR68.30-P-
16.1 On vehicles with spare wheel.
wheel recess 4620GZ
Remove stowage compartment below load
16.2 On vehicles with Tirefit.
compartment floor
Unclip cover, unscrew bolt (15) below, remove
17 Only on model 164.1
D-ring (16).
*BA68.50-P-
1002-03F
18 Remove bolts (17) Only on model 164.1
*BA68.50-P-
1003-03F
19 Remove screw (18) Only on model 164.1
Remove rear bolt from retaining panel for side So that it is possible to remove
20
paneling hydraulic lines later
21 Remove foam insert (20). Depending on equipment version.
22 Unclip electrical line from clips (21). Only on model 164.8
Unclip clip (23) from rear-end door control unit
24
(N111)
Remove rear-end door control unit (N111) from
25
working area
26 Open clips (24)
27 Open hydraulic pump housing (25)
If applicable, disconnect cable strap
or connectors to remove hydraulic
lines.
28 Remove hydraulic pump unit (26)
On model 164.1: Lift longitudinal
member cover (19), unthread
hydraulic hoses.
AR00.19-P-
30 Perform basic programming Only on model 164.8
0200GZ
Check pinch protection for proper
function to prevent injury.
CARGO RETAINERS
BA68.50-P-1002-03F Bolt, anchoring lug to luggage compartment floor Nm 24
BA68.50-P-1003-03F Bolt, longitudinal member cover to body Nm 24
TAILGATE
BA72.20-P-1002-02J Bolt for hydraulic cylinder to body Nm 23
AIRBAG
BA91.60-P-1005-01H Bolt of bracket for windowbag check strap to body Nm 8

BA91.60-P-1006-01H Bolt, windowbag to body Nm 8

REMOVE/INSTALL REAR DOOR CLOSING SYSTEM SWITCH - AR72.20-P-3605GZ
MODEL 164 with CODE (890) Automatic rear-end door
Fig. 101: Identifying Lower Paneling And Close Rear Door Button
Remove/Install
Remove only lower AR72.20-P-
1 Remove door lining on rear-end door
paneling (1). 3520GZ
Unclip close rear door button (2) from lower paneling
2
(1) and remove
REMOVE/INSTALL REAR-END DOOR HANDLE STRIP/TAILGATE HANDLE MOLDING -

AR72.20-P-3650
Remove/install rear-end door handle strip - AR72.20-P-3650GZ
MODEL 164
Outer rear-end door handle strip

Fig. 102: Identifying Rear-End Door Handle Strip Components - Shown On Model 164.1
Remove/install
AR72.20-P-
1 Remove door lining on rear-end door
3520GZ
From inner side of
2 Unscrew nuts (2) from handle strip (1).
rear-end door
From outer side of
3 Unscrew bolts (3) from handle strip (1).
rear-end door
Disconnect electrical connector from left rear-end door license
4 plate lamp (E19/3au) and right rear-end door license plate lamp
(E19/4)
Risk of breakage! Do
5 Remove handle strip (1)
not scratch paint.
Remove/install tailgate handle molding - AR72.20-P-3650GZA
MODEL 164
Inner tailgate handle

Fig. 103: Identifying Electrical Connectors, Nuts And Handle - Shown On Model 164.1 With Keyless Go,
Code 889
Remove/install
1 Remove liner on tailgate AR72.20-P-3520GZ
2 Disconnect electrical connectors (1) from handle (3).
3 Unscrew nuts (2) and remove handle (2)
REMOVE/INSTALL REAR DOOR CLOSING CONTROL MODULE - AR72.20-P-7551GZ
Fig. 104: Identifying Rear Door Closing Control Module Components - Shown On Model 164.1
MODIFICATION NOTES
Remove/install

AH54.00-P-
0001-01A
discharge
1 Open tailgate
Set up load compartment floor (1) and
2
secure against folding down.
Loosen clips (3) and remove stowage Installation: Stowage box (2) should run
3
box (2) below trunk sill cover (4)
4 Disconnect electrical connectors (5)
Removal: Press clip (6) to side (arrow)
Unclip rear-end door closing control unit Installation: Ensure that rear-end door closing
5
(N121/1) and remove from bracket (8) control unit (N121/1) is seated correctly in
brackets (7).
Synchronize rear door closing control Only when replacing rear-end door closing
7
module (N121/1) control unit (N121/1).
REMOVE/INSTALL SWITCHES FOR REAR DOOR POWER WINDOWS - AR72.29-P-0002GZ
MODEL 164
Fig. 105: Identifying Switches Components For Rear Door Power Windows
Remove/Install
AR72.12-P-
1010GZ
Slightly loosen insulating mat in area of left rear power
Loosen insulating mat
2 window switch (S21/3) or right rear power window switch
carefully to prevent damage
(S21/4)
Pull electrical connector (2) through loosened insulating
3
mat
4 Remove bolt (3)
Installation: Do not tighten
bolt (3) too tightly

Unlock clip (4) and remove left rear power window switch
5
(S21/3) or right rear power window switch (S21/4)
REMOVE/INSTALL FRONT DOOR POWER WINDOW SWITCH - AR72.29-P-0100GZ
MODEL 164
Switch in front passenger door
Fig. 106: Identifying Front Door Power Window Switch Components

Remove/install
Lay door lining front side down on AR72.10-P-
suitable subsurface to prevent damage! 1000GZ
Disconnect electrical connector from right
2 Do not damage ribbon cable
front power window switch (S20/1s2)
3 Remove screw (1)
Unclip right front power window switch
4
(S20/1s2) from catch lug (2)
Remove right front power window switch
5
(S20/1s2) toward front
REMOVE/INSTALL FRONT DOOR POWER WINDOW SWITCH GROUP - AR72.29-P-0110GZ
MODEL 164

Fig. 107: Identifying Front Door Power Window Switch Components - Shown On Model 164.1
Remove/install
Driver side.
Lay door lining front side down on AR72.10-P-
suitable subsurface to prevent 1000GZ
damage!
Treat ribbon cable carefully to
prevent damage
Treat ribbon cable carefully to
prevent damage
3 Unscrew bolt (2)
On model 164.8, the right bolt is
located below a ribbon cable bracket.
Loosen clips (3), remove driver power window
4 and outside mirror adjustment switch group
(S20/1)
REMOVE/INSTALL AUTOMATIC REAR-END DOOR SWITCH - AR72.29-P-0130GZ
MODEL 164 with CODE (890) Automatic rear-end door

Fig. 108: Identifying Automatic Rear-End Door Switch Components

Remove/Install
AR72.10-P-
1 Remove door lining on front door
1000GZ
Carefully treat flat lead to
2 Disconnect electrical connector (1).
prevent damage
3 Unscrew bolt (2).
Remove driver-side opening and closing rear-end
4
door switch (S15/3)
REMOVE/INSTALL FRONT DOOR CONTROL UNIT - AR72.29-P-1000GZ
MODEL 164
Fig. 109: Identifying Front Door Control Unit Components

MODIFICATION NOTES
Remove/install
Connect STAR DIAGNOSIS and read out basic
When replacing left front door
data from left front door control unit (N69/1) or
1 control unit (N69/1) or right front
right front door control unit (N69/2) with STAR
door control unit (N69/2).
DIAGNOSIS and store intermediately
memory 2000-04A
system
Installation: Transfer buffered *WH58.30-Z-
basic data to left front door control 1048-13A

unit (N69/1) or right front door
control unit (N69/2)
Removal: Do not disconnect door
lining electrically, because it is AR72.10-P-
2 Remove door lining from left or right front door
necessary to move up the crank 1000GZ
window.
Electrically disconnect door lining from left or right
3
front door
Disconnect electrical connectors (2) from left front
4 door control unit (N69/1) or right front door control
unit (N69/2)
*WH58.30-Z-
5 Drill out rivets (3) with 4.5 mm dia. bit Cordless drill/driver
1007-20A
*WH58.30-Z-
Hand riveter
1003-29A
Remove left front door control unit (N69/1) or right
6 front door control unit (N69/2) from door module
(1)
Completely remove rivet residues
Remove left front door speaker (H4/5) or right front AR82.62-P-
7 from door to prevent corrosion
door speaker (H4/6) 7845GZ
damage.

Number Designation
REMOVE/INSTALLING FRONT DOOR POWER WINDOW MOTOR - AR72.29-P-1860GZ
MODEL 164

Fig. 110: Identifying Front Door Power Window Motor Components - Illustrated On Model 164.1
Remove/install
AR72.10-P-
1000GZ
3 Unscrew bolt (2)
Installation: Lubricate gears (arrow) on
Press off left front power window motor
left front power window motor (M10/3)
4 (M10/3) or right front power window motor
or right front power window motor
(M10/4) from door module (3) and remove
(M10/4)
*BR00.45-Z-
Lock cylinder grease spray 50 ml
1012-06A
Normalize left front power window motor
Hold down power window switch for at
(M10/3) or right front power window motor
6 least 1 s in corresponding end position of
(M10/4) by completely opening and closing
crank window.
crank window.

REPAIR MATERIALS
BR00.45-Z-1012-06A Lock cylinder grease spray 50 ml A 002 989 06 51
REMOVE/INSTALL POWER WINDOW MOTOR IN REAR DOOR - AR72.29-P-1880GZ
MODEL 164
Fig. 112: Identifying Power Window Motor Components In Rear Door - Shown On Model 164.1
Remove/install
AR72.12-P-
1010GZ
2 front power window motor (M10/5) or right
front power window motor (M10/6)
Secure left rear power window motor or
3 Unscrew bolt (2) right rear power window motor against
falling down..
Pry left rear power window motor or right Installation: Lubricate gear (arrow) for
4 rear power window motor off of door left rear power window motor or right rear
module with mounting wedge. power window motor before installation.
*BR00.45-Z-
Lock cylinder grease spray 50 ml
1012-06A
Normalize left rear power window motor or The normalization procedure is described AR00.19-P-
6
right rear power window motor. in the basic programming. 0200GZ

REPAIR MATERIALS
BR00.45-Z-1012-06A Lock cylinder grease spray 50 ml A 002 989 06 51
TIGHTENING TORQUES: PASSENGER CARS: DOORS - BA72.00-Z-9999AZ
MODEL all
Front door MODEL 170, 202, 203, BA72.10-P-1000-01A

208.3 /4, 209, 210
Front door MODEL 171, 230 MODEL BA72.10-P-1000-01AB
211
Front door MODEL 168, 414.700 BA72.10-P-1000-01B
Front door MODEL 140.051 /057 with BA72.10-P-1000-01C
CODE (979) Special protection
execution
Front door MODEL 163 BA72.10-P-1000-01D
Front door MODEL 215, 220, 240 BA72.10-P-1000-01E
Front door MODEL 220 with CODE BA72.10-P-1000-01EA
(Z04) Light armoring MODEL
220 with CODE (Z07) Highest
protection
Front door MODEL 220 with CODE BA72.10-P-1000-01EB
(Z04) Light armoring MODEL
220 with CODE (Z07) Top
protection
Front door MODEL 209 BA72.10-P-1000-01G
Front door MODEL 211 with CODE BA72.10-P-1000-01I
(Z04) Light armoring
Front door MODEL 199.376 BA72.10-P-1000-01J
Front door MODEL 169.0 /3, 245.2 BA72.10-P-1000-01L

Front door MODEL 219.3 BA72.10-P-1000-01M
Front door MODEL 164.1 /8 BA72.10-P-1000-01O
Front door MODEL 251 BA72.10-P-1000-01P
Front door MODEL 216 MODEL 221 BA72.10-P-1000-01Q
except CODE (Z07) Top
protection
Front door MODEL 221 with CODE BA72.10-P-1000-01R
(Z07) Top protection
Front door MODEL 204 BA72.10-P-1000-01S
Rear door MODEL 202, 203, 210, 211 BA72.12-P-1000-01A
Rear side door MODEL 168 BA72.12-P-1000-01B
Rear door MODEL 163 BA72.12-P-1000-01C
Rear door MODEL 220, 240 BA72.12-P-1000-01D
Rear door MODEL 220 with CODE BA72.12-P-1000-01DA
MODEL 220 with CODE
(Z07) Highest protection
Rear door MODEL 211 with CODE BA72.12-P-1000-01F
Rear door MODEL 169.0, 245.2 BA72.12-P-1000-01H
Rear door MODEL 219.3 BA72.12-P-1000-01J
Rear door MODEL 164.1 /8 BA72.12-P-1000-01K
Rear door MODEL 251 BA72.12-P-1000-01L
Rear door MODEL 221 except CODE BA72.12-P-1000-01M
Rear door MODEL 221 with CODE BA72.12-P-1000-01N
Rear door MODEL 204 BA72.12-P-1000-01O
Center door MODEL BA72.14-P-1000-01A
220.874 /875 /876 /878
Rear door MODEL 202.07 /08 /18, BA72.20-P-1000-02A
203.0 /2 /7, 210.2, 211.2 /6
Tailgate MODEL 168 BA72.20-P-1000-02B
Tailgate MODEL 163 BA72.20-P-1000-02C
Rear-end door MODEL 169.0 /3, 245.2 BA72.20-P-1000-02I
Rear-end door MODEL 164.1 /8 BA72.20-P-1000-02J
Rear-end door MODEL 251 BA72.20-P-1000-02K
Electrical system - Side MODEL 163, 170, 171, BA72.29-P-1000-01A
doors 199.376, 202, 203, 208, 209,
210, 211, 215, 219.3, 220, 230
Electrical system - side MODEL 221 BA72.29-P-1000-01B
doors
FRONT DOOR - BA72.10-P-1000-01O
Model 164
FRONT DOOR
BA72.10-P-1001-01O Bolt, crank window to power window Nm 7
BA72.10-P-1002-01O Bolt, door hinge to front door Nm 32
BA72.10-P-1003-01O Bolt, door hinge to A-pillar Nm 32
BA72.10-P-1004-01O Bolt, locking eye to B-pillar Nm 28
BA72.10-P-1005-01O Bolt to door hinge leaf connection Nm 10
REAR DOOR - BA72.12-P-1000-01K
Model 164
REAR DOOR
BA72.12-P-1001-01K Bolt, clamping guide in door handle mechanism Nm 3
BA72.12-P-1002-01K Bolt, door hinge to rear door Nm 32
BA72.12-P-1003-01K Bolt, door hinge to B-pillar Nm 32
BA72.12-P-1004-01K Screw, locking eye to C-pillar Nm 28
BA72.12-P-1005-01K Bolt, door hinge leaf connection Nm 10
REAR-END DOOR - BA72.20-P-1000-02J
Model 164
REAR-END DOOR
BA72.20-P-1002-02J Bolt, hydraulic cylinder to body Nm 23
BA72.20-P-1005-02J Bolt, door hinge to rear-end door Nm 34
BA72.20-P-1007-02J Bolt, door lock to rear-end door Nm 11
BA72.20-P-1008-02J Nut, rear-end door hinge to body Nm 34
2007 MERCEDES-BENZ ML320, ML350, ML500 & ML63
2007 MERCEDES-BENZ
ML320, ML350, ML500 & ML63
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
On engine compartment fuse & relay box. See Fig.
AIR Pump Relay (E)
63.
Air Suspension Compressor Relay (G)
63.
Circuit 15 Relay (H)
63.
Circuit 15 Relay (N) On load compartment fuse & relay box. See Fig. 60.
Circuit 15R Relay (R) On load compartment fuse & relay box. See Fig. 60.
Coolant Circulation Pump Relay (C)
63.
Engine Circuit 87 Relay (D)
63.
Fanfare Horn Relay (F)
63.
Fuel Pump Relay Module (O) On load compartment fuse & relay box. See Fig. 60.
Rear Window Defroster Relay (M) On load compartment fuse & relay box. See Fig. 60.
Rear Wiper Relay (P) On load compartment fuse & relay box. See Fig. 60.
Socket Circuit 15R Relay (With Run-On) (K) On load compartment fuse & relay box. See Fig. 60.
Starter Relay (I)
63.
Trailer Circuit 30X Relay (L) On load compartment fuse & relay box. See Fig. 60.
Wiper Level 1/2 Relay (A)
63.
Wiper ON/OFF Relay (B)
63.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
Battery Compartment Prefuse Box Under right front seat.
Cockpit Fuse Box Behind right end of dash.
Engine Compartment Fuse & Relay Box Right side of engine compartment. See Fig. 62.
Front Prefuse Right rear of engine compartment. See Fig. 61.
Load Compartment Fuse & Relay Box Right rear of cargo area. See Fig. 59.
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
Airmatic Control Unit Under front of driver's seat.
Backup Camera Voltage Supply Module Under spare tire compartment liner. See Fig. 89.
Blower Regulator On bottom of blower motor.
Booster Blower Electronic Blower Controller On blower motor.
Central Gateway Control Module Under driver's seat. See Fig. 93.
Driver Front Seat Adjustment Control Module With
Under driver's seat.
Memory
DTR Control Unit Behind front bumper.
Electronic Compass Behind instrument cluster. See Fig. 44.
Emergency Call System Control Unit Under left seat of 2nd seat row.
ESP Control Module Left front corner of engine compartment.
Folding Rear Bench Seat Control Unit Under left seat of 2nd seat row. See Fig. 88.
Front Passenger Front Seat Adjustment Control
Under front passenger's seat.
Module With Memory
Front SAM Control Unit Under right front seat. See Fig. 84.
Headlamp Range Adjustment Control Module Under right front seat. See Fig. 90.
HRA (LWR) Power Module (Left/Right) Inside rear of respective headlight assembly.
HS (SIH) Seat Ventilation & Steering Wheel Heater
Under left seat of 2nd seat row. See Fig. 87.
Control Unit
Keyless Go Control Module Right side of cargo area.
Left Front Door Control Module In left front door.
Left Front Seat Ventilation Blower Regulator In driver's seat back.
Left Fuel Pump Control Unit Under right seat of 2nd seat row. See Fig. 94.
ME-SFI (ME) Control Module Top center of engine.
Multifunction Steering Wheel Electronics Unit Inside steering wheel. See Fig. 10.
PTS Control Module Under left front seat.
Rear AC Blower Regulator On rear blower motor.
Rear Audio Control Unit Under rear of driver's seat.
Rear Axle Differential Lock Control Module Under left seat of 3rd seat row.
Rear-End Door Closing Control Module Right rear of trunk, under carpet.
Rear SAM Control Module Right rear of cargo area. See Fig. 85.
Restraints System Control Module Under center console.
Right Front Door Control Module In right front door.
Right Front Seat Ventilation Blower Regulator In front passenger's seat back.
Right Fuel Pump Control Unit Under right seat of 2nd seat row.
SDAR Control Unit Under left seat of 2nd seat row. See Fig. 92.
Steering Column Module Top of steering column. See Fig. 91.
TPM Control Module Right side of cargo area.

TPM (RDK) Control Module Right rear of cargo area.
Traction System Hydraulic Unit Left front of engine compartment. See Fig. 1.
Transfer Case Control Module Under right front seat.
Transfer Case Control Module Under front passenger's seat.
Universal Portable CTEL Interface (UPCI (UHI))
Under left seat of 2nd seat row.
Control Module
WSS Control Unit (Weight Sensing System) On right front seat frame. See Fig. 83.
Xenon Headlamp Control Module (Left/Right) Behind respective headlamp.
Xenon Headlamp Ignition Module (Left/Right) Behind respective headlamp.
Xenon Headlamp Ignition Module (Left/Right) Inside rear of respective headlight assembly.
MOTORS
MOTORS LOCATION
Component Location
AIRmatic Compressor Unit Behind right side of front bumper. See Fig. 3.
Air Pump Front of engine.
Backrest Angle Adjustment Motor (Driver) In driver's seat back.
Backrest Angle Adjustment Motor (Front
In front passenger's seat back. See Fig. 77.
Passenger)
Blower Motor Under right side of dash.
Booster Blower Motor Rear of center console.
Coolant Circulation Pump In left front wheelwell. See Fig. 73.
Diverter Flap Actuator Motor (M16/27) On HVAC unit. See Fig. 69.
Driver Door CL Motor Rear of driver's door.
Dynamic Cornering Lamp Motor (Left/Right) Inside rear of respective headlight assembly.
Electric Suction Fan Engine & AC With Integrated
Behind radiator.
Control
Fresh Air/Air Recirculation Flaps Actuator Motor
On HVAC unit. See Fig. 69.
(M2/5)
Front Seat Height Adjustment Motor (Driver) In driver's seat back.
Front Seat Height Adjustment Motor (Front
Passenger)
Front Throttle Valve Actuator (M16/3) In cylinder head. See Fig. 74.
Fuel Filler Flap CL Motor In right rear wheelwell.
HCS Pump On washer fluid reservoir.
Headlamp Range Adjustment Motor (Left/Right) Inside rear of respective headlight assembly.
Head Restraint Motor (Driver) In driver's seat back.
Head Restraint Motor (Front Passenger) In front passenger's seat back.
High Pressure & Return Pump Inside hydraulic unit.
Inlet Port Shutoff Motor Top center of engine. See Fig. 81.
Intelligent Servo Module (DIRECT SELECT) On transmission housing. See Fig. 11.
Left Blending Air Flap Actuator (M2/6) On HVAC unit. See Fig. 69.
Left Center Air Flap Actuator Motor (M16/23) On HVAC unit. See Fig. 69.
Left Defroster Vent Flap Actuator Motor (M2/8) On HVAC unit. See Fig. 69.
Left Electrically Adjustable & Heated Exterior
On driver's door.
Mirror
Left Folding Backrest Motor Under left seat of 3rd seat row.
Left Footwell Flap Actuator Motor (M2/10) On HVAC unit. See Fig. 69.
Left Front Power Window Motor Center of left front door.
Left Front Reversible Emergency Tensioning
Base of left "B" pillar.
Retractor
Left Front Seat Backrest Ventilation Motor Group In driver's seat back.
Left Front Seat Cushion Ventilation Motor Group Under driver's seat.
Left Fuel Pump (M3/2) Top of fuel tank. See Fig. 71.
Left Rear Door CL Motor Rear of left rear door.
Left Rear Power Window Motor Center of left rear door.
Left Vent Window Motor In left "D" pillar.
Lumbar Pump Left rear of cargo area. See Fig. 77.
Mirror Fold-In Motor (Left/Right) Integral to respective rearview mirror.
Mirror In/Out Adjustment Motor (Left/Right) Integral to respective rearview mirror.
Mirror Up/Down Adjustment Motor (Left/Right) Integral to respective rearview mirror.
Pneumatic Pump For Dynamic Seat Control Left rear of cargo area. See Fig. 78.
Rear Air Conditioning Blower Motor Left side of cargo area. See Fig. 70.
Rear Air Conditioning Refrigerant Shutoff Motor Left side of cargo area. See Fig. 75.
Rear Air Distribution Flap Actuator Motor (M2/21) On HVAC unit. See Fig. 69.
Rear Axle Differential Actuator Motor On differential. See Fig. 82.
Rear Door Hydraulic Pump Right rear of cargo area. See Fig. 80.
Rear Seat Height Adjustment Motor (Driver) In driver's seat back.
Rear Seat Height Adjustment Motor (Front
Passenger)
Rear Shutoff Flap Actuator Motor (M2/12) On HVAC unit. See Fig. 69.
Rear Throttle Valve Actuator (M16/4) In cylinder head.
Right Blending Air Flap Actuator (M2/7) On HVAC unit. See Fig. 69.
Right Center Air Flap Actuator Motor (M16/24) On HVAC unit. See Fig. 69.
Right Defroster Vent Flap Actuator Motor (M2/9) On HVAC unit. See Fig. 69.
Right Electrically Adjustable & Heated Exterior
On front passenger's door.
Mirror
Right Folding Backrest Motor Under right seat of 3rd seat row.
Right Footwell Flap Actuator Motor (M2/11) On HVAC unit. See Fig. 69.
Right Front Door CL Motor Rear of right front door.
Right Front Power Window Motor Center of right front door.

Right Front Reversible Emergency Tensioning
Base of right "B" pillar.
Retractor
Right Front Seat Backrest Ventilation Motor Group In front passenger's seat back.
Right Front Seat Cushion Ventilation Motor Group Under front passenger's seat.
Right Fuel Pump (M3) Under right seat of 2nd seat row. See Fig. 14.
Right Rear Door CL Motor Rear of right rear door.
Right Rear Power Window Motor Center of right rear door.
Right Vent Window Motor In right "D" pillar.
Seat Fore/Aft Adjustment Motor (Driver) In driver's seat back.
Seat Fore/Aft Adjustment Motor (Front Passenger) Under front passenger's seat.
Starter Left side of engine.
Steering Column Forward/Back Motor (M20/1) On steering column. See Fig. 76.
Steering Column Raise/Lower Motor (M20/2) On steering column. See Fig. 76.
Tailgate Wiper Motor Center of tailgate.
Throttle Valve Actuator (V6) On throttle body.
Throttle Valve Actuator (V8) Rear of intake manifold.
Tilting/Sliding Roof (SR (SHD)) Drive Unit Front center of roof. See Fig. 72.
Transfer Case Actuator Motor On transfer case. See Fig. 79.
Windshield Washer Fluid Pump On washer fluid reservoir.
Wiper Motor Rear of engine compartment.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
Component Location
Accelerator Pedal Sensor At top of accelerator pedal.
Actual Value Potentiometer (Sliding Contact 1) Center rear of engine.
Actual Value Potentiometer (Sliding Contact 2) Center rear of engine.
Ambient Temperature Display Temperature Sensor Behind left side of front bumper.
Camshaft Hall Sensor (M642) Top right front of engine. See Fig. 19.
Center Left Front PTS Ultrasonic Sensor Left side of front bumper.
Center Rear Interior Temperature Sensor Under right rear of center floor console.
Center Right Front PTS Ultrasonic Sensor Right side of front bumper.
Charge Air Temperature Sensor Right front of engine. See Fig. 34.
Charge Pressure Sensor Right front of engine. See Fig. 17.
Coolant Temperature Sensor (M272 & M273) Left rear of engine. See Fig. 30.
Coolant Temperature Sensor (M642) Top left side of engine. See Fig. 31.
Crankshaft Hall Sensor Rear of left cylinder bank.
Crankshaft Position Sensor (V8) Rear of left cylinder bank.
Dew Point Sensor Under right side of dash, near blower motor.
Driver-Side Frontal Acceleration Sensor Left front of engine compartment. See Fig. 53.
Dual Sun Sensor Top center of dash.
Right rear corner of engine compartment. See Fig.
Emissions Sensor
50.
ESP Brake Pressure Sensor On brake master cylinder. See Fig. 51.
Evaporator Temperature Sensor Under center of dash. See Fig. 26.
Exhaust Back Pressure Sensor Rear of engine, in exhaust. See Fig. 57.
Front Door Pressure Sensor (Driver's Side) In driver's door.
Front Door Pressure Sensor (Front Passenger's Side) In right front door.
Fuel Filter Water Level Sensor Top rear of engine. See Fig. 58.
Fuel Pressure Sensor Front of left fuel rail. See Fig. 16.
Fuel Tank Pressure Sensor In fuel tank.
Fuel Temperature Sensor Top left front of engine. See Fig. 55.
Hall Sensor 1 (Sliding Roof) Integral to tilting/sliding roof drive unit.
Hall Sensor 2 (Sliding Roof) Integral to tilting/sliding roof drive unit.
Hot Film MAF Sensor Center rear of engine.
Inner Left Front PTS Ultrasonic Sensor Left center of front bumper.
Inner Left Rear PTS Ultrasonic Sensor Left side of rear bumper.
Inner Right Front PTS Ultrasonic Sensor Right center of front bumper.
Inner Right Rear PTS Ultrasonic Sensor Right side of rear bumper.
Intake Air Temperature Sensor Rear of engine. See Fig. 33.
Left Center Outlet Temperature Sensor Behind center of dash. See Fig. 29.
Left Exhaust Camshaft Hall Sensor (M156) Left front of engine. See Fig. 24.
Left Exhaust Camshaft Hall Sensor (M272 &
Left front of engine. See Fig. 23.
M273)
Left Footwell Temperature Sensor Under left center of dash.
Left Front Body Lateral Acceleration Sensor Top of left front shock tower. See Fig. 39.
Left Front Level Sensor In left front wheelwell. See Fig. 36.
Left Fuel Level Sensor (B4/1) Under left seat of 2nd seat row. See Fig. 14.
Left Hot Film MAF Sensor (M156) Top left rear of engine. See Fig. 13.
Left Intake Camshaft Hall Sensor (M156) Left front of engine. See Fig. 21.
Left Intake Camshaft Hall Sensor (M272 & M273) Left front of engine. See Fig. 20.
Left Intake Manifold Position Flap Position Sensor
Left side of intake manifold. See Fig. 48.
(V6)
Left Knock Sensor 1 (M156) Left side of engine.
Left Knock Sensor 2 (M272 & M273) Under intake manifold.
Left O2 Sensor Downstream TWC (KAT) Left of transmission. See Fig. 67.
Left O2 Sensor Upstream TWC (KAT) Left of transmission. See Fig. 65.
Left Rear Level Sensor Under left rear of vehicle. See Fig. 35.
Left Side Airbag Sensor Base of left "B" pillar. See Fig. 7.
Left Side Outlet Temperature Sensor Under left side of dash. See Fig. 28.
Micromechanical Turn Rate Sensor AY Pickup On floor, under right front seat. See Fig. 42.
Oil Sensor (Oil Level, Temperature & Quality) Lower right front of engine. See Fig. 52.
Oil Temperature Sensor (M156) Lower left front of engine.
Oil Temperature Sensor (M642) Left side of engine oil pan.
Outer Left Front PTS Ultrasonic Sensor Left corner of front bumper.
Outer Left Rear PTS Ultrasonic Sensor Left corner of rear bumper.
Outer Right Front PTS Ultrasonic Sensor Right corner of front bumper.
Outer Right Rear PTS Ultrasonic Sensor Right corner of rear bumper.
O2 Sensor 1 Upstream TWC (KAT) Under right side of engine. See Fig. 64.
Passenger-Side Frontal Acceleration Sensor Right front of engine compartment. See Fig. 54.
Pedal Value Sensor In left rear corner of engine compartment.
Pressure Differential Sensor (DPF) On rear of differential.
Pressure Sensor (Air Cleaner) (M642) Downstream of air cleaner. See Fig. 47.
Pressure Sensor (M156) Top right side of engine. See Fig. 46.
Pressure Sensor (M272 & M273) Top left side of engine. See Fig. 45.
Rail Pressure Sensor Rear of right fuel rail. See Fig. 15.
Rear Air Conditioning Evaporator Temperature
On rear HVAC unit. See Fig. 27.
Sensor
Rear Door Pressure Sensor (Driver's Side) In left rear door.
Rear Door Pressure Sensor (Passenger's Side) In right rear door.
Rear-End Door Closing Obstruction Sensor Strip
At respective "D" pillar.
(Left/Right)
Rear-End Door Opening Angle Recognition Sensor Right rear of roof. See Fig. 43.
Rear Headroom AC Temperature Sensor Top of left "C" pillar.
Refrigerant Pressure Sensor In left front wheelwell. See Fig. 32.
Right Center Outlet Temperature Sensor Behind center of dash.
Right Exhaust Camshaft Hall Sensor (M156) Right front of engine. See Fig. 25.
Right Exhaust Camshaft Hall Sensor (M272 &
Right front of engine.
M273)
Right Footwell Temperature Sensor Under right center of dash.
Right Front Body Lateral Acceleration Sensor Top of right shock tower. See Fig. 40.
Right Front Level Sensor In right front wheelwell. See Fig. 37.
Right Fuel Level Sensor (B4/2) Under right seat of 2nd seat row. See Fig. 14.
Right Hot Film MAF Sensor (M156) Top right rear of engine.
Right Intake Camshaft Hall Sensor (M156) Right front of engine. See Fig. 22.
Right Intake Camshaft Hall Sensor (M272 & M273) Right front of engine.
Right Intake Manifold Position Flap Position Sensor
Right side of intake manifold. See Fig. 49.
(V6)
Right Knock Sensor 1 (M156) Right side of engine. See Fig. 12.
Right Knock Sensor 1 (M272) Under intake manifold. See Fig. 4.
Right Knock Sensor 1 (M273) Under intake manifold. See Fig. 5.
Right O2 Sensor Downstream TWC (KAT) Right of transmission. See Fig. 68.
Right O2 Sensor Upstream TWC (KAT) Right of transmission. See Fig. 66.
Right Rear Body Lateral Acceleration Sensor At right side of cargo area. See Fig. 41.
Right Rear Level Sensor In right rear wheelwell. See Fig. 38.
Right Side Airbag Sensor Base of right "B" pillar. See Fig. 8.
Right Side Outlet Temperature Sensor Under right side of dash.
Steering Angle Sensor Part of steering column module.
Sun Sensor Top center of dash.
Temperature Sensor (Diesel Particulate Filter) Upstream of diesel particulate filter.
TPM (RDK) Wheel Sensor (4) Inside wheels. See Fig. 9.
Transfer Case Absolute Sensor On rear of transfer case. See Fig. 18.
Transfer Case Absolute Sensor On rear of transfer case. See Fig. 56.
TWC (KAT) Temperature Sensor Right side of transmission.
Vent Window Obstruction Sensor Strip (Left/Right) Top of respective rear windows.
Wheel Speed Sensors (4) On respective wheel hub assemblies.
WSS Sensor (Weight Sensing System) (Left/Right Under respective front corner of front passenger's
Front) seat.
WSS Sensor (Weight Sensing System) (Left/Right Under respective rear corner of front passenger's
Rear) seat.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
A/C Compressor Left front of engine.
Activated Charcoal Canister Shutoff Valve In right rear wheelwell.
Activated Charcoal Filter Shutoff Valve In right rear wheelwell.
Air Injection Combination Valve, Left Cylinder
Left front of engine.
Bank (V6)
Air Injection Combination Valve, Right Cylinder
Right front of engine.
Bank (V6)
AIRmatic Pressure Reduction Valve Part of AIRmatic compressor unit.
AIRmatic Valve Unit Behind right side of front bumper.
Air Pump Switchover Valve On front of engine.
Air Pump Switchover Valve Right front of engine.
Automatic Rear-End Door Closing Control Valve Right side of cargo area.
BAS Solenoid Valve Part of brake booster.
Charge Pressure Positioner Top rear of engine.
Front Axle Inlet Solenoid Valve Inside hydraulic unit.
Front Axle Switchover Solenoid Valve Inside hydraulic unit.
Heating System Shutoff Valve Rear of engine.
Injectors (LH-SFI, HFM-SFI, PEC (LH, HFM,

Top of engine, above cylinders.
PMS))
Intake Manifold Tumble Flap Switchover Valve On front of engine.
Left Camshaft Exhaust Solenoid Left front of engine.
Left Camshaft Intake Solenoid Left front of engine.
Left Exhaust Gas Recirculation Positioner Left rear of engine.
Left Front Axle Damping Valve Unit In left front wheelwell.
Left Front Axle Solenoid Valve (Hold) Inside hydraulic unit.
Left Front Axle Solenoid Valve (Release) Inside hydraulic unit.
Left Rear Axle Damping Valve Unit At left rear wheel.
Left Rear Axle Solenoid Valve (Hold) Inside hydraulic unit.
Left Rear Axle Solenoid Valve (Release) Inside hydraulic unit.
Power Steering Pump Pressure Regulator Valve Lower left front of engine.
Pressure Regulator Valve Left front of engine.
Purge Control Valve Left front of engine compartment.
Rear Axle Inlet Solenoid Valve Inside hydraulic unit.
Rear Axle Switchover Solenoid Valve Inside hydraulic unit.
Right Camshaft Exhaust Solenoid Right front of engine.
Right Camshaft Intake Solenoid Right front of engine.
Right Front Axle Damping Valve Unit In right front wheelwell.
Right Front Axle Solenoid Valve (Hold) Inside hydraulic unit.
Right Front Axle Solenoid Valve (Release) Inside hydraulic unit.
Right Rear Axle Damping Valve Unit At right rear wheel.
Right Rear Axle Solenoid Valve (Hold) Inside hydraulic unit.
Right Rear Axle Solenoid Valve (Release) Inside hydraulic unit.
SPS (PML) Solenoid Valve In left front wheelwell.
Three-Disk Thermostat Valve Front of engine.
Variable Intake Manifold Switchover Valve On front of engine.
Volume Control Valve Left front of engine.
SWITCHES
SWITCHES LOCATION
Component Location
ATA (EDW) Hood Switch Left front of engine compartment.
BAS Release Switch Part of brake booster.
Brake Fluid Indicator Switch In brake fluid reservoir.
Coolant Level Indicator Switch Left side of engine compartment.
Driver Seat Belt Buckle & Seat Belt Warning
In driver's seat belt buckle.
Switch
Front Passenger Seat Belt Buckle & Seat Belt In right front seat belt buckle.
Warning Switch
Oil Level Switch In engine oil pan.
Parking Brake Indicator Switch Left front footwell.
Right Front Brake Pad Contact Sensor On right front brake assembly.
Right Rear Brake Pad Contact Sensor On right rear brake assembly.
Stoplight Switch On brake pedal support.
Windshield Washer Fluid Level Indicator Switch In washer fluid reservoir.
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
Alarm Signal Horn Right rear corner of engine compartment.
Auxiliary Battery Under right front seat.
BAS Brake Booster Near brake master cylinder. See Fig. 2.
Battery Under right front seat.
Central TPM (RDK) Antenna Under right center of vehicle.
Cockpit Keyless Go Antenna Under front of center floor console.
Cylinder 1 Ignition Coil (M156) Top of right cylinder bank. See Fig. 97.
Cylinder 1 Ignition Coil (M272 & M273) Top of right cylinder bank. See Fig. 95.
Cylinder 2 & 3 Ignition Coils (M272 & M273) Top of right cylinder bank.
Cylinder 2, 3, & 4 Ignition Coils (M156) Top of right cylinder bank.
Cylinder 4 Ignition Coil (M272 & M273) Top of left cylinder bank. See Fig. 96.
Cylinder 5 Ignition Coil (M156) Top of left cylinder bank. See Fig. 98.
Cylinder 5 & 6 Ignition Coils (M272 & M273) Top of left cylinder bank.
Cylinder 6, 7 & 8 Ignition Coils (M156) Top of left cylinder bank.
Data Link Connector (DLC) Below left side of dash.
Drive Actual Value Potentiometer Part of front throttle valve actuator.
Driver Airbag Ignition Squib 1 In steering wheel.
Driver Airbag Ignition Squib 2 In steering wheel.
Driver Belt Force Limiter Base of left "B" pillar.
Driver Buckle ETR Squib Left side of driver's seat.
Driver Side Airbag Squib In driver's seat back.
EGR (ARF) Vacuum Transducer Rear of engine.
E-Net Compensator Left rear of cargo area. See Fig. 6.
Fanfare Horns & Airbag Clock Spring Contact Inside steering wheel hub.
Fanfare Horns (Left/Right) Behind center of front bumper.
FM Rear Window Antenna Amplifier Left side of tailgate.
Front Passenger Airbag Ignition Squib 1 Behind right side of dash.
Front Passenger Airbag Ignition Squib 2 Behind right side of dash.
Front Passenger Belt Force Limiter Base of right "B" pillar.
Front Passenger Buckle ETR Squib Left side of front passenger's seat.
Glowtime Output Stage Top front of engine. See Fig. 86.
GPS Antenna Splitter Under left seat of 2nd seat row.
Hands-Free System Microphone Group Part of rearview mirror unit.
Ignition Coils 1, 2, 3 & 4 (V8) Top right of engine, on cylinder head.
Ignition Coils 5, 6, 7 & 8 (V8) Top left of engine, on cylinder head.
Interference Filter 1 Center rear of roof.
Interior Keyless Go Antenna Under left seat of 2nd seat row.
Keyless Go Left Rear Door Antenna In left rear door.
Keyless Go Right Rear Door Antenna In right rear door.
Keyless Go Trunk Antenna Left side of tailgate.
Left Front IR Receiver In left front door handle.
Left Window Airbag Squib Behind left side of dash.
Left 2nd Row ETR (GUS) Squib In left "C" pillar.
Left 2nd Row Side Airbag Ignition Squib In seat back of left seat of 2nd seat row.
Left 3rd Row ETR (GUS) Squib On left "D" pillar.
Radio Interference Suppression Capacitor 1 Top right side of engine.
Radio Interference Suppression Capacitor 2 Top left side of engine.
Right Side Airbag Ignition Squib In front passenger's seat back.
Right Window Airbag Squib Behind right side of dash.
Right 2nd Row ETR (GUS) Squib In right "C" pillar.
Right 2nd Row Side Airbag Ignition Squib In seat back of right seat of 2nd seat row.
Right 3rd Row ETR (GUS) Squib On right "D" pillar.
Roof Antenna Module Center rear of roof.
TELE AID Spare Antenna In right "D" pillar.
Throttle Valve Actual Value Potentiometer Part of front throttle valve actuator.
CONNECTORS
CONNECTORS LOCATION
Component Location
X4/39 Under left side of dash.
X8/4 Right rear of cargo area. See Fig. 194.
X8/16 Left rear door. See Fig. 195.
X8/17 Right rear door. See Fig. 196.
X18 (1) Right kick panel. See Fig. 197.
X18 (2) Right kick panel. See Fig. 198.
X18/2 (1) Right rear of cargo area. See Fig. 199.
X22/6 Right rear of engine compartment. See Fig. 203.

X25/2 Right front footwell. See Fig. 204.
X26 Right front of engine compartment. See Fig. 205.
X26/32 Left front bumper. See Fig. 206.
X26/36 Right front bumper. See Fig. 207.
X30/4 Right front footwell. See Fig. 208.
X30/6 Left front footwell. See Fig. 209.
X35/1 Left front door. See Fig. 210.
X35/2 Right front door. See Fig. 211.
X35/3 Left rear door. See Fig. 212.
X35/4 Right rear door. See Fig. 213.
X35/28 Left rear bumper. See Fig. 214.
X39/70 Under left rear seat. See Fig. 215.
X55/3 Under left front seat. See Fig. 216.
X55/4 Under right front seat. See Fig. 217.
X55/6 Under right rear seat. See Fig. 218.
X55/21 Under left seat of 3rd seat row. See Fig. 219.
X55/22 Under right seat of 3rd seat row. See Fig. 220.
X55/23 Under left seat of 2nd seat row. See Fig. 221.
X55/24 Under right seat of 2nd seat row. See Fig. 222.
X58/28 Right rear of cargo area. See Fig. 223.
X62/32 Under left rear of vehicle. See Fig. 224.
X62/33 Under right rear of vehicle. See Fig. 225.
X62/35 In left front wheelwell. See Fig. 226.
X62/36 In right front wheelwell. See Fig. 227.
X81/4 Top front of engine. See Fig. 228.
X99/15 Behind right side of dash. See Fig. 229.
X122/1 Under front of center console. See Fig. 230.
X122/3 (1) Left side of cargo area. See Fig. 231.
X122/3 (2) Left side of cargo area. See Fig. 267.
X122/4 Under front of center console. See Fig. 232.
X205 Front of engine. See Fig. 233.
GROUNDS
GROUNDS LOCATION
Component Location
W2 Behind right headlight. See Fig. 234.
W2/1 In right front wheelwell. See Fig. 235.
W6 Behind trim, at left rear of cargo area. See Fig. 236.
W6/6 Left rear of cargo area. See Fig. 237.
Behind trim, at right rear of cargo area. See Fig.

W7
238.
W7/7 Right rear of cargo area. See Fig. 239.
W8 Behind trim, on right side of tailgate. See Fig. 240.
W8/1 Left side of tailgate. See Fig. 241.
W8/2 Right side of tailgate. See Fig. 242.
W9 Left side of engine compartment. See Fig. 243.
W10 Under front passenger's seat. See Fig. 244.
W11 (M156) Right front of engine. See Fig. 246.
W11 (M642) Left rear of engine. See Fig. 245.
W11w1 Rear of right cylinder bank. See Fig. 249.
W11w2 Rear of left cylinder bank. See Fig. 250.
W11/1 Left front of engine. See Fig. 247.
W11/4 Attached to generator. See Fig. 248.
W15/1 Under right front footwell. See Fig. 251.
W15/2 Under left front footwell. See Fig. 252.
W16/3 Left rear of engine compartment. See Fig. 253.
W17 (GL Class) Under right rear seat. See Fig. 254.
W17 (M Class) Under right rear seat. See Fig. 264.
W17/1 (GL Class) Under left seat of 2nd seat row. See Fig. 255.
W17/1 (M Class) Under left rear seat. See Fig. 265.
W17/3 Under right rear seat. See Fig. 256.
Under center console, on SRS mounting bolt. See
W26
Fig. 257.
W29/2 At right kick panel. See Fig. 258.
W29/8 Top of left "D" pillar. See Fig. 259.
W29/9 Top of right "D" pillar. See Fig. 260.
W48/3 (GL Class) Right rear of cargo area. See Fig. 261.
W48/3 (M Class) Right rear of cargo area. See Fig. 266.
Beneath vehicle, at right rear of engine, above
W51/2
steering gear. See Fig. 262.
W70 Left front of engine compartment. See Fig. 263.
SPLICES
SPLICES LOCATION
Component Location
Z1 Top center of engine. See Fig. 99.
Z2 Top left rear of engine. See Fig. 100.
Z2z1 Top center of engine. See Fig. 101.
Z3/11 Behind center of dash. See Fig. 102.
Z3/51 Under center console. See Fig. 103.

Z5 (M156) Right side of transmission. See Fig. 187.
Z5 (M272 & M273) Top right side of engine. See Fig. 104.
Z5 (M642) Left rear of engine. See Fig. 188.
Z5z2 (M272 & M273) Top right side of engine. See Fig. 105.
Z6 (M156) Right rear of engine compartment. See Fig. 189.
Z6 (M642) Left rear of engine. See Fig. 106.
Z6z1 (M272 & M273) Right side of engine. See Fig. 107.
Z6z2 (M272 & M273) Left side of engine. See Fig. 108.
Z6/8 Left front of engine compartment. See Fig. 109.
Z6/12 In left rear door. See Fig. 110.
Z6/13 In right rear door. See Fig. 111.
Z6/14 In center console. See Fig. 112.
Z6/15 In center console. See Fig. 113.
Z6/26 (M272 & M273) Right side of engine. See Fig. 114.
Z6/27 Right front of engine. See Fig. 115.
Z6/30z1 Front of right cylinder bank. See Fig. 116.
Z6/30z2 Left front of engine. See Fig. 117.
Z6/35 In left front door. See Fig. 118.
Z6/36 In right front door. See Fig. 119.
Z6/47 At left front door sill. See Fig. 120.
Z6/62 At right front footwell. See Fig. 121.
Z7/5 Left rear of engine. See Fig. 122.
Z7/35z1 (M156) Left rear of engine. See Fig. 190.
Z7/35z1 (M272 & M273) Top right side of engine. See Fig. 123.
Z7/35z2 (M156) Right rear of engine compartment. See Fig. 191.
Z7/35z2 (M272 & M273) Top left side of engine. See Fig. 124.
Z7/35z3 Top left rear of engine. See Fig. 125.
Z7/35z4 Top right rear of engine. See Fig. 126.
Z7/36 (M156) Right rear of engine. See Fig. 192.
Z7/36 (M272 & M273) Top right side of engine. See Fig. 127.
Z7/36z2 (M272 & M273) Top left side of engine. See Fig. 129.
Z7/38z2 (M272 & M273) Top rear of engine. See Fig. 131.
Z7/43 (M272 & M273) Top right side of engine. See Fig. 132.
Z7/43 (M642) Left rear of engine. See Fig. 193.
Z7/43z1 Top rear of engine. See Fig. 133.
Z7/44 (M272 & M273) Top rear of engine. See Fig. 134.
Z7/61 Right rear of engine compartment. See Fig. 135.
Z7/88 Under right seat of 2nd seat row. See Fig. 136.
Rear of right cylinder bank. See Fig. 137.

Z7/98z2 Left rear of engine. See Fig. 138.
Z7/98z3 Right rear of engine compartment. See Fig. 139.
Z9 Right front of engine. See Fig. 140.
Z21 Under right rear footwell. See Fig. 141.
Z28/44 At left rear door sill. See Fig. 142.
Z36/1 Behind left side of rear bumper. See Fig. 145.
Z36/2 Behind left side of rear bumper. See Fig. 146.
Z36/3 Behind center of front bumper. See Fig. 147.
Z36/4 Behind center of front bumper. See Fig. 148.
Z43 Top left of tailgate. See Fig. 150.
Z50/4 Behind right side of dash. See Fig. 152.
Inside wiring harness under center console. See Fig.
Z50/5
141.
Z51/6 In right front footwell. See Fig. 154.
Z53/20 Under rear of center console. See Fig. 155.
Z53/25 Under left rear seat. See Fig. 156.
Z53/26 In right rear footwell. See Fig. 141.
Z54/7 Under rear of center console. See Fig. 157.
Z55/1 Right side of tailgate. See Fig. 158.
Z55/4 Right side of tailgate. See Fig. 159.
Z57/15 Right front of engine compartment. See Fig. 160.
Z60/4 Behind left side of front bumper. See Fig. 161.
Z61/10 In driver's seat back. See Fig. 164.
Z61/11 In driver's seat back. See Fig. 165.
Z61/12 Under left seat of 2nd seat row. See Fig. 166.
Z61/14 In right rear doorsill. See Fig. 168.
Z61/15 In right rear doorsill. See Fig. 169.

Z84/1 Front of engine. See Fig. 176.
Z84/2 Front of engine. See Fig. 177.
Z100/2 Near left "B" pillar. See Fig. 142.
Z204/1 Left rear of cargo area. See Fig. 180.
Z204/2 Right rear of cargo area. See Fig. 181.
Z204/3 Under right rear seat. See Fig. 182.
Z204/4 In right front footwell. See Fig. 183.
Z204/5 In left front footwell. See Fig. 184.
Z204/6 Under left rear seat. See Fig. 185.
Z204/7 In left front footwell. See Fig. 186.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
Fig. 1: Left Front Of Engine Compartment

Fig. 2: Left Rear Of Engine Compartment

Fig. 3: Behind Right Side Of Front Bumper

Fig. 4: Top Of Engine (M272)


Fig. 6: Left Side Of Cargo Area

Fig. 7: Left "B" Pillar

Fig. 8: Right "B" Pillar

Fig. 9: Wheels
Fig. 10: Steering Wheel

Fig. 11: Under Right Front Of Vehicle

Fig. 12: Right Side Of Engine (M156)


Fig. 14: Fuel Tank

Fig. 15: Top Rear Of Engine (M642)

Fig. 16: Top Front Of Engine (M156)

Fig. 17: Right Front Of Engine (M642)

Fig. 18: Under Front Of Vehicle


Fig. 20: Top Left Front Of Engine (M272 & M273)

Fig. 21: Left Front Of Engine (M156)


Fig. 23: Left Front Of Engine (M272 & M273)



Fig. 26: Under Center Of Dash

Fig. 27: Left Rear Of Cargo Area

Fig. 28: Under Left Side Of Dash

Fig. 29: Behind Center Of Dash

Fig. 30: Rear Of Engine (M272 & M273)


Fig. 32: Left Front Wheelwell

Fig. 33: Rear Of Engine (M156)


Fig. 35: Under Left Rear Of Vehicle


Fig. 37: Right Front Wheelwell

Fig. 38: Right Rear Wheelwell


Fig. 40: Right Rear Of Engine Compartment

Fig. 41: Right Side Of Cargo Area

Fig. 42: Under Right Front Seat

Fig. 43: Right Rear Of Roof

Fig. 44: Behind Instrument Cluster

Fig. 45: Top Of Engine (M272 & M273)







Fig. 52: Bottom Front Of Engine


Fig. 54: Right Front Of Engine Compartment


Fig. 56: Under Center Of Vehicle

Fig. 57: Rear Of Engine

Fig. 58: Top Rear Of Engine (M642)

Fig. 59: Right Rear Of Cargo Area

Fig. 60: Load Compartment Fuse & Relay Box


Fig. 62: Right Side Of Engine Compartment

Fig. 63: Engine Compartment Fuse & Relay Box

Fig. 64: Under Right Side Of Engine

Fig. 65: Under Vehicle, Near Left Side Of Transmission

Fig. 66: Under Vehicle, Near Right Side Of Transmission

Fig. 67: Under Vehicle, Near Left Side Of Transmission

Fig. 68: Under Vehicle, Near Right Side Of Transmission

Fig. 69: HVAC Unit


Fig. 71: Fuel Tank

Fig. 72: Front Center Of Roof


Fig. 74: Engine (V8)


Fig. 76: Steering Column



Fig. 79: Under Front Of Vehicle

Fig. 80: Right Rear Floor Of Cargo Area

Fig. 81: Top Center Of Engine (M642)

Fig. 82: Under Rear Of Vehicle

Fig. 83: Under Front Passenger's Seat




Fig. 87: Under Left Seat Of 2nd Seat Row


Fig. 89: Cargo Area

Fig. 90: Under Right Front Seat

Fig. 91: Steering Column


Fig. 93: Under Driver's Seat

Fig. 94: Under 2nd Row Seats









Fig. 103: Under Center Console



Fig. 106: Left Rear Of Engine (M642)


Fig. 108: Left Rear Of Engine (M272 & M273)


Fig. 110: Left Rear Door

Fig. 111: Right Rear Door





Fig. 116: Right Side Of Engine (M156)


Fig. 118: Left Front Door

Fig. 119: Right Front Door

Fig. 120: Left Front Doorsill

Fig. 121: Right Front Doorsill



Fig. 124: Left Side Of Engine (M272 & M273)


Fig. 126: Right Rear Of Engine (M156)

Fig. 127: Right Side Of Engine (M272 & M273)










Fig. 137: Right Rear Of Engine (M156)




Fig. 141: Right Rear Footwell

Fig. 142: Left Rear Footwell



Fig. 145: Behind Rear Bumper

Fig. 146: Behind Rear Bumper

Fig. 147: Behind Front Bumper



Fig. 150: Tailgate


Fig. 152: Behind Right Side Of Dash


Fig. 154: Right Front Footwell


Fig. 156: Under Left Rear Seat


Fig. 158: Tailgate

Fig. 159: Tailgate

Fig. 160: Right Front Of Engine Compartment




Fig. 164: Driver's Seat

Fig. 165: Driver's Seat



Fig. 168: Right Front Doorsill

Fig. 169: Right Rear Doorsill













Fig. 182: Under Right Rear Seat


Fig. 184: Left Front Footwell



Fig. 187: Right Of Transmission (M156)


Fig. 189: Right Rear Of Engine Compartment (M156)


Fig. 191: Right Rear Of Engine Compartment (M156)






Fig. 197: Behind Right Kick Panel

Fig. 198: Behind Right Kick Panel





Fig. 203: Rear Of Engine Compartment



Fig. 206: Behind Left Side Of Front Bumper

Fig. 207: Behind Right Side Of Front Bumper



Fig. 210: Left Front Door

Fig. 211: Right Front Door



Fig. 214: Behind Left Side Of Rear Bumper


Fig. 216: Under Driver's Seat



Fig. 219: Under 3rd Row Seats

Fig. 220: Under 3rd Row Seats




Fig. 224: Under Left Rear Of Vehicle

Fig. 225: Under Right Rear Of Vehicle

Fig. 226: In Left Front Wheelwell

Fig. 227: In Right Front Wheelwell


Fig. 229: Behind Right Side Of Dash




Fig. 233: Front Of Engine (M272 & M273)


Fig. 235: In Right Front Wheelwell





Fig. 240: Right Side Of Tailgate

Fig. 241: Left Side Of Tailgate

Fig. 242: Right Side Of Tailgate

Fig. 243: Left Side Of Engine Compartment





Fig. 248: Right Front Of Engine










Fig. 258: Right Kick Panel

Fig. 259: Top Of Left "D" Pillar

Fig. 260: Top Of Right "D" Pillar


Fig. 262: Under Right Front Of Vehicle






2006-2008 ACCESSORIES & BODY, CAB Electrical System, Equipment & Instructions - 164 Chassis
Electrical System, Equipment & Instructions - 164 Chassis
GENERAL INFORMATION
INFORMATION ON PREVENTING DAMAGE TO ELECTRONIC COMPONENTS DUE TO
ELECTROSTATIC DISCHARGE - AH54.00-P-0001-01A
All models
Electrostatic charge
The friction between two non-conducting materials causes the materials to be charged electrostatically. Plastics
generally produce the highest electrostatic charge.
We come across electrostatic charge or discharge in lots of everyday situations, e.g. with:
 Combs
 Walking on carpets or plastic floors
 Putting on and taking off textiles
 Disembarking from the vehicle
 Contact between various electrostatically chargeable packaging materials in shelves or in the transport
container
The following electrostatic discharge (E lectro S tatic D ischarge (ESD)) can be so strong that a small electric
shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to
electronic components and control units.
Effects and consequences of ESD
Electronic components and control units are very sensitive to ESD. The damage is often not immediately
obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle
electronics, various procedures and safety precautions must be taken into account and followed.
Risks of damage occur during transport, handling, testing, removal and installation of electronic components in
production as well as during repair work.
The following electronic components listed as an example can be damaged by ESD:
 Airbag components
 Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN),
local interconnect network (LIN) etc.)
 Sensors
 Mechatronic components (actuators etc.)
 Antenna amplifier
 Receivers and displays (Radio, TV, GPS, telephone etc.)
Modes of behavior and safety precautions
 Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body).
 Wear suitable clothing made of cotton.
 The ESD workplace must conform to the ESD guidelines.
ESD protection
 Wear ESD safety shoes with conducting soles.
ESD safety shoes can be ordered via the catalog of work protection range 2007-2009 under
order no.: 2380 1002 50
Fax:+49 (0) 7031 6288 1058
 Special antistatic seat upholstery covers must be used for repair work on the vehicle.
The antistatic seat upholstery covers are available from Datex Werkstatt Schutzbezuge GmbH
for example under the order no. D-E 3000.
Tel: +49(0)2363 34579
Fax: +49(0)2363 34444
Email: service@datex-covers.de
 Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut
open carefully.
 Before unpacking, discharge ESD protective packaging at the ESD workplace.
ESD protection
 Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam.
 Use only original packaging or specially labeled and defined packaging and transport materials.
 Electronic components which have been removed must be put down on an ESD workplace.
ESD protection
 Only take hold of electronic components by the housing, not by the pins or contacts.
 Electronic components must be installed before they are connected so that potential equalization with the
body can take place.
 Shelves and worktables must stand directly on the floor, there must not be any insulating materials
between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed,
the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal
shelf to a heating pipe).
 Do not place a conductive transport container/box on an insulated surface (e.g. on a wooden pallet),
otherwise potential equalization cannot take place.
 Do not place control units and electronic components removed from the vehicle on electrostatically
chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control
unit or electronic component. An ESD service kit or a connected ESD table mat must be used.
 For information on safety regulations and safety precautions refer to the brochure:
"ESD risk factor, understand and avoid electrostatic discharges".
Order no. 6516 1310 00
This brochure can be ordered via
www.gsp-ti-shop.de
Returning electronic components in warranty and goodwill cases
When returning electronic components it is absolutely essential to observe the procedure and safety precautions
listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid.
This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned.
E-Mail: customer.support@daimlerchrysler.com.
Outside Germany please consult the contact person responsible for your market.
ESD protection is only effective when the safety regulations and safety precautions are followed.
EVALUATING ELECTRONIC COMPONENTS AFTER REPAIR AND PAINTING WORK AND

AFTER ACCIDENTS - AH54.00-P-1000-01A
All models
1. With paint drying in drying oven

Electronic components, such as the switching unit for the ignition system, the control unit for the
electronic fuel/diesel injection system, the ABS system, airbag, emergency tensioning retractors etc. may
only be heated up to an object temperature of maximum 90°C.
In cases of doubt the temperature at these points should be checked by a series of measurements (remove
electronic components beforehand) by means of a mercury maximum thermometer during the baking
phase.
If the maximum permissible temperature is not exceeded, the electronic components need not be
removed.
No particular safety measures are required at an object temperature up to max. 60°C (air injection
temperature max. 90°C).
2. With welding
Always disconnect and cover the negative terminal of the battery. Disconnect airbag 10-pin data link
connector (color red) in the right footwell after waiting for 2 seconds after disconnecting the battery or as
of 07/93 detach the coupling on the airbag control unit using the insertion and removal aid.
3. After accidents
Replacing electronic control units after an accident is only necessary if at least one of the following
conditions is met:
 The housing is recognizably deformed or damaged.

 The contact surface or bearing bracket is deformed; externally the unit does not appear damaged.
 The connector is damaged or corroded by moisture.
 Faults are established by a function test or self-diagnosis of the unit.
If electronic components, such as the ABS control unit, have been removed for repair and are then used
again, these should be checked for proper operation after assembly.
Read fault memory and erase
NOTES ON BATTERY - AH54.10-P-0001-01A
All models
General information on batteries
 Do not store batteries over a longer period at a storage point with direct solar radiation.
 Discharged or defective batteries can freeze, therefore store free from frost.
 Avoid polarity reversal and short-circuits.
 Do not place tool or other conducting objects on the battery (risk of short-circuit).
 Before removal and installation of batteries all switchable current consumers should be switched off, as
well as the engine switched off so that inadvertent arcing is ruled out.
 Always disconnect the negative terminal first and always connect the positive terminal first
 Only charge batteries with DC, 10 % of the capacity is recommended as charging current for slow
charging and 50 % of the capacity recommended for fast charging.
 Only switch on the charger after connecting to the terminals and switch off before disconnecting.
 We recommend greasing the batteries slightly with battery terminal grease.
 If the battery is to remain in the parked vehicle for a longer time, the negative terminal should be
disconnected.
 If possible batteries should be kept clean and dry.
 Batteries should not be stored over a longer period without recharging.
Notes on lead-gel batteries (additional battery for special bodies)
 Lead-gel batteries are free from gassing, acid does not run out of them and are completely independent of
position and maintenance free.
 When fast charging ensure that the housing of the lead-gel battery does not heat up excessively otherwise
a pressure relief valve will be opened and the lead-gel battery will be defective.
Notes on lead acid batteries
 Always store lead lead-acid batteries horizontally to prevent acid leaking out and do not tilt during
transportation.
 When fast charging ensure that the housing of the lead-acid battery does not heat up excessively.
NOTES ON AGM BATTERY - AH54.10-P-0002-01A
All models
As of Autumn 2000 new batteries with AGM technology will be used.
The external differentiation features between these batteries and conventional batteries are:
 Black housing
 VRLA battery labeling
 Non-detachable covers (A)
Fig. 1: Identifying VRLA Battery Labeling And Non-Detachable Cover

AGM battery structure
Instead of the acid in a conventional battery, a conductive fabric (bonded fiber) (V) is used.
Special properties:
 High cycle strength (long service life)

 Improved cold starting characteristics
 No escaping acid if housing damaged
 Improved deep-discharge resistance
 Absolutely maintenance-free
Fig. 2: Identifying AGM Battery Structure And Conductive Fabric (Bonded Fiber)
Distinguishing features
 No stop plugs
 No acid level markings

 No externally vented stop plugs
 Information plate on the battery
If the battery is replaced, the vent hose with an elbow to one side of the battery and the stop plugs on the
other side of the battery must be pressed in.
NOTES ON PROGRAMMING CONTROL UNITS - AH54.21-P-0001-03Y
Offline programming with SDflash Release-CD
Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220,
221, 230, 240, 245, 251
Model 461.302/331/332/342/345,
463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/308/309/322/323/332/33
Model 450, 451, 452, 454

Programming with STAR DIAGNOSIS (SDflash)
S TAR D IAGNOSIS flash : "SDflash" is the name given to the DaimlerChrysler standard for programming
control units.
In the process a distinction is made between two types of programming:
 Offline programming with SDflash Release-CD

 Offline programming with SDflash Special Release-CD
Further explanation of terms:
 Flashing: Programming of control units

 Software: Control unit software
 SDflash Release CD: Control unit software, integrated on DAS DVD
 SDflash Special Release CD: Special CD which contains software updates
Deliveries and costs
The SDflash Release-CD is integrated on the DAS-DVD and together with the WIS-DVD is delivered monthly
by the DC-AG. Delivery is free of charge for the case of repair.
Offline programming with SDflash Release-CD
The control unit software of the SDflash Release-CD can be installed on the hard disk in the case of the "STAR
DIAGNOSIS Compact" diagnosis system.
Installation of the dat in not possible in the case of the "STAR DIAGNOSIS Basic" diagnosis system. In this
case, the SDflash
Release CD must be placed in the CD or DVD drive.
 The information on the SDflash Release-CD is:

 applies to all divisions
 applies to all model series
 applies to all control units
 The information on the SDflash Release CD provides a "basic supply" of control unit software for the
vehicle. The current software releases of all programmable control units are located on the SDflash
Release-CD. An old software release can therefore be repeatedly replaced (updated) by a new software
release.
 If a plant service measure requires a change in software release in a programmable control unit, the
workshop can carry out this change with the SDflash Release CD.
NOTES ON PROGRAMMING CONTROL UNITS - AH54.21-P-0001-03Z

Offline programming with SDflash Special Release-CD
Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220,
221, 230, 240, 245, 251
Model 461.302/304/331/332/334/342/344/345/346,
463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/308/309/322/323/332/33
Model 450, 451, 452, 454
Programming with STAR DIAGNOSIS (SDflash)
S TAR D IAGNOSIS flash : "SDflash" is the name given to the DaimlerChrysler standard for programming
control units.
In the process a distinction is made between two types of programming:
 Offline programming with SDflash Release-CD

 Offline programming with SDflash Special Release-CD
Further explanation of terms:
 Flashing: Programming of control units

 Software: Control unit software
 SDflash Release CD: Control unit software, integrated on DAS DVD
 SDflash Special Release CD: Special CD which contains software updates
 The SDflash Special Release CD is a special CD which contains software updates

 The workshop must ask for the SDflash Special Release CD at the STAR DIAGNOSIS user help desk
and request it via the usual ordering channels
 Manual redocumentation required in the vehicle documentation system (FDOK)
FLOW CHART FOR OFFLINE PROGRAMMING WITH SD FLASH SPECIAL RELEASE-CD -

AH54.21-P-0001-04Z
Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220,
221, 230, 240, 245, 251
Model 461.302/304/331/332/334/342/344/345/346,
463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/308/309/322/323/332/33
Model 450, 451, 452, 454
Fig. 3: Flow Chart For Offline Programming With SD Flash Special Release-CD
NOTES ON SCN CODING OF CONTROL UNITS - AH54.21-P-0004-01X
Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220,
221, 230, 240, 245, 251
Model 461.302/304/331/332/334/342/344/345/346,
463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/308/309/322/323/332/33
Model 450, 451, 452, 454
Model 639
Model 906
The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units relevant
to exhaust emission as of model year 2002.
Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN.
As a number the SCN consists of 16 numbers. The first 10 places correspond to the object number to be coded
(mostly object number of control unit software).
The next 2 places designate the manufacturing plant or field organization, in which the vehicle has been coded.
The last 4 places are a number of the variants of the coding string of the vehicle-specific as-built configuration.
This number is serially numbered for each newly formed variant.
codes must be added to the central system before requesting the SCN coding data. The appropriate national
organization must be contacted (MPC) for this.
BASIC KNOWLEDGE
CAN DATA BUS DATA TELEGRAM - GF54.00-P-0005-01A
During normal operation, messages consist of the following transfer frames:
 Data frame for transmitting CAN messages (such as coolant temperature, etc.).
 Remote frame for requesting CAN data from a different control unit.
 Error frame informs all connected control units that an error has occurred and that the most recent CAN
message is invalid.
The CAN protocol supports two different data frame formats, with the only difference residing in the length of
the identifier:
 Standard format
 Expanded format
Only the standard format is currently in use at DaimlerChrysler.
Fig. 4: CAN Data Bus Telegram

The data telegram for transmitting CAN messages through the CAN data bus consists of seven sequential
blocks:
 Start of Frame: (Start bit) Marks the start of a CAN message and synchronizes all stations.
 Arbitration Field: (identifier and) request) This field consists of the identifier (address) with 11 bits and
one control bit (remote transmission request bit). This control bit indicates if the message contains a data
frame or a remote frame without bytes.
 Control Field: (control bits) To distinguish between the standard and expanded format the control field (6
bit) contains a reserved bit for future expansions and the number of bytes contained in the data field in the
last 4 bits.
 Data Field: (data) The data field can contain between 0 and 8 bytes of data. A CAN message with a
length of 0 can be employed to synchronize distributed processes.
 CRC Field: (check field) The CRC Field (Cyclic-Redundancy-check field) consists of 16 bits and is used
to detect transmission errors.
 ACK Field: (receipt confirmation) The ACK Field (Acknowledgment Field) contains a confirmation
signal from all receivers that have received the CAN message without error.
 End of Frame: (frame end) Identifies the end of the data telegram
 Intermission:
(Intermission) Interval between two data telegrams
The interval must contain at least 3 bits. The next message can then be sent by any control unit.
 IDLE: (idle)
If no control unit transmits, the CAN data bus remains idle until the next message is sent.
CAN DATA BUS SPECIFICATION - GF54.00-P-0005-02A
In order to be able to process data in real time, it must be possible to transfer data quickly.
This presupposes not only a quick physical data path but also demands a quick CAN data bus division when
multiple control units simultaneously want to transfer.
To distinguish between the importance of different CAN messages that are being sent over the CAN data bus
there exists priorities for the individual messages.
The ignition angle, for example is assigned high priority, the slip value medium priority and the outside
temperature has a lower priority.
The priority by which the CAN message is established is through the identifier of the (address) particular CAN
message An identifier which corresponds to a low binary number has a high priority and vice versa.
The CAN log is based on two logical states: The bits are either "recessive state" (logical 1) or "dominant
state" (logical 0). If a dominant bit is sent by at least one station, recessive bits sent by other stations are
overwritten.
Example
If several control units transmit a message at the same time, the conflict of bus access is solved by means of bus
arbitration using the appropriate identifiers.
The transmitter checks every bit when the arbitration field is sent whether it is able to be sent or whether
another control unit is sending a CAN transmission of higher priority.
If a recessive bit transferred by the first sending unit is overwritten by a dominant bit from another sending unit,
the first sending unit looses its right to transmit (arbitration) and it becomes a receiver.
The first control unit (N I) looses arbitration with bit 3.
The third control unit (N III) looses arbitration with bit 7.
The second control unit (N II) retains bus access and can send its CAN message.
Fig. 5: CAN Data Bus Specification

The other control units then try to send their CAN messages when the CAN data bus is free. The send
authorization is then allocated again in accordance with the priority of the CAN message.
CAN DATA BUS FAULT RECOGNITION - GF54.00-P-0005-03A
Faults which occur during data transfer can result in errors. These transmission errors must therefore be
detected and rectified. A distinction is made between two levels of fault identification in the CAN protocol:
 Mechanisms at the data frame level

 Mechanisms at the bit level
Mechanisms at the data frame level
Cyclic redundancy check:
The transmitter establishes test bits from the CAN messages that are to be sent in the data telegram "CRC Field"
The receiver calculates these test bits from the received CAN message and compares them to the received test
bits.
Frame check:
This mechanism checks the structure of the transferred frame by comparing the bit fields with the specified
fixed format and frame length.
Errors detected using the frame check are referred to as format errors.
Mechanisms at the bit level
Monitoring:
During transmission every station observes the CAN data bus gauge and recognizes the difference between sent
and received bits. Both global and local bit errors which occur at the sending unit can therefore be detected.
Bit stuffing:
In each message, a maximum of 5 successive bits may have the same polarity between the "start of frame" and
the end of the "CRC field". After 5 consecutive identical bits, the sending unit inserts a bit of the opposite
polarity into the bit stream. The receiver removes these bits again after the CAN message reception.
Error handling
If any station on the CAN data bus detects an error, it interrupts the current transmission by sending an error
message. The error message consists of 6 dominant bits.
When an error message appears a local error is distributed to all the connected control units so that they ignore
the transmitted CAN message.
After a short interruption the other control units can transmit CAN messages again according to their priority.
The control unit whose CAN message caused the error also begins to send its CAN message again (Automatic
Repeat Request).
CAN DATA BUS APPLICATIONS - GF54.00-P-0005-04A
Application areas for the CAN data bus
At this time different CAN data bus systems are used for the engine compartment and the passenger
compartment. They differ from one another by the rate of transmission.
The engine compartment CAN (CAN-C) has a transfer rate of 500 kbit/ sec, the interior CAN (CAN-B) only
has a transfer rate of 83 kbit/sec due to the less time-critical CAN messages.
Data is exchanged between the two data bus systems via so-called "Gateways", control units which are
connected to both.
CAN C/CAN engine compartment

On the last control unit on each side there is a so-called data bus terminator, a resistor with 120, which is
connected between the two message, the two lines.
The CAN engine compartment is only active when the ignition is turned on.
CAN B/CAN passenger compartment
Many of the control units that are found in the CAN passenger compartment are not dependent upon the
activation of the ignition (for example, central locking).
In this case the CAN passenger compartment has to be accessible with out ignition. This means that it can
transmit data telegrams without the ignition being activated.
To keep the resting energy consumption as low as possible the CAN data bus goes into a "sleeping mode" if no
data telegrams are being transmitted and is activated again when the data bus is accessed.
If when the interior CAN is "sleeping" a control unit (e.g. on model 202: overhead control panel control unit
(N70) ) transmits a CAN message, the CAN-message is only received from the master (e.g. on model 202: EIS
[EZS] control unit (N73) ). The respective master control unit stores the CAN message and transmits a wake-
up message (Wake-up) to all control units on the interior CAN For "wake-up" the control unit (N73) checks the
presence of all participants on the CAN data bus and then sends the message stored previously.
CAN DATA BUS, FUNCTION - GF54.00-P-0005A
MODELS 124, 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463
The CAN data bus (C ontroller A rea N etwork) is a data bus system specifically designed for used in vehicles.
The CAN data bus is a bi-directional bus, that is, each connected control unit is able to send and receive
information.
The CAN data bus consists of a special twisted two-core cable. The users (control units) are connected to this
cable. Transmission of data takes place redundantly via both cables, whereby the data bus levels are mirrored
(that is, if the level on one cable is 0, the other cable transmits level 1 and vice versa). Two-line operation is
used for two reasons: for fault detection and as a safety concept.
If a voltage peak occurs on just one line (e.g. due to EMC problems), the receivers can identify this as a fault
and ignore the voltage peak.
If a short circuit or a discontinuity occurs on one of the two CAN lines, then due to a safety concept coupled to
the software/hardware, the system can change over to single-line operation. The defective data line is shut
down.
A specific data protocol controls how and when the participants can send and receive.
The CAN data bus is significantly different to other data bus systems that are based on the participant
addressing principle, in that it uses a message-related addressing system.
That means, every CAN message is assigned a fixed address (identifier), which identifies the CAN message
content (e.g. coolant temperature). The CAN log permits up to 2048 different CAN messages, the addresses of
2033 to 2048 being permanently assigned. Data capacity per CAN message is 8 bytes.
A recipient only evaluates those CAN messages (data messages) which are stored in its list of CAN messages to
be accepted (acceptance filtering).
Data messages can only be sent when the CAN data bus is free (i.e. once a 3 bit interval has elapsed after the
last data message, and no control unit starts to send). The data bus level is then in recessive state (logical 1).
If several control units simultaneously start to send, a procedure is applied whereby the CAN message with the
highest priority takes precedence, without loss of time or bits (attributing).
Each control unit which looses the attributing becomes a receiver automatically and repeats its transmission
attempt as soon as the CAN data bus is free again.
Besides data messages, there is also a request message used for calling a particular CAN message.
The control unit that can provide the requested data message then reacts to the request.
CAN data bus data telegram GF54.00-P-0005-01A

CAN data bus specification GF54.00-P-0005-02A
CAN data bus fault recognition GF54.00-P-0005-03A
CAN data bus applications GF54.00-P-0005-04A
CAN DATA BUS, FUNCTION - GF54.00-P-0005BK
MODEL 164.1 with ENGINE 113.964
Shows model 219

Fig. 6: CAN Data Bus Function Diagram - Engine 113.964

CAN stands for "C ontroller A rea N etwork". This is an electrical bus system for carrying data over two wires.
The tasks are:
 Data transfer between individual control units

 Readying sensor signals for several systems
 Reducing the number of electric cables
 Improve electromagnetic compatibility.
The CAN data bus consists of a special twisted two-core data line that connects all CAN users (control units) in
parallel.
The two lines of the data line must not be mixed up (LOW-/HIGH-level). The ME control unit always
represents a terminal with regard to bus adaptation.
A 120 ohms terminating resistor is therefore installed in the motor electronics control unit.
The data are transmitted digitally over the CAN databus at various intervals. The individual data blocks are
defined in a data protocol and it is specified which data are received or transmitted by a control unit.
Each connected control unit is able to transmit or receive data (bidirectional bus). The sum of the data blocks,
the short break between two transmission intervals and additional properties of the CAN data bus are checked
constantly. Detected faults are stored and placed in the fault memory.
In the vehicle a distinction is made between a fast engine CAN data bus (CAN CLASS "C") for the drive and
chassis systems and the slightly slower body CAN data bus (CAN CLASS "B") for the vehicle interior.
The interface of the two CAN data buses (gateway) takes place in the central gateway control unit (N93), which
also represents the interface between the control units on the CAN data bus and the line to the data link
connector (X11/4) for STAR DIAGNOSIS.
When a control unit is replaced, the new control unit must be coded again.
This control unit coding is via a menu of the STAR DIAGNOSIS menu.
CAN data bus, see also wiring diagrams.
The international standardized network management "OSEK" (open systems and their interfaces for
electronics in vehicles) is used for all control units on the CAN data bus.

CAN DATA BUS, FUNCTION - GF54.00-P-0005GZ
Fig. 7: CAN Data Bus Function Diagram - Engine 156.980

The tasks are:
 Data transfer between individual control units

 Reducing the number of electric cables
 Improving the electromagnetic compatibility (EMC)
parallel.
The two lines of the data line must not be mixed up (low level/high level). The ME control unit always
represents a terminal with regard to bus adaptation.
A 120 ohms terminating resistor is therefore installed in the motor electronics control unit.
The data are transmitted digitally over the CAN databus at various intervals. The individual data blocks are
defined in a data protocol and it is specified which data are received or transmitted by a control unit. Each
connected control unit is able to transmit or receive data (bidirectional bus).
The sum of the data blocks, the short break between the two transfer intervals and other properties of the CAN
data bus are checked constantly. Detected faults are stored and placed in the fault memory.
In the vehicle a distinction is made between the fast (500 kbit/s) drive train CAN data bus for the engine
systems, transmission systems and chassis systems and the slower (83.3 kbit/s) interior CAN data bus for the
systems in the vehicle interior.
In addition for vehicle diagnosis there is a diagnosis CAN data bus with a speed of 500 kbit/s.
The interface between the three CAN data buses (Gateway) is located in the central gateway control unit.
The instrument cluster, the EIS [EZS] control unit and the steering column module are connected both to the
interior CAN data bus and to the drive train CAN data bus and exchange data with both data bus systems.
However they do not serve as an interface (Gateway) between tow data bus system
When a control unit is replaced, the new control unit must be coded again.
This control unit coding takes place via a STAR DIAGNOSIS menu.
The international standardized network management "OSEK" (O pen systems and their I nterfaces for E
lectronics in motor vehicles) is used for all control units of the CAN data bus.
ME-SFI [ME] control unit, component description GF07.61-P-6000AMG
CAN DATA BUS, FUNCTION - GF54.00-P-0005VA
MODEL 203, 209 with ENGINE 272.940

The tasks are:
 Data exchange between the individual control units

 Reducing the number of wires
 Improving the electromagnetic compatibility (EMC)
parallel.
The two wires of the data line must not be mixed up (low level / high level). The motor electronics (N3/10)
control unit is always a consumer with regard to bus adaptation.
A 120 ohms terminating resistor is therefore installed in the Motor electronics control unit.
The data are transmitted digitally over the CAN data bus at various intervals. The individual data blocks are
defined in a data protocol and it is specified which data are received or transmitted by a control unit.
Each connected control unit is able to transmit or receive data (bidirectional data bus).
The sum of the data blocks, the short break between two transmission intervals and additional properties of the
CAN data bus are checked constantly. Detected faults are stored and placed in the fault memory.
In the vehicle a distinction is made between the fast (500 kbit/s) engine compartment data bus and diagnostic
CAN-data bus and the slower (83.3 kbit/s) interior CAN data buses.
The new control unit must be coded when a control unit is replaced.
This control unit coding takes place via a STAR DIAGNOSIS menu.
The international standardized network management "OSEK" (O pen systems and their I nterfaces for E
lectronics in motor vehicles) is used for all control units of the CAN data bus.
ME-SFI [ME] control GF07.61-P-6000V

unit, component
description
FUSE AND RELAY BOX, AS-BUILT CONFIGURATION - GF54.15-P-0800GZ
MODEL 164
Shown on model 164.1 before production period 31.05.2006
Fig. 8: Identifying Fuse And Relay Box Components - Shown On Model 164.1 Before Production Period
31.05.2006
Shown on model designation 164.1 as of production period 01.06.2006
Fig. 9: Identifying Fuse And Relay Box Components - Shown On Model Designation 164.1 As Of
Production Period 01.06.2006
Fuse assignment of fuse and relay box in right engine compartment GF54.15-P-1256-02GZ
Fuse assignment of front prefuse box GF54.15-P-1256-07GZ
Fuse assignment of load compartment fuse and relay box GF54.15-P-1256-14GZ
Fuse assignment of battery compartment prefuse box GF54.15-P-1256-15GZ
Fuse assignment of fuse box in cockpit GF54.15-P-1256-16GZ
Relay assignment of fuse and relay box in right engine compartment GF54.15-P-1257-02GZ
Relay assignment of the load compartment fuse and relay box GF54.15-P-1257-08GZ
FUSE ASSIGNMENT OF FUSE AND RELAY BOX IN RIGHT ENGINE COMPARTMENT - GF54.15-
P-1256-02GZ
The engine compartment fuse and relay box is located in the right of the engine compartment.
Fig. 10: Identifying Fuse And Relay Box

Fuse Clamping Cable ID (cable Fused function Rating in

device fused) amperes (A)
f100 30 -  For wiper motor (M6/1) via wiper level relay 30

1/2 (F58kA)
f101 87 1.0 PK  AAC with integrated control additional fan 15

motor (M4/7)
1.0 PKWH Valid for engine 113:
 Purge control valve (Y58/1)
1.0 PKWH Valid for engines 272, 273:

 Purge control valve
1.0 PK  Suction-type fan control unit (N65/2)
1.5 PKBU  Terminal 87M1e connector sleeve (Z7/35)
 CDI control unit (N3/9)
 O2 sensor upstream of CAT (G3/2)
1.0 PK  Suction fan control unit
2.5 PKBK Valid for engine 642:
 CDI control unit
2.5 PKWH  O2 sensor upstream TWC
1.0 PK  Suction fan control unit
f102 0.75 RDBU Valid for engine 642: 15

 Recirculation pump for transmission oil

cooler (M13/7)
Valid for engine 156:
 engine coolant circulation pump (M45)
f103 87 1.0 PKBK Valid for engines 113, 272, 273: 25
 ME-SFI [ME] control unit (N3/10/)
1.5 PKBK  Circuit 87M1e connector sleeve

f104 87 0.75 WHBU Valid for engine 113: 15
 ME control unit
1.5 PKBK Valid for engines 272, 273:
 Terminal 87 M2e connector sleeve (Z7/36)

 Terminal 87 connector sleeve (Z7/5)
 Circuit 87 connector sleeve
f105 87 1.5 PKBK Valid for engine 113: 15
 circuit 15 connector sleeve, fused (Z3/29)
1.5 PKBK Valid for engines 272, 273:
 ME control unit
1.0 PK  Terminal 87 M1i connector sleeve (Z7/38)
 Starter (M1) 25
f106 - - - -
f107 4.0 GNWH Valid for engine 113: 40
 Electric air pump (M33)
4.0 WHBU Valid for engine 272:

 Electric air pump
Valid for code 214 Adaptive damping system
f108 4.0 GYWH 40
(ADS) with skyhook and level control:
 AIRmatic compressor unit (A9/1)
f109 30 2.5 RD 25
 ESP control unit (N47-5)
f110 30  Alarm signal horn with additional battery 10

(H3/1)
f111 30 2.5 RDBK  Intelligent servo module for DIRECT 30

SELECT (A80)
f112 15 1.5 BK  Left front lamp unit (E1) 7.5
1.5 BKBU Right front lamp unit (E2)
f113 15 1.5 BUWH Via fanfare horn relay (F58kF): 15
 Left fanfare horn (H2)
 Right fanfare horn (H2/1)
f115 15 0.75 BKBU  ESP control unit 5
f116 15 1.0 RD Electric controller unit (VGS) (Y3/8) 7.5
f117 15 DTR controller unit (A89) 7.5
f118 15 0.75 BKBU Valid for engine 272: 5
ME control unit
0.5BKBU Valid for engine 642:
f119 - - - -
f120 30 1.0RDBK Valid for engine 113: 10
ME control unit
0.75RDBK Valid for engines 272, 273:
ME control unit
0.75RDBK Valid for engine 629:
As of production period 01.06.2006, valid for

f121 30 20
code 494 USA version:
Code 228 Stationary heater
f122 50 2.5 GYWH Valid for engine 113: 25
ME control unit
2.5 RDWH Valid for engines 272, 273:
ME control unit
2.5 PK Valid for engine 629:
 Starter
2.5 PK Valid for engine 642:

 Starter
f123 - - - -
f124 - - - -
f125 - - - -
FUSE ASSIGNMENT OF FRONT PREFUSE BOX - GF54.15-P-1256-07GZ
The prefuse box is located next to the air inlet of the air conditioning.
Fig. 11: Identifying Front Prefuse Box


- - - -
- - - -
f6 30z RD 4.0  ESP control unit (N47-5) 40
f7 30z 12,0 RD  AAC with integrated control additional 100

fan motor (M4/7)
f8 30z 10,0 RD  Engine compartment fuse and relay box 150

(F58)
FUSE ASSIGNMENT OF LOAD COMPARTMENT FUSE AND RELAY BOX - GF54.15-P-1256-14GZ
Fuse assignment before production period 31.05.2006
The load compartment fuse and relay box is installed in the load compartment on the right of the wheelhouse.
Fig. 12: Identifying Load Compartment Fuse And Relay Box

Fuse assignment as of production period 01.06.2006
Fig. 13: Identifying Load Compartment Fuse And Relay Box

Fuse Clamping Cable ID Fused function Rating in

device (cable fused) amperes
(A)
f20 30 0.75 RD  Roof antenna module (A2/93) 5

f21 30 0.5 RD  RCP [HBF] control unit (N72/2/) 5
f22 30 0.5 RD Valid for code 220 Parktronic system (PTS): 5
 PTS control unit (N62)
with code 228 Stationary heater, except code 430
30 5
Offroad package, as of production period 01.06.2006:
 Telestart stationary heater
f23 30 0.75 RD Valid for code 159 Rear audio system: 10
 Rear audio control unit (N66/8)
Valid for code 864 Rear entertainment system:
 DVD player (A40/4)
0.5 RDWH Valid for code (498) Japanese version:
 Portable CTEL separation point (X39/37)
Valid except code 494 USA version and except code 498
1.0 RDWH
Japan version:
 E-net compensator (A28/3/)
 Universal Portable CTEL Interface (UPCI [UHI])
control unit (N123/1/)
Valid for code 242 Electrically adjustable front
f24 30 4.0 RD passenger seat with memory (only with PRE-SAFE 40
system):
 Right front reversible emergency tensioning retractor
(A76/1)
f25 30 1.5 RD Valid for code 528 HIGH Class USA: 15
 COMAND operating, display and controller unit
(A40/3/)
Valid for code 530 COMAND APS USA (with
navigation):
Valid for code 498 Japan version:
f26 30 2.5 RD  Right front door control unit (N69/2/) 25
f27 30 2.5 RDBU  Front passenger seat adjustment comfort relay 30

(K24/2)
Valid for code 242 Electrically adjustable front
2.5 RD
passenger seat with memory:
 Passenger-side front seat adjustment control unit with
memory (N32/2/)
f28 30 2.5 RDWH  Driver seat adjustment comfort relay (K24/1) 30
Valid for code 275 Electrically adjustable driver seat,

2.5 RD
steering column and outside mirrors with memory:
 Driver-side front seat adjustment control unit, with
memory (N32/1)
Valid for code 275 Electrically adjustable driver seat,
f29 30 4.0 RD 40
steering column and outside mirrors with memory
Only on PRE-SAFE system:
 Left front reversible emergency tensioning retractor
(A76)
f30 30 2.5 RDBK Valid for engine 156: 40
 Left fuel pump control unit (N118/3)
 Right fuel pump control unit (N118/4)
Valid for code 401 Front luxury seats, including heated
f31 30 0.75 RD 10
seats and seat ventilation:
 HS [SIH], seat ventilation and steering wheel heater
control unit (N25/7)
Valid for code 489 Airmatic (semi-active air suspension)
and/or code 213 speed-sensitive power steering and/or
f32 30 1.5 RDWH 15
code 214 Adaptive damping system (ADS) with skyhook
and level control:
 AIRmatic control unit (N51)
f33 30 2.5 RD Valid for code (889) Keyless Go: 25
 Keyless Go control unit (N69/5/)
f34 30 2.5 RD  Left front door control unit (N69/1/) 25
f35 30 4.0 RDBK Valid for code (810) sound system: 30
 Amplifier for sound system (N40/3)
f36 30 0.75 RD Valid for code (359) TELE AID emergency call system: 10
 Emergency call system control unit (N123/4/)
Valid for code (498) Japanese version:
 Emergency call system control unit
with code 218 Backup camera system, except code 849
spare tire holder/spare tire holder, except code 498
f37 0.5 RDBK 5
Japan version, except code 494 USA version, as of
production period 01.06.2006:
 Backup camera voltage supply module (N66/10)
with code 218 Backup camera system, except code 849
spare tire holder/spare tire holder, valid for code 498
Japan version, as of production period 01.06.2006:
 Backup camera control unit (N66/2/)
f38 30 2.5 RD Valid for code 498 Japan version: 10
 Audio gateway control unit (N93/1/)

With TV combination tuner (analog/digital) (A90/1),
0.75RDBK except code 498 Japan version, except code 494 USA
version:
 TV combination tuner (analog/digital)
f39 30 0.5 RDBK Valid for code 494 USA version 7.5
 SDAR control unit (N87/5)
0.75 RD Valid for code 475 Tire pressure monitor:
 TPM [RDK] control unit (N88)
f40 30 4.0 RD Valid for code 890 Automatic rear-end door: 40
 Rear-end door closing control unit (N121/1)
f41 30 2.5 RD  Overhead control panel control unit (N70) 25
with code 414 Power glass tilting/sliding roof:
f42 30 25
SR motor (M12m1),
f43 30 Up to production period 31.05.2006: 20
 Tailgate wiper motor (M6/4)
- - As of production period 01.06.2006: -
 Not assigned
f44 87 2.5 BKBU Up to production period 31.05.2006: 20
 Left 2nd seat row socket (X58/19)
 Right 2nd seat row socket (X58/20)
 Not assigned
f45 30 1.5 BKBU  Front interior socket (X58/17) 20
Up to production period 31.05.2006:
2.5 BKBU  Cargo area connector box (X58/4)
f46 87 1.5 BKBU  Front cigar lighter with ashtray illumination (R3) 15
f47 - - - -
f48 - - - -
f49 4.0 RDBK  Heated rear window (R1) 30
f50 30 1.0 BUBK Up to production period 31.05.2006: 10
 Tailgate wiper motor
15R 1.0 RDBK As of production period 01.06.2006: 15
 Tailgate wiper motor
f51 15 0.75 RDWH  Activated charcoal filter shutoff valve (Y58) 5
f52 15 0.5BKBU  Emergency tensioning retractor 5
Valid for code (489) Airmatic (semi-active air
f53 15 0.5 PKWH 5
suspension) and code (214) Adaptive damping system
(ADS) with skyhook and level control:

 Airmatic control unit
Valid for engine 156:
 Left fuel pump control unit (N118/3)
 Right fuel pump control unit (N118/4)
f54 15 0.35 PK  Front SAM control unit (N10) 5
As of production period 01.06.2006, with Bi-xenon
headlamp unit, code 615:
 Headlamp range adjustment control unit (N71)
 Rotary light switch (S1)
f55 15 0.5BKBU 7.5
f56 15 0.5BKBU Up to production period 31.05.2006: 5

 Data link connector (X11/4/)
 not assigned
f57 2.5 RDWH  Fuel pump with fuel gauge sensor (M3/3) 20
f58 30 0.5 RD  Data link connector 7.5
0.75 RD  Central gateway control unit (N93)
f59 - - - -
f60 15R 0.5BKBU  Glove compartment illumination with switch (E13/2) 5
0.5 VT  Engine compartment fuse and relay box (F58) for

Wiper ON/OFF relay (F58kB)
Valid for code 386 Preinstallation for telephone
0.5 BKWH
"Handy", UPCI system:
 CTEL separation point
0.5 BKWH Valid for code 498 Japan version:
 VICS+ETC voltage supply separation point (X137/1)
0.5 PKWH Rear SAM control unit (N10/8)

Valid for code 494 USA version and/or valid for code
0.75 BKWH
359 TELE AID emergency call system:
 Emergency call system control unit
f61 15R 0.5BKBU  Restraint systems control unit (N2/7/) 10
0.75 BKWH  Right front seat contacting strip (X55/4)
f62 15R 2.5 BKBU  Front passenger seat adjustment switch (S23) 30
f63 15R 2.5 BKWH  Driver seat adjustment switch (S22) 30
f64 - - - -
f65 - - - -
f66 - - - -
Not valid for model designation 164.1, valid for code 582
f67 30 25
Rear air conditioner:
 Booster blower motor (M2/1)
f68 30 2.5 RD 401 Front comfort seats, incl. seat heating and seat 25
ventilation:
 Left 2nd row seat heated cushion (R13/5)
 Right 2nd row seat heated cushion (R13/7)
f69 - - - -
f70 30 2.5 RD Valid for code 550 Trailer hitch: 20
0.35  Trailer hitch socket (7-pin) (X58/11)
15  Trailer hitch socket (13-pin) (X58) 15
f71 30 2.5 RD 30
550 Trailer hitch:
 Electric brake control separation point (X58/28)
f72 15R  Trailer hitch socket (13-pin) 15
FUSE ASSIGNMENT OF BATTERY COMPARTMENT PREFUSE BOX - GF54.15-P-1256-15GZ
The battery compartment prefuse box is located next to the power supply battery below the front passenger seat.
Fig. 14: Identifying Battery Compartment Prefuse Box And Fuses


f78 30  PTC heater booster (R22/3) 150
f79 30 6,0 RD
 Rear SAM control unit (N10/8) 60

f80 30 6,0 RD  Rear SAM control unit 60
f81 - - - -
f82 30 10,0 RD  Load compartment fuse and relay box 150

(F4)
f83 30 0.5 RD  WSS (Weight Sensing System) control 5

unit (N2/13)
f84 30 0.75RDBK  Restraint systems control unit (N2/7/) 10
f85 30 2.5 RDVT  Intelligent servo module for DIRECT 30

SELECT (A80)
f86 30 4.0 RDBK  Cockpit fuse box (F3) 30
f87 30 2,5 RDWH Valid for code 430 Offroad package: 30
 Transfer case control unit (N15/7)
f88 30 6,0 RD  Front SAM control unit (N10) 70
f89 30 6,0 RD  Front SAM ECU 70
f90 30 6,0 RD  Front SAM ECU 70
f91 30 4,0 RD  Blower regulator (A32n1) 40
FUSE ASSIGNMENT OF FUSE BOX IN COCKPIT - GF54.15-P-1256-16GZ
The cockpit fuse box is located in the cockpit on the passenger-side.
Fig. 15: Identifying Cockpit Fuse Box And Fuses


f10 30 1.0 RD  Booster blower electronic blower 10

controller (N29/2)
f11 30 0.5 RDWH  Instrument cluster (A1) 5
 AAC [KLA] control and operating unit

f12 30 1.5 RDBK (N22) 15

f13 30 0.5 RDBU  Steering column module (N80) 5
0.5 RDBU  Upper control panel control unit

(N72/1/)
F14 30 0,75 RDWH  EIS [EZS] control unit (N73) 7.5
0,75 RDWH Valid for code 819 CD changer (6CDs):
 CD changer (A2/6/)
f15 30  Electronic compass (B26) 5
F16 - - - -
F17 - - - -
F18 - - - -
RELAY ASSIGNMENT OF FUSE AND RELAY BOX IN RIGHT ENGINE COMPARTMENT -

GF54.15-P-1257-02GZ
The engine compartment fuse and relay box is located in the right of the engine compartment.
Fig. 16: Relay Assignment Of Fuse And Relay Box In Right Engine Compartment
Relays Designation
A Wiper level relay 1/2
B Wiper ON / OFF
Valid for engine 642: additional circulation pump for transmission oil cooling
C
Valid for engine 156: engine coolant circulation pump (M45)
D Terminal 87 engine
E Secondary air injection pump

F Fanfare horn
G Air suspension compressor
H Circuit 15
I Starter
RELAY ASSIGNMENT OF THE LOAD COMPARTMENT FUSE AND RELAY BOX - GF54.15-P-
1257-08GZ
Relay assignment before production period 31.05.2006
Fig. 17: Identifying Load Compartment Fuse And Relay Box - Relay Assignment Before Production
Period 31.05.2006
Relay assignment as of production period 01.06.2006

Fig. 18: Identifying Load Compartment Fuse And Relay Box - Relay Assignment As Of Production
Period 01.06.2006
Relays Designation
Before production period 31.05.2006
 Terminal 15R power outlet relay, with power-down

K
As of production period 01.06.2006
 Circuit 15R seat adjustment

Valid for code 550 Trailer hitch:
L
Terminal 30X
M Heated rear window relay
N Circuit 15 relay / terminal 87FW
O Fuel pump relay
P Rear wiper relay
R Circuit R relay 115R
S -
T
 Circuit 30, socket for 2nd seat row and load compartment
U
 Circuit 30, trailer

V
-
CENTRAL GATEWAY CONTROL UNIT, COMPONENT DESCRIPTION - GF54.21-P-4170GZ
MODEL 164
Fig. 19: Identifying Central Gateway Control Unit

Location
The central gateway control unit (N93) is located in the driver footwell on the left in the direction of travel.
Tasks
 Gateway between the CAN class B and CAN class C as well as CAN class D
 Global variant coding (with networked control units the central gateway transmits global information
such as model series and national version to the CAN-B control unit, CAN-C control unit and CAN-D
control unit)
 Router between CAN-class B and diagnostic CAN
 Router between CAN class C and diagnostic CAN
 Diagnosis between CAN class B and diagnostic CAN
 Diagnosis between CAN-class C and diagnostic CAN
 Data container
In the vehicles there are 3 CAN buses which are connected by the central gateway control unit:
 Diagnostic CAN with a transfer rate of 500 kbit/s

 CAN-Class B with a transfer rate of 83.3 kbit/s
 CAN-Class C with a transfer rate of 500 kbit/s
RAIN/LIGHT SENSOR, COMPONENT DESCRIPTION - GF54.21-P-6000GZ
MODEL 164
Location
The rain/light sensor is located on the inside of the windshield under the inside rearview mirror.
Task
Measuring light intensity and quantity of water on windshield.
Fig. 20: Identifying Rain/Light Sensor Location

Function principle of rain sensor
Infrared light is beamed from the infrared transmitter unit (1) and is directed to the windshield (3). The intensity
of light reflected at the windshield (3) is measured by the IR-receiver unit (2) If the windshield (3) is dry in the
area of the rain/light sensor (picture A), then the light is almost completely reflected and the IR-receiver unit (2)
measures a high light intensity.
If the windshield (3) is wet in the area of the rain/light sensor (picture B), then part of the light is scattered out
of the glass of the windshield (3). As a result the intensity of the reflected light reduces and the IR-receiver unit
(2) measures a lower light intensity.
The light intensity measured by the IR receiver unit (2) is a dimension for the quantity of water on the
windshield (3). The lower the measured light intensity the greater the amount of water on the windshield (3).
Fig. 21: Function Principle Of Rain Sensor

Function principle of light sensor
The rain/light sensor measures the outside light intensity.
The information is transmitted to CAN class B by the overhead control panel control unit (N70).
UPPER CONTROL PANEL CONTROL MODULE COMPONENT DESCRIPTION - GF54.21-P-

6040GZ
MODEL 164.1 /8 with CODE (489) Airmatic (air suspension with level adjustment and adaptive damping
system ADS) except CODE (430) Offroad package
Location
The upper control panel control unit is located in the center console.
Fig. 22: Identifying Upper Control Panel Control Unit - Shown On Model 164.8
Task
Scanning the following switches:
 ESP OFF switch (N72/1s1)

 Level adjustment switch (N72/1s2)
 Hazard warning system switch (N72/1s5)
 PTS OFF switch (N72/1s8)
 Left front HS [SIH] switch (N72/1s10)
 Right front HS [SIH] switch (N72/1s11)
 Left front seat ventilation switch (N72/1s13)
 Right front seat ventilation switch (N72/1s14)
 Downhill Speed Regulation switch (N72/1s24)
 Offroad program switch (N72/1s25)
 Stationary heater switch (N72/1s30)
 Comfort/Sport switch (ADS) (N72/1s31)
Reading in the following function indicator lamps:
 Automatic child seat recognition airbag OFF indicator lamp (N72/1e1)

 ATA [EDW] function indicator (N72/1e2)
Voltage supply and reading in of data:
 of rotary light switch (S1) over an LIN bus

 of lower control panel control unit (N72) over an LIN bus
Function
ESP OFF switch
The ESP Off switch can be used to switch the anti-slip control of the "Electronic Stability Program" on and off.
The function requirements for this switch is circuit 15 "ON". The function of the ESP systems is indicated in the
Level control switch
 Term. 15 "ON"
Switch actuations enable the driver to choose between a highway level and a raised level. The vehicle is in the
highway level state (no function indicator). If the vehicle is lifted to the raised level, the LED in the switch
flashes on and off. When the level is reached the LED remains constantly on. The last stage selected with
function indicator is active once the engine is started again.
Hazard warning system switch
Pressing the hazard warning system switch wakes-up the upper control panel control unit from its "Sleep mode"
and the hazard warning system function is activated. The message is sent cyclically (every 100 ms) until the
function is deactivated by pressing the hazard warning system switch again. The flashing function illumination
of the hazard warning system switch is triggered by the CAN message of the rear SAM control unit (N10/8).
There is no faster flashing of a defective indicator lamp for the hazard warning flasher system. As soon as the
hazard warning flasher function is activated the switch and controls illumination for the hazard warning system
switch is switched off. The function illumination of the hazard warning system is not dimmed.
The selected function is confirmed when the indicator lamps (LEDs) light up. The pulse to light up is sent by
each respective control unit.
PTS OFF switch
The Parktronic system is activated or deactivated via the PTS OFF switch. If the switch is actuated, the upper
control panel control unit sends a signal to the PTS control unit (N62) via CAN-B. The PTS control unit then
sends a message requesting actuation of the status LED in the PTS OFF switch back to the upper control panel
control unit.
Left front HS [SIH] switch and right front HS [SIH] switch
The heated seats have 3 stages. One-time actuation of the SIH switch activates stage 3 of the heated seats (all 3
red LEDs light up). Further actuations switch to stage 2 (the two lower LEDs go on), to stage 1 (the lowest LED
goes on), or the heated seats are switched off (no function indicator). The function requirements for this switch
is circuit 15R "ON". Each press of the left front HS [SIH] switch and right front HS [SIH] switch is sent by the
upper control panel control unit over the CAN-B.
Left front seat ventilation switch and right front seat ventilation switch (only model 164.8)
When the left front and right front seat ventilation switch is actuated, the upper control panel control unit sends
a signal to the HS [SIH], seat ventilation and steering wheel heater control unit (N25/7) via CAN-B.
The switch is used to switch the seat ventilation in the respective seat on and off, and also to control the
ventilation output. The level of ventilation output is displayed by indicator lamps in the respective switch.
Downhill Speed Regulation switch
The driver can switch the DSR on and off using the Downhill Speed Regulation switch. A red LED integrated
into the switch indicates whether the function is active or not. Downhill Speed Regulation is an aid for driving
down hills with an adjustable speed that can be set between 4 and 18 km/h.
Offroad program switch
The offroad program switch is used to adjust the dynamic characteristics of the vehicle in order to optimize
traction and forward propulsion in offroad operation (e.g. by changing the shifting behavior of the automatic
transmission).
STH switch
The function of the STH switch depends on the current terminal status. Whenever the stationary heater is
activated, the AAC [KLA] control and operating unit (N22) receives a query as to whether heating or
ventilation is required. The currently active function is displayed by an indicator lamp in the STH switch as
follows:
 Indicator lamp red: Heating mode

 Indicator lamp blue: Ventilation mode
 Indicator lamp yellow: Activation of stationary heater via timer
Function with terminal 15R OFF
If the switch is actuated, the system is switched on or off immediately. When switched on, the upper control
panel control unit sends a signal to the heater booster control unit (N33/2). The latter then sends the command
to switch on the stationary heater to the AAC [KLA] control and operating unit.
Since the AAC [KLA] control and operating unit needs time to decide whether heating or ventilation is
required, the red indicator lamp is activated by the upper control panel control unit immediately after the switch
is actuated.
The AAC [KLA] control and operating unit permanently switches the indicator lamp to the appropriate color
depending on whether heating or ventilation is required.
Function with terminal 15R ON
If the switch is actuated for less than 2 s with the system switched off, the timer menu is shown in the
multifunction display (A1p13) in the instrument cluster. The system will be activated if the switch is pressed for
a longer time.
If the system is already activated, it is switched off again immediately without the timer menu being displayed.
Comfort/Sport switch (ADS)
The driver can program the damping level as desired using the Comfort/Sport switch (ADS):
1. "AUTO" Skyhook mode

2. "SPORT" Firm damping
3. "COMFORT" Soft damping
In the "SPORT" setting the upper LED goes on and for the "COMFORT" setting the lower LED goes on. If the
vehicle is in the "AUTO" mode nothing is displayed in the Comfort/Sport switch (ADS).
Discrete inputs:
 Circuit 30
 Circuit 31
 CAN-B
Discrete outputs:
 Circuit 30
 Circuit 31
 LIN bus
Voltage limit:
The operating voltage is between 12 and 14 V.

6040GZA
MODEL 164.8 with CODE (489) AIRmatic (air suspension with level adjustment without ADS adaptive
damping system) with CODE (494) USA version
Location
Fig. 23: Identifying Upper Control Panel Control Unit

Task

 Level adjustment switch (N72/1s2)
 Downhill Speed Regulation switch (N72/1s24)
 Offroad program switch (N72/1s25)


Function
ESP OFF switch
PTS OFF switch
control unit.
Left front seat ventilation switch and right front seat ventilation switch (only model 164.8)
When the left front and right front seat ventilation switch is actuated, the upper control panel control unit sends
a signal to the HS [SIH], seat ventilation and steering wheel heater control unit (N25/7) via CAN-B.
The switch is used to switch the seat ventilation in the respective seat on and off, and also to control the
ventilation output. The level of ventilation output is displayed by indicator lamps in the respective switch.
Level control switch
 Term. 15 "ON"
Function:
Switch actuations enable the driver to choose between a highway level and a raised level. The vehicle is in the
highway level state (no function indicator).
If the vehicle is lifted to the raised level, the LED in the switch flashes on and off. When the level is reached the
LED remains constantly on. The last stage selected with function indicator is active once the engine is started
again.
Downhill Speed Regulation switch
Offroad program switch
The offroad program switch is used to adjust the dynamic characteristics of the vehicle in order to optimize
traction and forward propulsion in offroad operation
(e.g. by changing the shifting behavior of the automatic transmission).
Discrete inputs:
 Circuit 30
 Circuit 31
 CAN-B
Discrete outputs:
 Circuit 30
 Circuit 31
 LIN bus
Voltage limit:

6040GZU
MODEL 164.1 /8 with CODE (489) Airmatic (air suspension with level adjustment and adaptive damping
system ADS) with CODE (430) Offroad package with CODE (494) USA version

Fig. 24: Identifying Upper Control Panel Control Unit - Shown On Model 164.1
Location
Task

 Comfort/Sport switch (ADS) (N72/1s31)
 Transmission mode switch (N72/1s32)


Function
ESP OFF switch
PTS OFF switch
control unit.
Comfort/Sport switch (ADS)
The driver can program the damping level as desired using the Comfort/Sport switch (ADS):
1. "AUTO" Skyhook mode

2. "SPORT" Firm damping
3. "COMFORT" Soft damping
In the "SPORT" setting the upper LED goes on and for the "COMFORT" setting the lower LED goes on. If the
vehicle is in the "AUTO" mode nothing is displayed in the Comfort/Sport switch (ADS).
Transmission mode switch
Pressing the transmission mode switch enables the driver to choose between a comfort-oriented and a sporty
transmission program. The transmission mode switch is read in by the upper control panel control unit and sent
to the CAN-B. The central gateway control unit (N93) reads in this message and then sends it over the CAN-C
to the fully integrated transmission control (VGS) control unit (Y3/8n4). Each respective transmission program
is selected in the fully integrated transmission control (VGS) control unit.
The function requirements for this switch is circuit 15R "ON".
Discrete inputs:
 Circuit 30
 Circuit 31
 CAN-B
Discrete outputs:
 Circuit 30
 Circuit 31
 LIN bus
Voltage limit:
STEERING COLUMN MODULE COMPONENT DESCRIPTION - GF54.21-P-6050GZ
MODEL 164.1/8
Fig. 25: Identifying Steering Column Module

Location
The steering column module is located on the steering column in the vehicle interior.
Task
Reading the following switches:
 Combination switch (S4)

 Left and right turn signal switch (S4s1) (turn signaling/onetouch turn signaling)
 Wipe switch (S4s5)
 Windshield washer system switch (S4s4)
 Rear-end door intermittent wash switch (S4s13)
 Rear-end door window washer system switch (S4s12)
 Headlamp flasher/high beam switch (S4s2)
 Steering column adjustment switch (S59)

 Steering column in/out, up/down
 Steering column adjustment/steering wheel heater switch (S59/1) (only 164.8 with steering wheel heater,
code 443)
 Steering column adjustment up/down, in/out switch (S59/1s1)
 Steering wheel heater switch (S59/1s2) (only 164.8 with steering wheel heater, code 443)
 DIRECT SELECT gear selector switch (S16/13)

 actuated in vertical direction (drive positions)
 R - Reverse
 N - Up - Neutral
 0 - Park position
 N - Down - Neutral
 D - Forward
 actuated in axial direction

 P - Park pawl engaged
 Cruise control switch ( S40, except S40/4)

 DTR distance potentiometer ( S40r1, except S40/4r1)
 Steering angle sensor (N49)
 Switches of multifunction steering wheel
Communication between the steering column module and steering wheel takes place over the LIN bus (Local
Interconnect Network).
The steering angle sensor no longer has to be initialized with circuit 30 "OFF".
Actuation of:
 Steering wheel heater function illumination (only 164.8 with steering wheel heater, code 443)
 Switch and controls illumination in multifunction steering wheel (controlled via LIN bus)
The voice control system is designed as a preinstallation (dealer option) and is special equipment for the
multifunction steering wheel.
LOWER CONTROL PANEL CONTROL UNIT, COMPONENT DESCRIPTION - GF54.21-P-6060GZ
MODEL 164 with CODE (489) Airmatic (air suspension with level adjustment and adaptive damping
system ADS) with CODE (430) Offroad package
Location
The lower control panel control unit is located in the center console.
Fig. 26: Identifying Lower Control Panel Control Unit Location

Task
 Downhill Speed Regulation switch (N72s30)

 Low Range switch (N72s31)
 Level adjustment high switch (N72s32)
 Level adjustment low switch (N72s33)
 Differential lock thumb wheel (N72s34)
 Level control function indicator (N72e4)
Function
Downhill Speed Regulation switch (DSR)
Low Range switch
Via the Low Range switch the driver can switch from the on-road ratio (High) to the off-road ratio (Low). A red
LED integrated into the switch provides indicates the current operating condition.
Level adjustment high switch
 Term. 15 "ON"
Function:
By actuating switches the driver can raise the level of the vehicle to offroad level 3. Until each respective
level is reached the relative LED flashes on and off in the level control function indicator. When the level
is reached the LED remains constantly on.
Level adjustment low switch
 Term. 15 "ON"
Function:
By actuating switches the driver can lower the level of the vehicle to highway level.
Until each respective level is reached the relative LED flashes on and off in the level control function indicator.
When the level is reached the LED remains constantly on.
If the Highway level is reached, there is no display in the level control function indicator.
Differential lock thumb wheel
The driver can use the differential lock thumb wheel to select various stages (transfer case and rear axle
differential lock):
A. Automatic locking of the transfer case (interaxle differential lock) and rear axle differential (interwheel
differential lock).
B. The transfer-case differential (interaxle differential lock) is manually locked (100 %), the rear axle
differential (interwheel differential lock) is automatically locked.

C. The transfer case (interaxle differential lock) and rear axle differential (interwheel differential lock) are
manually locked (100 %).
Discrete inputs:
 Circuit 30
 Circuit 31
 LIN bus
The lower control panel control unit is not a direct user of CAN-B, but rather it is connected via a LIN bus to
the upper control panel control unit (N72/1) to CAN-B.
LOWER CONTROL PANEL CONTROL UNIT, COMPONENT DESCRIPTION - GF54.21-P-

6060GZA
MODEL 164.8 with CODE (430) Offroad package
Location
The lower control panel control unit is located in the center console.
Fig. 27: Identifying Lower Control Panel Control Unit Location

Task
 Downhill Speed Regulation switch (N72s30)

 Low Range switch (N72s31)
 Differential lock thumb wheel (N72s34)
 Level control selector wheel, low (N72s35)
 Level control function indicator (N72e4)
Function
Downhill Speed Regulation switch (DSR)
Low Range switch
Via the Low Range switch the driver can switch from the on-road ratio (High) to the off-road ratio (Low). A red
LED integrated into the switch provides indicates the current operating condition.
Turning the level control selector wheel
 Term. 15 "ON"
Function:
By turning the level control selector wheel to the right the driver can raise the vehicle level up to the Offroad
level 3 and lower down to the Highway level by turning to the left. The associated LED in the level control
function indicator flashes until the level is reached in each case. When the level is reached the LED remains
constantly on.
If the Highway level is reached, there is no display in the level control function indicator.
Differential lock thumb wheel
The driver can use the differential lock thumb wheel to select various stages (transfer case and rear axle
differential lock):
A. A Automatic locking of the transfer case (interaxle differential lock) and rear axle differential (interwheel
differential lock).
B. B The transfer-case differential (interaxle differential lock) is manually locked (100 %), the rear axle
differential (interwheel differential lock) is automatically locked.
C. C The transfer case (interaxle differential lock) and rear axle differential (interwheel differential lock) are
manually locked (100 %).
Discrete inputs:
 Circuit 30
 Circuit 31
 LIN bus
The lower control panel control unit is not a direct user of CAN-B, but rather it is connected via a LIN bus to
the upper control panel control unit (N72/1) to CAN-B.
FRONT SAM CONTROL UNIT, COMPONENT DESCRIPTION - GF54.21-P-7010GZ
MODEL 164
Location
The front SAM control unit is located in the right underfloor assembly below the front seat.
General
For data exchange purposes the front SAM control unit is connected to the Controller Area Network bus class B
(interior) (CAN-B).
Fig. 28: Identifying Front SAM ECU Control Unit Location - Shown On Model Series 164.1
Task
The front SAM control unit reads in the following signals, sensors and switches, and actuates the function and
switch and controls illumination and then actuates the following relay and consumers by way of semiconductor
switches.
Control
 Front exterior lights

 Footwell lights
 Washer nozzle heater
 Front wiper system
 Windshield washer fluid pump
 Headlamp cleaning system (for headlamp cleaning system, code 600)
 Heated windshield washer system (for heated windshield washer system, code 875)
 Heated front seats via a timer control
 Power windows for rear side windows
 Left rear door central locking system
 Additional battery charging process (G1/7)
Reading in and outputting the following signals:
 Circuit 31b
 Circuit 61 (engine 113 only)
 Circuit 58d
 Air suspension wake-up signal
Reading in following switches, pickups and sensors:
 Left rear power window switch (S21/3)

 Right rear power window switch (S21/4)
 Brake fluid indicator switch (S11)
 Parking brake switch (S12)
 Coolant level indicator switch (S41)
 Windshield washer system fluid level indicator switch (S42)
 Right front brake pad contact sensor (S10/2)
 Right rear brake pad contact sensor (S10/4)
Switching of following relay:
 Fanfare horn relay (F58kF)

 Wiper level relay 1/2 (F58kA), Wiper ON/OFF relay (F58kB)
 Circuit 15 relay (F58kH)
Switching internal relay

 Safety relay for switching off heated seats, if an implausible signal is recognized.
Switching consumers via semiconductor switches
 Left high beam (E1e1)

 Left low beam (E1e2)
 Left standing and parking lamp (E1e3)
 Left turn signal lamp (E1e5)
 Right high beam (E2e1)
 Right low beam (E2e2)
 Right standing and parking lamp (E2e3)
 Right turn signal lamp (E2e5)
 Left front fog lamp (E5/1)
 Right fog lamp (E5/2)
 right front footwell lamp (E17/15)
 left front footwell lamp (E17/16)
 Right rear footwell lamp (E17/17) (SA)
 Left rear footwell lamp (E17/18) (SA)
 Additional battery
 Windshield washer fluid pump (M5/1)
 SRA pump (M5/2)
 Left rear power window motor (M10/5)
 Right rear power window motor (M10/6)
 Left rear door CL [ZV] motor (M14/8)
 Left heated windshield washer nozzle (R2/2)
 Right washer nozzle heater (R2/3)
 Left front seat heated cushion (R13/1)
 Left front backrest heated cushion (R13/2)
 Right front seat cushion heater element (R13/3)
 Right front backrest seat cushion heater element (R13/4)
 Air spring wake-up signal
 Left side-marker lamp (E1e6) (for USA version, code 494)
 Right side-marker lamp (E2e6) (for USA version, code 494)
Heated seats actuation
The heating resistors of the seats for driver and front passenger are actuated by the front SAM control unit in
accordance with the following tables:
Heating stage Heater capacity Duty cycle (on) Function indicator

1 Low 0 - 40 % 1 LED
2 middle 41 - 70 % 2 LEDs
3 high 71 - 100 % 3 LEDs
OPERATION OF HEATED SEAT SWITCH WITH FUNCTION INDICATOR

Switch actuation Actuation Function indicator
None Heating OFF No LED switched on
Once Heating stage 3 on 3 LEDs
2 times Heating stage 2 on 2 LEDs
3 times Heating stage 1 on 1 LED
4 times Heating OFF No LED switched on
5 times Heating stage 3 on 3 LEDs
REAR SAM CONTROL UNIT, COMPONENT DESCRIPTION - GF54.21-P-7030GZ
MODEL 164
Location
The rear SAM control unit is located in the right rear luggage compartment on the wheelhouse.
General
The rear SAM control unit serves to exchange data and is connected to the Controller Area Network bus Class
B (interior) (CAN-B).
Fig. 29: Identifying Rear SAM Control Unit Location - Shown On Model Series 164.1
Task
The rear SAM control unit reads in the following components, sensors, pick-ups and switches, and actuates the
function and switch and controls illumination and then actuates the following relay and consumers by way of
semiconductor switches.
Controlling
 Heated rear window (R1)

 Rear exterior lights
 Turn signal functions
 Right rear door central locking system
 Central locking, rear-end door
 Rear-end door power closing
 Trunk illumination
 Trailer recognition and trailer illumination
 Rear wiper
 Left and right rear door illumination
 Left and right rear vent window
 Anti-theft alarm system [EDW]
(for anti-theft alarm system (ATA [EDW]), code 551)
Reading in and outputting the following signals:

 Circuit 30
 Circuit 31
 Circuit 15
 Circuit 54
Reading in following switches, pickups and sensors:
 Rear door locking unit (A72)

 Fuel level sensor, left half of tank (B4/1)
 Fuel level sensor, right half of tank (B4/2)
 Left vent window obstruction sensor strip (B51/5)
 Right vent window obstruction sensor strip (B51/6)
 Right front door rotary tumbler microswitch (M14/5s1)
 Left front door rotary tumbler microswitch (M14/6s1)
 Left rear door rotary tumbler microswitch (M14/8s1)
 Right rear door rotary tumbler microswitch (M14/9s1)
 Spare tire carrier "locked" switch (S151/1)
 Spare tire carrier "open" switch (S151/2)
 Right easy entry feature microswitch, 2nd seat row (S159/1)
 Stop light switch (S9/1)
 Engine hood ATA switch (S62)
 Rear-end door handle switch (S88/9)
 Interference filter 1 (A49/1)
 Alarm signal horn with additional battery (H3/1)
(with anti-theft alarm system (ATA [EDW]), code 551)
Switching in the following relays:
 Socket circuit 15R relay (with run-on) (F4kK)

 Heated rear window relay (F4kM)
 Rear wiper relay (F4kP)
 Trailer circuit 30X relay (F4kL)
 Circuit 15R relay (F4kR)
 Front passenger seat adjustment comfort relay (K24/2)
The fuel pump relay (F4kO) is located on the load compartment fuse and relay box (F4), but it is actuated by
the ME-SFI [ME] control unit (N3/10).
Switching consumers via semiconductor switches

 Rear door locking unit

 Left taillamp (E3)
 Left turn signal lamp (E3e1)
 Taillamp and left rear fog lamp (E3e2)
 Left backup lamp (E3e3)
 Left stop lamp (E3e4)
 Right taillamp (E4)
 Right turn signal lamp (E4e1)
 Taillamp and right rear fog lamp (E4e2)
 Right backup lamp (E4e3)
 Right stop lamp (E4e4)
 Right luggage compartment lamp (E18/4)
 Left luggage compartment lamp (E18/5)
 Left rear-end door license plate lamp (E19/3)
 Right rear-end door license plate lamp (E19/4)
 Center high-mounted stop lamp (E21)
 Alarm signal horn with additional battery
(for anti-theft alarm system (ATA [EDW]), code 551)
 Right rear door CL [ZV] motor (M14/9)

 fuel filler flap CL [ZV] motor (M14/10)
 Central locking motor, spare tire carrier (M14/13)
 Left vent window motor (M21/8)
 Right vent window motor (M21/9)
 Lumbar pump (M25/1)
 Overall trailer lighting
For USA version, code 494:
 Alarm horn (H3)
INSTRUMENT CLUSTER (IC), OPERATING INFORMATION - GF54.30-P-0002-05GZ

Fig. 30: Identifying Instrument Cluster (IC) Operating Information

Multifunction steering wheel controls
Fig. 31: Identifying Multifunction Steering Wheel Controls Function Selection Buttons - Shown On
Model 164.1
This document covers the following points:
 Operating the multifunction display (A1p13)

 Call display of different systems
 Browse within a system
 Individual settings
Operating the multifunction display (A1p13)
If the instrument cluster (A1) is activated by opening the driver's door, for example, the basic display of the
basic system always appears in the multifunction display (A1p13) (trip odometer and total mileage, outside
temperature).
 Change settings
 Example: Change over temperature display from degrees Celsius to degrees Fahrenheit
 Recall the factory settings
 Call stored fault and warning messages
 Acknowledge fault and warning messages in the multifunction display (A1p13)
 Set brightness of lighting
 Switch on ESP rolling test
Calling up display of different systems
Function precondition:
"Circuit 15R ON"
If the driver presses the system select/voice control push-button (S110s3) of the multifunction steering wheel,
the multifunction display (A1p13) switches to the main screen of the next system. Once the driver has scrolled
through all systems the main screen of the base function appears again.
System selection via the multifunction steering wheel using the system selection button (S110s3)
Fig. 32: Overview And Sequence Of Basic Menu Item

The above system selection illustration shows the possible systems on a circle. Each time the driver presses the
system select/voice control push-button (S110s3) the display jumps to the next system.
Scrolling within a system
"Circuit 15R ON"
In addition to the main screen, most systems also feature other screens.
Scrolling within a system takes place via the scroll forward/back button (S110s1).
The display jumps one screen further each time the driver presses the scroll forward/back push-button (S110s1)
(?).
The display scrolls either forwards or backwards depending on which portion of the scroll forward/back push-
button (S110s1) the driver presses (?, ?).
The driver can jump to another system from any screen by pressing the system selection button (S110s3).
With the exception of the trip computer, the main screen of the relevant system now appears. If you change to
the trip computer system, the last system displayed for the trip computer system appears on the display.
Only systems and functions with which the vehicle is equipped are displayed. If a system is not present, it is
skipped by pressing the system selection button (S110s3).
Overview and sequence of the Settings menu item
Fig. 33: Overview And Sequence Of Settings Menu Item

Press the system selection button (S110s3) until the menu "Settings...Reset: Press reset button for 3 seconds"
appears in the multifunction display (A1p13). Go to the menu point settings with the scroll forward and
backward buttons (S110s1) (?). The desired menu item is selected via the + and - button, adjustment of specific
functions and volume control (S111s1).
Individual settings
"Circuit 15R ON"
The "Settings" function allows the driver to change various presets.
In the instrument cluster (A1) the following adjustments can be performed e.g. B.: setting the time (hours and
minutes only on vehicles without COMAND operating and display system (code 352)).
Temperature display
You can switch the outside temperature display between degrees Celsius and degrees Fahrenheit. The
instrument cluster (A1) also sends a message for the air conditioning on the passenger compartment CAN.
Speedometer
You can switch the tachometer between miles and kilometers per hour. This changeover also affects the display
of the trip computer integrated in the instrument cluster (A1). The instrument cluster (A1) also sends an
appropriate message on the engine compartment CAN.
The following settings are also possible:
 Auto door lock(s) (On or Off)

 Speed limit for winter tires (160 km/h to 210 km/h or off)
 Driving light switching (manual driving light, automatic driving light
 Ambient illumination function
 Automatic headlamp on
 Interior light courtesy delay
 "Ambient" light
 Station search (frequency/memory)
 Stationary heater on time for stationary heater (code 228)
 Activate access aid (steering column or steering column and seat)
 Parking assist mirror adjustment (ON/OFF)
More information about these settings can be found in the function descriptions for the associated systems.
Text/language
You can select the language in which the texts appear in the instrument cluster (A1).
The instrument cluster (A1) also sends a message on the passenger compartment CAN. The language setting on
the COMAND system has no effect on the language setting in the instrument cluster (A1).
Overview and sequence of settings for the "Instrument cluster" menu item
Fig. 34: Overview And Sequence Of Settings For Instrument Cluster Menu Item
Change settings in menu item instrument cluster
Press system selection button (S110s3) until the "Settings" function appears in the multifunction display
(A1p13). Skip to the corresponding menu item using the scroll forward/back button (S110s1) (?).
Press the button + and -, setting of specific functions and volume control (S111s1) towards + or - until the
desired menu item is active in the multifunction display (A1p13).
Press the scroll forward/back button (S110s1) (?) until the display of the setting to be changed appears in the
multifunction display (A1p13).
Press the + and -, setting specific functions and volume control button (S111s1) in either the "+ A1p13" or "-"
direction until the value you require is displayed on the multifunction display.
The activated value becomes effective immediately.
Overview and sequence of settings in the Illumination menu item

Fig. 35: Overview And Sequence Of Settings In Illumination Menu Item

Change the settings in the menu item Illumination
Press the system selection button (S110s3) until the "Settings" function appears in the multifunction display
(A1p13), then go to the corresponding menu item using the scroll forward/back button (S110s1) (?).
Overview and sequence of adjustments in "Vehicle" menu item

Fig. 36: Overview And Sequence Of Adjustments In Vehicle Menu Item

Change settings in menu item vehicle
(A1p13), then go to the corresponding menu item using the scroll forward/back button (S110s1) (?).
Overview and sequence of settings in the menu item "Comfort"

Fig. 37: Overview And Sequence Of Settings In Menu Item Comfort

Change settings in menu item comfort
Press the scroll forward/back button (S110s1) (?) until the display of the settings to be changed appears in the
direction until the value you require is displayed on the multifunction display. The activated value becomes
effective immediately.
Settings are selectable regardless of the vehicle speed.
Example
Switching over temperature display from degrees Celsius to degrees Fahrenheit
Press the button + and -, adjustment of specific functions and -, adjustment of specific functions and volume
control(S111s1) towards + or - until the menu item "Instrument cluster" is active in the multifunction display
(A1p13). Press the scroll forward/back button (S110s1) (?) until the "TEMPERATURE DISPLAY" display
appears in the Multifunction display (A1p13).
Press the button - on the right-hand side of the steering wheel so that Fahrenheit is now active in the
multifunction display (A1p13). The setting becomes effective immediately.
Recalling the factory settings
All the settings possible here are erased by a reset and the manufacturer default settings reproduced by a reset.
Performing a reset:
(A1p13). Press the trip odometer reset button (A1s3) for at least 3 seconds.
"RESET SETTINGS, CONFIRMATION WITH RESET BUTTON" appears in the multifunction display
(A1p13).
Press the trip odometer reset button (A1s3) once more within 5 seconds. All settings are now reset to the factory
settings.
"RESET TO MANUFACTURER DEFAULT SETTINGS" appears in the multifunction display (A1p13).
If the trip odometer reset button (A1s3) is not pressed within these 5 seconds, the display switches back to the
basic display. The settings are not then reset.
If a reset is performed while driving, the setting menu "Driving lights on" in the "Illumination" menu and the
setting menu "Speed limit (winter tires) in the "Vehicle" menu are not reset for safety reasons.
The message: "NOT COMPLETELY RESET TO MANUFACTURER DEFAULT SETTINGS" appears.
Calling up stored fault and warning messages
When the instrument cluster (A1) is active, you can scroll though the saved messages:
 Press the system selection button (S110s3) until the display "PROBLEMS" appears in the multifunction
display (A1p13).
 Scroll through the error messages using the + and - push-button, specific function setting and volume
control (S111s1). The messages are displayed in the order in which they were acknowledged.
Confirm malfunction and warning messages
These messages are divided into 3 categories according to their priority.
Category 2 and 3 messages in the multifunction display (A1p13) can be acknowledged by pressing the trip
odometer reset button (A1s3) as well as with the system selection button (S110s3) of the multifunction steering
wheel and then stored in the fault memory Messages of category 1 (highest priority) cannot be acknowledged.
Indicator or warning lamps that light up at the same time cannot be acknowledged.
Certain fault and warning messages are also accompanied by a chime.
Fault messages and warning messages are for example:

"Close rear-end door"
These are not stored in the fault memory.
Set brightness of lighting
Using the trip odometer reset button (A1s3) the brightness of the illumination of the instrument cluster (A1) as
well as the search and switch illumination can be adapted to the individual needs:
 Turning clockwise ? brighter

 Turning counterclockwise ? darker
Switch on ESP rolling test
Basic prerequisite:
"Circuit 15R ON"
In the rolling test, the rotational speeds of the driven axle are mirrored on the non-driven axle. To do this:
 Adjusting standard display (basic status with current total mileage recorder and trip odometer and outside
temperature).
 Depending on the version, press the trip odometer reset button (A1s3) approx. 20 s to 30 s or 2.5 s 3 times
until a beep is audible.
 Press the scroll forward/back button (S110s1) once towards ?. The rolling test display appears.
 Switch on rolling test using the + and -, specific function setting and volume control button (S111s1).
Even if "circuit 15R ON" has been switched off in the meantime, the rolling test remains active until it is
switched off with the + and - button, adjustment of specific functions and volume control (S111s1).
INSTRUMENT CLUSTER (IC), FUNCTION - GF54.30-P-0002GZ
MODEL 164
Instrument cluster (A1), function
The instrument cluster serves the visual display of all dynamic and static vehicle conditions and driver
information on all systems fitted in the vehicle:
 Display of vehicle operating conditions, e.g. vehicle speed, fuel tank level, coolant temperature, rpm
 for warning of critical operating states by means of warning and indicator lamps
 As a central display of various systems, e.g. Audio, telephone
 To function as a display for the "Active Service System" (ASSYST)
 As display for the Distronic (DTR) code 219
 Function as a trip computer
To display these states, the instrument cluster is equipped with the multifunction display (A1p13), various
meters and gauges, various warning and indicator lamps, the warning buzzer (A1h1) for the acoustic warning
signals, and the audible turn signal indicator (A1h2).
For the engine compartment CAN and/or interior CAN various signals, e.g. vehicle speed ("circuit 58d") are
produced and passed on by the instrument cluster.
The necessary information is passed on from the various control units via the engine compartment CAN or the
interior CAN to the instrument cluster, except the signal for the airbag indicator and warning lamp (A1e15), this
is transmitted via a discrete line.
Via the instrument cluster a warning is displayed when the remaining distance or the remaining time up to the
next service is not reached. Warning messages on the instrument cluster alert the driver to an imminent or
overdue service date. Irrespective of this under certain operating conditions of the vehicle the user of the vehicle
can have this and other information displayed by requesting it through the service menu on the instrument
cluster.
The instrument cluster contains a microprocessor to process the incoming data.
The program and necessary data are stored in an electronic memory chip. Various menu items can be actuated
via the multifunction steering wheel with the system selection button (S110s3) and the scroll forward/back
button (S110s1).
Diagnosis takes place via STAR DIAGNOSIS.
Function overview
The instrument cluster is connected with the engine compartment CAN and the interior CAN. Data is
exchanged with virtually all the control units over the two bus systems.
However, the instrument cluster does not act as an interface (gateway) between the two data bus systems.
This function is reserved for the central gateway control unit (N93). The basic CAN messages for the functions
of the instrument cluster, including trip computer and ASSYST PLUS should be cited here.
The connections of the instrument cluster are described in the last section of this document.
The input signals are supplied by the following components:
 The wheel speeds from the ESP control unit (N47-5) via the engine compartment CAN
 The engine speed signal from the ME-SFI [ME] control unit (N3/10) or CDI control unit (N3/9) via the
engine compartment CAN
 The shift range and transmission mode from the fully integrated transmission control (VGS) control unit
(Y3/8n4) via the engine compartment CAN
 The drive position from the control unit for the intelligent servo module for DIRECT SELECT (A80) via
the engine compartment CAN

 The fuel tank level from the rear SAM control unit (N10/8) via the interior CAN
 The coolant temperature from the ME-SFI [ME] control unit or CDI control unit via the engine
compartment CAN
 The fuel-consumption signal from the ME-SFI [ME] control unit or CDI control unit via the engine
compartment CAN
 The oil level from the ME-SFI [ME] control unit or CDI control unit via the engine compartment CAN
 The oil temperature from the ME-SFI [ME] control unit or CDI control unit via the engine compartment
CAN
 The outside temperature signal from the front SAM control unit (N10) via the interior CAN
 Standing lamp ON/OFF from the front SAM control unit via the interior CAN
 The coolant level from the front SAM control unit via the interior CAN
 The washer fluid level from the front SAM control unit via the interior CAN
 Tire pressure from the TPM [RDK] control unit (N88) via the interior CAN
 the time via the interior CAN from the audio gateway control unit (N93/1) and the latter via MOST from
the COMAND operating, display and controller unit (A40/3); on vehicles fitted with COMAND
 The condition "circuit 15R ON" and "circuit 15C" by the EIS [EZS] control unit (N73) via the interior
CAN
 The left multifunction steering wheel button group (S110) and right multifunction steering wheel button
group (S111) of the multifunction steering wheel
 VCS [SBS] off button (S110s4) and VCS [SBS] on button (S111s4) from the steering column module
(N80) to the instrument cluster via the engine compartment CAN, and from this via the interior CAN to
the COMAND operating, display and controller unit
The following input signals are required for indicator and warning lamps:
 Signal for left turn signal indicator lamp (A1e1) and right turn signal indicator lamp (A1e2)
 Signal for high beam indicator lamp (A1e3) from front SAM control unit via interior CAN, with turn
signaling from steering column module via interior CAN, with hazard warning flasher via Controller
Area Network interior from lower control panel control unit (N72), with ATA flashing from front SAM
control unit via interior CAN
 Signal for brake fluid and parking brake warning lamp (A1e7) from front SAM control unit via interior
CAN
 Signal for ESP warning lamp (A1e41) from ESP control unit via engine compartment CAN
 Signal for DTR warning lamp (A1e59) from ESP control unit via engine compartment CAN; with
Distronic (DTR) Code 219
 Signal for tire pressure monitor warning lamp (A1e66) from TPM [RDK] control unit via interior CAN
 Seat belt warning lamp (A1e9) from the driver-side front seat adjustment control unit with memory
(N32/1) and front passenger front seat adjustment control unit with memory (N32/2) via the interior CAN
 Signal for engine diagnosis indicator lamp (A1e58) or CHECK ENGINE indicator lamp (A1e26) from
ME control unit via engine compartment CAN
The airbag indicator and warning lamp is not actuated via the CAN bus, but via a discreet line
Reception messages for the multifunction display
All signals for the messages in the multifunction display come via the engine compartment CAN or interior
CAN.
Information about the signal paths and other details concerning the individual messages can be found in the
function descriptions for the relevant systems.
The following transmitted messages come from the instrument cluster:
 Displayed speed to passenger compartment CAN

 Current time to the interior CAN
 Temperature units (Celsius and Fahrenheit) to the interior CAN.
 Headlamp switching manual/always-on (ON/OFF) to the interior CAN.
 Interior light courtesy delay to the interior CAN
 Headlamp switch-off delay to the interior CAN
 Outside temperature signal to the engine compartment CAN
 Time-controlled stationary heater operation on interior CAN
 "Circuit 58d" to the engine compartment CAN and interior CAN
 "Circuit 61e" to the engine compartment CAN
 Engine OFF time to the engine compartment CAN.
 Winter tires maximum speed to the engine compartment CAN.
CAN messages of push-buttons of multifunction steering wheel
In view of the fact that the push-buttons of the multifunction steering wheel perform several functions, the
signals of these push-buttons must be conditioned accordingly:
 All the buttons of the left multifunction steering wheel button group and right multifunction steering
wheel button group are voltage-coded and are read in by a LIN bus converter.
 The steering column module reads the corresponding messages and conveys them on the interior CAN.
They are then received by the instrument cluster.
 The instrument cluster interprets these messages in combination with the systems just displayed in the
multifunction display and passes these back again on the interior CAN.
 The message from the left steering wheel gear shifter button (S110/2) or right steering wheel gear shifter
button (S111/2) is received from the fully integrated transmission control (VGS) control unit. The fully
integrated transmission control (VGS) control unit processes this message and sends it to the
multifunction display via the engine compartment CAN.
This interpretation is necessary because the operation of some of the buttons depends on the current content of
the multifunction display.
Example:
If the button + and -, setting of specific functions and volume control of the multifunction steering wheel is
pressed then normally the volume of the audio system is increased. Although if the multifunction display just
shows a setting, e.g. OFF delay time of interior light, then this setting is changed when the button is pressed.
The volume stays the same.
Connections
The number reduces due to the connection from the instrument cluster to the engine compartment CAN and the
CAN interior. The inputs and outputs (including voltage supply) are at the following connections:
 CAN-C Low (engine compartment CAN)

 CAN-C high (engine compartment CAN)
 CAN-B Low (passenger compartment CAN)
 CAN-B high (interior CAN)
 "Circuit 31" (ground)
 "Circuit 30" (battery positive, serves the voltage supply of almost the complete electronics of the
instrument cluster.)
 "Circuit 15g" (switched positive, serves the airbag indicator and warning lamp and diagnostic interface of
the instrument cluster as a voltage supply.)
 Clock GND, ground to external clock module.
 "Circuit 15g" control input for limp-home
 Clock supply, output and battery.
 Data line for external clock.
 Input for the airbag indicator and warning lamp (this input is directly connected to the appropriate output
of the restraint systems control unit (N2/7)).
Instrument cluster (IC), operating information with USA version code 494 GF54.30-P-0002-05GZ
Except USA version, code 494 GF54.30-P-0002-05GZE
Activate instrument cluster, function GF54.30-P-2006GZ
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF INSTRUMENT CLUSTER (IC) -

GF54.30-P-0997GZ
MODEL 164
GF54.30-P-
Instrument cluster (IC), function
0002GZ
With USA version, GF54.30-P-0002-
Instrument cluster (IC), operating information
code 494 05GZ
Except USA version, GF54.30-P-0002-
code 494 05GZE
GF54.30-P-
Activate instrument cluster, function
2006GZ
Display monitoring/warning messages via multifunction GF54.30-P-
display, function 2012GZ
Display monitoring/warning messages via indicator lamps, With USA version, GF54.30-P-
function code 494 2011GZ
Except USA version, GF54.30-P-
code 494 2011GZE
GF54.30-P-
Indicator lamp test and engine running detection, function
2014GZ
GF54.30-P-
Output acoustic warning messages, function
2013GZ
GF54.30-P-
Display speed, function
3025GZ
GF54.30-P-
Display fuel quantity, function
3018GZ
GF54.30-P-
Display outside temperature, function
3019GZ
GF54.30-P-
Display coolant temperature, function
3020GZ
GF54.30-P-
Display engine speed, function
3021GZ
GF54.30-P-
Display distance, function
3022GZ
GF54.30-P-
Display transmission information, function
3023GZ
GF54.30-P-
Display time, function
3024GZ
GF54.30-P-
Battery charge/alternator monitoring, function
3027GZ
GF54.30-P-
Instrument cluster illumination, function
2007GZ
GF54.30-P-
Setting push-button unit illumination, function
2010GZ
GF54.30-P-
Coolant/washer fluid level voltage coding, function
4001GZ
Overview of system components, instrument cluster (IC) GF54.30-P-
ACTIVATE INSTRUMENT CLUSTER, FUNCTION - GF54.30-P-2006GZ
MODEL 164

Fig. 38: Activate Instrument Cluster Function - Shown On Model 164.1

Activation of instrument cluster (A1)
Because it relies on black-screen technology, the details on the instrument cluster (A1) (e.g. displays, gauges,
etc.) are clearly visible only when the instrument cluster (A1) has been activated. If the instrument cluster (A1)
is activated, the current contents are shown in the displays and the illumination of the instrument (A1) is
switched on as well as the fuel reserve indicator lamp (A1e4) actuated.
The instrument cluster is activated by switching on "circuit 15g" A1. After "circuit 15g" is switched off the
instrument cluster (A1) remains active for a further 30 seconds, but can be extended up to 2 minutes in the event
of the occurrence of active warnings. The instrument cluster is activated with "circuit 15g OFF" A1 under the
following conditions:
 The instrument cluster is activated for 30 seconds by the instrument and controls illumination button, dim
(A1s5) or instrument and controls illumination button, bright (A1s4) and trip odometer reset button
(A1s3)A1).
 The instrument cluster is activated for 30 seconds when the driver's door is opened or closed A1.
 When the standing lamp or driving lamps are switched on, the instrument cluster (A1) remains in
operation for as long as the standing lamp is switched on.
If one of the stated conditions occurs while the instrument cluster (A1) is already active, then the instrument
cluster (A1) remains activated for a further 30 seconds from this point in time.
Networking
The status of the left front door rotary tumbler microswitch (M14/6s1) is read in by the rear SAM control unit
(N10/8) and placed as a CAN message on the CAN interior.
The status of the standing lamp (ON/OFF) is placed on the CAN interior by the front SAM control unit (N10).
Display monitoring/warning messages via multifunction display, function GF54.30-P-2012GZ

INSTRUMENT CLUSTER ILLUMINATION, FUNCTION - GF54.30-P-2007GZ
MODEL 164
Activating instrument cluster lighting
The lighting of the instrument cluster (A1) is switched on automatically when the instrument cluster is
activated. The details of the instrument cluster (A1) are only now clearly visible because of the "black-screen
technology".
The instrument cluster (A1) is activated when the following events occur:
 CAN message side lights "ON"

 Circuit 15R ON
 Operation of trip odometer reset button (A1s3) or operation of Instrument and controls illumination
button, dim (A1s5) or instrument and controls illumination button, bright (A1s4)
 The driver door is opened/closed
 Operation of the left multifunction steering wheel button group (S110) or right multifunction steering
wheel button group (S111)
The intensity of the lighting is dependent on:
 the CAN message from the rain/light sensor (B38/2)

 the status of "circuit 58d" (standing lamp information)
 the position of the Instrument and controls illumination button, dim (A1s5) or instrument and controls
illumination button, bright (A1s4)
Controlling the display lighting
With the CAN message standing lamp "ON" the current position is transmitted by the trip odometer reset button
(A1s3) via the CAN interior.
In this state, the signal from the rain/light sensor (B38/2) via the overhead control panel control unit (N70) is
disregarded.
Controlling display lighting by means of sensor
"circuit 58d" is set to 0% by the CAN message standing lamp "OFF". As a result the CAN message is now read
in by the rain/light sensor (B38/2) via the Overhead control panel control unit (N70) and the "day"/"night"
signal transmitted on CAN B.
Night signal:
The brightness of the instrument cluster (A1) can be regulated via the instrument and controls illumination
button, dim (A1s5) or instrument and controls illumination button, bright (A1s4).
Day signal:
The brightness of the instrument cluster (A1) is regulated via the photo transistor. Only one minimum setting is
possible via the instrument and controls illumination button, dim (A1s5) or instrument and controls illumination
button, bright (A1s4).
The display brightness via the rain/light sensor (B38/2) is only dependent on the ambient brightness.
In the event of a defect in the rain/light sensor (B38/2) "circuit 58d" is set to 100% by the overhead control
panel control unit (N70). The display brightness is now adjustable via the instrument and controls illumination
button, dim (A1s5) or instrument and controls illumination button, bright (A1s4).
Setting push-button unit illumination, function GF54.30-P-2010GZ
SETTING PUSH-BUTTON UNIT ILLUMINATION, FUNCTION - GF54.30-P-2010GZ
MODEL 164
Fig. 39: Setting Push-button Unit Illumination Function Diagram

Data flow image for circuit 58d
The switch and controls illumination is activated by the following components:
 Switching on vehicle lighting (so long as side lights are active)

 Automatic running lights by means of the rain/light sensor (B38/2)
When the standing lamp is switched on the position of the Instrument and controls illumination button, dim
(A1s5) or Instrument and controls illumination button, bright (A1s4) is used as a controlled variable by the
overhead control panel control unit (N70). The rain/light sensor (B38/2) is not taken into account. When
automatic driving lights are on, the brightness of the switch and controls illumination is determined via the
rain/light sensor (B38/2).
Its signals are analyzed by the overhead control panel control unit (N70) and the intensity is regulated in this
way by the control unit.
Presentation of duty cycle
Fig. 40: Presentation Of Duty Cycle

Terminal 58d on/off ratio
The lamps of the switch and controls illumination are actuated by means of a square-wave voltage U (see top
illustration):
 The lamps are energized in the time t1, this is then followed by a break. The lamps are energized again
after the break and so on.
The change occurs so quickly as to remain imperceptible to the human eye.
 The ratio of times t1 to T is called the duty cycle. where T is the constant cycle duration and t1 is the time
during which power flows during a cycle.
 The greater the duty cycle (that is to say the power flow duration t1 ), the greater the average power and
therefore the brighter the lamps.
The voltage curve U58d is sketched in the illustration as it is 58d applied to the outputs "Circuit 58d" of the
various control units. The upper sketch shows a duty cycle of 80 %, the lower a duty cycle of 40 %.
A duty cycle of 100 % corresponds to normal direct voltage. Power is not supplied when the duty cycle is 0 %.
Advantages of this type of illumination adjustment:

 Considerably more efficient,

 The brightness of the lamps remains independent of the number of lamps.
 every control unit connected to the interior or engine compartment CAN can trigger lamps with the
intensity specified by the instrument cluster (A1).
When the standing lamp is "OFF" the instrument cluster (A1) transmits the message "duty cycle circuit 58d
= 0 %". When the standing lamp is "ON" the duty cycle transmitted can be adjusted between 12 % and 100 %
using the Instrument and controls illumination button, dim (A1s5) or instrument and controls illumination
button, bright (A1s4).
Coolant/washer fluid level voltage coding, function GF54.30-P-4001GZ
DISPLAY MONITORING/WARNING MESSAGES VIA INDICATOR LAMPS, FUNCTION -

GF54.30-P-2011GZ
Fig. 41: Display Monitoring/Warning Messages Via Indicator Lamps

Up to production period 31.07.2006

Fig. 42: Display Monitoring/Warning Messages Via Indicator Lamps

Turn signal indicator lamps
As an optical check the left turn signal indicator lamp and right turn signal indicator lamp is integrated in the
instrument cluster. These lamps are activated differently according to function.
When functioning as direction indicators, only one of the two indicator lamps is actuated at a time.
The signal for actuating the respective indicator lamp comes via the interior CAN from the steering column
module (N80) to the SAM control unit (N10/8).
If one of the turn signal lamps fails, the triggered indicator lamp flashes at twice the frequency.
The left turn signal indicator lamp and right turn signal indicator lamp is actuated for hazard warning flashing
and ATA flashing. The signal for actuating the lamps as hazard warning flashers comes over the interior
compartment CAN from the upper control panel control unit (N72/1).
The signal for actuating the anti-theft alarm system flashing comes from the rear SAM control unit via the
interior CAN.
While the direction indicator function is available only with "circuit 15 ON", the other flasher modes are also
possible with "circuit 15 OFF". An acoustic signal accompanies the rhythmic flashing of the indicator lamp
(A1h2).
When different demands for flasher operation are present, the system assigns hierarchical priorities in the
following sequence:
 Electronic alarm system flashers (highest priority)

 Hazard warning flashers (2nd priority)
 Turn indicators (3rd priority)
High beam indicator lamp
With high beam "ON" and headlamp flasher the actuation takes place via the interior CAN through the front
SAM control unit (N10).
Fuel reserve indicator lamp
The fuel reserve warning lamp lights up as soon as the reserve level is reached. The actuation is closely linked
to the fuel level and reserve indicator.
Brake fluid and parking brake warning lamp
This warning lamp is actuated if at the start of a journey the parking brake is not released or the minimal brake
fluid level is not reached.
The signal for actuating the lamp comes from the front SAM control unit via the interior CAN.
Seat belt warning lamp
The seat belt warning lamp is actuated as follows:
 The seat belt warning lamp lights up when "circuit 61 is ON", the vehicle speed is > 25 km/h and the
driver seat belt buckle and seat belt warning switch (S68/1) is not connected. The seat belt warning lamp
goes out as soon as the driver seat belt buckle and seat belt warning switch is closed.
 The seat belt warning lamp lights up when "circuit 61 is ON", the vehicle speed is > 25 km/h, the front
passenger seat occupied and child seat recognition sensor (B48) has detected a person or a child seat and
the front passenger seat belt buckle and seat belt warning switch (S68/2) is not closed. The seat belt
warning lamp goes out as soon as the front passenger seat belt buckle and seat belt warning switch is
closed
Safety system lamps
The airbag indicator and warning lamp is actuated when there is a fault in the supplemental restraint system
(SRS).
It is triggered directly by the restraint systems control unit (N2/7).
The ABS indicator lamp is actuated if there is a fault in the ABS. The signal for actuating the lamp comes via
the engine compartment CAN from the ESP control unit (N47-5).
The signal to actuate the lamp comes from the ME-SFI control unit (N3/10) or CDI control unit (N3/9) via the
engine compartment CAN.
Tire pressure monitor warning lamp
This lamp is only fitted on vehicles with tire pressure monitor code 475.
In addition to the multifunction display it lights up yellow, when a rapid pressure loss of > or = 0.2 bar/min is
detected.
The signal to activate the lamp is sent by the TPM [RDK] control unit (N88) via the interior CAN.
DTR warning lamp
This lamp is only fitted on vehicles with Distronic (DTR) Code 219. In addition to the red multifunction display
it lights up when a minimum distance previously set by the driver is not reached. The signal for actuating the
lamp comes from the ESP control unit via the CAN-interior.
Light sources
The high beam indicator lamp and the preglow indicator lamp are equipped with bulbs as the means of lighting.
All the other indicator and warning lamps in the instrument cluster are equipped with light emitting diodes
(LED).
Apart from the actuations described above all the indicator and warning lamps are also actuated on the lamp
test with the exception of the left turn signal indicator lamp, right turn signal indicator lamp and high beam
indicator lamp are also actuated on the lamp test.
The actuation of some indicator and warning lamps, e.g. the CHECK ENGINE indicator lamp, is
accompanied by the appearance of a fault message in the multifunction display. While some categories of
message can be acknowledged and canceled, the warning and indicator lamps remain on for as long as the
problem remains present. These indications cannot be canceled!
Indicator lamp test and engine running GF54.30-P-

detection, function 2014GZ
"CHECK ENGINE" indicator lamp GF54.30-P-
Model 164 with engine 156.980
component description 5011AMG
GF54.30-P-
Model 164.1 with engine 113.964
5011BK
Model 164.1 with engine 272.967, Model GF54.30-P-
164.8 with engine 273.923/ 963 5011V
DISPLAY MONITORING/WARNING MESSAGES VIA MULTIFUNCTION DISPLAY, FUNCTION -

GF54.30-P-2012GZ
MODEL 164
Function menu
Starting from the basic screen, the following views can be called up in the central status area using the System
Selection push-button (S110s3) and the Forward/Back push-buttons (S110s1):
 Digital speedometer
 Service required
 Tire pressure
 Check engine oil level
In the multifunction display (A1p13) and starting from the basic display "driving mode" described, various
adjustment menus and information menus can be transmitted by changing the display level by means of the
system selection button on the multifunction steering wheel.
The information is always displayed in the central status area of the multifunction display.
Only those functions that are actually installed in the vehicle will be displayed:
 Audio displays
 Radio
 CD
 CC
 TV tuner (SA)
 Navigation (special equipment)
 Distronic (ART) (special equipment)
 PRESAFE
 Vehicle configuration
 Stationary heater (special equipment) (ECE)
 Telephone display (SA)
 Trip computer
 Fault and warning messages
Partitioning the multifunction display
Lower status range:
This status range has two display ranges.
The outside temperature is displayed on the left. In the right-hand range of the line the selected transmission
mode and display of the selected drive position or the engaged gear on manual transmission is displayed.
Upper status range:
Navigation is displayed in this range.
Display priority:
The displays and functions appear in relation to their situation and priority. The instrument cluster (A1)
differentiates between the primary and secondary priority of each message.
The multifunction display first shows the messages in the sequence of the respective main priority. If there are a
number of message of the same high priority, the value of the secondary priority of the messages is used to
decide the display sequence. New messages have the highest priority.
After it has been displayed once, the message is entered in the display sequence.
The messages are divided into the following three categories according to their priority.
 Messages of the highest priority belong to category 1. These messages cannot be acknowledged. When
they occur, a brief warning tone is sounded. Any errors of categories 2 and 3 are hidden.
 Messages of medium priority belong to category 2. The messages can be acknowledged with the trip
odometer reset button (A1s3). When they occur, a brief warning tone is sounded. Any faults of category 3
are hidden.
 Messages of the lowest priority belong to category 3. These messages can be acknowledged with the trip
odometer reset button. There is no warning tone.
Fault storage
The messages are stored in 3 roller memories according to their priority:
U roll: This is the directory of all unacknowledged warning messages which are shown in the multifunction
display. Displays of the same of a higher priority are displayed once the minimum display time of the preceding
message has elapsed.
After the minimum display time for the warning with the lowest secondary priority has elapsed, the error roll
starts again with the warning with the highest secondary priority (ring buffer).
W-roll All faults occurring and acknowledged while driving are recorded here. It can be called up at any time in
the menu tree in the multifunction display. When the roll is called up, a start screen showing the number of
errors that occurred is first displayed, followed by the errors in main priority sequence.
N-roll After disconnecting "circuit 15R", all messages entered in the fault roll are automatically called up in the
N-roll in secondary priority sequence.
The number of errors entered in shown in the start screen. The warning buzzer (A1h1) sounds briefly when the
start screen is displayed.
The displayed messages must be acknowledged. The N roll stops when all the warnings have been
acknowledged.
If there are no messages recorded, or if all the recorded messages have been acknowledged, the multifunction
display is switched off after 30 s. If there are still unacknowledged messages present, the shutoff occurs after 2
minutes.
If the N-roll is interrupted by a higher-priority message, it begins again from the start screen.
Some messages (including dynamic curve illumination) are accompanied by the lighting of a warning or
indicator lamp. These lamps remain lit until the fault is rectified. This applies even if the corresponding
message was acknowledged.
Acknowledging messages
Warning and error messages can be acknowledged automatically or manually. Manual acknowledgment takes
place by pressing the steering wheel buttons scroll forward/back button and system selection button or
instrument and controls illumination button, dim (A1s5), instrument and controls illumination button, bright
(A1s4) and trip odometer reset button.
If the cause of an automatically acknowledgeable message ceases to be applicable, the warning is displayed for
the duration of its minimum display time in the multifunction display. In the case of faults which also
necessitate the actuation of an indicator lamp, the lamp lights up at the same time as the multifunction display.
The lamp remains on as long as the fault persists, regardless of whether the fault display on the multifunction
display has already been acknowledged.
Reminder of acknowledged messages
If messages have been acknowledged while driving, these are displayed again as a reminder when "circuit 15R
is ON". In this case, current messages, e.g. lights warning, hide this reminder function. If there are no messages,
the main screen appears after "Terminal 15R ON".
Display stored error messages
It is possible to scroll through the stored messages when the instrument cluster is activated:
 Press the system selection button until the "FAULTS" display appears in the multifunction display
 Scroll through the error messages using the + and - push-button, specific function setting and volume
control (S111s1). The messages are displayed according to their priority.
Faults in PRESAFE system are displayed as follows as a warning message in the multifunction display:
"PRE-SAFE NOT AVAILABLE"
"SEE OPERATOR'S MANUAL"

Example
In order to inform the customer about the low performance of the battery, the message "Electrical consumers
switched off" appears in the multifunction display, if the battery control unit (N82) detects a poor condition.
Messages presented in white only have information functions. Consumers that do not impair driving safety
are shut off until the overall state of the on-board electrical system has stabilized again.
Two examples of how the consumer shutoff function is indicated are the flashing of the heated rear window
symbol or the heated seats symbol.
Message (white) in instrument cluster
 "Fault, electrical consumer switched off"
The charge level of the battery is too low (consumer shutoff level 1, fault code 9051).
Message (white) in instrument cluster
 "Fault, electrical consumer switched off"
The battery charge level is very low (consumer shutoff stage 2, fault code 9050).
Message (red) in instrument cluster
 "Battery/alternator, locate workshop + electrical consumer switched off"
"Terminal 61" not on the CAN data bus
Message (red) in instrument cluster
 "Battery/alternator, locate workshop + electrical consumer switched off"
Consumer shutoff:
 Fault code 9051 (shutoff level 1)

 Fault code 9050 (shutoff level 2)
 Fault code 9092 (backup battery < 10.5 V or open circuit (short circuit) in line to battery control unit
Consumer shutoff:
The following systems are affected by the consumer shutoff (shutoff level 1, fault code 9051):
 Blower motor (A32m1) (reduced to 69 %)

 Steering wheel heater/fanfare horns electronics (A74)
 left front door inside handle illumination (E17/11)

 right front door inside handle illumination (E17/12)
 left rear door inside handle illumination (E17/13)
 right rear door inside handle illumination (E17/14)
 left front door entrance and exit lamp (E17/3)
 right front door entrance and exit lamp (E17/4)
 left rear door entrance and exit lamp (E17/5)
 right rear door entrance and exit lamp (E17/6)
 SRA pump (M5/2)
 Left front seat cushion ventilation motor group (M18/9)
 Left front seat backrest ventilation motor group (M18/10)
 Right front seat cushion ventilation motor group (M18/11)
 Right front backrest ventilation motor group (M18/12)
 Driver seat longitudinal adjustment motor (M27/1)
 Front passenger seat longitudinal adjustment motor(M28/1)
 Driver-side front seat adjustment control unit, with memory (N32/1)
 Passenger-side front seat adjustment control unit with memory (N32/2/)
 Heated rear window (R1)
 Left front seat heated cushion (R13/1)
 Right front seat cushion heater element (R13/3)
 Left front backrest heated cushion (R13/2)
 Right front backrest seat cushion heater element (R13/4)
 Left 2nd row seat heated cushion (R13/5)
 Left 2nd row backrest heated cushion (R13/6)
 Right 2nd row seat heated cushion (R13/7)
 Right 2nd row backrest heated cushion (R13/8)
The following systems are affected by the consumer shutoff (shutoff level 2, fault code 9050):
 Blower motor (reduced to 53 %)

 Left interior lamp, 1st seat row (N70e4)
 Right interior lamp, 1st seat row (N70e5)
 Dome lamp, 3rd seat row (E15/3)
 right front footwell lamp (E17/15)
 left front footwell lamp (E17/16)
 right rear footwell lamp (E17/17)
 left rear footwell lamp (E17/18)
 Tailgate hydraulic pump (M51/1)
 Left electrically adjustable and heated outside mirror (M21/1)

 Right electrically adjustable and heated outside mirror (M21/2)
 PTS control unit (N62)
 Center washer nozzle heater (R2/1)
 Left heated windshield washer nozzle (R2/2)
 Right washer nozzle heater (R2/3)
 Washer nozzle hose heater (R2/11)
 Front cigar lighter with ashtray illumination (R3)
Display monitoring/warning messages via indicator With USA version, code GF54.30-P-
lamps, function 494 2011GZ
Except USA version, GF54.30-P-
code 494 2011GZE
OUTPUT ACOUSTIC WARNING MESSAGES, FUNCTION - GF54.30-P-2013GZ
MODEL 164
Acoustic warning function
The acoustic turn signal indicator (A1h2) is integrated within the instrument cluster (A1). It is a type of
contactless relay. The turn signal flasher is always accompanied by an acoustic clicking sound generated in the
same rhythm. The audible turn signal indicator is actuated differently depending on function:
Turn signals
The signal for actuating the audible turn signal indicator comes from the steering column module (N80) via the
interior. If one of the turn signals fails, the audible turn signal indicator is actuated at twice the normal
frequency.
Via the CAN-interior the information turn signal lamp defective from the control unit which actuates the
defective turn signal lamp.
Hazard warning flashers
The signal for actuating the audible turn signal indicator comes from the upper control panel control unit
(N72/1) via the interior CAN.
ELECTRONIC ALARM SYSTEM flashers
The signal for actuating the audible turn signal indicator comes from the front SAM control unit (N10) via the
interior CAN.
Warning signal
The instrument cluster is equipped with a warning buzzer (A1h1) that responds to various malfunctions and
operating states by generating an acoustic warning signal with a frequency of around 2048 Hz and a duration of
approx. 0.2 s.
A warning chime is emitted:
 When a fault or warning message of medium or top priority occurs. In addition a message is displayed in
the multifunction display (A1p13).
 When the seat belt warning lamp (A1e9) lights up. This indicator lamp is not provided in all national
markets. The signal to actuate comes from the restraint systems control unit (N2/7) via the interior
compartment CAN.
 The brake fluid level and parking brake warning lamp (A1e7) light up if the vehicle starts to move before
the parking brake is released. The signal for actuation comes from the front SAM control unit via the
interior CAN.
 If the transmitter key (A8/1) is inserted in the EIS [EZS] control unit with "circuit 15C" (N73) and the
driver door is open, there is the CAN message "status information - transmitter key" and "ignition
Off" (via interior CAN from EIS [EZS] control unit) and the door contact signal is transmitted by the rear
SAM control unit (N10/8).
 When the standing lamps are on, the transmitter key (A8/1) is withdrawn and the driver door is open
(lights warning). The "ignition key status information" comes from the EIS [EZS] control unit via the
interior CAN. The door contact signal from the rear SAM control unit as well as the standing lamp signal
from the front SAM control unit are present.
 when the vehicle exceeds a speed of 120 km/h (only Gulf States version, code 623). The acoustic warning
signal is canceled as soon as the speed drops back below 117 kph.
 When the speed set on the variable speed limiter is exceeded, e.g. due to inertial acceleration.
The displayed speed is used. The adjusted maximum speed comes from the ME-SFI [ME] control unit (N3/10)
via the CAN engine compartment via the CDI control unit (N3/9).
Sequence of seat belt reminder warning
In countries with a legally specified seat belt reminder warning the seat belt warning lamp is always actuated for
the first t = 6 s (±2s). In the national versions USA, Canada, Korea and the Gulf States the warning phase starts
from a recognized Engine start (terminal 61 ON) and in the national version already from terminal 15 ON.
There are the following warning tone phases for the seat belt reminder warning:
Warning tone phase 1
 If the vehicle drives off, the first warning tone phase starts to run in the background. However the
warning tone is first output as of a speed of v > or = 25 km/h via the speaker inside the instrument cluster.
In the first phase the warning tone is output as an individual tone (gong), which is repeated at a low
volume every t = 2 s. The first warning phase runs for a maximum of t = 20 s and then changes
automatically into the second warning tone phase.

 If the first warning tone phase has expired (after t = 20 s) the second warning tone phase begins. However
the warning tone is first output as of a speed of v > or = 25 km/h via the speaker inside the instrument
cluster. In the first phase the warning tone is output as an individual tone (gong), which is repeated at a
low volume every t = 1 s. The second warning phase runs for a maximum of t = 20 s and then changes
automatically into the third warning tone phase.
 If the second warning tone phase has expired (after t = 40 s) the third warning tone phase begins.
However the warning tone is first output as of a speed of v > or = 25 km/h via the speaker inside the
instrument cluster. In the third phase the warning tone is output as an individual tone (gong), which is
repeated at a low volume every t = 0,4 s. The third warning phase runs for a maximum of t = 20 s and
then changes automatically into the fourth warning tone phase in vehicles with EURO-NCAP.
In vehicles with expanded NCAP the seat belt reminder warning is deactivated automatically after the third
warning tone phase has expired.
Warning tone phase 4 (EURO-NCAP)
 If the third warning phase has expired (after t = 60 s) the fourth warning tone phase begins. However the
warning tone is first output as of a speed of v > or = 25 km/h via the speaker inside the instrument cluster.
The warning tone in the fourth phase is a continuous signal (audible beep), which is output permanently
in a high volume. The fourth warning tone phase lasts for t = 93 s and remains active for this period, even
if the vehicle has come to a standstill in the meantime. The seat belt reminder warning is deactivated
automatically after the fourth warning tone phase.
Additional information on the function of the seat belt reminder warning is contained in the function of the
supplemental restraint system (SRS).
Display speed, function GF54.30-P-3025GZ
INDICATOR LAMP TEST AND ENGINE RUNNING DETECTION, FUNCTION - GF54.30-P-2014GZ
MODEL 164
Networking
Fig. 43: Indicator Lamp Test And Engine Running Detection Function Diagram - Shown On Model 164.1
Indicator lamp test
An indicator lamp test is performed via the instrument cluster at "circuit 15 ON". In the process all the indicator
and warning lamps (where fitted as per equipment variants and national variants) are actuated, except:
 left turn signal indicator lamp (A1e1),

 right turn signal indicator lamp (A1e2), and
 High beam indicator lamp (A1e3),
 Seat belt warning lamp (A1e9),
 Preglow indicator lamp (A1e16).
The indicator lamp test only takes place as long as "terminal 61" is on "LOW"-level (terminal 61 < 9 V) and the
alternator is not working yet as well as the engine speed is less than 200 rpm. If no malfunctions are present the
indicator lamps will go out as soon as the engine starts to run.
Engine running recognition "circuit 61e"
The instrument cluster combines the CAN messages "circuit 61" and "engine speed" for the CAN-message
"circuit 61e" engine running detection.
This CAN message can have either a "HIGH" or "LOW" status. It is "LOW" when "Terminal 61" is "LOW"
and the engine speed is less than 200 rpm.
The CAN message is "HIGH" if the engine speed is higher than 200 rpm.
The signal "circuit 61e" is placed on the engine compartment CAN as a CAN message from the instrument
cluster and is thus available to the control units of this bus system which require this CAN message.
Networking
The following CAN messages are required:

 "Circuit 61" (alternator check)
The signal "circuit 61" from the alternator (alternator check) is read in by the front SAM control unit. This then
relays the message "Terminal 61 HIGH" (alternator operating) or "Terminal 61 LOW" (alternator not operating)
onto the interior compartment CAN.
Engine speed
The pulses from the crankshaft position sensor (engine 113, 156, 629 only) or from the crankshaft Hall sensor
(engine 272, 273, 642 only) are read in by the ME-SFI [ME] control unit or by the CDI control unit.
The control units place the engine speed message on the CAN engine compartment.
The instrument cluster receives these messages and evaluates them as described above.
The same CAN messages are used for the charge indicator warning "BATTERY/ALTERNATOR VISIT
WORKSHOP." This message appears in the multifunction display (A1p13), if "terminal 61" is on "LOW" and
the engine speed is more than 200 rpm.
The following chart recapitulates the interrelationships portrayed in the above section.
Terminal 61 Engine speed Term. 61e Instrument cluster

low (< 4.5 V) too low LOW Indicator lamp test
low (< 4.5 V) o.k. HIGH "BATTERY/GENERATOR - GO TO GARAGE
high (> 9 V) too low HIGH -
high (> 9 V) o.k. HIGH -
HIGH (< 4.5 V) Signal fault LOW Indicator lamp test
high (> 9 V) Signal fault HIGH -
Output acoustic warning messages, function GF54.30-P-2013GZ
DISPLAY FUEL QUANTITY, FUNCTION - GF54.30-P-3018GZ
MODEL 164
Networking
Fig. 44: Fuel Quantity Function Diagram - Shown On Model 164.1

Function
The fuel level and reserve gage (A1p2) is a 39-segment LCD bar graph indicator. Switching on and off of the
fuel level and reserve gage (A1p2) takes place via instrument cluster (A1).
The display readings are shown immediately after "Terminal 15 ON"; the display run-up is dampened, but the
run-down is not. A hysteresis is implemented to prevent segment jittering of readings near the segment limits.
Fuel level gage sensor
The left fuel level sensor (B4/1) and right fuel level sensor (B4/2) are planned for the fuel level measurement.
The instrument cluster (A1) registers this percentage from the interior compartment CAN and uses this
information as the basis for controlling the fuel level and low fuel display (A1p2) as well as the low fuel
warning lamp (A1e4) as required.
Fuel level display
If the EIS [EZS] control unit (N73) is in the position "circuit 15 ON" the current tank capacity is displayed in
the fuel level and reserve indicator (A1p2).
During refueling when the EIS [EZS] control unit (N73) is in position "circuit 15 ON", refueling is only
detected (updating of the display) as of a replenishment quantity of at least 9 l. Once "circuit 15 ON" is
switched on again the display is updated. There is always a delay before the display is updated. This inhibits
fluctuations in the display, e.g. due to cornering.
Reserve range
The reserve range extends from "0" to "Reserve". This corresponds to a quantity of 0 to approx. 9 l.
When the reserve level is reached, the fuel reserve indicator lamp (A1e4) lights up in yellow when the engine is
running. The lamp is triggered with a delay period to prevent the lamp flickering.
The system responds to malfunctions by moving the needle in the fuel level and reserve display (A1p2) to
"0." The fuel reserve warning lamp (A1e4) does not come on.
Display outside temperature, function GF54.30-P-3019GZ
DISPLAY OUTSIDE TEMPERATURE, FUNCTION - GF54.30-P-3019GZ
MODEL 164
Fig. 45: Outside Temperature Function Diagram

Networking
The outside temperature indicator in the multifunction display uses the following data to display the
temperature:
 Outside temperature value

 Vehicle speed signal
 Engine running time
Displaying outside temperature
The instrument cluster conditions this data and actuates the display accordingly.
The fact that the outside temperature indicator in the multifunction display is dependent on the vehicle speed,
the engine running time and the coolant temperature helps to prevent the display of too high a temperature when
the vehicle is stationary or traveling slowly, such as might occur e.g. due to heat radiating from the engine.
The display behaves differently according to the coolant temperature and the engine running time.
Coolant temperature below 60°C:
 The current outside temperature value is always displayed when the instrument cluster is activated.
Coolant temperature equal to or greater than 60°C:
 At "circuit 15C" the last measured temperature is stored and then displayed for a maximum of 60
minutes.
 The stored temperature value is displayed when the instrument cluster is activated.
If the measured outside temperature falls below the stored value, the current measured temperature is displayed
after 8 seconds. If the engine is off, the current outside temperature is displayed after six times the engine
running time. This is based on the previous engine running time.
Example:
The preceding engine running time was 5 minutes. The delay period was then 6 times 5 minutes. The current
temperature is thus only displayed after 30 minutes.
If the engine running time was more than 10 minutes, a maximum of 10 minutes is taken into account when
calculating the delay time. The maximum delay is thus 60 minutes.
When the vehicle is moving, the delay periods depend on the vehicle speed. At speeds above 45 km/h rising
outside temperatures are displayed after a delay period of 1.5 minutes. At speeds of 20 km/h to 45 km/h rising
outside temperatures are displayed after a delay period of 3 minutes. If the vehicle speed falls below 20 km/h
(slowing from higher speeds), the display is only changed if the measured value falls.
Range
The display range is -40°C to +85°C or -40°F to 185°F. The temperature is displayed in increments of 0.5°C or
1°F.
Switching from degrees Celsius to degrees Fahrenheit
The driver can switch between degrees Celsius and degrees Fahrenheit using the "Settings" function in the
multifunction display.
Data for outside temperature
The outside temperature indicator temperature sensor (B14) changes its resistance according to the outside
temperature. The sensor is an NTC resistor, i.e. its resistance decreases as the temperature rises.
The resistance value from the outside temperature indicator temperature sensor is read in by the AAC [KLA]
control and operating unit (N22).
The AAC [KLA] control and operating unit converts the resistance value from the outside temperature display
temperature sensor into a temperature value and passes the temperature value onto the instrument cluster via the
interior CAN.
Vehicle speed signal
The ABS, BAS and traction system hydraulic unit (A7/3) are integrated in the ESP control unit.
The following signals are read in by the ESP control unit Left front rpm sensor
 Right front rpm sensor

 Left rear rpm sensor
 Right rear rpm sensor
The ESP control unit places the four wheel speed signals on the engine compartment CAN.
The instrument cluster determines the vehicle speed from this.
Coolant temperature
The coolant temperature sensor changes its resistance according to the coolant temperature. (The sensor is an
NTC resistor, i.e. its resistance decreases as the temperature rises.)
The resistance from the coolant temperature sensor is read in via the ME-SFI [ME] control unit or the CDI
control unit.
The ME-SFI [ME] control unit or CDI control unit converts the resistance values from the coolant temperature
sensor into a temperature value
This temperature value is placed on the CAN engine compartment by the ME-SFI [ME] control unit or by the
CDI control unit.
Engine running time
The engine running time is calculated internally in the instrument cluster using the integral timer.
The instrument cluster processes this data and actuates the display accordingly.
Notes on diagnosis
If the display indicates the minimum temperature of -40°C or -40°F although the actual temperature is
obviously higher, this could indicate a defective sensor or an open wire in the circuit. If the display indicates the
maximum temperature of 85°C or 185°F, although the actual temperature is obviously colder, this could
indicate a short circuit in either sensor or wiring.
If the coolant temperature sensor is defective and no valid coolant water temperature is passed on from the
CAN engine compartment, processing changes over into the range for coolant temperature of 60°C.
Display coolant temperature, function GF54.30-P-3020GZ
DISPLAY COOLANT TEMPERATURE, FUNCTION - GF54.30-P-3020GZ
MODEL 164
Fig. 46: Coolant Temperature Function Diagram - Shown On Model 164.1

The coolant temperature sensor is an NTC resistor, this changes its resistance value depending on coolant
temperature. The resistance value reduces as the temperature increases. The coolant temperature sensor is read
in by the ME-SFI [ME] control unit or by the CDI control unit and transmitted to the instrument cluster via the
CAN C.
The instrument cluster receives these signals and actuates the coolant temperature display in the multifunction
display.
The display takes place in the form of a bar graph display digitally in the upper display of the multifunction
display.
The coolant temperature display is actuated via a so-called plateau characteristic, in other words the temperature
display in the instrument cluster remains at 95 degrees Celsius, when the real temperature remains within a
range of 95 and 115 degrees Celsius.
This characteristic was introduced in order to compensate the permanently changing coolant temperatures, so
that driver is not disturbed by a fluctuating temperature display. All the real temperatures are displayed again
above 120 degrees Celsius.
Problems
If the signal of a defective engine fan is placed on CAN C by the ME-SFI [ME] control unit or the CDI control
unit, then the instrument cluster actuates the coolant temperature display without the plateau characteristic. The
real temperatures are then displayed in this case.
If the instrument cluster receives an implausible or even no coolant temperature from the ME-SFI [ME] control
unit or CDI control unit, then the smallest display value is actuated.
Warnings
The red warning range encompasses all temperature as of 120 degrees Celsius. As of this temperature value the
bar graph display is represented filled out to the full extent.
As of coolant temperatures of 130 degrees Celsius and higher, in addition the red stored warning note
"Coolant, stop, engine Off" is displayed in the multifunction display.
Instrument cluster, component description GF54.30-P-6000GZ
DISPLAY ENGINE SPEED, FUNCTION - GF54.30-P-3021GZ
MODEL 164
Networking
Fig. 47: Engine Speed Function Diagram - Shown On Model 164.1

Networking
The rpm is recorded by the crankshaft position sensor (engine 113, 156, 629 only) or by the crankshaft Hall
sensor (engine 272, 273, 642 only).
The signals are read in by the ME-SFI [ME] control unit or by the CDI control unit and placed on the CAN
engine compartment as a CAN message (in rpm)
The instrument cluster receives the CAN message and actuates the stepper motor for the tachometer relative to
the engine speed.
Warning range
The warning range (marked in red on the scale) is below the end value of the scale. The final scale value on
vehicles with gasoline engines is 7000 rpm.
Adjustment for the number of cylinders
An adaptation for the tachometer to the number of cylinders of the engine is not correct.
If implausible CAN messages occur, the needle of the tachometer is moved to the left-hand side of the scale.
An error bit is also stored in the fault memory.
Display distance, function GF54.30-P-3022GZ
DISPLAY DISTANCE, FUNCTION - GF54.30-P-3022GZ
MODEL 164
Measuring mileage
To calculate the mileage and the vehicle speed, the processor in the instrument cluster (A1) evaluates the
following wheel speed signals:
 Left front rpm sensor (L6/1/)

 Right front rpm sensor (L6/2/)
 Left rear rpm sensor (L6/3/)
 Right rear rpm sensor (L6/4/)
The instrument cluster (A1) receives the wheel speeds in rpm from the ESP control unit via the CAN-engine
compartment (N47-5). The system also includes tire size in its calculations of speed and distance. The tire size
is encoded using the STAR DIAGNOSIS tool.
Displaying the total mileage
The 6-digit display appears in kilometers or miles in the start screen below the multifunction display (A1p13) as
soon as the instrument cluster (A1) is activated.
The range for the total mileage odometer is from 0 to 999999 kilometers or miles. If the maximum mileage is
reached, the counter is not reset to "0".
The internal counter continues to operate up to a maximum of 1,677,721 km or 1,000,000 miles. Processing
cluster (A1).
Saving mileage counts
The total mileage figure remains stored for at least 5 years, even if the voltage supply is disconnected.
Functional integrity is guaranteed under normal conditions over the full service life of the vehicle (15 years or
10,000 operating hours). Every change in the least significant digit position is saved and protected against loss.
Displaying the trip mileage
The trip mileage is displayed as a 5-figure number on the main screen of the multifunction display (A1p13) in
kilometers or miles as soon as the instrument cluster (A1) is activated. The range for the trip mileage odometer
is from 0 to 9999.9 kilometers or miles. The display is reset to 0 once the maximum mileage is reached.
Resetting the trip mileage odometer
The trip odometer is reset to "0" by pressing the trip odometer reset button (A1s3) for more than t = 2 s.
Requirements:
 The instrument cluster (A1) is activated and the A1p13 basic display (total mileage and trip mileage) is
shown in the multifunction display.
Switching between kilometers and miles
The driver can switch the display from kilometers to miles using the "Settings" function.
If implausible CAN messages are received for all wheel speed signals, the total and trip mileage displays are
"frozen" and an error bit is set. The instrument cluster (A1) also relays the current odometer reading to the
interior compartment CAN.
Storage of data
With the battery disconnected, the overall mileage reading remains stored for a period of at least 10 years. The
trip mileage is also protected against data loss if the battery is removed for a short period of time.
Display transmission information, function GF54.30-P-3023GZ
DISPLAYING TRANSMISSION INFORMATION, FUNCTION - GF54.30-P-3023GZ
MODEL 164
Drive position display
The current drive position is displayed in the multifunction display (A1p13) in the instrument cluster (A1).
The drive position (P, R, N, D) of the 7-speed automatic transmission (code 427) (NAG2) selected by the
intelligent servo module control unit for DIRECT SELECT (A80) is shown on this display.
Transmission mode display
The transmission mode Comfort "C" or Sport "S" and the current gear (1, 2, 3, 4, 5, 6, D) are shown by the fully
integrated transmission control (VGS) control unit (Y3/8n4) in the multifunction display (A1p13).
The gear indicator and the transmission mode display appear after "circuit 15 ON".
The necessary data come via the engine compartment CAN.
The display remains blank if there are errors in the CAN signals.
Displaying time, function GF54.30-P-3024GZ
DISPLAYING TIME, FUNCTION - GF54.30-P-3024GZ
MODEL 164
The time is displayed in analog form via hour and minute hands on the electronic clock (A1p6). The minute
hand moves in steps of 1 minute. The hour hand is coupled to the minute pointer by a mechanical gear ratio.
Model 164 except COMAND APS (with navigation) code 527
The electronic clock (A1p6) is set via the "Settings" menu in the multifunction display (A1p13) using the
following buttons on the multifunction steering wheel:
 Scroll forward/back button (S110s1)

 System selection button (S110s3)
 Buttons + and - for setting specific functions and volume control (S111s1)
Model 164 with COMAND APS (with navigation) code 527
The electronic clock (A1p6) is set automatically.
The time information is placed by the COMAND operating, display and control unit (A40/3) as a message on
the Controller Area Network bus Class B (CAN-B) and is read in by the instrument cluster (A1).
If the GPS antenna splitter (A2/5) is receiving signals, these can be used to switch between summer and winter
time and vice versa automatically.
Battery charge/alternator check, function GF54.30-P-3027GZ
DISPLAY SPEED, FUNCTION - GF54.30-P-3025GZ

MODEL 164
Fig. 48: Speed Function Diagram - Shown On Model 164.1

The electronic speedometer (A1p8) displays the vehicle speed. The electronic speedometer (A1p8) is driven by
a stepper motor. In addition the vehicle speed can also be displayed digitally in the multifunction display
(A1p13).
Measuring the vehicle speed
To calculate the vehicle speed the wheel speeds of the following sensors are evaluated by the instrument cluster
(A1):
 Left front rpm sensor (L6/1)

 Right front rpm sensor (L6/2)
 Left rear rpm sensor (L6/3)
 Right rear rpm sensor (L6/4)
The instrument cluster (A1) receives the wheel speeds as rpm from the ESP control unit (N47-5) over the
Controller Area Network bus Class C (CAN-C).
As the tire circumference differs only very slightly among all the approved tires, no coding of the tire
circumference is necessary.
Digital speedometer
The vehicle speed is displayed digitally in the multifunction display (A1p13). The display of vehicle speed in
km/h or mph is stored country-specific nonvolatile memory and can be changed in the "settings" menu. The
digital speed display is matched to the electronic speedometer (A1p8) by a performance map.
Evaluating the wheel speed signals

Since the wheels do not always rotate at the same speed, all 4 wheel speeds must be evaluated. The actual
process is relatively complex, which is why only a general description is provided here:
 The individual wheel speeds are compared and submitted to a plausibility check. If no significant
deviations of individual wheel speed signals are to be detected, the vehicle speed is detected from the rpm
of the left front wheel.
 If the individual wheel speed signals differ considerably, the speed signals may be faulty or the vehicle
may be cornering.
 If the instrument cluster (A1) ascertains by means of suitable comparisons (lateral comparisons) of the
wheel speeds that the vehicle is cornering, the vehicle speed is calculated from the mean value of the front
wheel speeds.
 If the comparisons indicate one or more incorrect wheel speeds, the speed is calculated from the highest
wheel speed. This also applies if an error message is received instead of a rotational wheel speed. In this
case, an appropriate error message is stored in the memory.
If fault messages are received for all wheel speeds, the speed 0 km/h or 0 mph is displayed.
This evaluation of the wheel speed signals also applies for evaluating the distance traveled since the distance
is calculated from the vehicle speed.
Speed limiting with winter tires
A permanent speed limit (adjustable in 10-km/h steps of 160 km/h to 240 km/h) can be activated and adjusted
with the right multifunction steering wheel button group (S111) and left multifunction steering wheel button
group (S110).
Limiter
The limiter function status is displayed over the LIM (variable speed limiter) function lamp (A1e33) in the
BATTERY CHARGE/ALTERNATOR MONITORING, FUNCTION - GF54.30-P-3027GZ
MODEL 164
Networking
Fig. 49: Battery Charge/Alternator Monitoring Function Diagram

Battery charge/alternator check
In the event of an alternator fault the battery symbol and the message "Locate workshop" (this message belongs
to category 2) or "Battery/alternator-stop!" is displayed in the multifunction display in the instrument cluster.
This message belongs to Category 1.
It appears when the alternator is not operating correctly (circuit 61), but the engine speed is higher than 200
rpm.
There is no message when the engine is OFF.
Networking
The following CAN messages are required:
 "Circuit 61" alternator check

 "Terminal 61 (= D +)" from alternator.
The alternator check "circuit 61" is read in by the front SAM control unit.
The front SAM control unit then places the message "terminal 61 HIGH" (voltage terminal 61 > 9 V) or
"terminal 61 LOW" (alternator not working properly) on the CAN-interior.
Engine speed
The pulses from the crankshaft position sensor (engine 113, 156, 629 only) or from the crankshaft Hall sensor
(engine 272, 273, 642 only) are read in by the ME-SFI [ME] control unit or by the CDI control unit.
The control units place the message motor speed (in rpm) on the CAN engine compartment. The instrument
cluster receives these messages and evaluates them.
Alternator monitor, tml. 61 (= D+)
The CAN message "term. 61" can have the status "high" and "low". This status depends on the effective voltage
at the input of the front SAM control unit. The status is "HIGH" if the voltage is greater then 9 V. It is "LOW"
when the voltage drops back below 4.5 V.
Excitation current for the alternator
The excitation winding is supplied with excitation current through a resistor located in the wiring harness.
When "Terminal 15R ON", the voltage at "Terminal 61" is small since the excitation winding almost short
circuits the voltage.
If, when the engine is running, the alternator voltage rises above the battery voltage, the excitation winding is
supplied with current by the alternator. The voltage at "Terminal 61" increases to the alternator voltage.
The battery charge/alternator check function is closely linked to the lamp test and engine running detection
("terminal 61e").
Instrument cluster illumination, function GF54.30-P-2007GZ
VOLTAGE CODING OF COOLANT/WINDSHIELD WASHER FLUID LEVEL, FUNCTION -

GF54.30-P-4001GZ
MODEL 164
Voltage coding
For voltage coding, the switches "s1 " and "s2 " are connected in parallel with the resistors "r1 " and "r2 " (the
values of "r1 " and "r2 " must be different).
When the switches are open, these resistors, together with "r3 " of the front SAM control unit (N10), form a
voltage divider which is supplied with the constant voltage "U const ."
The voltage "Ue " at the input of the front SAM control unit (N10) therefore depends on the positions of the
switches and the values of the resistors.
With the two switches, there are therefore four possible switch combinations (see table).
Each of these combinations produces a different voltage value "Ue " at the input of the front SAM control unit
(N10).
Evaluation
The voltage "Ue " is present at the input of the analog/digital converter of the front SAM control unit (N10).
The analog/digital converter converts the analog voltage into a digital value.
This is necessary because the processor of the front SAM control unit (N10) can only work with digital values.
The processor compares the values to the threshold values stored in memory and if necessary, relays an
appropriate message (coolant and/or washer fluid level too low) over the interior CAN. The instrument cluster
(A1) reads this message and actuates the multifunction display (A1p13) for the image and text accordingly.
When the resistances and voltage "Uconst " are known, "Ue " can be calculated with the following formula:
Ue = Uconst X (r1 + r2 )/(r1 + r2 + r3 ). The following table shows the warning messages which appear according
to the status of the switches.
These messages can be acknowledged by pressing the trip odometer reset button (A1s3) on the instrument
cluster (A1).
Status Coolant level Status Windshield washer Warning message in the multifunction display
indicator switch (S41) fluid level indicator switch (A1p13)
(S42)
Open Open No message
Open Closed "CHECK WASHER FLUID LEVEL"
Closed Open "CHECK COOLANT LEVEL"
"CHECK COOLANT LEVEL" (The message
Closed Closed "CHECK WASHER FLUID LEVEL" has a
lower priority.)
COMPONENT DESCRIPTION FOR THE "CHECK ENGINE" INDICATOR LAMP - GF54.30-P-

5011AMG
MODEL 164, 251 with ENGINE 156.980 with CODE (494) USA version
MODEL 209 with ENGINE 156.982 with CODE (494) USA version
MODEL 211, 219 with ENGINE 156.983 with CODE (494) USA version
Location for model 164, 251
The indicator lamp (labeled CHECK ENGINE in yellow) is located on the right in the instrument cluster (A1).
Fig. 50: Identifying CHECK ENGINE MIL Indicator Lamp - Location For Model 164, 251
Location on models 209, 211, 219
The indicator lamp (labeled CHECK ENGINE in yellow) is located on the right in the instrument cluster (A1).
Fig. 51: Identifying CHECK ENGINE MIL Indicator Lamp - Location For Model 209, 211, 219
Task
The indicator lamp alerts the driver to the reoccurrence of faults relevant to exhaust emissions.
Function
The ME-SFI control unit (N3/10) actuates the indicator lamp by transmitting an appropriate signal via the CAN
data bus to the instrument cluster.
As a function check the indicator lamp is actuated at "Ignition ON". It goes out after engine start if there are no
faults relevant to exhaust emissions.
"CHECK ENGINE" MIL - DESCRIPTION OF COMPONENTS - GF54.30-P-5011BK

MODEL 164.1 with ENGINE 113.964 with CODE (494) USA version
Shows model 219
Location
The "CHECK ENGINE" MIL is located in the instrument cluster.
Fig. 52: Identifying Check Engine Indicator Lamp

Task
The "CHECK ENGINE" MIL alerts the driver to emissions-relevant malfunctions.
Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. As a
check of the function it lights up when the ignition is ON and for approx. 1 second as of an engine speed of
approx. 500 rpm. The indicator lamp goes out if there is no fault present.
COMPONENT DESCRIPTION FOR THE "CHECK ENGINE" INDICATOR LAMP - GF54.30-P-

5011V
MODEL 203 with ENGINE 272.920 except CODE (494) USA version
MODEL 203, 209 with ENGINE 272.940 except CODE (494) USA version
Shows model 219
Location
The "CHECK ENGINE" indicator lamp is located in the instrument cluster.
Task
To indicate faults in the fuel injection system
Fig. 53: Identifying Check Engine MIL - Shows Model 219

Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. To
check the function it lights up with ignition on ON and as of an engine speed of approx. 500 rpm for approx. 1
s. If there is no fault, the indicator lamp goes out
INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-P-6000GZ
MODEL 164
Location
Fig. 54: Identifying Instrument Cluster Location

Location
The instrument cluster is located in the dashboard on the driver-side.
Task
The instrument cluster displays the dynamic and static status of the vehicle.
It also controls:
 Input/output signals on CAN-B and CAN-C for the various operations, displays and warning messages
 Illumination of the multifunction display (A1p13) depending on:
 the brightness buttons +/-
 the rain/light sensor (B38/2)
 the photo-transistor
 Outputs to the multifunction display

 Displaying the time using an analog clock
 Reading in the brightness buttons +/-
 Reading in the reset button (R)
The acoustic warning and information signals are output by a speaker that generates the turn signal indicator
clicking sound using a relay:
 Flashing "ON" (turn signal indicator clicking sound)

 Lights ON warning (gong)
 Parking brake warning (gong tone)
 Key reminder (gong tone)
 National vehicle speed warning (gong tone)
 Door warning (gong tone)
 Child safety lock (gong tone)

 Front passenger airbag shutoff by ACSR automatic child seat recognition (gong tone)
 Seat belt reminder warning (gong tone, audible beep)
 Engine oil level warning (gong tone)
 Configurations which can also be set while driving are with the exception of:
 Switch daytime running lamps on/off
 Engine oil level measurement
 Key dependency
 The instrument cluster actuates the stepper motors of the following analog displays:
 Tachometer (A1p5)
 Electronic clock (A1p6) (analog display)
 Electronic speedometer (A1p8)
 Fuel supply and reserve indicator (A1p2)
Variants
 Left-hand drive vehicle

 Right-hand drive vehicle
 Instrument cluster with segment display with Distronic (DTR) code 219
 Instrument cluster without segment display without Distronic (DTR) code 219
National versions
 National version ECE, Canada, Rest of the World (km)

 Single scale "km/h"
 Speedometer ring with 26 sections
 Segment ring for the speed control systems adapted to the km/h scale (with Distronic (DTR) code
219)
 Gasoline engine/diesel
 National version for USA, UK (miles)

 Single scale "miles"
 Speedometer ring with 32 sections
 Segment ring for speed control systems adapted to the miles scale
 Gasoline engine/diesel
OVERVIEW OF SYSTEM COMPONENTS, INSTRUMENT CLUSTER (IC) COMPONENT

MODEL 164
GF54.30-P-
6000GZ
Component description for the engine with engine 156.980 except USA version GF54.30-P-
diagnosis indicator lamp code 494 5010AMG
Model 164.1 with engine 113.964 except GF54.30-P-
USA version code 494 5010BK
Model 164.1 with engine 272.967 except
USA version code 494, Model 164.8 GF54.30-P-
with engine 273.923/ 963 5010V
except USA version code 494
"CHECK ENGINE" indicator lamp with engine 156.980 with USA version GF54.30-P-
component description code 494 5011AMG
Model 164.1 with engine 113.964 with GF54.30-P-
USA version code 494 5011BK
Model 164.1 with engine 272.967 with
USA
version code 494, GF54.30-P-
Model 164.8 with engine 273.923/ 963 5011V
with
USA version code 494
Table of contents for function description of GF54.30-P-
instrument cluster (IC) 0997GZ
TRIP COMPUTER (TRIP), FUNCTION - GF54.50-P-0001GZ
MODEL 164
Statistical data can be called up and displayed in the Trip computer menu. The trip computer is integrated into
the instrument cluster (A1). Displays are shown in the multifunction display (A1p13) in the instrument cluster.
There are two different data memory options:
The contents of the short distance memory are shown in the display screen "as of start", the contents of the long
distance memory are shown in the "as of reset".
The trip computer can be reset using the instrument and controls illumination button, bright (A1s4), instrument
and controls illumination button, dim (A1s5) or the trip odometer reset button (A1s3).
The following functions are provided by the trip computer:
 Distance driven "since start" or "since reset"

 Time elapsed since "start" or since the last "reset"
 Average speed since "start" or since last "reset"
 Average fuel consumption since "start" or since last "reset"
The range with the amount of fuel in the tank can also be displayed on the multifunction display.
Operation:
The trip computer is operated using the left multifunction steering wheel button group (S110).
All information for the trip computer functions are received by the Instrument cluster over the engine
compartment CAN and over the interior CAN.
Function overview
The trip computer is integrated in the instrument cluster. The instrument cluster is connected to the:
 engine compartment CAN and to

 interior CAN.
Data is exchanged with virtually all the control units over the two bus systems.
The instrument cluster does not however act as an interface between the two data bus systems. This function
is reserved for the central gateway control unit (N93).
Listed below are the CAN messages that are important for the functions of the instrument cluster including the
trip computer.
The connections for the instrument cluster are described in the last section of this document.
The trip computer receives the following input signals:
 Wheel speeds from the ESP control unit (N47-5) via the engine compartment CAN
 Fuel consumption signal via the engine compartment CAN from the ME control unit (N3/10)
 Time over the interior CAN from the audio gateway control unit (N93/1) and this over the MOST of the
COMAND operating, display and control unit (A40/3), for vehicles with COMAND operating, display
and control unit
 "Terminal 15" status over the interior CAN from the EIS [EZS] control unit (N73) and "Key in ignition"
 Actuation signals from the multifunction steering wheel buttons over the interior CAN from the steering
column module (N80)
 Fuel tank level from the rear SAM control unit (N10/8) over the interior CAN
CAN messages of push-buttons of multifunction steering wheel
In view of the fact that the push-buttons of the multifunction steering wheel perform several functions, the
signals of these push-buttons must be conditioned accordingly:
 All push-buttons of the left multifunction steering wheel push-button group and the right multifunction
steering wheel push-button group (S111) are voltage-coded and are read in by the steering column
module.
 The steering column module sends the relevant messages to the interior CAN.
 These CAN messages are received by the instrument cluster.
 The instrument cluster interprets these messages in combination with the systems currently displayed on
the multifunction display and then relays the interpreted messages back onto the interior CAN.
Reception messages for the multifunction display
All the signals for the messages in the multifunction display are received over the engine compartment CAN or
interior CAN. Information about the signal paths and other details about the different messages can be found in
the function descriptions for the relevant systems.
Kilometers/miles switchover, function GF54.50-P-2002GZ
CONTENTS, FUNCTION DESCRIPTION, TRIP COMPUTER (TRIP) - GF54.50-P-0999GZ
MODEL 164
Trip computer (TRIP), function GF54.50-P-0001GZ

Kilometers/miles switchover, function GF54.50-P-2002GZ
Travel time, function GF54.50-P-2004GZ
Range, function GF54.50-P-2006GZ
Fuel consumption, function GF54.50-P-2007GZ
Mileage, function GF54.50-P-2008GZ
Average speed, function GF54.50-P-2009GZ
Reset, function GF54.50-P-2010GZ
Compass calibration, function GF54.50-P-2013GZ
Setting the compass zone, function GF54.50-P-2014GZ
Overview of system components of trip computer (TRIP), component description GF54.50-P-9998GZ
KILOMETERS/MILES SWITCHOVER, FUNCTION - GF54.50-P-2002GZ
MODEL 164
The units of measurement do not need to be specifically changed for the trip computer because it adopts the
settings and coding of the instrument cluster (A1).
The units of measurement can be changed the instrument cluster from miles to kilometers (or vice versa) by
selecting "Settings" in the "Combi" submenu in the multifunction display (A1p13) using the multifunction
steering wheel.
The only requirement is to preset the unit of measurement used to monitor the distance (kilometers or miles).
The other units that are relevant for the trip computer are then converted automatically.
The coding for US gallons/UK gallons is changed via the national version using STAR DIAGNOSIS.
Travel time, function GF54.50-P-2004GZ

Scanning of switch positions, function Except Japan version, code 498 GF82.90-P-3001GZ
TRAVEL TIME, FUNCTION - GF54.50-P-2004GZ
MODEL 164
Travel time display "as of start" (short distance memory) function
Time elapsed since start.
Fig. 55: Display Of Travel Time - As Of Start

Travel time display "as of reset" (long distance memory) function
Time elapsed since the last reset.
Fig. 56: Display Of Travel Time - As Of Reset

The display screen "as of start" or "as of reset" for the travel time can be activated via the system selection
button (S110s3) and scroll forward/back button (S110s1) of the multifunction steering wheel.
As the time is only counted for "circuit 15 ON", the Instrument cluster (A1) needs the information about the
status of circuit 15. This information is placed on the interior CAN by the EIS [EZS] control unit (N73) and
read by the instrument cluster. The time is calculated internally in the instrument cluster.
If the display of travel time of travel distance exceeds the maximum display value (99:59 hours or 40959
miles (65535 km)), then the travel time and the travel distance of the respective memory are reset automatically.
This preserves the relationship between travel time and mileage.
Fuel consumption, function GF54.50-P-2007GZ
RANGE, FUNCTION - GF54.50-P-2006GZ
MODEL 164
Inquire after range in kilometers
Fig. 57: Display Of Fuel Consumption - Inquire After Range In Kilometers

Inquire after range in miles

Fig. 58: Display Of Fuel Consumption - Inquire After Range In Miles

The range can be called up on the multifunction steering wheel using the system selection button (S110s3) in
the first function of the multifunction display (A1p13). The scroll forward/back button (S110s1) displays the
range.
To determine the corresponding range the trip computer in the instrument cluster (A1) needs the fill level of the
fuel tank. The left tank half fuel level sensor (B4/1) and right tank half fuel level sensor (B4/2) is read in by the
rear SAM control unit (N10/8) and the corresponding message placed on the interior CAN. The instrument
cluster receives this message, evaluates it and displays the corresponding value as the tank contents.
As the time is only counted for "circuit 15 ON", the instrument cluster needs the information about the
condition of "circuit 15". This information is placed on the interior CAN by the EIS [EZS] control unit (N73)
and read by the instrument cluster. The time is calculated internally in the instrument cluster.
If the display of travel time ot travel distance exceeds the maximum display value (99:59 hours or 40959
miles (65535 km)), then the travel time and the travel distance of the respective memory are reset automatically.
This preserves the relationship between travel time and mileage.
Reset, function GF54.50-P-2010GZ
FUEL CONSUMPTION, FUNCTION - GF54.50-P-2007GZ
MODEL 164
Fuel consumption "since start" (short-distance memory), function
Average gasoline consumption since start.

Fig. 59: Display Of Fuel Consumption - Average Gasoline Consumption Since Start
Fuel consumption "Since reset" (long-distance memory), function
Average gasoline consumption since last reset.
Fig. 60: Display Of Fuel Consumption - Average Gasoline Consumption Since Last Reset
The display screen "as of start" or "as of reset" for the travel time can be activated via the system selection
Depending on the unit setting (miles/kilometers) and the national variant coding of the instrument cluster (A1)
the fuel consumption is displayed in:
 Miles per gallon

 Liters per 100 kilometers or
 Kilometers per liter (only if national variant Japan is coded)
The trip computer calculates the average fuel consumption figures from the mileage traveled and the fuel
consumption signal.
The fuel consumption signal uses information on the amount of fuel injected within a specific period.
The instrument cluster receives this data in the following way:
 The fuel consumption signal is generated by the ME control unit (N3/10) and sent as a message on the
engine compartment CAN.
 The mileage traveled is calculated from the four wheel speeds. The signals are sent from the ESP control
unit (N47-5) over the engine compartment CAN.
Following a reset it may take up to three kilometers/miles or two minutes before sufficient data is available
in order to correctly calculate and display the consumptions. Depending on the unit setting (kilometers/miles)
and the national variant coding of the instrument cluster the fuel consumption is displayed in:
 litters per 100 kilometers (ECE)

 miles per gallon (USA)
 kilometers per litter (Japan)
It is quite normal for the "Since Start" display (short-distance memory) and "Since Reset" display (long-distance
memory) to show different values, since the two displays are based on different sets of data.
The "since start" display (short-distance memory) reacts much more sensitively to the current driving situation
than the "since reset" display (long-distance memory).
Mileage, function GF54.50-P-2008GZ
MILEAGE, FUNCTION - GF54.50-P-2008GZ
MODEL 164
Distance "Since start" (short-distance memory), function
Kilometers driven since last start.
Fig. 61: Display Of Mileage - Distance Since Start

Distance "Since reset" (long-distance memory), function
Distance driven since last reset.
Fig. 62: Display Of Mileage - Distance Since Reset

The display screen "Since start" or "Since reset" for the travel distance can be activated using the system
selection button (S110s3) and scroll forward/back button (S110s1) of the multifunction steering wheel.
The distances are calculated by processing the wheel speed signals. They are sent in the form of a message
from the engine compartment CAN from the ESP control (N47-5) to the instrument cluster (A1). The mileage
count occurs in parallel with the count for the odometer function in the instrument cluster.
If display of the travel distance or travel time exceeds the maximum display value (40959 miles (65535 km)
or 99:59 hours), then the travel time and mileage of each memory are automatically reset. This preserves the
relationship between travel time and mileage.
Average speed, function GF54.50-P-2009GZ
AVERAGE SPEED, FUNCTION - GF54.50-P-2009GZ
MODEL 164
Average speed "Since start" (short-distance memory), function
Average speed since start.

Fig. 63: Display Of Average Speed - Average Speed Since Start

Average speed "since reset" (long-distance memory), function
Average speed since last reset.
Fig. 64: Display Of Average Speed - Average Speed Since Last Reset
The "Since start" or "Since reset" display screen for the average speed can be activated via the system selection
The following information is required:
 Travel time: This is calculated internally in the instrument cluster (A1).

 Travel distance: This is determined from the four wheel
speeds. The wheel speeds are sent as engine compartment CAN messages from the ESP control unit (N47-5) to
the instrument cluster.
It is quite normal for the "Since Start" display (short-distance memory) and "Since Reset" display (long-
distance memory) to show different values, since the two displays are based on different sets of data. The "since
start" display (short-distance memory) reacts much more sensitively to the current driving situation than the
"since reset" display (long-distance memory).
Range, function GF54.50-P-2006GZ
RESET, FUNCTION - GF54.50-P-2010GZ
MODEL 164
Resetting the long-distance memory ("Since reset"):
 "Tml. 15 ON"
 Select the "SINCE RESET" display using the system selection button (S110s3) and scroll forward/back
button (S110s1) on the multifunction steering wheel.
 Press and hold the instrument and controls illumination button, dim (A1s5) or instrument and controls
illumination button, bright (A1s4) and the trip odometer reset button (A1s3) for one second.
 The display is reset.
Manual reset of the short-distance memory ("Since start"):
 "Tml. 15 ON"
 Use the system selection button and scroll forward/back button to select the "Since start" (short-distance
memory) display mask.
 Press and hold the instrument and controls illumination button, dim or instrument and controls
illumination button, bright and the trip odometer reset button for one second.
 The display is reset.
Automatic reset of short-distance memory ("Since start")
As the "Since start" display (short-distance memory) is intended for one driving cycle's data, the contents of the
"Since start" display (short-distance memory) are reset automatically.
If the EIS [EZS] control unit (N73) is in the "terminal 15C" position all the short-distance memory data are
reset after roughly four hours. If, during this period, "terminal 15C" is interrupted by "terminal 15R ON" or
Acceptance of data from previous driving cycles into short-distance memory
In some cases it may be useful to transfer the data from the previous driving cycle into the short-distance
memory, e.g. if you wish to record the data for a single tank of fuel during a vacation trip even with several
breaks in the journey. The data for the entire trip can then be stored in the long-distance memory ("since reset").
The procedure for this is as follows:
 Use the multifunction steering wheel's system selection button and scroll forward/back button to select
the "Since start" (short-distance memory) display mask.
 Start the engine.
 The "Since start" (short-distance memory) display flashes on and off for up to 2 km or miles or for 2 min
after starting the engine.
 With the display flashing on and off, press and hold the instrument and controls illumination button, dim
or instrument and controls illumination button, bright and the trip odometer reset button for one second.
 The values of the previous driving cycle are accepted into the short-distance memory
If display of the travel distance or travel time exceeds the maximum display value (40959 miles (65535 km)
or 99:59 hours), then the travel time and mileage of each memory are automatically reset. This preserves the
relationship between travel time and mileage.
After resetting it can take up to three kilometers or two minutes until the trip computer has sufficient data in
order to display the consumption figures correctly. During this time, depending on the unit setting (kilometers
or miles) and coding, the national version of the instrument cluster (A1) is displayed.
Activate instrument cluster, function GF54.30-P-2006GZ
CALIBRATE COMPASS FUNCTION - GF54.50-P-2013GZ
MODEL 164
Following an interruption to the voltage supply, e.g. if the battery was discharged or disconnected, then the
electronic compass (B26) has to be calibrated! During this procedure the electronic compass measures the
magnetic conditions of the vehicle. This in turn means that the compass can compensate for magnetic overlays,
which could otherwise result in course errors.
Magnetic environment
Ferromagnetic materials (e.g. iron and nickel) influence their surrounding magnetic field and thus locally also
the earth's magnetic field, which the compass also uses for calibration. The same applies for electrical currents.
Each conductor through which a current flows is surrounded by a magnetic field, the strength of which is
dependent on the amperage.
For these reasons, the above-mentioned conditions must be taken into consideration when performing
calibration.
Calibration trip
During a calibration trip it is important that the compass covers all cardinal points. For this reason, the
calibration will be completed fastest when the calibration trip is conducted on a circular path; the tangents on a
circle have a different orientation at each point of the circle.
Compass calibration
To perform a correct calibration the correct zone must first be entered or checked, before starting the calibration
trip ("Vehicle" configuration in Combi menu). The current zone (1 to 15), in which the vehicle is located must
be entered. The multifunction display (A1p13) in the instrument cluster (A1) shows the "CALIBRATION
ACTIVE" display and the message with the request "Please drive in a full circle". Following successful
calibration the multifunction display shows "Successfully completed" and the cardinal points are displayed.
Electronic compass component description GF54.50-P-4102GZ
SET COMPASS ZONE FUNCTION - GF54.50-P-2014GZ
MODEL 164
Set compass zone (declination):
 Determine corresponding compass zone (1 to 15) on the basis of the zone maps (declination maps) listed
below.
 Ignition: "ON"
 Press and keep pressing system selection button (S110s3) until the Settings menu appears in the
 Press and keep pressing Buttons + and - for setting specific functions and volume control (S111s1) until
the Vehicle submenu appears in the multifunction display.
 Press and keep pressing the scroll forward/back button (S110s1) until the Compass settings message
appears in the multifunction display.
 Press Mode key 2 x to return to the compass display and to save the displayed compass zone.
 Enter compass zone using the buttons + and - for setting specific functions and volume control.
Examples:
 Location San Francisco:
The North America zone map yields
compass zone 4.
 Location Berlin:
The Europe, Africa zone map yields compass zone 8 .

 Location Bonn:
The Europe, Africa zone map yields compass zone 9.
To achieve as accurate a course display as possible, it may be necessary under certain conditions to
change the compass zone during a route. For example, when traveling from Bonn to Berlin two compass
zones are passed through (cf. examples).
Earth's magnetic field
The compass uses the earth's magnetic field to determine the cardinal points.
The earth's magnetic poles (North/South) deviate however slightly from the geographical poles. When
compared with the earth's axis of rotation, the earth's magnetic axis is inclined by roughly 20°. If the earth's
magnetic field is to be used for determining the cardinal points, then correction factors must be considered for
various earth zone.
To this end 15 different compass zones are calculated. At each location within a zone the deviation (declination)
is approximately identical.
If the correct compass zone has been entered in the compass, then it can correct the geomagnetic data
accordingly and thus display the route relatively accurately (± 10°).
Europe and Africa zone map
Fig. 65: Identifying Europe And Africa Zone Map

Asia and Australia zone map

Fig. 66: Identifying Asia And Australia Zone Map

North America zone map
Fig. 67: Identifying North America Zone Map

South America zone map
Fig. 68: Identifying South America Zone Map

Electronic compass component description GF54.50-P-4102GZ
ELECTRONIC COMPASS COMPONENT DESCRIPTION - GF54.50-P-4102GZ
MODEL 164
Fig. 69: Identifying Electronic Compass

Electronic
The electronic compass, also known as the compass module, is mounted on a bracket,
compass
which is clipped into the combination bracket frame.
location
The electronic compass is used to measure the direction of the near-earth magnetic field
Electronic
and thus determines the heading direction of travel. Only 8 typical cardinal points (N,
compass task
NW, W, SW, S, SO, O, NO) are shown in the multifunction display (A1p13).
Electronic
 Magnetic field sensor for measuring alignment of near-earth magnetic field
compass
design  EPROM memory for continual storage of given calibration data and settings
 Transmission of direction information as from active CAN-B
Electronic
 Compensation of spurious magnetic fields such as, e.g. heated seat
compass
function  DIAGNOSABLE
 Performance of self-test, when ignition switched on
OVERVIEW OF SYSTEM COMPONENTS, TRIP COMPUTER (RRE) COMPONENT

MODEL 164

Electronic compass, component description GF54.50-P-4102GZ
Trip computer (TRIP) contents function description GF54.50-P-0999GZ
PARKTRONIC SYSTEM (PTS), BLOCK DIAGRAM - GF54.65-P-0001-01GZ

Fig. 70: Parktronic System (PTS) Block Diagram

PARKTRONIC SYSTEM (PTS), LOCATION OF COMPONENTS - GF54.65-P-0001-02GZ

Fig. 71: Parktronic System (PTS) Components Location - Shown On Model Designation 164.1
PARKTRONIC SYSTEM (PTS), FUNCTION - GF54.65-P-0001GZ
MODEL 164.1 /8 with CODE (220) Parktronic system (PTS)
Description
The Parktronic system (PTS) is an ultrasonic measuring system for detecting the distance to an obstacle. It helps
the driver to estimate distances to objects in front of and behind the vehicle.
 When selector lever position "D" is engaged and at a speed below 18 km/h the area (A) in front of the
vehicle is monitored, when selector lever position "R" or "N" is engaged the area (A) in front of and the
area (B) behind the vehicle is monitored. The maximum monitoring range is 100 cm at the front (a) and
120 cm at the rear (b). In areas (c1) and (c2) the Parktronic system (PTS) no longer receives defined
values (for technical reasons).
Fig. 72: Identifying Parktronic System Dimension

 On approaching an obstruction a visual (and, if necessary, an acoustic) warning is given.

 When the ignition is switched on, the PTS control unit (N62) performs a self-test.
Parktronic system (PTS), block diagram GF54.65-P-0001-01GZ

Parktronic system (PTS), location of components GF54.65-P-0001-02GZ
Driving, function GF54.65-P-3000GZ
Self-test, function GF54.65-P-2000GZ
BACKUP CAMERA (RFK) LOCATION OF COMPONENTS - GF54.65-P-0005-01GZ
Fig. 73: Identifying Backup Camera (RFK) Components Location

BACKUP CAMERA (RFK), BLOCK DIAGRAM - GF54.65-P-0005-02GZ
Fig. 74: Backup Camera (RFK) Block Diagram

BACKUP CAMERA (RFK), FUNCTION - GF54.65-P-0005GZ
MODEL 164 with CODE (218) Backup camera with CODE (494) USA version except CODE (849) Spare
wheel holder/spare wheel
MODEL 251 with CODE (218) Backup camera with CODE (494) USA version
Fig. 75: Backup Camera (RFK) Function Diagram

Data flow chart shown on model designation 164
Fig. 76: Backup Camera (RFK) Function Diagram - Shown On Model Designation 164
Data flow chart shown on model designation 251
Complete description of backup camera system (RFK)
The backup camera system (RFK) assists the driver when parking and when backing up. With the aid of the
backup camera in the rear-end door, the entire surrounding area to the rear of the vehicle is displayed in CVBS
format on the display of the COMAND operating, display and controller unit. At the same time as the video is
displayed on the screen, warnings appear which urge the driver not to neglect actual events in the area
surrounding the vehicle.
If the driver assist system is activated, the backup camera voltage supply module supplies voltage to the backup
camera in the rear-end door.
The backup camera then transmits an analog video picture back to the backup camera voltage supply
component.
The backup camera voltage supply module loops the video signal through and transfers the video picture to the
operating, display and controller unit over a screened coaxial line.
CVBS stands for Composite Video Base-band Signal. This is an analog video signal, which combines all
relevant information (e.g. color and brightness values etc.) in just one signal.
External environmental influences such as darkness, dust, fog or precipitation can however restrict the
functionality of the backup camera.
System components
 COMAND operating, display and control unit

 Voltage supply module, backup camera
 Backup camera in rear-end door
 Circuit 15 ON
 Reverse gear engaged (selector lever position "R") via DIRECT SELECT gear selector switch (S16/13)
 COMAND operating, display and controller unit activated.
Activation of COMAND operating, display and control unit
The COMAND operating, display and controller unit shows the video pictures from the backup camera in the
display as soon as it receives the digital signal "Reverse gear engaged" via CAN B.
The electric signals generated by the driver through the DIRECT SELECT gear selector switch for transmission
position "R" are transferred from the steering column module (N80) to the intelligent servo module for DIRECT
SELECT via CAN C.
The intelligent servo module for DIRECT SELECT then transfers the message "Reverse gear engaged" to the
central gateway control unit via CAN C and from there to the COMAND operating, display and controller unit
via CAN B.
Voltage supply module, backup camera
The backup camera voltage supply module supplies voltage to the backup camera and transfers the video
pictures to the COMAND operating, display and controller unit over a discrete line. The basis for activation of
the backup camera voltage supply module is the digital signal "Reverse gear engaged". The intelligent servo
module for DIRECT SELECT transmits the position of the DIRECT SELECT gear selector switch to the
central gateway control unit via CAN C.
The central gateway control unit transmits the request to switch on the left backup lamp (E3e3) and right
backup lamp (E4e3) to the rear SAM control unit (N10/8), which switches on the backup lamps discretely.
On model designation 164, the activated left backup lamp supplies the electrical pulse to activate the backup
camera voltage supply module component over a discrete line (on model designation 251 the right backup lamp
performs this function). The backup lamp is then supplied with voltage.
Priority management of COMAND operating, display and control unit
A priority management system integrated in the COMAND operating, display and controller unit ensures that
the many functions operate in the correct sequence. Functions of higher priority are carried out before functions
of lower priority. A function of lower priority that is currently running (e.g. backup camera system) is
automatically deactivated if a function of higher priority (e.g. E-call or Roadside Assistance) is started.
Function restrictions
 Rear-end door open
The backup camera in the rear-end door is positioned so that it functions optimally when the rear-end door is
closed. If the rear-end door is open, the driver assist function is not deactivated but the sky (for example) is
displayed instead of the entire area to the rear of the vehicle.
 Trailer
A trailer does not affect the driver assist function. The display still appears in the COMAND operating, display
and controller unit. Particularly with larger trailers and the associated visibility restrictions, it may be the case
that the driver does not have a full view of events in the area to the rear of his/her own vehicle.
Driver termination of backup camera system
 After terminal change (e.g. Tml. 15 ON to tml. 15R ON)

 Gear change out of reverse gear position (selector lever position "R")
 Selection of another system function via soft-key buttons in COMAND operating, display and controller
unit.
Termination of backup camera system by COMAND operating, display and controller unit
In case of the following malfunctions, the backup camera system (RFK) is terminated by the COMAND
operating, display and controller unit
 Backup camera in rear-end door fails

 Left backup lamp (model designation 164) defective
 Right backup lamp (model designation 251) defective.
Backup camera (RFK) location of components Model 164 GF54.65-P-0005-01GZ

Model 251 GF54.65-P-0005-01RT
Backup camera (RFK), block diagram Model 164 GF54.65-P-0005-02GZ
Model 251 GF54.65-P-0005-02RT
BACKUP CAMERA (RFK) FUNCTION DESCRIPTION, CONTENTS - GF54.65-P-0995GZ
MODEL 164 with CODE (218) Backup camera except CODE (849) Spare wheel holder/spare wheel
MODEL 251 with CODE (218) Backup camera
Backup camera (RFK), function With USA version, code 494 GF54.65-P-0005GZ
Except USA version, code
494 GF54.65-P-
Except Japan version, code 0005GZE
498
GF54.65-P-
With Japan version, code 498
0005GZJ
GF54.65-P-
Back-in parking, function With Japan version, code 498
2005GZJ
GF54.65-P-
Parallel parking, function With Japan version, code 498
2006GZJ
Overview of backup camera (RFK) system
GF54.65-P-9997GZ
components
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF PARKTRONIC SYSTEM (PTS) -

GF54.65-P-0999GZ
Parktronic system (PTS), function GF54.65-P-0001GZ

Parktronic system (PTS), block diagram GF54.65-P-0001-01GZ
Parktronic system (PTS), location of components GF54.65-P-0001-02GZ
Operation, function GF54.65-P-3000GZ
Self-test, function GF54.65-P-2000GZ
Overview of system components of Parktronic system (PTS) GF54.65-P-9998GZ
SELF-TEST, FUNCTION - GF54.65-P-2000GZ
Function
The PTS control unit (N62) performs a self-test when the ignition is switched on (circuit 15 ON).
The following are checked:
 PTS control unit

 PTS warning indicator, driver side instrument panel (A44/1)
 Rear dome lamp PTS warning indicator (A44/3)
 Front PTS ultrasonic sensors
 Rear PTS ultrasonic sensors
 All the wiring
After the self-test, both warning indicators are actuated for approx. 1 s at 60% brightness, i.e. all the LEDs light
up. If there are no malfunctions or faults, this is indicated by the lighting of the standby bar in the middle of the
warning indicators; the background illumination is adjusted according to the ambient brightness.
The PTS control unit performs further self-tests at regular intervals. In this process the Parktronic system (PTS)
distinguishes between a malfunction and a fault.
Malfunction
If a warning indicator receives no valid signals within t = 0.5 seconds of the ignition being switched on, the two
red LEDs of the relevant warning indicator light up and a warning tone sounds. After t = 20 s the warning
display is switched off.
A malfunction can be caused by a defect in a component of the Parktronic system (PTS) or a short-term
interference from outside (e.g. an induction loop at traffic lights).
Fault
If a self-test during normal driving continues to detect a fault, the red LEDs of the relevant warning indicator
are actuated the next time the vehicle speed falls below 16 km/h and a warning tone also sounds for approx. 2
seconds.
After a further 20 s the Parktronic system (PTS) shuts down and the fault is stored in the fault memory of the
PTS control unit.
Sensors, component description GF54.65-P-5010GZ

Warning indicator, component description GF54.65-P-5020GZ
Parktronic system (PTS) control unit, component description GF54.65-P-5000GZ
DRIVING, FUNCTION - GF54.65-P-3000GZ

Fig. 77: Driving - Function Diagram

 Circuit 15 ON
 Parking brake not operated
General
When the ignition is switched on (circuit 15 ON), the PTS control unit performs a self-test. If there are no
malfunctions or faults, this is indicated by the lighting of the standby bar in the middle of the warning
indicators.
Activating or deactivating the Parktronic system (PTS) (with offroad package code 430)
The Parktronic system (PTS) can be switched off or on manually via the PTS OFF switch in the upper control
panel control unit. When the Parktronic system (PTS) is off, the function LED in the PTS OFF switch is lit;
conversely the LED is off when the Parktronic system (PTS) is activated.
When the ignition is switched on (circuit 15 ON) the Parktronic system (PTS) is automatically activated, even if
it was deactivated in the previous ignition sequence.
Activating or deactivating the Parktronic system (PTS) (except offroad package code 430)
The Parktronic system (PTS) can be switched on or off using the menu in the instrument cluster.
When the ignition is switched on (circuit 15 ON) the Parktronic system (PTS) is automatically activated, even if
it was deactivated in the previous ignition sequence.
Trailer operation
The detection area at the rear of the vehicle is deactivated when a trailer is connected. The rear SAM control
unit detects the trailer connector and sends a corresponding signal to the PTS control unit.
The brightness of the warning indicators is automatically adjusted to suit the ambient light conditions. When the
rain/light sensor reports "night", the warning indicators are dimmed. Conversely by "day" the warning
indicators are actuated at full brightness. With an acoustic warning, the PTS control unit sends a command to
the COMAND operating, display and control unit which passes this information via MOST to the amplifier for
the sound system. The amplifier for the sound system switches the entire sound system to MUTE.
When the vehicle is in operation, the Parktronic system (PTS) enters standby mode at speeds below 40 km/h to
16 km/h, i.e. the PTS control unit, the warning indicators and the sensors are supplied with power but do not yet
function.
Front monitoring range active (Selector lever position "D")
When the vehicle drops below the lower limit speed of 16 km/h, the Parktronic system (PTS) changes to
measurement mode.
If obstructions are detected in front of the vehicle, the driver is alerted visually at first by the lighting of various
LEDs in the driver-side instrument panel PTS warning indicator. When the range drops below a certain
distance, the warning also becomes acoustic, first with an intermittent tone and then with a continuous signal
(see table below).
When the vehicle exceeds the upper limit speed of 18 km/h, the Parktronic system (PTS) changes back to the
standby mode.
Front and rear monitoring ranges active (Selector lever position "R" or "N")
When the vehicle drops below the lower limit speed of 16 km/h, the Parktronic system (PTS) changes to
measurement mode. If obstructions are detected in front of or behind the vehicle, the driver is alerted visually at
first by the lighting of various LEDs in the driver-side instrument panel PTS warning indicator and/or in the rear
dome lamp PTS warning indicator. When the range drops below a certain distance, the warning also becomes
acoustic, first with an intermittent tone and then with a continuous signal (see table below).
When the vehicle exceeds the upper limit speed of 18 km/h, the Parktronic system (PTS) changes back to the
standby mode.
ACTUATION OF THE DRIVER-SIDE INSTRUMENT PANEL PTS WARNING INDICATOR

Warning message LED Warning chime Distance
Outside (cm) Inside (cm)
1 (yellow) - - < 100
2 (yellow) - - < 80
3 (yellow) - - < 70
Visual
4 (yellow) - < 60 < 60
5 (yellow) - < 50 < 50
6 (yellow) - < 40 < 40
7 (red) Intermittent signal approx. 6 Hz < 30 < 30
optical and acoustical
8 (red) Continuous signal < 15 < 20
ACTUATION OF REAR DOME LAMP PTS WARNING INDICATOR

Warning message LED Warning chime Distance
Outside (cm) Inside (cm)
1 (yellow) - - < 120
2 (yellow) - - < 100
3 (yellow) - < 80 < 80
Visual
4 (yellow) - < 65 < 65
5 (yellow) - < 50 < 50
6 (yellow) - < 40 < 40
7 (red) Intermittent signal approx. 6 Hz < 30 < 30
optical and acoustical
8 (red) Continuous signal < 20 < 20
GF54.65-P-
Sensors, component description
5010GZ
Warning indicator, component GF54.65-P-
description 5020GZ
Rain/light sensor, component GF54.21-P-
description 6000GZ
Parktronic system (PTS) control GF54.65-P-
With AIRmatic (air suspension with level adjustment
and adaptive damping system ADS), code 489, except
GF54.21-P-
adjustment without adaptive damping system ADS),
6040GZA
code 489, and USA version, code 494
With Airmatic (air suspension with level adjustment and
GF54.21-P-
adaptive damping system ADS), code 489, with Offroad
6040GZU
GF80.57-P-
6000GZ
description
PARKTRONIC SYSTEM (PTS) CONTROL UNIT, COMPONENT DESCRIPTION - GF54.65-P-

5000GZ
Fig. 78: Identifying Parktronic System (PTS) Control Unit Location

Location
The PTS control unit is located below the driver seat.
Task
 The PTS control unit takes over the Voltage supply of the sensors and warning elements.
 Evaluation of echo journey times
 Bidirectional data transfer from and to the warning elements
 Dimming of warning elements
 The PTS control unit takes over the actuation of the following sensors:
 Outer left front PTS ultrasonic sensor (B8/1)
 Center left front PTS ultrasonic sensor (B8/2)
 Inner left front PTS ultrasonic sensor (B8/3)
 Inner right front PTS ultrasonic sensor (B8/4)
 Center right front PTS ultrasonic sensor (B8/5)
 Outer right front PTS ultrasonic sensor (B8/6)
 Outer right rear PTS ultrasonic sensor (B8/7)
 Inner right rear PTS ultrasonic sensor (B8/8)
 Inner left rear PTS ultrasonic sensor (B8/9)
 Outer left rear PTS ultrasonic sensor (B8/10)
Function
between the vehicle and obstacle from the run-time of the echoes and actuates the warning indicators.
The PTS control unit carries out a self-test after the ignition (circuit 15 ON). The control unit, the sensors plus
all the lines to the sensors, the warning elements, as well as the lines to the warning elements. After the self-test
all the warning indicators are actuated fully for approx. t = 1 s.
 Circuit 15 ON
 If the speed drops below v = 40 km/h (Parktronic system is supplied with voltage) or drops below the
lower limit speed vu = 16 km/h (Parktronic system activated)
Discrete inputs and outputs
 PTS ultrasonic sensors

 PTS warning indicator, driver side instrument panel (A44/1)
 Rear dome lamp PTS warning indicator (A44/3)
For exchange of data the PTS control unit is connected to the Controller Area Network-bus class B (interior)
(CAN-B)
Inputs via CAN-B
 Intelligent servo module for DIRECT SELECT reverse gear signal (A80)
 Terminal status from EIS [EZS] control unit (N73)
 Vehicle speed from instrument cluster (A1)
 Day/night detection by rain/light sensor (B38/2) via overhead control panel control unit (N70)
 Signal of parking brake indicator switch (S12) from front SAM control unit (N10)
 Signal on manual deactivation of the Parktronic system (PTS) from PTS OFF switch (N72/1s8) in the
upper control panel control unit (N72/1) on vehicles except code 228 Stationary heater, with code 430
Offroad package.
 Signal on manual deactivation of the Parktronic system (PTS) via the menu on the 1st level of the
instrument cluster (ON/OFF) on vehicles with code 228 Stationary heater, except code 430 Offroad
package.
Outputs via CAN-B
 Signal for muting the audio components on the COMAND operating, display and controller unit (A40/3).
SENSORS, COMPONENT DESCRIPTION - GF54.65-P-5010GZ

Fig. 79: Identifying Parktronic System Sensors (PTS) - Shown On Model Designation 164.1
Task
The sensors in the bumpers are transmitters and receivers for the ultrasonic signals necessary for measuring the
distance to an obstacle.
Function
When actuated by the PTS control unit (N62), the sensors emit an ultrasonic signal. After a short decay time the
sensors are ready to receive. Each sensor receives the echo of its own signal and that of the other sensors. The
distance to the obstacle is calculated from the elapsed time between transmission and reception.
WARNING INDICATOR, COMPONENT DESCRIPTION - GF54.65-P-5020GZ
Fig. 80: Identifying PTS Warning Indicator, Driver Side Instrument Panel And Rear PTS Warning
Location
The PTS warning indicator, driver side instrument panel is located at the top of the center console.
The PTS warning indicator, rear dome lamp is located in the headliner in the dome lamp.
Design
Each warning indicator incorporates 12 yellow and 4 red LEDs, two standby bars, one sound transmitter and a
microprocessor. The microprocessor manages the bidirectional data exchange with the PTS control unit (N62).
Task
When an obstruction is detected in front of or behind the vehicle, the ranges are communicated to the driver
visually at first by the lighting of the yellow LEDs, then by the lighting of the red LEDs and then also by the
output of an acoustic warning.
After a successful self-test and up to a speed of 18 km/h, the standby bar lights up to inform the driver that the
Parktronic system (PTS) is ready to operate.
If the Parktronic system (PTS) detects a fault during the self-test or while driving, this is signaled to the driver
by the lighting of the two red LEDs.
BACKUP CAMERA COMPONENT DESCRIPTION - GF54.65-P-5040GZ
MODEL 164 with CODE (218) Backup camera except CODE (498) Japan version except CODE (849)
Spare wheel holder/spare wheel
MODEL 251 with CODE (218) Backup camera except CODE (498) Japan version
Location
The backup camera is installed on the left next to the handle for opening the rear-end door.
Fig. 81: Identifying Backup Camera Location - Shown On Model 164.1

Task
The entire area surrounding the rear is recorded with the backup camera.
The backup camera is supplied with voltage by the backup camera voltage supply module component (N66/10)
after the backup camera system is activated via the COMAND operating, display and controller unit (A40/3).
The backup camera then transmits an analog video picture back to the backup camera voltage supply module
component.
The backup camera is a color image camera with wide-angle lens.
OVERVIEW OF BACKUP CAMERA (RFK) SYSTEM COMPONENTS - GF54.65-P-9997GZ
MODEL 164 with CODE (218) Backup camera except CODE (849) Spare wheel holder/spare wheel
MODEL 251 with CODE (218) Backup camera
GF54.65-P-
Backup camera control unit component description With Japan version, code 498
5030GZJ
Except Japan version, code
Backup camera component description GF54.65-P-5040GZ
498
GF54.65-P-
With Japan version, code 498
5040GZJ
Backup camera (RFK) function description,
GF54.65-P-0995GZ
contents
OVERVIEW OF SYSTEM COMPONENTS OF PARKTRONIC SYSTEM (PTS) - GF54.65-P-9998GZ

GF54.65-P-
Sensors, component description
5010GZ
Warning indicator, component GF54.65-P-
description 5020GZ
Rain/light sensor, component GF54.21-P-
description 6000GZ
Parktronic system (PTS) control GF54.65-P-
With AIRmatic (air suspension with level adjustment
and adaptive damping system ADS), code 489, except
GF54.21-P-
adjustment without adaptive damping system ADS),
6040GZA
code 489, and USA version, code 494
With Airmatic (air suspension with level adjustment and
GF54.21-P-
adaptive damping system ADS), code 489, with Offroad
6040GZU
GF80.57-P-
6000GZ
description
Parktronic system (PTS), GF54.65-P-
contents, function description 0999GZ
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS - AS54.10-Z-0001-01A
Risk of explosion from gas.
Risk of poisoning and burns from swallowing battery electrolyte.
Risk of injury to eyes and skin as result of caustic burns from battery electrolyte or from handling
damaged lead-acid batteries.
No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and eye protection. Pour
battery electrolyte only into suitable and appropriately marked containers.
Possible hazards
Risk of explosion
A highly explosive gas mixture is produced when charging lead-acid batteries.
Risk of poisoning
If battery electrolyte is swallowed , this can result in manifestations of poisoning such as headaches, dizziness,
stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps.
Battery electrolyte mist causes caustic burns to the eyes. If swallowed , this can result in caustic burns to the
mucous membranes and respiratory passages.
The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead
compounds are considered to represent a reproductive hazard.
Injury hazard
Battery electrolyte contains sulfuric acid which can cause severe caustic burns to skin and eyes. Strict caution is
required when handling damaged lead-acid batteries (removing from vehicle damaged in accident) because of
the sharp edges on the fractured housing and direct contact with the lead plates.
Protective measures/rules of conduct
 Charge lead-acid batteries only in well ventilated areas.

 No fire, sparks, naked flames or smoking.
 Do not place any tool or other conducting objects onto the lead-acid battery (risk of short-circuit).
 Disconnect and remove lead-acid batteries for charging.
 Always disconnect negative terminal first of all; always connect positive terminal first of all.
 Do not switch on the charger until after it has been connected to the terminals; switch it off before
disconnecting.
 Keep lead-acid batteries and battery electrolyte away from unauthorized persons.
Pour battery electrolyte only into suitable and appropriately marked containers.
 Always store lead-acid batteries horizontally.

 Ensure the gassing line is properly connected.
 Ensure the gassing line does not have any kinks and is not blocked at any point.
 Pay attention to instructions for use of the particular lead-acid battery and the operating instructions of the
vehicle.
 Wear acid-resistant clothing and eye protection with side guards.
First-aid measures
Eye contact
 Rinse out eyes immediately with plenty of water.
Skin contact
 Take off moistened clothing.

 Immediately neutralize acid splashes on skin or clothing with acid converter or soap suds and rinse off
with plenty of water.
Inhaling battery electrolyte mist
 Take the affected person out into the fresh air.
Swallowing battery electrolyte
 Have the person affected drink plenty of water with the addition of activated charcoal.
As a general rule, the person affected should consult a medical service or doctor after first-aid has been
rendered.
Fire protection measures
Suitable extinguishing agents
 CO2 and dry extinguishing agent
Warning instructions for lead-acid batteries

Fig. 82: Identifying Warning Instructions For Lead-Acid Batteries

TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - AR54.00-Z-9164AA
MODEL 164
Disconnect/connect battery's ground AR54.10-P-

MODEL 164
cable 0003GZ
AR54.10-P-
Removing and installing battery MODEL 164
0005GZ
Treatment of battery if vehicle taken AR54.10-P-
MODEL 164
out of service 0006GZ
AR54.10-P-
Removing, installing auxiliary battery MODEL 164
0007GZ
AR54.10-P-
Remove/install cargo area socket MODEL 164
0010GZ
AR54.10-P-
Remove/install 12 Volt socket MODEL 164, 251
1000RT
AR54.10-P-
Remove/install 12 Volt socket MODEL 164, 251 Second seat row
1000RTA
AR54.10-P-
Check quiescent current consumption MODEL 164
1030GZ
AR54.10-P-
Check condition of battery MODEL 164
1129GZ
Charge battery MODEL 164 AR54.10-P-
1130GZ
MODEL 163, 164, 168, 169, 170, 171, 203, 204,
Check battery condition before vehicle AR54.10-P-
208, 209, 211, 215, 216, 219, 220, 221, 230, 240,
delivery 1132A
245, 251, 414 ...
Removing and installing fuse and relay AR54.15-P-
MODEL 164 with Engine 113
box in engine compartment, right front 1258GZ
Remove/install fuse and relay box in MODEL 164 with ENGINE 156, 272, 273, 642, AR54.15-P-
engine compartment, right front 629 1258GZA
Remove/install housing for fuse and AR54.15-P-
relay box 1259GZ
Remove/install housing for fuse and MODEL 164 with ENGINE 156, 272, 273, 642, AR54.15-P-
relay box 629 1259GZA
AR54.15-P-
Remove fuse and relay box in rear MODEL 164
1261GZ
Remove/install on-board electrical
AR54.15-P-
network line pyrofuse in vehicle power MODEL 164.828
1262GZ
supply control unit
Remove/install passenger's side interior AR54.15-P-
MODEL 164
fuse box 1311GZ
AR54.15-P-
Remove/install front prefuse box MODEL 164
1330GZ
Remove/install interior compartment AR54.15-P-
MODEL 164
prefuse box 1350GZ
MODEL 124, 126, 129, 140, 163, 164, 168, 169,
Repair supplemental restraint system 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, AR54.18-P-
(SRS) squib wiring harness 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 0600A
463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
203, 204, 208, 209, 210, 211, 215, 216, 219, 220, AR54.21-P-
Programming of control units
221, 230, 240, 245, 251, 450, 452, 454, 461, 0014Y
463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
Programming of control units 203, 204, 208, 209, 210, 211, 215, 216, 219, 220,
0014Z
221, 230, 240, 245, 251, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
203, 204, 208, 209, 210, 211, 215, 216, 219, 220, AR54.21-P-
SCN coding of control units
221, 230, 240, 245, 251, 450, 452, 454, 461, 0015X
463 ...
Central gateway control unit (ZGW), AR54.21-P-
MODEL 164
remove and install 0817GZ
AR54.21-P-
Remove/install front SAM control unit MODEL 164
1254GZ
Remove/install upper control panel AR54.21-P-
MODEL 164
control unit 1262GZ
Removing and installing lower control AR54.21-P-

MODEL 164
panel control unit 1263GZ
AR54.21-P-
Remove/install rear SAM control unit MODEL 164
1269GZ
AR54.25-P-
Remove/install combination switch MODEL 164
2800GZ
Remove/install steering column AR54.25-P-
MODEL 164
module 2802GZ
AR54.25-P-
Remove/install cruise control switch MODEL 164
2803GZ
Removing and installing steering MODEL 164 with CODE (441) Electrically AR54.25-P-
column adjustment switch adjustable steering column 2804GZ
Remove/install button unit on AR54.25-P-
MODEL 164, 251
multifunction steering wheel 2840GZ
Removing and installing light switch AR54.25-P-
MODEL 164
module 3270GZ
AR54.30-P-
Remove/install instrument cluster MODEL 164
6015GZ
Remove/install outside temperature AR54.30-P-
MODEL 164
indicator sensor 6341GZ
AR54.35-P-
Remove/install fanfare horns MODEL 164
1555GZ
Remove/install Parktronic system MODEL 164 with CODE (220) Parktronic system AR54.65-P-
(PTS) sensors in front bumper (PTS) 0001GZ
Remove/install Parktronic system MODEL 164 with CODE (220) Parktronic AR54.65-P-
(PTS) sensors in rear bumper System (PTS) 0002GZ
Removing and installing Parktronic
MODEL 164 with CODE (220) Parktronic system AR54.65-P-
system (PTS) warning display in
(PTS) 0003GZ
instrument panel
Remove/install Parktronic system MODEL 164 with CODE (220) Parktronic AR54.65-P-
(PTS) control unit System (PTS) 0006GZ
Remove/install Parktronic system
MODEL 164 with CODE (220) Parktronic AR54.65-P-
(PTS) warning indicator in rear
System (PTS) 0007GZ
passenger compartment
AR54.65-P-
Calibration of the backup camera MODEL 164 ...
0022GZ
Remove/install backup camera control MODEL 164 with CODE (218) Backup camera AR54.65-P-
unit with CODE (498) Japan version 0025GZ
MODEL 164, 251 with CODE (218) Backup AR54.65-P-
Remove/install backup camera
camera 0030GZ
Remove/install voltage supply of MODEL 164.1 with CODE (218) Backup camera AR54.65-P-
backup camera except CODE (498) Japan version 0032GZ
Remove/install passenger-side outside MODEL 164, 251 with CODE (218) Backup AR54.65-P-
mirror backup camera camera with CODE (498) Japan version 0035GZ
DISCONNECT/CONNECT BATTERY'S GROUND CABLE - AR54.10-P-0003GZ
MODEL 164
Fig. 83: Identifying Battery's Ground Cable, Nut, Cover, Passenger Seat And Battery
Remove/install
AH54.10-P-
0001-01A
AH54.10-P-
0002-01A
Move front passenger seat
1 (1) toward front as far as
possible.
Switch off all electrical All the electrical consumers must be switched
2 off, otherwise they may be damaged when
consumers
unclipping and clipping on ground line (4).
remove the transmitter key Keyless Go start/stop button repeatedly until
3 ignition is switched off. Remove transmitter key
unit from vehicle and store it in a location beyond its
Loosen nut (3) on battery
negative pole clamp and Ensure that no jumper start device is connected
5
disconnect ground line (4) of to vehicle.
battery (G1)
*BA54.10-P-
1012-01C
AR00.19-P-
0200GZ
Connect STAR
DIAGNOSIS, read out fault *WH58.30-
memory and erase if Z-1048-13A
necessary
BATTERY
BA54.10-P-1012-01C Nut, battery cable to battery terminal M6 Nm 6


Number Designation
REMOVING AND INSTALLING BATTERY - AR54.10-P-0005GZ
MODEL 164
Fig. 85: Identifying Battery Remove/Install Components

Fig. 86: Identifying Battery Remove/Install Components - Shown On Model 164.1

Remove/install
gas. Risk of poisoning and caustic burns No fire, sparks, open flames or smoking.
caused by swallowing battery acid. Risk of Wear acid-resistant gloves, clothing and AS54.10-Z-
injury caused by burns to skin and eyes safety glasses. Only pour battery acid 0001-01A
from battery acid or when handling into suitable and appropriately marked
damaged lead-acid batteries containers.
AH54.10-P-
0001-01A
AH54.10-P-
0002-01A
If the head restraint is not moved all
Move head restraint on front passenger the way down, the sun visor may be
1
seat (1) all the way down damaged when inclining the seat
backrest.
Move front passenger seat (1) as far
2 forward as possible and upwards, tilt seat
backrest forward
3 Remove cover (2).
The floor covering (3) has already
Separate floor covering (3) at both marked been separated, if at an earlier stage work
4
positions (arrows) was performed on or in the battery
compartment.
Move front passenger seat (1) all the way
5
to rear
Fold floor covering (3) forwards, move
front passenger seat (1) as far forward as Make sure that the folded-over floor
6
possible, until the battery compartment is covering (3) does not tear at the fold.
completely accessible
7 transmitter key from the EIS [EZS] control repeatedly until ignition is switched off.
unit
Remove spreader clip (5) and detach air Installation: Replace spreader clip
8
outlet (4) (5), if it is damaged.
9 Remove battery cover (12)
All consumers must be switched off,
as otherwise the vehicle electrical system
Undo nut on clamping device for battery
may be damaged. AR54.10-P-
10 negative pole (8), disconnect ground line
It must be ensured that a jump- 0003GZ
of battery (G1)
starting device is not connected to the
vehicle.
*BA54.10-
P-1012-01C
11 Remove positive battery terminal cover

(6), undo nut on clamping device for *BA54.10-
positive battery terminal (7), remove P-1012-01C

positive lead
Detach bleed hose (11) including plastic Installation: Route vent hose (11)
12
support from battery (G1) without kinks.
*BA54.10-
13 Undo nuts (10), remove retaining panel (9)
P-1024-01C
Installation: Before installation of
the battery (G1) make sure that no cables
are located within the area of the battery
fixture, as they may be damaged when
14 Remove battery (G1) the battery (G1) is installed.
Make sure that the maxi fuses on the
prefuse box in the battery compartment
are not unintentionally loosened when
removing and installing the battery (G1).
AR00.19-P-
0200GZ
BATTERY
BA54.10-P-1024-01C Nut, battery retaining plate to frame floor M8 Nm 24
TREATMENT OF BATTERY IF VEHICLE TAKEN OUT OF SERVICE - AR54.10-P-0006GZ
MODEL 164
Shown on model 251
Fig. 87: Identifying Battery Ground Cable And Ground Line For Auxiliary Battery - Shown On Model
251
Risk of explosion caused by oxyhydrogen gas. Risk of

poisoning and caustic burns caused by swallowing
battery acid. Risk of injury caused by burns to skin and
eyes from battery acid or when handling damaged lead-
AS54.10-Z-0001-01A
acid batteries No fire, sparks, open flames or smoking.
Wear acid-resistant gloves, clothing and glasses. Only pour
battery acid into suitable and appropriately marked
containers.
AR54.10-
1 Check battery, charge battery if necessary
P-1129GZ
When the vehicle is
laid up for more than 4
weeks. This prevents the AR54.10-
2 Disconnect ground line of battery (1)
battery being discharged P-0003GZ
by closed-circuit
accessories.
When the vehicle is
laid up for more than 4
weeks. This prevents the
3 Disconnect ground line of additional battery (2)
battery being discharged
by closed-circuit
accessories.
When battery is
disconnected every 6
months at the latest and AR54.10-
4 Charge battery
when the battery is P-1130GZ
connected every 6 weeks
at the latest.
REMOVING, INSTALLING AUXILIARY BATTERY - AR54.10-P-0007GZ
MODEL 164
Fig. 88: Identifying Auxiliary Battery Remove/Install Components

Remove/install
Risk of poisoning and caustic burns caused smoking. Wear acid-resistant gloves,
AS54.10-Z-
by swallowing battery acid. Risk of injury clothing and safety glasses. Only
0001-01A
caused by burns to skin and from battery acid pour battery acid into eyes suitable
or when handling damaged lead-acid batteries and appropriately marked containers.
AH54.10-P-
0001-01A
AH54.10-P-
0002-01A
AR54.10-P-
1 Remove battery
0005GZ
*BA54.10-
P-1012-01C
*BA54.10-
P-1024-01C
Detach plug on negative terminal (4) of
2
additional battery (G1/7)
Detach plug on positive terminal (5) of
3
additional battery (G1/7)
Installation: Make sure that the
4 Undo bolt (3), open retaining clamp (1) anchor fitting (2) engages into the
frame-side retaining panel.
*BA54.10-
P-1025-01C
5 Remove additional battery (G1/7)
AR00.19-P-
0200GZ
BATTERY
BA54.10-P-1025-01C Bolt, additional battery retaining clamp M6 Nm 5
REMOVE/INSTALL CARGO AREA SOCKET - AR54.10-P-0010GZ
MODEL 164
Fig. 89: Identifying Cargo Area Socket Remove/Install Components - Shown On Model 164.1
Remove/install
Model 164.1: The load compartment socket (X58/4) is

located in the side trim (1) on the right of the load
compartment.
1 Open tailgate
Model 164.8: The load compartment socket (X58/4) is
located in the side trim (1) on the left of the load
compartment.
2 Fold up housing lid (2)
Do not turn the load compartment socket (X58/4)
Use pliers to release load when pulling out
compartment socket (X58/4) from Installation: Ensure that the two guides (arrows B) are
3
housing (3) and to pull it out (arrow inserted in the grooves of the housing (3). Insert the load
A) compartment socket (X58/4) until it latches in the housing
(arrow C).
Fig.
Pliers 90
Remove housing (3) from trim (1) at Loosen the housing (3) at the two catch tabs (5) and
5
the side of the load compartment pull out of the side trim in the load compartment.

REMOVE/INSTALL 12 VOLT SOCKET - AR54.10-P-1000RT
MODEL 164, 251
Fig. 91: Identifying 12 Volt Socket Remove/Install Components

Remove/install
The interior socket (X58/1) is located in the trim (1) on

1 Fold up housing lid (2)
the bottom right-hand side of the cockpit.
Do not turn the interior socket (X58/1) when pulling out
Use pliers to detach the interior Installation: Ensure that the two guides (arrows B) are
2 socket (X58/1) from the housing (3) inserted in the grooves of the housing (3). Slide in the
and pull out (arrow A) interior socket (X58/1) until it latches in the housing (3)
(arrow C).
Fig.
Pliers 90
4 Remove housing (3) from the trim Loosen the housing (3) at the two catch lugs (5) and
(1) pull out of the trim (1).


REMOVE/INSTALL 12 VOLT SOCKET - AR54.10-P-1000RTA
MODEL 164, 251
Second seat row
Fig. 93: Identifying 12 Volt Socket Remove/Install Components

Remove/install
The left 2nd seat row socket (X58/19) and right 2nd
1 Fold up housing lid (2) seat row socket (X58/20) are located in the center
console (1).
Do not turn the left 2nd seat row socket (X58/19) or
Detach left 2nd seat row socket right 2nd seat row socket (X58/20) when pulling out
(X58/19) or right 2nd seat row socket Installation: Ensure that the two guides (arrows B)
(X58/20) from the housing (3) using are inserted in the grooves of the housing (3). Push in
pliers and pull out (arrow A) the left 2nd seat row socket (X58/19) or right 2nd seat
2
row socket (X58/20) until it latches in the housing (3)
(arrow C).
Fig.
Pliers 90
Remove housing (3) from the center Loosen the housing (3) at both catch lugs (5) and
4
console (1) pull out of the center console (1).

LOCATE DEFECTIVE CONSUMERS VIA POWER SUPPLY - AR54.10-P-1030-09GZ

Number Designation
WH58.30-Z-1001-
Multimeter
09A
WH58.30-Z-1013- Current clamp with display and multimeter connection for quiescent current
09A measurement
WH58.30-Z-1014-
Current clamp with multimeter connection for quiescent current measurement
09A
WH58.30-Z-1015-
Current clamp with display for quiescent current measurement
09A
WH58.30-Z-1016-
Clamp-on probe
09A

Fig. 95: Identifying Battery Compartment Prefuse Box And Engine Compartment Fuse And Relay Box -
Fig. 96: Identifying Battery Compartment Prefuse Box And Engine Compartment Fuse And Relay Box -
1.1 When measuring with multimeter:
Measure voltage drop directly at fuses in front prefuse box (F32) and in battery compartment prefuse box
(F33).
Use measuring tips.
Perform measurements with fuses still inserted - defective consumer cannot be identified if fuse is
removed.
Increased quiescent current consumption exists at a consumer if the voltage drop exceeds 100 mV.
1.2 When measuring with current clamp:

Measure quiescent current at terminals 30 in front prefuse box (F32) and in battery compartment prefuse
box (F33).
removed.
2.1 If increased quiescent current consumption has been detected at a consumer which is directly
connected to one of the prefuse boxes:
See step 3.
2.2 If increased quiescent current consumption has been detected in the engine compartment fuse and
relay box (F58), the load compartment fuse and relay box (F4) or the cockpit fuse box (F3):
Measure voltage drop at fuses in engine compartment fuse and relay box (F58), cockpit fuse box (F3) or
load compartment fuse and relay box (F4) using multimeter, depending at which prefuse a voltage
drop greater than 100 mV has been detected or a quiescent current consumption between 0.05 and 1.6 A
has been detected. See also wiring plan information in main document.
Use measuring tips.
removed.
Increased quiescent current consumption exists at a consumer if the voltage drop exceeds 100 mV.
3 Remove fuse of consumer identified as being defective and check whether quiescent current
consumption drops below 0.05 A. If this is the case, defective consumer has been located. If this is not the
case, repeat defective consumer search.
LOCATE DEFECTIVE CONSUMER VIA CAN BUS - AR54.10-P-1030-10GZ

Number Designation
WH58.30-Z-1001-09A Multimeter
1. Measure "low" level and "high" level of engine compartment CAN bus (CAN-C) with respect to ground
using multimeter. See also wiring plan information in main document.
2.1 If "low" level and/or "high" level of engine compartment CAN bus (CAN-C) is energized:
Detach connectors of CAN-C stations in sequence at CAN voltage distributor in front passenger footwell
and observe quiescent current consumption. If quiescent current consumption drops below 0.05 A,
defective consumer has been located. See wiring plan information in main document.
Detach and then reattach connector before moving on to next connector.

2.2 If "low" level and "high" level of engine compartment CAN bus (CAN-C) are de-energized:
Measure "low" level and "high" level of interior CAN bus (CAN-B) with respect to ground using
multimeter. See also wiring plan information in main document.
12 V must be measured at one of the two levels; 0 V must be measured at the other level.
3.1 If neither of the two levels of interior CAN bus (CAN-B) is 0 V: Detach connectors of CAN-B
stations in sequence at right CAN voltage distributor and at cockpit CAN voltage distributor and observe
quiescent current consumption. If quiescent current consumption drops below 0.05 A, defective consumer
has been located. See wiring plan information in main document.
Detach and then reattach connector before moving on to next connector.
3.2 If 12 V is measured at one of the two levels and 0 V is measured at the other level:
Locate defective consumer via power supply: see step 17.1 in main document.
CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P-1030GZ
MODEL 164
Fig. 97: Identifying Passenger Seat, Floor Mat, Cover, Air Nozzle, Spreading Clip, And Positively Battery
Terminal Cover Components
Removing
oxyhydrogen gas. Risk of No fire, sparks, open flames or smoking. Wear
poisoning and caustic burns acid-resistant gloves, clothing and safety AS54.10-Z-
caused by swallowing battery acid. glasses. Only pour battery acid into suitable 0001-01A
Risk of injury caused by burns to and appropriately marked containers.
skin and eyes from battery acid or
when handling damaged lead-acid
batteries
AH54.10-P-
0001-01A
AH54.10-P-
0002-01A
Switch off ignition and remove the Press Keyless Go start/stop button repeatedly
1 transmitter key from the EIS [EZS] until ignition is switched off. Remove
control unit
2 m).
If the head restraint is not moved all the
Move head restraint on front
2 way down, the sun visor may be damaged
passenger seat (1) all the way down
when inclining the seat backrest.
Move front passenger seat (1)
forward and upward as far as
3
possible and tilt seat backrest
forward
4 Remove cover (2).
The floor covering (3) has already been
Separate floor covering (3) at both
5 separated, if at an earlier stage work was
marked positions (arrows)
performed on or in the battery compartment.
Move front passenger seat (1) all
6
the way to rear
Fold floor covering (3) forwards,
move front passenger seat (1) as far
Make sure that the folded-over floor
7 forward as possible, until the
battery compartment is completely covering (3) does not tear at the fold.
accessible
Remove spreader clip (5) and Installation: Replace spreader clip (5), if it
8
detach air outlet (4) is damaged.
Remove battery cover (12) and
9 detach cover from positive battery
terminal (6)
Close engine hood, trunk lid and all
10
doors (except rear right door)
When measurements have been completed,
the rotary tumbler must be unlocked again by
actuating the exterior door handle, otherwise
Move rotary tumbler in lock of rear the rotary tumbler could be destroyed when
11 right door to "closed" position the door is closed.
while door is open When the rotary tumbler is set to the
"closed" position, the interior light will be
switched off after a delay of approx. 10
seconds.
It must be ensured that no remote starting

unit is connected to the vehicle.
The time between locking the vehicle and
performing the measurements must be at least
12 Lock vehicle from outside 35 minutes. The vehicle must remain
completely motionless during this time. No
doors should be opened or closed, the vehicle
should not be locked and unlocked, and none
of the switches and instruments should be
operated.
Measure
Connect positive measurement
13.1 cable of multimeter to ground When measuring with multimeter.
connection of body
Electrical connection set Fig. 98
*WH58.30-
Multimeter Z-1001-09A
When measuring with multimeter.
The circuit should not be broken as this
could delete faults that may be stored in the
Undo nut on battery negative pole control units.
terminal (8), carefully lift off If the multimeter cannot be attached
battery negative pole terminal and without breaking the circuit, an additional
14.1
simultaneously connect negative battery must be connected parallel to the
measurement cable of multimeter power supply battery. After the measuring
to battery negative pole equipment has been connected and the CAN
bus has deactivated (after at least 35 minutes),
the additional battery must be disconnected
again.
*WH58.30-
Completely detach battery negative
15.1 pole terminal from battery negative When measuring with multimeter.
pole
A measured value of 50 mA must not be

exceeded. Possible causes for increased
values:?
Check quiescent current If the measured value is between 0.05
16 
consumption and 1.6 A, this usually indicates that a
control unit has failed to switch itself
off. However, this can also be caused by
an electric or electronic component (e.g.
switch or relay).
 If the measured value is above 1.6 A,

this usually indicates that a defective
control unit is preventing the engine
compartment CAN bus or interior CAN
bus from switching off.
Measurement with multimeter:?

*WH58.30-
When measuring with current clamp:? *WH58.30-
Current measurement pliers Z-1016-09A
Current clamp with display and multimeter *WH58.30-
connection for checking quiescent current Z-1013-09A
Current clamp with multimeter connection *WH58.30-
for checking quiescent current Z-1014-09A
Current clamp with display for checking *WH58.30-
quiescent current Z-1015-09A
With quiescent current consumption
Locate defective consumers via AR54.10-P-
17.1 between 0.05 and 1.6 A (after a waiting time 1030-09GZ
power supply
of at least 35 minutes).
Fuse assignment of front prefuse GF54.15-P-
box 1256-07GZ
Fuse assignment of battery GF54.15-P-
compartment prefuse box 1256-15GZ
Fuse assignment of fuse and relay GF54.15-P-
box in right engine compartment 1256-02GZ
Fuse assignment of fuse box in GF54.15-P-
cockpit 1256-16GZ
Relay assignment of the load GF54.15-P-
compartment fuse and relay box 1257-08GZ
Relay assignment of fuse and relay GF54.15-P-
Locate defective consumer via With quiescent current consumption above AR54.10-P-
17.2 1.6 A (after a waiting time of at least 35
CAN bus 1030-10GZ
minutes).
PE00.19-P-
Wiring diagram CAN bus interior Voltage distributor X30/4 and X30/6, sheet 1
2300MAA
PE00.19-P-
Voltage distributor X30/7, sheet 2
2300MAB
Only model 164.8, voltage distributor X30/5, PE00.19-P-
sheet 3 2300MAC
Wiring diagram CAN bus engine Only with engine 113, 272, 642. PE00.19-P-
Only with engine 156 as of 1.1.06. 2200MAA

Fully attach battery negative pole
terminal to battery negative pole When measuring with multimeter.
18.1
and tighten nut on battery negative The circuit must not be broken.
pole terminal (8)
*BA54.10-
P-1012-01C
Remove/install
Remove consumer identified as
19 being defective and fit new
consumer
*WH58.30-
20 Read out fault memory and erase STAR DIAGNOSIS diagnosis system
Z-1048-13A
Measure
Recheck quiescent current
21
consumption
Install
Fit battery positive pole cover (6)
22
and clip on battery cover (12)
Fit air outlet (4) and secure
23 Replace expansion clip (5).
expansion clip (5)
Move front passenger seat (1) to
original position, fold floor
24
covering (3) back again and clip on
cover (2)
Move rotary tumbler in lock of rear The rotary tumbler must be unlocked again
right door to "open" position by by actuating the exterior door handle,
25
actuating exterior door handle and otherwise the rotary tumbler could be
then close door destroyed when the door is closed.
BATTERY
Fig. 98: Identifying Electrical Connection Kit (220 589 00 99 00)


Number Designation
WH58.30-Z-1001-
Multimeter
09A
WH58.30-Z-1013- Current clamp with display and multimeter connection for quiescent current
09A measurement
WH58.30-Z-1014-
Current clamp with multimeter connection for quiescent current measurement
09A
WH58.30-Z-1015-
Current clamp with display for quiescent current measurement
09A
WH58.30-Z-1016-
Clamp-on probe
09A
WH58.30-Z-1048-
STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
13A
CHECK BATTERY - AR54.10-P-1129-01A
Risk of poisoning and caustic burns caused by swallowing battery acid.
Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid
batteries
Reduce increased voltage after charging process
No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery
acid into suitable and appropriately marked containers.
Modification notes
24.2.06 Cold test current 12 Ah *BE54.10-P-1002-01A
Test and adjustment values for the battery

Number Designation 12 Ah 30 Ah 35 Ah 46 Ah
BE54.10-P- Cold test as per EN A 170 540 520 420
1002-01A current

Number Designation 60 Ah VRLA 60 Ah VRLA 62 Ah
BE54.10-P- Cold test as per EN A 680 510 480
1002-01A current

70 Ah 80 Ah
Number Designation VRLA 74 Ah VRLA 84 Ah
1002-01A current

1002-01A current
Always perform test with battery installed and connected. Do not clip on tester at the jump start or charging
support point but always directly at the battery.
Battery tester/test equipment, as well as test terminals see GOTIS http://gotis.aftersales.daimlerchrysler.com
All test steps and entries must be performed thoroughly, otherwise the test result will be distorted.
Test requirements:
 Tester with software release 2.0

 Ignition off
 Rotary light switch in position "0"
 Radio Off or Command APS Off
 Battery voltage higher than 12.4 V
 Good contact of the tester on the battery
If the message "Surface voltage" is displayed during the test, the tester has detected that the battery voltage is
apparently too high. This increased voltage can be reduced as follows:
 Battery installed: Decrease increased voltage as per the specifications of the tester (e.g. switch on driving
lights).
 Battery removed: Decrease increased voltage as described in the document "Decrease increased voltage
as per charging process".
As an example, the test procedure for passenger cars is described below.
1. Clip tester (1) on to battery.
Once the tester is connected the current measured battery voltage is displayed for approx. 2 s. If a so-
called "System noise" is detected by the tester, check whether all consumers are switched off and wait
(for approx. 2 min), until the quiescent current is minimized and the bus systems are switched off.
Fig. 99: Identifying Clip Tester

2. Follow the menu and select according to the situation:

 In vehicle (battery connected to on-board electrical system)
 Not in vehicle (battery disconnected from on-board electrical system) Confirm selection with
"Enter".
Fig. 100: Screen Display - In Vehicle And Not In Vehicle

3. Follow the menu and select according to the situation:

 12 - 114 AH (battery capacity 12 -114 Ah)
 115 AH > (capacity of battery < or = 115 Ah)
Confirm selection with "Enter".

Fig. 101: Screen Display - 12 - 114 AH And 115 AH

4. Follow menu and select battery type:

 Normal
 VRLA
Fig. 102: Screen Display - Normal And VRLA

5. Follow the menu selection and select the test standard for the cold cranking amps.
The test standard (e.g. EN, DIN, SAE, IEC, JIS) is printed behind the cold cranking amps
specification.
If the test standard imprint is not present, select cold cranking amps EN (European standard).
Example: 12 V 46 Ah 420 A --> Select EN.

Fig. 103: Screen Display - Test Standard (e.g. EN, DIN, SAE, IEC, JIS)
6. Read off cold cranking amps and enter in tester.
Example: 12 V 46 Ah 420 cold cranking amps --> Confirm input with "Enter".
Fig. 104: Screen Display - Cold Cranking AMPS

The battery test starts after confirmation of the cold cranking amps entry.
The test result or one of the following messages appears after approx. 15 s:
Test code --> Step 7

 Vehicle model --> Step 9
 Temperature > 0 °C/< 0 °C --> Step 10
 Before charging / After charging --> Step 11
 Surface voltage detected (see above)
7. Read off test code with "Enter" and continue accordingly:

 "Battery in good condition":
No further measures required.
 "Charge and test":
Fully charge battery and retest (battery voltage > 12.4 V).
 "Replace battery":
Replace battery if this message appears.
8. Print out test code and file in a tamperproof manner.

9. Follow the menu and select test mode:
 Cars
 Taxi
Fig. 105: Screen Display - Cars And Taxi


 > 0°C
 < 0°C
If this message appears, the battery condition cannot be evaluated.
Fig. 106: Screen Display - Above 0 Degrees C And Below 0 Degrees C


 Before charge
 After charge
Fig. 107: Screen Display - Before Charge And After Charge

12. Perform additional menu-assisted functions (e.g. starting engine several times and turning on consumers).
Only in taxi test mode if displayed in menu.
CHECK BATTERY VOLTAGE BY MEANS OF THE INSTRUMENT CLUSTER (IC) - AR54.10-P-

1129-02A
The voltage display can be called up via the basic menu in the instrument cluster.
1. Switch on ignition.
The displays for trip odometer and temperature appear in the basic menu.
2. Press the reset button on the instrument cluster (IC) 3 times within 1.5 seconds.
3. Read off electrical system voltage.
To exit the workshop menu, switch off ignition.
REDUCE INCREASED VOLTAGE AFTER CHARGING PROCESS - AR54.10-P-1129-03A
Risk of explosion
Risk of poisoning and caustic burns
Risk of injury
No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour
battery acid into suitable and appropriately marked containers.
Test prerequisites:
 Battery removed or disconnected
 On the battery test "Surface voltage" appears in the display of the battery tester/test equipment.
For battery tester/test equipment as well as volt-amp(s) tester see GOTIS
1. Disconnect battery tester/test equipment.

2. Observe basic setting of the volt-amp(s) tester (1), if necessary adjust the knob (3) to 16 V and knob (4)
to 50 A.
3. Clip load clamps (5) on battery.
4. Connect terminals (7) to corresponding load clamps (5).
5. Position current clamp (6) around positive line.
Pay attention to current direction. The measurement takes place via an inductive coil in the current
clamp (6).
6. Switch on volt-amp(s)-tester (1) via the operating lever (2) and load battery with 20 to 30 A for approx 60
s.
The increased voltage is now reduced.

Fig. 108: Identifying Volt-Amp(S)-Tester, Operating Lever, Knob, Clamps And Terminal
CHECK CONDITION OF BATTERY - AR54.10-P-1129GZ
MODEL 164
MODIFICATION NOTES
24.2.06 Cold test current 12 Ah *BE54.10-P-1002-01A
Checking
AH54.10-P-
0002-01A
In the event of leakage: Replace
1 Visual inspection for external leaks
battery, see: ?
AR54.10-P-
Remove/install battery
0005GZ
OS54.10-P-
Dispose of battery
0001-01Z
AR54.10-P-
2 Check battery
1129-01A
*BE54.10-P-
Cold cranking amps as per EN
1002-01A
Midtronics MCR 717 battery *WH58.30-
tester and analyzer Z-1008-09A
Red terminal for Midtronics *WH58.30-

battery tester and analyzer Z-1009-09A
MCR 717
Black terminal for Midtronics *WH58.30-
battery test and analyzer MCR 717 Z-1010-09A
On a battery, that is disconnected
from the on-board electrical system
Reduce increased voltage after charging and with the message "Surface AR54.10-P-
3.1
process voltage" in the display of the 1129-03A
Midtronics battery tester and analyzer
MCR 717
Midtronics MCR 717 battery *WH58.30-
tester and analyzer Z-1008-09A
Volt ampere Tester ETT 011.00
*WH58.30-
After reducing increased voltage, Z-1003-09A
test battery again.
If test code "Charge and test" is
displayed on Midtronics battery tester AR54.10-P-
4.1 Charge battery and analyzer MCR 717 1130GZ
After charging, test battery again.
TEST AND ADJUSTMENT VALUES FOR THE BATTERY

BE54.10-P-1002-01A Cold test current as per EN A 170 540 520 420

BE54.10-P-1002-01A Cold test current as per EN A 680 510 480

Number Designation 70 Ah VRLA 74 Ah 80 Ah VRLA 84 Ah
BE54.10-P-1002-01A Cold test current as per EN A 760 680 800 700

BE54.10-P-1002-01A Cold test current as per EN A 950 850 760

Number Designation
WH58.30-Z-1003-09A Volt ampere tester

WH58.30-Z-1008-09A Battery tester and analyzer
WH58.30-Z-1009-09A Red terminal clamp for battery tester and analyzer
WH58.30-Z-1010-09A Black terminal clamp for battery tester and analyzer
CHARGE BATTERY - AR54.10-P-1130GZ
MODEL 164
Check
caused by swallowing battery acid. Risk of
clothing and safety glasses. Only pour Z-0001-
injury caused by burns to skin and eyes from
battery acid into suitable and 01A
battery acid or when handling damaged lead-
acid batteries
AR54.10-
1 Check condition of battery
P-1129GZ
Charging
Do not reverse polarity. Risk of
short circuit! Ensure that the vent hose
and battery stop plugs are installed in
2 Connect charger to battery
the correct position, otherwise
escaping battery acid will damage the
vehicle.
Normal charging: charging current
max. 10 % of battery capacity: e.g.
max. 10 A charging current for a 100
3 Charge battery Ah battery. Rapid charging: charging
current max.
50 % of battery capacity for 30 min:
e.g. max. 50 A charging current for a
100 Ah battery.
Always switch off charger
4 Disconnect battery charger
beforehand in order to prevent arcing.
Checking
5 Test battery after charging, see:?
AR54.10-
Check condition of battery
P-1129GZ
CHECK BATTERY CONDITION BEFORE VEHICLE DELIVERY - AR54.10-P-1132A
MODEL 163, 164, 168, 169, 170, 171, 203, 204.0 /2, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240, 245,
251, 414
Checking
1 Switch on driving This reduces the surface voltage of the
lamps for 60 seconds battery.
2.1 Measure battery Model 163, 170, 208, 414 AR54.10-P-1136-
voltage by means of a Model 203 up to 31.5.02 01A
digital multimeter Model 209, 230 up to 31.05.03
Model 211.0 up to 28.2.03
Model 215, 220 up to 31.8.02
Model 168 up to vehicle identification
end no.
1J 859 999
Perform measurement directly on the
battery or at the jump-starting point.
Digital multimeter, see GOTIS
2.2 Check battery voltage Model 164, 169, 171, 211.2, 211.6, 219, AR54.10-P-1129-
by means of the 240, 245, 251 02A
instrument cluster
(IC)
Model 203 as of 1.6.02
Model 209, 230 as of 1.6.03
Model 211.0 as of 1.3.03
Model 215, 220 as of 1.9.02
Model 204.0/2 without code (442) AR54.10-P-1129-
Comfort multifunction steering wheel 02CWA
Model 204.0/2 with code (442) Comfort AR54.10-P-1129-
multifunction steering wheel 02CWB
Model 216, 221 AR54.10-P-1129-
02SX
Model 168 as of vehicle identification AR54.10-P-1129-
end no. 1J 860 000 02B
3 Check battery If battery voltage less than 12.4 V.
Model 169, 245 AR54.10-P-1129AK
Model 204.0/2 AR54.10-P-1129CW
Model 164 AR54.10-P-1129GZ
Model 240 AR54.10-P-1129H
Model 215, 220, 230 AR54.10-P-1129I
Model 203, 209 AR54.10-P-1129P
Model 251 AR54.10-P-1129RT
Model 216, 221 AR54.10-P-1129SX
Model 211, 219 AR54.10-P-1129TX
Model 171 AR54.10-P-1129V
Model 163, 168, 170, 208, 414 AR54.10-P-1129Z
4 Document measured
battery voltage in
handover report
REMOVING AND INSTALLING FUSE AND RELAY BOX IN ENGINE COMPARTMENT, RIGHT
FRONT - AR54.15-P-1258GZ
Fig. 109: Identifying Fuse And Relay Box Remove/Install Components

Remove/install
Risk of poisoning and caustic burns caused smoking. Wear acid-resistant
by swallowing battery acid. Risk of injury gloves, clothing and safety glasses. AS54.10-Z-
caused by burns to skin and eyes from battery Only pour battery acid into suitable 0001-01A
AR54.10-P-
0003GZ
Remove bolts (2) and remove the cover of the To unlock, press the two catch
2
fuse and relay box (1) lugs (arrows).
*BA54.15-
3 Detach electrical line (positive lead) (3)
P-1001-01D
To unlock, press the five
retaining clamps (5) and in the
process pull the fuse and relay box
Unlock fuse and relay box (6) from housing for (6) upwards.
4
fuse and relay box (6) To make handling easier, the
cable glands (4) should be released
from the housing for the fuse and
relay box (6) if necessary.
Turn over the fuse and relay box (6) and
5
separate the electrical connectors
Only when installing a new fuse
and relay box (6).

Note component set before
removal.
Remove component set from fuse and relay
6.1 Installation: Fit out the fuse
box (6)
and relay box (6) depending on the
equipment, see:
?
AR00.19-P-
0200GZ
FUSE BOX
BA54.15-P-1001-01D Nut, electrical line (positive line) to fuse and relay box Nm 12
REMOVE/INSTALL FUSE AND RELAY BOX IN ENGINE COMPARTMENT, RIGHT FRONT -

AR54.15-P-1258GZA
MODEL 164 with ENGINE 156, 272, 273, 642, 629
Fig. 110: Identifying Fuse And Relay Box Remove/Install Components

Remove/install

Risk of poisoning and caustic burns caused smoking. Wear acid-resistant AS54.10-Z-
by swallowing battery acid. Risk of injury gloves, clothing and safety glasses. 0001-01A
caused by burns to skin and eyes from battery Only pour battery acid into suitable
AR54.10-P-
0003GZ
Detach lock (1) and remove the cover of the Two locks in model 164 with
2
fuse and relay box (2) engine 629.
If necessary, remove the
electrical line (positive line) (3)
3 Detach electrical line (positive line) (3) together with the cable passages
from the housing and place to one
side.
*BA54.15-
P-1001-01D
Detach fuse and relay box (4) from housing for
4 Detach from fixings (arrows).
fuse and relay box (4)
The number of electrical
Turn over the fuse and relay box (4) and
5 connectors may vary depending on
separate the electrical connectors
the vehicle model and equipment.
Only when installing a new fuse
and relay box (4).
Note component set before
Remove components from fuse and relay box removal.
6.1 Installation: Fit components in
(4)
the fuse and relay box (4)
according to the equipment fitted in
the vehicle; see:
?
AR00.19-P-
0200GZ
FUSE BOX
BA54.15-P-1001-01D Nut, electrical line (positive line) to fuse and relay box Nm 12
REMOVE/INSTALL HOUSING FOR FUSE AND RELAY BOX - AR54.15-P-1259GZ

Fig. 111: Identifying Housing For Fuse And Relay Box Remove/Install Components (1 Of 2)
Fig. 112: Identifying Housing For Fuse And Relay Box Remove/Install Components (2 Of 2)
Remove/instal
Risk of explosion caused by No fire, sparks, open flames or smoking.
oxyhydrogen gas. Risk of poisoning and Wear acid-resistant gloves, clothing and
AS54.10-
caustic burns caused by swallowing safety glasses. Only pour battery acid into
Z-0001-
battery acid. Risk of from battery acid or
injury caused by burns to skin and eyes
01A
when handling damaged lead-acid suitable and appropriately marked
AR54.10-
P-0003GZ
Remove bolts (2) and remove the cover of To unlock, press the two catch lugs
2
the fuse and relay box (1) (arrows).
Remove cable glands (3) out of housing
3
for fuse and relay box (9)
To unlock, press the five retaining
4 Detach fuse and relay box (5)
clamps (4).
5 Pull fuse and relay box (5) out of housing Carefully place fuse and relay box (5)
for fuse and relay box (9) to one side.

6 Unscrew nut (6, 7)
Detach bracket (8) from threaded stud.
Installation: Ensure that the rubber
Remove housing for fuse and relay box guide (11) is installed properly. The pilot
7
(9) stud (10) of the fuse and relay box (5)
must be inserted in the rubber guide (11)
when installing.
AR00.19-
P-0200GZ
REMOVE/INSTALL HOUSING FOR FUSE AND RELAY BOX - AR54.15-P-1259GZA
MODEL 164 with ENGINE 156, 272, 273, 642, 629
Fig. 113: Identifying Housing For Fuse And Relay Box Remove/Install Components - Shown On Model
164.1 With Engine 642
Remove/instal
by swallowing battery acid. Risk of injury
clothing and safety glasses. Only Z-0001-
caused by burns to skin and eyes from battery
pour battery acid into suitable and 01A
batteries
AR54.10-
P-0003GZ
Detach lock (1) and remove the cover of the Two locks in model 164 with
2
fuse and relay box (2) engine 629.
3 Pull off locking lug (4)

Detach fuse and relay box (6) from mounts
4
(arrows)
Pull fuse and relay box (6) out of housing for
Carefully place the fuse and relay
5 fuse and relay box (7); when doing so, remove
box (6) to one side.
cable passage (3, 5)
6 Unscrew nut (8, 9)
Remove housing for fuse and relay box (7)
7.1 Modify the bracket if necessary.
together with bracket
AR00.19-
P-0200GZ
REMOVE FUSE AND RELAY BOX IN REAR - AR54.15-P-1261GZ
MODEL 164
Fig. 114: Identifying Fuse And Relay Box In Rear Remove/Install Components - Shown On Model 164.1
Remove/instal
AR54.10-P-
0003GZ
Remove cover (1) from load
2
compartment side trim
The number of electrical connectors (2) and fuse
3 Separate electrical connectors (2) assignment of the load compartment fuse and relay
box (F4) varies depending on the vehicle model and
equipment.
Disconnect the positive line (3)
from the load compartment fuse

4
and relay box (F4)
To do this, press back with catch hooks (arrow).
Unclip fuse carrier (5) from the Number of fuse carriers if equipped.
5 load compartment fuse and relay Installation Y: Color coding of fuse carriers
box (F4) varies.
Route electric cables without crossing over.
Installation: Route electric cables without
6 (2) from the load compartment
fuse and relay box (F4) crossing over.
Unclip and pull out load
Pull out until the back of the load compartment
7 compartment fuse and relay box
(F4) from retaining clamps (4) fuse and relay box (F4) is accessible.
Unlock and detach connector on The number of connectors on the back of the load
8 the back of the load compartment compartment fuse and relay box (F4) varies
fuse and relay box (F4) depending on the vehicle model and equipment.
Remove load compartment fuse
9
and relay box (F4)
AR00.19-P-
0200GZ
REMOVE/INSTALL ON-BOARD ELECTRICAL NETWORK LINE PYROFUSE IN VEHICLE

POWER SUPPLY CONTROL UNIT - AR54.15-P-1262GZ
MODEL 164.828
Fig. 115: Identifying On-Board Electrical Network Line Pyrofuse In Vehicle Power Supply Control Unit
Remove/Install Components
Remove/instal

Risk of explosion caused by oxyhydrogen gas. smoking.
Risk of poisoning and caustic burns caused by Wear acid-resistant gloves,
AS54.10-Z-
swallowing battery acid. Risk of injury caused by clothing and glasses. Only pour
0001-01A
burns to skin and from battery acid or when battery acid into suitable eyes
handling damaged lead-acid batteries and appropriately marked
containers.
AR54.10-P-
0003GZ
AR68.20-P-
2 Remove front floor covering Right. 2070GZ
3 Unscrew nuts (1).
4 Unscrew bolt (2)
5 Remove intermediate bottom (3)
6 Remove molded part (4)
7 Detach adhesive tape (5)
adhesive tape (5).
*BA54.15-
9 Unscrew nuts (7).
P-1002-01D
10 Remove lines (8)
11 Remove pyrotechnical separating element (K88)
FUSE BOX
BA54.15-P-1002-01D Nut, pyrofuse to vehicle power supply control unit Nm 18
REMOVE/INSTALL PASSENGER'S SIDE INTERIOR FUSE BOX - AR54.15-P-1311GZ
MODEL 164
Fig. 116: Identifying Instrument Panel Side Panelling And Cock Pit Fuse Box
Remove/instal
clothing and safety glasses. Pour Z-0001-
through burns to skin and eyes from battery
battery acid only into suitable and 01A
batteries
AR54.10-
P-0003GZ
AH54.10-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
2 Remove instrument panel side paneling (1) Long wedge Fig. 117
Lever off cockpit fuse box (F3)
3 Remove cockpit fuse box (F3)
using long wedge (arrow).
Long wedge Fig. 117
Disconnect electrical lines from cockpit fuse Installation: Route electric
4
box (F3) cables without crossing over.
Wiring harness repair kit Fig. 118

Fig. 118: Identifying Wiring Harness Repair Kit (220 589 02 99 00)
REMOVE/INSTALL FRONT PREFUSE BOX - AR54.15-P-1330GZ
MODEL 164
Fig. 119: Identifying Front Prefuse Box Remove/Install Components - Shown On Model 164.1 With
Engine 272
Remove/instal

batteries
AR54.10-
P-0003GZ
AH54.10-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
AR88.40-
P-1000GZ
3 Remove plastic sleeve (1) for nut (2)
Unscrew nut (2) and remove positive line,
4
circuit 30 (3)
Detach front prefuse box (F32) from engine
5
compartment
Detach cover (4) carefully, it can
6 Detach cover (4) from front prefuse box (F32)
break easily.
Unscrew nuts (5) and lines, remove circuit 30
7
(6)
8 Remove front prefuse box (F32)
AR00.19-
P-0200GZ
REMOVE/INSTALL INTERIOR COMPARTMENT PREFUSE BOX - AR54.15-P-1350GZ
MODEL 164
Fig. 120: Identifying Interior Compartment Prefuse Box Remove/Install Components

Remove/instal
AS54.10-Z-
swallowing battery acid. Risk of injury safety glasses. Only pour battery acid into
0001-01A
caused by burns to skin and eyes from suitable and appropriately marked
battery acid or when handling damaged containers.
lead-acid batteries
AH54.10-P-
0001-01A
AH54.10-P-
0002-01A
AR54.10-P-
1 Remove battery
0005GZ
*BA54.10-
P-1012-01C
*BA54.10-
P-1024-01C
*BA54.10-
2 Undo nut (3), remove clamping device
P-1026-01C
Installation: Note plug's color coding.
3 Detach plug of maxi fuses (4) When replacing the battery compartment
prefuse box (F33) change the maxi fuses
(4).
Carefully unclip battery compartment
Unclip battery compartment prefuse box
4 prefuse box (F33). If the clip is bent too far
(F33) (arrow A)
it may break.
Release locks (arrows B) using suitable
The number of fuses may vary
tool, disconnect fuse carrier with fuses
5 depending on the vehicle model and
(2) from battery compartment prefuse
equipment.
box (F33)
The electrical connections must be
clearly assigned to the corresponding
contact of the battery compartment prefuse
box (F33) before being detached. Otherwise
Undo nuts (1), detach electrical during installation mixups may occur which
6
connections could ultimately induce faults in the vehicle
electrical system.
The number of electrical connections
may vary depending on the vehicle model
and equipment.
*BA54.10-
P-1026-01C
Remove battery compartment prefuse
7
box (F33)
AR00.19-P-
0200GZ
BATTERY
164.1/8
BA54.10-P-1012-
Nut, battery cable to battery terminal M6 Nm 6
01C
BA54.10-P-1024-
Nut, battery retaining plate to frame floor M8 Nm 24
01C
BA54.10-P-1026- Nut for line connection on battery compartment prefuse M6 Nm 7
01C box M8 Nm 21
CHECKING WIRING HARNESS - AR54.18-P-0600-01A

Fig. 122: Identifying 126-Pin Socket Box (129 589 00 21 00)

During tests on the airbag control unit a corresponding test cable must be used in combination with the
126-pin socket box.
1. Connect electrical connection kit with test cable.

2. Check lines for resistance using a continuity meter as per the wiring diagram, starting at the
corresponding control unit.
The resistance must be < 0.5 ohms.
3. Perform system test in accordance with diagnosis specifications.
REPAIR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SQUIB WIRING HARNESS - AR54.18-P-

0600A
MODEL 124, 129, 140, 163, 164, 168, 169, 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220,
221,230,240,245,251,414, 461 as of 1.4.94, 463 MODEL 126 with CODE (291) Airbag for driver and front
passenger (for front passenger only if driver airbag standard) with CODE (442) Airbag in steering wheel
Fig. 123: Identifying Supplemental Restraint System (SRS) Squib Wiring Harness Components
Remove/install
Risk of injury Store airbag units with deployment side facing AS91.00-Z-0001-
caused by up; do not expose to temperatures greater than 01A
performing testing 100 °C. When working on these units,
or repair work on disconnect the power supply.
airbag or
emergency
tensioning
retractor units.
Risk of injury Store airbag units with deployment side facing AS91.00-Z-0001-
caused by up; do not expose to temperatures greater than 01B
performing testing 100 °C. When working on these units,
or repair work on disconnect power supply and unplug the SRS
airbag or test connector (X11/13).
emergency
tensioning
retractor units.
Risk of injury to Wear safety gloves, protective clothing and AS00.00-Z-0002-
skin and eyes safety glasses, if necessary. 01A
caused by
handling hot or
glowing objects.
Risk of injury Work in well ventilated rooms only. Wear safety AS00.19-Z-0001-
caused by burns glasses with side protection and protective 01A
to skin and eyes. gloves.
Risk of poisoning
caused by
inhaling fumes
when working
with heat-
shrinkable tubing.
Assessment of Model 129, 202 up to 30.6.93 AH91.00-P-0006-
airbag and belt Model 124, 126, 140 01A
tensioner units in
accident vehicles
Notes on AH00.19-P-
replacement of 1000-08A
safety-relevant
and special
components
Assessment of Model 129 as of 1.7.93, 163, 164, 168, 169, 170, AH91.00-P-
airbag and belt 171, 202 as of 1.7.93, 203, 204, 208, 209, 210, 0006-01B
tensioner units in 211, 215, 216, 219, 220, 221, 230, 240, 245, 251,
accident vehicles 414, 461 as of 1.4.94, 463
Notes on cable AH00.19-P-
protection 1000-11A
1 Remove
detachable body
components in
area to be repaired
2 Repairing wiring AR00.19-P-
harness using 0100-09A
solder connectors
Wiring harness repair kit, basic Fig. 125
New passenger vehicle wiring harness repair Fig. 124
kit
Wire stripper Fig. 127
Reflector Fig. 126
Adapter Fig. 128
Welding bead catcher Fig. 131
Heat gun, see GOTIS
3.1 Protect the repair AR00.19-P-
point with heat- 0100-08A
shrinkable tube
after repairing the
line
point with 0100-08B
corrugated hose
after repairing the
line
point with fabric 0100-08C
tape after
repairing the line
4 Checking wiring Function check on completion of repair. AR54.18-P-
harness 0600-01A
126-pin socket box Fig. 122
5 Install in the
reverse order
Fig. 124: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 125: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 126: Identifying Reflector (220 589 01 99 41)

Fig. 127: Identifying Wire Stripper (220 589 01 99 40)



Fig. 130: Identifying 126-Pin Socket Box (129 589 00 21 00)

Fig. 131: Identifying Welding Bead Catcher (129 589 01 98 00)

SCN CODING WITH SDFLASH ONLINE - AR54.21-P-0013-02X
The following work instructions describes the procedure for Online SCN coding with "SDflash".
"SDflash" is the product designation of the program for determining the SCN coding and parameterization data.
Prerequisite for Online SCN coding with "SDflash":
 Networked STAR DIAGNOSIS diagnosis system

 Access to "SDflash" with corresponding rights
Entry into the coding in the diagnosis assistant system (DAS)
1. Select menu item "control unit adaptations" or "initial startup". Continue with "F3".
2. Select the menu item "SCN coding" in the further program run.
Continue with "F3".
The program run may differ depending on the control unit.
3. Select menu item "Online (networked STAR DIAGNOSIS device)".
Continue with "F3".
4. Confirm note on sequence of SCN coding with "F2".

5. Confirmation of the correct vehicle identification number with "F3".
A note on further action follows.
Coding steps in "SDflash Online"
6. Start Star Browser with "F5" button.
The program can also be opened via "Start/program/Star Browser".
If "SDflash" is already open, it is possible to change into the program with the button combination "ALT
TAB" or via the task bar.
7. Logging on in "SDflash" with user name and password.

8. Call up "SDflash" with "Start" button.
9. Open vehicle data record with "F3".
If special equipment has been installed in or removed from the vehicle, the SA codes must be entered
in the fields provided for this in "SDflash":
 "Positive SA codes": The SA codes entered here are fitted in the vehicle for the first time. They are
taken into account for the generation of the SCN coding data
 "Negative SA codes": The SA codes entered here have currently been removed from the vehicle.
They are no longer taken into account for the generation of SCN coding data
10. Use "F3" to start the request for forming the SCN coding data.
End of coding in DAS
11. Use "F3" to select menu item "Carry out SCN coding".
12. Confirm the vehicle identification number with "F3".
13. The control unit is coded after confirmation with "F3".

14. Fill in missing data in the order protocol and then print out with "F11" and enclose with the repair order.
The order protocol can also be stored in the STAR DIAGNOSIS device. After printing "F11" it is to
be specified in the print dialog that printing to file should take place. This takes place by clicking on
"print to file", selection of "printout of test step" and giving a file name.
In "StarUtilities" with the "StarPad" program the order log can be displayed and printed out under the
item "log" --> "DAS log" --> "printout of test step".
15. Continue with "F2"
The online SCN coding of the control unit is thus successfully completed.
SCN CODING WITH SDFLASH OFFICE - AR54.21-P-0013-03X
The following work instructions describes the procedure for SCN coding with the "SDflash Online"
program.
"SDflash" is the product name of the program used to determine the SCN coding and parameterization data.
"SDflash Office" is the designation of the Office SCN process.
Coding by means of "SDflash Office" is not permissible for the company-owned sales and service outlets of
DaimlerChrysler Sales Organization Germany.
Prerequisite for SCN coding with "SDflash Online":
 "SDflash Office" software incl. user rights.

 PC with Intranet and Internet connection incl. CD burner.
 Printer for printout of coding string or CD blank and CD burner for preparing the SCN repair CD.
2. Select the menu item "SCN coding" in the further program sequence. Continue with "F3".
3. Select menu item "Offline (FDOK, FAX, Office)". Continue with "F3".
5. Select menu item "vehicle data for SCN coding". Continue with "F3".
7. Print out vehicle data with "F11".
8. Start "SDflash" program.
Coding steps in "SDflash Office"
SCN coding in DAS can be carried out with 2 different methods:
 Coding with printed-out coding data

 Coding with an SCN repair CD to be prepared.
9. Enter vehicle identification number, select category, select control unit category ("engine control unit",
"transmission control unit" or "other"). Continue with "F2".
10. In the "Coding" index enter the part number and, if available, the control unit software numbers and
check digit 1.
For control units relevant to exhaust emission the legislator requires a number, the so-called "Software
Calibration Number" (SCN). This SCN represents the software release of the control unit. Control units
which contain more than one software, form a different SCN for each software, so that more than one
SCN is assigned to the complete control unit.
In order to meet the legislation, a group SCN is formed via all SCNs formed. In this case, the part number
which is formed from the object number of the control unit and the control unit software number must be
entered in the rows below the row "Control unit software".
11. Confirm entries in the "coding" index with "F3".
The starts the interrogation of SCN coding data in the central system.
12. Confirm message about successful SCN generation and coding string formation.
13. Use "F11" to print out the coding string, SCN and check digit 2.
When coding takes place with printed-out coding data.
Only carry out the following steps 14 to 16 if coding is performed using an SCN Repair CD.
14. Insert suitable blank in the CD-burner. Use "F7" to call up the CD burning program.
If the CD burning program is called up for the first time, call up this with "F6" "Select burning program".
15. Change into the directory
"C:\\userdata\\csd\\writefil\\create\\flashfil" with the CD burning program. From there change into the
vehicle category directory, then into the model series directory and then into the vehicle VIN/VIN
directory.
Creating a link to the folder

"C:\\userdata\\csd\\writefil\\create\\flashfil" facilitates access to the subdirectories.
16. Burn all files which are found in this directory onto the CD.
To ensure that the CD cannot be confused with other CDs, we recommend noting the following
information on the CD:
 CD type: SCN Repair CD

 VIN: ... (enter the vehicle identification number of the vehicle here)
 CU object number: ... (enter the object number of the control unit here)
 Date: ... (here enter the date on which the coding string of the central systems was supplied and
burnt onto the CD)
Completion of coding in the DAS
17. In the menu "Offline (FDOK, FAX, Office)" select the menu item "Carry out SCN-coding". Continue
with "F3".
18.
1. Enter the SCN coding data (SCN, coding string and check digit 2). Continue with "F3".
Only if coding of the control unit is performed using the printed-out coding data.
2. Insert a finish-burnt SCN Repair CD in the STAR DIAGNOSIS CD drive. Continue with "F3".
If the coding takes place with the SCN Repair-CD.
19. Start the coding with "F3".
20. Print out the order log with "F11" and enclose the repair order.
The order log can also be stored in STAR DIAGNOSIS. After printing "F11" it is to be specified in the
print dialog that printing to file should take place. This takes place by clicking on "print to file", selection
of "printout of test step" and giving a file name.
In "StarUtilities" with the "StarPad" program the order log can be displayed and printed out under the
item "log" --> "DAS log" --> "printout of test step".
Depending on the control module model the ignition must then be switched on and off again.
To do this, follow the instructions in DAS.
When coding the control unit with printed-out coding data, a control unit reset takes place following the
coding.
21. Continue with "F2".
SCN coding of the control unit is thus successfully concluded.
22. After successful coding, destroy the SCN Repair CD as per the guideline for theft-relevant parts (DRT
69/00).
When coding has been carried out with the SCN-Repair CD. The destruction is to be documented on
the repair order.
OFFLINE SCN CODING - AR54.21-P-0013-04X
The following work instructions describes the three different procedures for Offline SCN coding with the
STAR DIAGNOSIS diagnosis system which is not networked:
A. Request coding data in paper format by fax
Requirements:
 STAR DIAGNOSIS diagnosis system with printer and fax machine

 Correct date and time setting in STAR DIAGNOSIS
If special equipment is installed or removed from the vehicle, the SA codes must be redocumented
in the vehicle documentation system (FDOK).
B. Request coding data on CD by fax, coding using SCN Repair CD
Requirements:
 STAR DIAGNOSIS diagnosis system, PC with Internet connection and fax machine
 Correct date and time setting in STAR DIAGNOSIS
If special equipment is installed or removed from the vehicle, the SA codes must be redocumented
in the vehicle documentation system (FDOK).
C. Determine coding data via "SDflash", "Office" variant on office PC
Coding via "SDflash", "Office" variant is not permissible for branches of the DaimlerChrysler Sales
Organization Germany.
Requirements:
 "SDflash" software, "Office" variant with PC user rights

 plus Intranet or Internet connection and CD writer
 Printer for printing out the coding data or CD blank for preparing an SCN Repair CD
If special equipment has been installed in or removed from the vehicle, the SA codes must be
redocumented in the FDOK.
2. Select the menu item "SCN coding" in the further program sequence. Continue with "F3".
3. Select menu item "Offline (STAR DIAGNOSIS not networked)". Continue with "F3".
5. Select menu item "Determine vehicle data for Offline SCN coding from the vehicle". Continue with "F3".
A) Request coding data in paper form by fax:
7. In the SCN coding main menu (in the DAS system) select the menu item "Offline (STAR DIAGNOSIS
not networked)". Continue with "F3".
9. Use "F4" to open the "Software Calibration Number" inquiry form.
10. Fill in the request form displayed.
Fill in all fields marked with "*".
11. Print out the filled-in request form and transmit to the specified fax number.
The answer fax is sent immediately with the SCN coding data.

13. Select the menu item "Carry out SCN coding" and confirm using "F3".
14. Find the SCN coding data (Software Calibration Number (SCN), coding string and check digit 2) from
the reply fax and enter them in the DAS screen.
Depending on the control module model the ignition must then be switched on and off again. To do
this, follow the instructions in DAS.
of "printout of test step" and giving a file name. In Star Utilities using the program StarPad the order log
can be displayed and printed out under the under the item "log" --> "DAS log" --> "printout of test step".
17. Continue with key "F2".
The SCN coding is successfully concluded with the help of the coding data requested in paper form.
B) Request coding data on CD, coding by means of SCN Repair CD
18. In the SCN coding main menu (in the DAS system) select the menu item "Offline (STAR DIAGNOSIS
not networked)". Continue with "F3".
20. Use "F5" to open the request form of SCN repair CD.
21. Fill in the request form displayed.
Fill in all fields marked with "*".
22. Print out the filled-in request form and transmit to the specified fax number.
The reply fax with the part number for the SCN Repair CD to be ordered is transmitted without delay.
23. Order the repair CD via the replacement parts ordering system (e.g. StarOrder) quoting the VIN.
The SCN Repair-CD is sent.
24. In the menu "Offline (STAR DIAGNOSIS not networked)" select the menu item "Carry out SCN
coding". Continue with "F3".
25. Insert the SCN Repair-CD in the CD-drive of STAR DIAGNOSIS. Continue with "F3".
of "printout of test step" and giving a file name.
In Star Utilities using the program StarPad the order log can be displayed and printed out under the item
"log" --> "DAS log" --> "printout of test step".
SCN coding is thus successfully concluded with the help of the requested SCN repair CD.
29. After successful coding, destroy the SCN Repair CD as per the guideline for theft-relevant parts (DRT
69/00).
The irreparable damage should be documented on the repair order and on screen 2116 in the vehicle
documentation system.
C) Determine the coding data via "SDflash", "Office" variant on office PC
The coding via "SDflash", "Office" variant is not permissible for company-owned sales and service
outlets of the DaimlerChrysler Sales Organization Germany.
Two different methods can be used for carrying out SCN coding in the DAS:
 Coding with printed-out coding data

 Coding with an SCN Repair CD to be prepared
30. Print out vehicle data with "F11" in Diagnosis Assistance System.
31. Start "SDflash" program on office PC.
32. Enter vehicle identification number, select category, select control unit category ("engine control unit",
"transmission control unit" or "other control unit") and confirm with "F2".
33. In the "coding" index enter the control unit part number, if available the control unit software numbers
and the check digit 1.
If special equipment has been installed in or removed from the vehicle, the SA codes must be entered
in the fields provided for this in "SDflash":
"Positive SA codes": The SA codes entered here are included in the vehicle for the first time. They
are taken into account for the generation of the SCN coding data
 "Negative SA codes": The SA codes entered here have been currently removed from the vehicle.
They are no longer taken into account for the generation of SCN coding data
34. Confirm entries in the "coding" index with "F3".
35. Confirm note concerning successful SCN generation and coding string formation.
36. Use "F11" to print out the coding string, SCN and check digit 2.
With manual entry in Diagnosis Assistance System.
37. Insert CD blank in the CD hot space and burn the data on the CD.
With electronic data take-over.
Use "F7" to call up the CD burning program. Before using the burning program for the first time this
must be set up. To do this, press "F6" (select burning program) and select the "*.exe-file" of the burning
program.
With the CD burning program change into the directory "C:\\userdata\\csd\\writefil\\create\\flashfil".

Change from there into the category directory of the vehicle, then into the model series directory and after
this into the vehicle identification number directory of the vehicle.
Burn all files which are found in this directory onto the CD.
So that no danger of mixing up exists for the CD, identify it as follows:
 SCN Repair CD
 VIN
 control unit object number
 Date
38. In the menu "Offline (STAR DIAGNOSIS not networked)" select the menu item "Carry out SCN
coding". Continue with "F3".
39.
1. Enter SCN coding data (SCN, coding string and check digit 2). Continue with "F3".
With manual entry in Diagnosis Assistance System.
2. Insert prepared SCN repair CD in the STAR DIAGNOSIS CD drive. Continue with "F3".
40. Start "F3" coding.
With manual coding of the control unit a control unit reset is carried out subsequent to the coding.
41. Use "F11" to print out the order log and enclose with the repair order.
of "printout of test step" and giving a file name. In Star Utilities using the program StarPad the order log
can be displayed and printed out under the item "log" --> "DAS log" --> "printout of test step".
SCN coding is thus successfully concluded with the shop-made SCN repair CD.
43. Destroy the SCN-Repair CD after successful coding, as per the guideline for theft-relevant parts (DRT
69/00). The destruction should then be documented on the repair order and on screen 2116 in FDOK.
PROGRAM CONTROL UNIT - AR54.21-P-0014-01Y

Offline programming with SDflash Release-CD.
1. Select vehicle.
2. Select control unit.
Selection of main menu, systems and select the control unit to be programmed.
3. Select the menu item "program control units" in the control unit menu.
4. Select the menu item "SDflash Release-CD/DAS-DVD".
5. With new software press the "F3" button and program the control unit.
Only perform the following steps, if no communication (communication error) is possible between the
diagnosis assistant system (DAS) and control unit.
6. Eliminate the cause of the error message using the test steps in the "error messages" menu.
If the cause of the error cannot be found or eliminated, please inform the STAR DIAGNOSIS User
Help Desk. Replace the control unit after consultation with the STAR DIAGNOSIS User Help Desk.
7. If necessary determine the part number of the control unit and replace the control unit.
8. Select menu item "Initial startup with automatic adoption of settings from the old control unit" or "Initial
startup without automatic adoption of the settings from the old control unit" in the main menu. Then
select "Repair functions" and carry out "Replace control unit".
If the control unit has been replaced.
PROGRAM CONTROL UNIT - AR54.21-P-0014-01Z
Offline programming with SDflash Special Release-CD.
1. Start Diagnosis Assistant System (DAS) and select category/vehicle model

2. Select control unit.
3. Select the menu item "control unit adaptations" in the control unit menu.
4. Select menu item "control unit programming".
5. Select menu item "CD or DVD".
6. Insert SDflash Special Release-CD.
The programming of the control unit now starts automatically.
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014Y
MODEL 129.058 /063 /067 /076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251, 461.302 /331 /332 /342 /345,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /308 /309 /32
450, 451, 452, 454 Offline programming with SDflash Release CD
During the
whole work
procedure, an
adequate
voltage
supply to the
vehicle
electrical
system is to
be ensured as
undervoltage
can damage
the control
units.
Notes on
programming
control units
1 Connect
STAR
DIAGNOSIS
and start
Diagnosis
Assistant
System
(DAS)
Connect Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 21
STAR 240, 245, 251, 461.302/331/332/342/345,
DIAGNOSIS 463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/3
and read out
fault memory
Model 450
Model 451
Model 452
Model 454
2 Program
control unit
3 Perform Only with exhaust emission-relevant and safety-relevant control units.

SCN coding
of control
units
4 Carry out Only on engine control unit.
sensor rotor
adaptation
5 Read fault
memory,
erase if
necessary
6 Close STAR
DIAGNOSIS
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014Z
MODEL 129.058 /063 /067 /076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251, 461.302 /331 /332 /342 /345,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /308 /309 /32
450, 451, 452, 454 Offline programming with SDflash Special Release CD
During the
whole work
procedure, an
adequate
voltage supply
to the vehicle
electrical system
is to be ensured
as undervoltage
can damage the
control units.
Notes on
programming
control units
Flow chart for
Offline
programming
with SDflash
Special Release-
CD
1 Connect STAR Communication with control unit is being established.
DIAGNOSIS,
start Diagnosis
Assistant
System (DAS)
and select
category/vehicle
model
Connect STAR Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209,
DIAGNOSIS 240, 245, 251, 461.302/331/332/342/345,
and read out 463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/30
fault memory
Model 450
Model 451
Model 452
Model 454
2 Determine the Only required if data cannot be read out of the control unit.
part number of
the control unit
with the help of
the current parts
catalog
3 Contact STAR If the control unit does not communicate with the DAS or the problem cannot be elimi
DIAGNOSIS or DAS-DVD.
User Help Desk Have the report of the initial quick test, the control unit version and any documenta
hand.
4 Fax log of initial This information is needed for problem solving. From this information the SDflash
quick test, LC/MPC GLC Germersheim.
control unit STAR DIAGNOSIS User Help Desk reports to the workshop and gives the replacemen
version and if SDflash Special Release CD.
necessary
documentation
on the repair
order to the
STAR
DIAGNOSIS
User Help Desk
5 Order SDflash "ES 2" is also to be specified next to the part number when ordering.
Special Release- Preparation and shipment of SDflash Special Release-CD at LC/MPC GLC Germershe
CD via the usual LC/MPC GLC Germersheim sends the SDflash Special Release-CD via the usual sales
ordering
channels
6 Program the
control unit after
receipt of the
SDflash Special
Release CD
7 Carry out Only after successful programming of the control unit.
redocumentation If no FDOK access is available, send a fax/mail to LC/MPC GLC Germersheim and ha
in the vehicle there.
documentation
system (FDOK)
in the vehicle
documentation
system screen
8 Perform SCN Only with exhaust emission-relevant and safety-relevant control units.
coding of
control units
9 Carry out sensor Only on engine control unit.
rotor adaptation
10 Read fault
memory, erase
if necessary
11 Close STAR
DIAGNOSIS
SCN CODING OF CONTROL UNITS - AR54.21-P-0015X
MODEL 129.058 /063 /067 /076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251, 461.302 /331 /332 /342 /345,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /308 /309 /32
450, 451, 452, 454
MODIFICATION NOTES
26.9.06 SCN coding sequences Steps 2.1 and 2.2
revised
During the
whole work
procedure,
an adequate
voltage
supply to the
vehicle
electrical
system is to
be ensured as
undervoltage
can damage
the control
units.
Notes on
SCN coding
of control
units
1 Connect
STAR
DIAGNOSIS
and start
Diagnosis
Assistant
System
(DAS)
Connect Model 129.058/063/067/076, 163, 164, 168, 169, 170, 171.4, 199, 203, 204, 208, 209, 21
STAR 240, 245, 251, 461.302/331/332/342/345,
DIAGNOSIS 463.206/208/209/232/233/240/241/243/244/245/246/247/248/249/250/254/270/271/303/3
and read out
fault
memory
Model 450
Model 451
Model 452
Model 454
2.1 Carry out With networked STAR DIAGNOSIS diagnosis system.

online SCN
coding with
SDflash
2.2 Carry out With non-networked STAR DIAGNOSIS diagnosis system.
Offline SCN
coding
3 Read fault
memory,
erase if
necessary
4 Close STAR
DIAGNOSIS
CENTRAL GATEWAY CONTROL UNIT (ZGW), REMOVE AND INSTALL - AR54.21-P-0817GZ
MODEL 164
Fig. 132: Identifying Central Gateway Control Unit

Fig. 133: Identifying Central Gateway Control Unit (ZGW) Remove/Install Components
MODIFICATION NOTES
Disconnect/connect battery ground line and carry out basic programming Steps 2 and
25.7.06
removed 17
Remove/instal
AH54.00-P-
0001-01A
Only when replacing the central
Read out coding from central
1 gateway control unit (N93) and if it can
gateway control unit (N93)
still be read out with STAR DIAGNOSIS.
*WH58.30-Z-
1048-13A
AR91.10-P-
2 Remove left front seat
1000GZ
AR68.30-P-
3 Remove left front entry trim
4100GZ
AR68.30-P-
4 Remove left rear door sill molding
4100GZ
Remove lower trim on the left B- AR68.30-P-
5
pillar 4700GZ
6 Remove cover (2).
Remove bolt (4) and remove Installation: Use anchoring lug (5)
8
anchoring lug (5) with its positioning lug properly.
*BA68.50-P-
1001-03F
9 Fold over rear left floor covering
Remove clip (6) and remove air duct
10
(7)
Remove nuts (8) and remove left
11
intermediate bottom (9)
Separate electrical connectors from
12
central gateway control unit (N93)
Loosen central gateway control unit
13 (N93) at the catch tabs (10) from the
bracket and remove
Code central gateway control unit Only when installing a new central
15
(N93) gateway control unit (N93).
*WH58.30-Z-
1048-13A
CARGO RETAINERS

Number Designation
REMOVE/INSTALL FRONT SAM CONTROL UNIT - AR54.21-P-1254GZ
MODEL 164
Fig. 134: Identifying Front SAM Control Unit Remove/Install Components

Remove/instal
AH54.10-P-
0001-01A
AH54.00-P-
0001-01A
discharge
AH54.10-P-
0002-01A
Only when replacing the front
Read out coding of front SAM control unit SAM control unit (N10) and if it
1.1
(N10) using STAR DIAGNOSIS can still be read out using STAR
DIAGNOSIS.
system Z-1048-13A
AR54.10-P-
2 Remove battery
0005GZ
*BA54.10-P-
1012-01C
*BA54.10-P-
1024-01C
Unlock all plugs (3) and disconnect from
3
front SAM control unit (N10)
Installation: Insert retaining

clamps (2) into corresponding
Undo bolts (1), remove front SAM control
4 openings, then fasten the front
unit (N10)
SAM control unit (N10) using bolts
(1).
Only when installing a new front
6.1 Code front SAM control unit (N10)
SAM control unit (N10).
system Z-1048-13A
AR00.19-P-
0200GZ
BATTERY

Number Designation
REMOVE/INSTALL UPPER CONTROL PANEL CONTROL UNIT - AR54.21-P-1262GZ
MODEL 164
Shown on vehicle with offroad package, code 430
Fig. 135: Identifying Upper Control Panel Control Unit Remove/Install Components - Shown On Vehicle
With Offroad Package, Code 430
Remove/instal
AH54.00-P-
0001-01A
(at least 2 m).
Disengage instrument panel
center part (1) at bottom edge Protect trim parts of the instrument panel and
2
(arrows A) and pull forward out center console from scratches.
of instrument panel
4 Remove screws (4)
Slacken screws (2) and remove
Only slacken the screws (2) (do not remove them
5 upper control panel control unit
(N72/1) fully).
REMOVING AND INSTALLING LOWER CONTROL PANEL CONTROL UNIT - AR54.21-P-1263GZ
MODEL 164
Fig. 136: Identifying Lower Control Panel Control Unit Remove/Install Components - Shown On Vehicle
With Offroad Package, Code 430
Remove/instal
AH54.00-P-
0001-01A
[EZS] control unit and store it in a location beyond its transmission
Disengage instrument panel
center part (1) at bottom edge Protect trim parts of the instrument panel and
2
(arrows A) and pull forward out center console from scratches.
of instrument panel
3
(2)
Remove screws (3) and remove
4 lower control panel control unit
(N72)
REMOVE/INSTALL REAR SAM CONTROL UNIT - AR54.21-P-1269GZ
MODEL 164
Fig. 137: Identifying Rear Sam Control Unit Remove/Install Components - Shown On Model 164.1
MODIFICATION NOTES
25.7.06 Disconnect/connect battery ground line and carry out basic programming removed Steps 2 and 9
Remove/instal
Notes on avoiding damage to electronic All models AH54.00-P-


Only when replacing the rear
SAM control unit (N10/8).
Connect STAR DIAGNOSIS and store
1 basic data from rear SAM control unit Installation: Transfer
(N10/8) temporarily in STAR DIAGNOSIS temporarily stored basic data to
new rear SAM control unit
(N10/8).
system 1048-13A
Remove cover (1) from load compartment
2
side paneling
Unclip rear SAM control unit (N10/8)
4 upwards out of retaining clamps (arrow) and
remove line routing.
6 Remove rear SAM control unit (N10/8)

Number Designation
REMOVE STEERING COLUMN SWITCH MODULE - AR54.25-P-2800-01TX
Shown on model 219
When the steering wheel is detached the fanfare horns and airbag clock spring contact (A45) must not be
twisted otherwise this can be damaged.
1. Unscrew bolt (1).
Bolt (1) is secured to prevent it from falling out.
2. Disconnect steering column switch module (2) complete with fanfare horns and airbag clock spring
contact (A45) from jacket tube.
Fig. 138: Identifying Steering Column Switch Module Components

REMOVE/INSTALL COMBINATION SWITCH - AR54.25-P-2800GZ
MODEL 164
Shown on model 164.1 with electrically adjustable steering column, code 441
Fig. 139: Identifying Combination Switch Remove/Install Components - Shown On Model 164.1
Remove/instal
Risk of poisoning and caustic burns caused No fire, sparks, open flames or AS54.10-
by swallowing battery acid. Risk of injury smoking. Wear acid-resistant gloves, Z-0001-
caused by burns to skin and eyes from battery clothing and safety glasses. Only 01A
acid or when handling damaged lead-acid pour battery acid into suitable and
batteries appropriately marked containers.

AR54.10-
P-0003GZ
AR91.60-
P-0660GZ
AR46.10-
P-0100GZ
AR54.25-
P-2802GZ
AR46.10-
P-0200GZ
AR46.10-
P-0300GZ
The number of bolts depends on
7 Remove bolts (7)
the equipment.
Only on vehicles with electrically
adjustable steering column, code
8.1 Detach steering column adjustment switch (6) 441.
connector.
9 Detach combination switch (5)
connector.
AR00.19-
P-0200GZ
REMOVE/INSTALL STEERING COLUMN MODULE - AR54.25-P-2802GZ
MODEL 164
Fig. 140: Identifying Install Steering Column Module Remove/Install Components

Remove/instal
The steering column module

(N80) and steering angle sensor
(N49) are one component and
can only be replaced together
AR46.10-
1 Remove clock spring contact
P-0200GZ
2 Remove screw (1)
Unclip the retaining lugs (a) of
3 the steering column module
(N80) from the carrier plate (5)
Installation: Check the basic position of the steering
angle sensor (N49) (observe arrows on steering angle
sensor and inner race (2)). If the steering angle sensor is
twisted, bring the steering angle sensor into the center
position before reinstalling:
Pull steering column module
4 ?
(N80) out of carrier plate (5)
Turn the inner race of the steering angle sensor
counterclockwise up to the limit stop (turn gently
towards the limit stop, risk of damage), then turn
approx. two revolutions clockwise until the arrows on
the steering angle sensor and inner race match.
REMOVE/INSTALL CRUISE CONTROL SWITCH - AR54.25-P-2803GZ
MODEL 164
Shown on model 164.1 with electrically adjustable steering column, code 441
Fig. 141: Identifying Cruise Control Switch Remove/Install Components - Shown On Model 164.1
Remove/instal

batteries
AR54.10-
P-0003GZ
DIRECT SELECT selector lever
Remove DIRECT SELECT selector lever (8)
(8) and cruise control push-button AR27.60-
2 together with the cruise control push-button
switch (9) form a unit which cannot P-0931GZ
switch (9)
be disassembled.
AR00.19-
P-0200GZ
REMOVING AND INSTALLING STEERING COLUMN ADJUSTMENT SWITCH - AR54.25-P-

2804GZ
MODEL 164 with CODE (441) Electrically adjustable steering column
Fig. 142: Identifying Steering Column Adjustment Switch Remove/Install Components

Remove/instal
Risk of poisoning and caustic burns caused No fire, sparks, open flames or
by swallowing battery acid. Risk of injury smoking. Wear acid-resistant gloves,

AS54.10-
caused by burns to skin and eyes from battery clothing and safety glasses. Only
Z-0001-
01A
AR54.10-
P-0003GZ
AR91.60-
P-0660GZ
AR46.10-
P-0100GZ
AR54.25-
P-2802GZ
AR46.10-
P-0200GZ
AR46.10-
P-0300GZ
Remove bolts (6) and remove the steering Do not damage electrical
7
column adjustment switch (5) connector.
AR00.19-
P-0200GZ
REMOVE/INSTALL BUTTON UNIT ON MULTIFUNCTION STEERING WHEEL - AR54.25-P-

2840GZ
MODEL 164, 251
Fig. 143: Identifying Button Unit On Multifunction Steering Wheel Remove/Install Components
Shown on the multifunction steering wheel removed with the Voice control system (VCS [SBS]) (code
813)
Remove/instal
Risk of poisoning and caustic burns caused by smoking. Wear acid-resistant AS54.10-
swallowing battery acid. Risk of injury caused gloves, clothing and glasses. Only Z-0001-
by burns to skin and eyes from battery acid or pour battery acid into suitable and 01A
when handling damaged lead-acid batteries appropriately marked containers.
AR54.10-
1 Disconnect ground cable from battery Model 164
P-0003GZ
AR54.10-
Model 251
P-0003RT
2 Move steering wheel (1) to horizontal position
AR91.60-
3 Remove airbag unit from steering wheel Model 164
P-0660GZ
AR91.60-
Model 251
P-0660RT
5 Unscrew bolt (2)
Remove the left steering wheel gear shifter
6 (S110/2) or right steering wheel gear shifter Do not disconnect electrically
(S111/2) to the rear
7 Remove bolts (3) Access from the back.
Remove left multifunction steering wheel button
8 group (S110) or remove right multifunction
steering wheel button group (S111)
REMOVING AND INSTALLING LIGHT SWITCH MODULE - AR54.25-P-3270GZ
MODEL 164

Fig. 144: Identifying Light Switch Module Remove/Install Components

Remove/instal
On vehicles with Keyless Go, code 889: Press Keyless Go

start/stop button repeatedly until ignition is switched off. Remove
transmitter key from vehicle and store it in a location beyond its
unit
Remove the side paneling of the
2
instrument panel
3 Undo screw (1, 2)
Lift the instrument panel (3) and
4 unclip rotary light switch (S1)
from the back on the left side
Unclip clips (arrows) on the right-
5 hand side and remove rotary light
switch (S1) forwards
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02GZ
Deactivate/activate easy entry/exit feature
2. Press the system selection button (S110s3) repeatedly until the "settings" menu appears in the
3. Press the scroll forward/back button (S110s1).
4. Press button + and -, adjustment of specific functions and volume control (S111s1), repeatedly until the
"comfort" menu item is marked.
Fig. 145: Identifying Scroll Forward/Back Button And Adjustment Of Specific Functions And
Volume Control With Multifunction Display
5. Press scroll forward/back button (S110s1) repeatedly until "activate access aid" appears in the
6. Press button + and -, adjustment of specific functions and volume control (S111s1), until the "off" menu
item is marked.
7. To activate the entry/exit aid, press the button + and -, adjustment of specific functions and volume
control (S111s1) repeatedly until the "steering column" or "steering column+seat" menu item is marked.
8. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02GZA
Activate tire pressure monitor.
Before activating tire pressure monitor: correct tire pressures of all wheels.
2. Press the system selection button (S110s3) repeatedly until the kilometer reading is displayed in the
3. Press the scroll forward/back button (S110s1) repeatedly until the tire pressure display appears in the
4. Press trip odometer reset button (A1s3).
Fig. 146: Identifying System Selection Button And Scroll Forward/Back Button With Odometer
Reset Button
5. Confirm the note in the multifunction display (A1p13) by pressing the button + and -, setting of specific
functions and volume control (S111s1)
The tire pressure display only appears after driving for a few minutes.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02GZC
Check engine oil level
The vehicle must be parked horizontal for at least 5 minutes with the engine switched off at operating
temperature. Otherwise there may be measurement errors
2. Press the system selection button (S110s3) repeatedly until the kilometer reading is displayed in the
3. Press scroll forward/back button (S110s1) repeatedly until "Engine oil level measurement in progress"
appears in multifunction display (A1p13).
Fig. 147: Identifying Multifunction Display And System Selection Button

4. Engine oil level is shown in multifunction display (A1p13).

5. Correct the engine oil level if necessary and check engine oil level again.
REMOVE/INSTALL INSTRUMENT CLUSTER - AR54.30-P-6015GZ
MODEL 164
Fig. 148: Identifying Instrument Cluster Remove/Install Components

MODIFICATION NOTES
26.7.06 Disconnect/connect battery ground line and carry out basic programming removed Steps 3 and 8
Remove/instal
Only when replacing the instrument cluster (A1).

Installation: Transfer basic data from STAR
DIAGNOSIS to instrument cluster (A1).
Transfer basic data from On vehicles with retrofitted iPOD and without
instrument cluster (A1) telephone the "Telephone" menu item in the

to STAR DIAGNOSIS "Instrument cluster" menu must be set from "NOT
1 PRESENT" to "PRESENT" with STAR
DIAGNOSIS, to enable the iPOD to be operated via the
multifunction steering wheel.
Connect STAR
AD00.00-P-
DIAGNOSIS and read
2000-04A
out fault memory
*WH58.30-
Z-1048-13A
Extend steering wheel
2
fully and lower fully
Insert pulling hooks into
slots (1) of instrument
3 Move pulling hooks upwards.
cluster (A1) and release
catch
Do not damage the dashboard.
Pull out instrument
4 Installation: Press the instrument cluster (A1) in
cluster (A1)
evenly.
Unplug electrical
connector (3) and
5
remove instrument
cluster (A1)
6
order
Read out fault memory *WH58.30-
and erase Z-1048-13A
Connect STAR
AD00.00-P-
DIAGNOSIS and read
2000-04A
out fault memory


Number Designation
REMOVE/INSTALL OUTSIDE TEMPERATURE INDICATOR SENSOR - AR54.30-P-6341GZ
MODEL 164
Shown on vehicle with headlamp cleaning system, code 600
Fig. 150: Identifying Outside Temperature Indicator Sensor Remove/Install Components

Remove/instal
AR88.40-P-
1 Open engine hood
1000GZ
Installation: Insert the temperature
Pull outside temperature display temperature
2 sensor in the bracket in the bumper
sensor (2) out of the bracket in the bumper
until it latches.
Detach outside temperature indicator connector
3 (2-pin) (1) and outside temperature display
temperature sensor (2)
REMOVE/INSTALL FANFARE HORNS - AR54.35-P-1555GZ
MODEL 164
Fig. 151: Identifying Fanfare Horns, Bolt And Electrical Connectors

Remove/instal
The removal and installation process

for the left and right fanfare horns is
identical
1 Open engine hood
Separate electrical connectors (1) on
2
left fanfare horn (H2)
Installation: Ensure that the left fanfare horn (H2) does
Unscrew bolt (2) and remove left
3 not make any contact with surrounding components. Maintain
fanfare horn (H2)
a minimum distance of at least 10 mm.
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN FRONT BUMPER - AR54.65-P-

0001GZ
MODEL 164 with CODE (220) Parktronic system (PTS)
Fig. 152: Identifying Parktronic System (PTS) Sensors In Front Bumper Remove/Install Components
Remove/instal
AR88.20-
P-2000GZ
3 Unlock the corresponding circlip (2) using the unlocking tool Unlocking tool Fig. 153
Take outer left front PTS ultrasonic sensor (B8/1) or center left front
PTS ultrasonic sensor (B8/2) or Inner left front PTS ultrasonic Installation:
4 sensor (B8/3) or inner right front PTS ultrasonic sensor (B8/4) or Check seal (3) and
center right front PTS ultrasonic sensor (B8/5) or outer right front replace if damaged.
PTS ultrasonic sensor (B8/6) out of the bumper

REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN REAR BUMPER - AR54.65-P-

0002GZ
MODEL 164 with CODE (220) Parktronic System (PTS)
Fig. 154: Identifying Parktronic System (PTS) Sensors In Rear Bumper Remove/Install Components
Remove/instal
AR88.20-P-
2200GZ
3 Unlock the corresponding circlip (2) using the unlocking tool Unlocking tool Fig. 153
Remove the outer right rear PTS ultrasonic sensor (B8/7) or
inner right rear PTS ultrasonic sensor (B8/8) or inner left rear Installation: Check
4 sealing ring (3) and
PTS ultrasonic sensor (B8/9) or outer left rear PTS ultrasonic
sensor (B8/10) from the bumper replace if damaged.

REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) WARNING DISPLAY IN

INSTRUMENT PANEL - AR54.65-P-0003GZ
Fig. 156: Identifying Parktronic System (PTS) Warning Display In Instrument Panel Remove/Install
Components
Remove/instal
Information on preventing damage AH54.00-

to electronic components due to All models P-0001-
Switch off ignition and remove the Keyless Go start/stop button repeatedly until
Carefully lever driver-side
Protect the instrument panel from scratches.
instrument panel PTS warning
2 indicator (A44/1) upwards out of Installation: Install the driver-side instrument
center cockpit speaker (centerfill) panel PTS warning indicator (A44/1) such that the
cover (2) LED indicators (arrows) face the interior.
Long wedge Fig. 117

REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) CONTROL UNIT - AR54.65-P-0006GZ

Fig. 158: Identifying Parktronic System (PTS) Control Unit

Fig. 159: Identifying Parktronic System (PTS) Control Unit Remove/Install Components
MODIFICATION NOTES
Disconnect/connect battery ground line and carry out basic programming Steps 2 and
26.7.06
removed 16
Remove/instal
AH54.00-P-
0001-01A
Read out coding from PTS control Only when replacing the PTS control
1 unit (N62) and if it can still be read out
unit (N62)
using STAR DIAGNOSIS.
*WH58.30-Z-
1048-13A
AR91.10-P-
2 Remove driver seat
1000GZ
AR68.30-P-
3 Remove left door sill moldings Front left and rear left. 4100GZ
AR68.30-P-
4 Remove paneling on B-pillar Bottom left. 4700GZ
5 Remove cover (2).
Remove bolt (4) and remove Installation: Use anchoring lug (5) with
7
anchoring lug (5) its positioning lug properly.
*BA68.50-P-
1001-03F
8 Fold down rear floor covering Left.

Remove clip (6) and remove air
9
duct (7)
Unscrew nuts (8) and remove the
10
left intermediate bottom (9)
11
from PTS control unit (N62)
Unscrew bolts (10) and remove
12
PTS control unit (N62)
14 Code PTS control unit (N62) Only when installing a new PTS control
unit (N62).
*WH58.30-Z-
1048-13A
CARGO RETAINERS

Number Designation
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) WARNING INDICATOR IN REAR

PASSENGER COMPARTMENT - AR54.65-P-0007GZ
MODEL 164 with CODE (220) Parktronic System (PTS)
Fig. 160: Identifying Parktronic System (PTS) Warning Indicator Remove/Install Components
Remove/instal
Unclip rear dome lamp PTS warning indicator (A44/3) by moving to Handle ribbon cable with
1
right (arrow A) and then remove by lowering (arrow B) care to prevent damage.
Disconnect electrical connector (1) from rear dome lamp PTS
2
warning indicator (A44/3)
REMOVE/INSTALL BACKUP CAMERA - AR54.65-P-0030GZ
MODEL 164, 251 with CODE (218) Backup camera
Fig. 161: Identifying Backup Camera Remove/Install Components

Remove/instal
AR72.20-P-
1 Remove liner on tailgate Model 164
3520GZ
AR72.20-P-
Model 251
3520RT
AR72.20-P-
2 Remove tailgate handle Model 164
3650GZ
AR72.20-P-
Model 251
3650RT
Separate backup camera connector
3 (B84/3x1) and loosen clip (1) from rear-end The clip (1) must be twisted for this.
door
Press in clip (2) and remove the backup

4 camera (B84/3) with bracket (3) outwards
from the rear-end door
On Japan version vehicles, code 498.
6 Calibration of backup camera (B84/3) If only the backup camera (B84/3) was AR54.65-P-
removed, the steering angle sensor does 0022GZ
not have to be calibrated.
REMOVE/INSTALL VOLTAGE SUPPLY OF BACKUP CAMERA - AR54.65-P-0032GZ
MODEL 164.1 with CODE (218) Backup camera except CODE (498) Japan version
Fig. 162: Identifying Backup Camera Remove/Install Components

Remove/instal

AH54.00-P-
0001-01A
(at least 2 m).
Remove cover and stowage
2 Only vehicles with stowage compartment
compartment
Press catch tab (1) and pull
backup camera voltage supply
3
module (N66/10) off bracket
(arrow) and remove
4
(2).

TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT
AND INSTRUMENTS - BE54.00-Z-9999AZ
MODEL all
Test values for battery, MODEL all BE54.10-P-1000-01A

voltage supply
Test values for generator MODEL 129, 163, 168, BE54.30-P-1000-01A
charge indicator lamp 170, 202, 203, 208, 210
TEST VALUES FOR BATTERY, VOLTAGE SUPPLY - BE54.10-P-1000-01A
All
MODIFICATION NOTES
24.2.06 Cold test current 12 Ah

BE54.10-P- Battery Acid density kg/dm 3 - > or = 1, 24 > or = 1, 24 > or = 1, 24
1001-01A test at 20 ° Maximum
C kg/dm3 - 0,04 0,04 0,04
permissible
difference
between
individual
battery cells
Load current A - 90 100 140
Load time s - 10 10 10
Voltage V - approx.10 approx.10 approx.10
1002-01A current

Number Designation 60 Ah 60 Ah 62 Ah
VRLA VRLA
BE54.10-P- Battery test at Acid density kg/dm3 - - > or =1, 24
1001-01A 20 °C Maximum kg/dm3 - - 0,04
permissible
difference
between
individual battery
cells
Load current A - - 190
Load time s - - 10
Voltage V - - approx.10
1002-01A current

VRLA VRLA
BE54.10-P- Battery test Acid density kg/dm3 - > or =1, 24 - -
1001-01A at 20 °C Maximum
kg/dm3 - 0,04 - -
permissible
difference
between
individual
battery cells
Load current A - 265 - -
Load time s - 10 - -
Voltage V - approx.10 - -
1002-01A current

Number Designation 90 Ah 95 Ah 100 Ah
VRLA VRLA
BE54.10-P- Battery test at Acid density kg/dm3 - - > or =1,24
1001-01A 20 °C Maximum kg/dm3 - - 0,04
permissible
difference
between
individual battery
cells
Load current A - - 300
Load time s - - 10
Voltage V - - approx.10
1002-01A current
MAINTENANCE
BATTERY (AGM/VRLA) - CHECK CONDITION - AP54.10-U-5453A
MODEL 129, 140, 163, 164, 170, 171, 199, 202, 203, 204, 208, 209, 210, 211, 215, 216, 220, 221, 230, 240,
463
Fig. 163: Identifying Battery (AGM/VRLA) Tester

Battery test with Midtronics MCR 717
With introduction of the new "Midtronics MCR 717" battery tester, a new testing method is applied for all types
of batteries used by DaimlerChrysler (wet cell and AGM/VRLA batteries).
AGM/VRLA batteries can no longer be tested with the previous methods. Additionally, the acid level can not
checked, do not open/ remove the cover from the AGM/VRLA battery.
In the future, measurement of the acid density, has been eliminated just as has testing the load for all types of
batteries.
This also eliminates the acid density test sheet when filling out warranty and goodwill claims. For this purpose
enter test code (indicated by tester) in text field "Message text" of the G/K proposal form in the event of a
negative test result
Important note:
Warranty/goodwill claims where a wet cell/lead calcium/AGM/VRLA battery is installed in the course of
repair, will now only be recognized when the test result (result code) is entered on the repair order and in the
message field on the warranty/goodwill claim.
Moreover, the hardcopy of the test report should be filed in the workshop.
Please review the MBUSA document: S-B-58.00/124 and the document (AR54.10-P-1129-01A) noted below,
before performing the battery test on AGM/VRLA batteries.
Check battery AR54.10-P-1129-01A

CHECK WARNING LAMPS, INDICATOR LAMPS AND INTERIOR LIGHTS - AP54.30-P-5452C
MODEL 164, 169, 171, 203, 204, 209, 211, 216, 219, 221, 230, 245, 251
Fig. 164: Identifying Instrument Cluster

Checking
Rectify defects against
separate repair order
1 Stop engine and switch on
ignition
2 Operate parking brake
3 Check that warning and
indicator lamps in
instrument cluster (A1) are
4 Switch on standing lamps
and check that
illumination of instrument
cluster (A1) is functioning
correctly
5 Switch off side light
6 Switch on lamps in Check the interior
passenger compartment lights, reading lamps and
and check that they are front and rear ambiance
functioning correctly illumination.
7 Switch off lamps in
passenger compartment
and switch off ignition

PERFORM VERSION CODING SUBSEQUENTLY - AZ54.65-P-0001-08Q

Number Designation
The described STAR DIAGNOSIS menu guidance corresponds to the German DAS version 09/2005 and
may deviate from other versions.
1. Connect STAR DIAGNOSIS to data link connector (X11/4).

2. Start DAS, enter vehicle model and select the "Control units" menu item.
3. In the "Control unit groups" menu, select the subgroups
 "Information and communication"
 "IC instrument cluster"
 "Control unit adaptations"
 "Special equipment"
one after the other.
4. In the "special equipment" menu, set the "TEL telephone" menu item from "not present" to "present" and
transfer the coding into the control unit
If the "TEL telephone" menu item is not present, proceed with operation step 6.
5. Finish and disconnect DAS.
Fig. 165: Identifying Data Link Connector

7. In the "customer specific settings" menu item set the "iPod: Operation via the multifunction steering
wheel" menu from "not possible" to "possible" and transfer coding into the control unit.
8. Finish and disconnect DAS.
TIGHTENING TORQUES: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - BA54.00-Z-9999AZ
MODEL all
Battery MODEL 163, 164, 171, BA54.10-P-1000-01C

203, 211, 215, 216, 219,
220, 221, 230, 240, 251,
463 ...
Battery MODEL 204 BA54.10-P-1000-01F
Fuse and relay box MODEL 171, 230 BA54.15-P-1000-01A
Fuse and relay box MODEL 163 BA54.15-P-1000-01B
Fuse and relay box MODEL 169 with BA54.15-P-1000-01C
ENGINE 266, 640
MODEL 245 with
ENGINE 266, 640
Fuse and relay box MODEL 164.1 /8 BA54.15-P-1000-01D
Fuse and relay box MODEL 251 BA54.15-P-1000-01E
Fuse and relay box MODEL 216, 221.0 /1 BA54.15-P-1000-01F
Cable duct MODEL 203 BA54.18-P-1000-01A
Control units/base module MODEL 171, 199.376 BA54.21-P-1000-01A
Jacket tube switch module MODEL 169, 245 BA54.25-P-1000-02A
Signaling system MODEL 171, 211, 230, BA54.35-P-1000-01A
240
Signaling system MODEL 199.376 BA54.35-P-1000-01C
Parktronic system MODEL 140 BA54.65-P-1000-01A
BATTERY - BA54.10-P-1000-01C
MODELS 163, 164, 171, 203, 211, 215, 216, 219.3, 220, 221, 230, 240, 251, 463
MODIFICATION NOTES
10.2.06 Nut, battery cable to Model 211
battery terminal
BATTERY
Number Designation Model 163 Model Model 171 Model 203
164.1/8
BA54.10-P- Nut, fuse in Nm - - - 4
1001-01C prefuse box
BA54.10-P- Nut, terminal Nm - - - 9
1002-01C 30 in prefuse
box
BA54.10-P- Adapter on Nm - - - -
1003-01C positive
battery
terminal
BA54.10-P- Nut, ground M8 Nm - - - -
1004-01C lead to battery
control unit
BA54.10-P- Bolt, battery M8 Nm - - - -
1005-01C control unit to
body
BA54.10-P- Nut, vehicle M6 Nm - - - -
1006-01C power supply
control unit to
bracket
BA54.10-P- Nut, line M6 Nm - - - -
1007-01C connection to
vehicle power
supply control M8 Nm - - - -
unit
BA54.10-P- Nut, line M6 Nm - - - -
rear prefuse M8 Nm - - - -
box
BA54.10-P- Nut, line M6 Nm - - 7 -
front prefuse M8 Nm - - 8 -
box
BA54.10-P- Nut, relay of M6 Nm - - - -
1010-01C additional
battery to
body
BA54.10-P- Nut, line M6 Nm - - - -
relay of
additional
battery
BA54.10-P- Nut, battery M6 Nm 6 6 6 6
1012-01C cable to
battery
terminal
1013-01C cable to
battery
terminal on
additional
battery
BA54.10-P- Nut, bracket M6 Nm - - - -
1014-01C for additional
battery
BA54.10-P- Nut to ground M6 Nm - - - -
1015-01C (taillamp in
luggage
compartment)
BA54.10-P- Nut to circuit M10 Nm - - - -
1016-01C 30Z terminal
block and
fuse box
BA54.10-P- Nut, ground Nm 18 - - -
1017-01C cable to body
BA54.10-P- Bolt, shield to Nm 20 - - -
1018-01C body
BA54.10-P- Nut for line Nm 15 - - -
1019-01C connector on
fire wall
BA54.10-P- Bolt to battery Nm - - - -
1020-01C cover
BA54.10-P- Bolt, battery Nm - - - -
1021-01C bearing
bracket to
front end
BA54.10-P- Nut, line M8 Nm - - - -
circuit 30 on
rear prefuse
box
BA54.10-P- Nut, power M8 Nm - - - -
1023-01C connection
circuit 30 to
front prefuse
box
BA54.10-P- Nut, battery M8 Nm - 24 - -
1024-01C retaining plate
to frame floor
BA54.10-P- Bolt, M6 Nm - 5 - -
1025-01C additional
battery
retaining
clamp
BA54.10-P- Nut for line M6 Nm - 7 - -
1026-01C connection on
battery
compartment M8 Nm - 21 - -
prefuse box
1027-01C bracket to
body M8 Nm - - - -
1028-01C ground line to
body
1029-01C cable to
battery
terminal on
additional
battery
BATTERY
Number Designation Model 211 Model 215 Model 216 Model
219.3
BA54.10-P- Nut, fuse in Nm - - - -
BA54.10-P- Nut, terminal Nm 7 - - 7
box
BA54.10-P- Adapter on Nm 7 - - 7
1003-01C positive
battery
terminal
BA54.10-P- Nut, ground M8 Nm 12 - - 11
control unit
BA54.10-P- Bolt, battery M8 Nm 20 - - 20
body
BA54.10-P- Nut, vehicle M6 Nm - - - -
control unit to
bracket
BA54.10-P- Nut, line M6 Nm - - 7 -
1007-01C connection to M8 Nm - - 10 -
vehicle power
supply control
unit
BA54.10-P- Nut, line M6 Nm 7 - - 7
rear prefuse M8 Nm 21 - - -
box
BA54.10-P- Nut, line M6 Nm 7 - - 7
front prefuse M8 Nm 14 - - -
box
BA54.10-P- Nut, relay of M6 Nm 8 - - 8
1010-01C additional
battery to
body
BA54.10-P- Nut, line M6 Nm 7 - - 7
relay of
additional
battery
1012-01C cable to
battery
terminal
BA54.10-P- Bolt, battery M6 Nm 3 - - -
1013-01C cable to
battery
terminal on
additional
battery
BA54.10-P- Nut, bracket M6 Nm 3 - - 3
battery
BA54.10-P- Nut to ground M6 Nm - 7 7 -
luggage
compartment)
BA54.10-P- Nut to circuit M10 Nm - 14 14 -
block and
fuse box
BA54.10-P- Nut, ground Nm - - - -
BA54.10-P- Bolt, shield to Nm - - - -
1018-01C body
BA54.10-P- Nut for line Nm - - - -

fire wall
1020-01C cover
BA54.10-P- Bolt, battery Nm - - - -
1021-01C bearing
bracket to
front end
BA54.10-P- Nut, line M8 Nm - - - 21
circuit 30 on
rear prefuse
box
BA54.10-P- Nut, power M8 Nm - - - 14
1023-01C connection
circuit 30 to
front prefuse
box
BA54.10-P- Nut, battery M8 Nm - - - -
to frame floor
BA54.10-P- Bolt, M6 Nm - - - -
1025-01C additional
battery
retaining
clamp
BA54.10-P- Nut for line M6 Nm - - - -
battery
compartment M8 Nm - - - -
prefuse box
BA54.10-P- Bolt, battery M6 Nm - - 8 -
1027-01C bracket to
body M8 Nm - - 23 -
BA54.10-P- Bolt, battery M8 Nm 20 - 16 20
body
BA54.10-P- Bolt, battery M6 Nm - - - 3
1029-01C cable to
battery
terminal on
additional
battery
Number Designation Model 220 Model 221 Model 230 Model 240
BA54.10-P- Nut, fuse in Nm - - - -
BA54.10-P- Nut, terminal Nm - - - -
box
BA54.10-P- Adapter on Nm 20 - - -
1003-01C positive
battery
terminal
BA54.10-P- Nut, ground M8 Nm - - - -
control unit
BA54.10-P- Bolt, battery M8 Nm 20 - - -
body
BA54.10-P- Nut, vehicle M6 Nm - - 6 -
control unit to
bracket
BA54.10-P- Nut, line M6 Nm - 7 7 -
vehicle power
supply control M8 Nm - 10 9 -
unit
BA54.10-P- Nut, line M6 Nm - - - -
rear prefuse M8 Nm - - - -
box
BA54.10-P- Nut, line M6 Nm - - - -
front prefuse M8 Nm - - - -
box
BA54.10-P- Nut, relay of M6 Nm - - - -
1010-01C additional
battery to
body
BA54.10-P- Nut, line M6 Nm - - - -
relay of
additional
battery
1012-01C cable to
battery
terminal
1013-01C cable to
battery
terminal on
additional
battery
BA54.10-P- Nut, bracket M6 Nm - - - -
battery
BA54.10-P- Nut to ground M6 Nm 7 - - -
luggage
compartment)
BA54.10-P- Nut to circuit M10 Nm 14 - - -
block and
fuse box
BA54.10-P- Nut, ground Nm - - - -
BA54.10-P- Bolt, shield to Nm - - - -
1018-01C body
BA54.10-P- Nut for line Nm - - - -
fire wall
1020-01C cover
BA54.10-P- Bolt, battery Nm - - - 20
1021-01C bearing
bracket to
front end
BA54.10-P- Nut, line M8 Nm - - - -
circuit 30 on
rear prefuse
box
BA54.10-P- Nut, power M8 Nm - - - -
1023-01C connection
circuit 30 to
front prefuse
box
BA54.10-P- Nut, battery M8 Nm - - - -
to frame floor
BA54.10-P- Bolt, M6 Nm - - - -
1025-01C additional
battery
retaining
clamp
BA54.10-P- Nut for line M6 Nm - - - -
battery
compartment M8 Nm - - - -
prefuse box
1027-01C bracket to
body M8 Nm - 23 - -
BA54.10-P- Bolt, battery M8 Nm - 16 - -
body
1029-01C cable to
battery
terminal on
additional
battery
BATTERY
Number Designation Model 251 Model 463.241
with code 979
BA54.10-P- Nut, fuse in Nm - -
BA54.10-P- Nut, terminal 30 Nm - -
1002-01C in prefuse box
BA54.10-P- Adapter on Nm - -
1003-01C positive battery
terminal
BA54.10-P- Nut, ground lead M8 Nm - -
1004-01C to battery control
unit
BA54.10-P- Bolt, battery M8 Nm - -
body
BA54.10-P- Nut, vehicle M6 Nm - -
control unit to
bracket
BA54.10-P- Nut, line M6 Nm - -
vehicle power
supply control M8 Nm - -
unit
1008-01C connection to rear
prefuse box M8 Nm - -
front prefuse box M8 Nm - -
BA54.10-P- Nut, relay of M6 Nm - -
1010-01C additional battery
to body
relay of additional
battery
BA54.10-P- Nut, battery cable M6 Nm 6 6
1012-01C to battery terminal
BA54.10-P- Bolt, battery cable M6 Nm - -
on additional
battery
BA54.10-P- Nut, bracket for M6 Nm 5 -
1014-01C additional battery
BA54.10-P- Nut to ground M6 Nm - -
luggage
compartment)
BA54.10-P- Nut to circuit 30Z M10 Nm - -
1016-01C terminal block
and fuse box
BA54.10-P- Nut, ground cable Nm - -
1017-01C to body
BA54.10-P- Bolt, shield to Nm - -
1018-01C body
BA54.10-P- Nut for line Nm - -
1019-01C connector on fire
wall
BA54.10-P- Bolt to battery Nm - 15
1020-01C cover
BA54.10-P- Bolt, battery Nm - -
1021-01C bearing bracket to
front end
circuit 30 on rear
prefuse box
BA54.10-P- Nut, power M8 Nm - -
1023-01C connection circuit
30 to front
prefuse box
BA54.10-P- Nut, battery M8 Nm 24 -
1024-01C retaining plate to
frame floor
BA54.10-P- Bolt, additional M6 Nm - -
1025-01C battery retaining
clamp
BA54.10-P- Nut for line M6 Nm - -
battery
compartment M8 Nm - -
prefuse box
1027-01C bracket to body M8 Nm - -
body
BA54.10-P- Bolt, battery cable M6 Nm - -
on additional
battery
FUSE AND RELAY BOX - BA54.15-P-1000-01D
Model 164
FUSE BOX
Number Designation Model 164.1/8 except Model
model 164.828 164.828
BA54.15-P-1001- Nut, electrical line (positive line) to
Nm 12 12
01D fuse and relay box
BA54.15-P-1002- Nut, pyrofuse to vehicle power supply
Nm - 18
01D control unit
MISCELLANEOUS NOTES
DISPOSE OF BATTERY - OS54.10-P-0001-01Z
All models
Information on recycling and disposing of lead-acid batteries and lead-gel batteries

 Old lead batteries up to 31.12.1998 are not classed as recyclable waste requiring special monitoring and
control. They bear the ISO symbol for return and recycling.
 The electrolyte, diluted sulfuric acid or acid gel should never be emptied in a careless manner. This
procedure must be carried out by specialist companies.
Picture shows ISO symbol for return and recycling
Fig. 166: Identifying ISO Symbol For Return And Recycling

 Old lead-acid batteries and lead-gel batteries should not be mixed together as this would make recycling
more difficult.
Always store lead-acid batteries horizontally and do not tilt during transport.
 Lead batteries can be taken back to the respective manufacturer, to sales outlets and to scrap metal dealers
and are recycled at lead recycling plants. Recycled lead is fed back into the production process. The
disposal of batteries as domestic waste is not permitted and is forbidden by law.
2006-2008 ENGINE Engine Cooling System - 164 Chassis
2006-2008 ENGINE
Engine Cooling System - 164 Chassis
GENERAL INFORMATION
NOTES ON COOLANT - AH20.00-N-2080-01A
All engines
Coolant composition
passenger car and commercial vehicle engines (normally)
50 water in % by volume and 50 corrosion/antifreeze agent in % by volume.
Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids
Tasks of corrosion and frost protection
 Corrosion and cavitation protection of all components in cooling system

 Antifreeze protection (frost protection)
 Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at
high coolant temperatures.
Antifreeze protection
50 % by volume of anticorrosion/ antifreeze agent offers antifreeze protection down to approx. -37 °C . A
higher concentration is only necessary if the ambient temperatures are even lower. 55 % by volume of
anticorrosion/antifreeze agent offers antifreeze protection down to approx. -45 °C
A concentration of more than 55 % by volume of anticorrosion/ antifreeze agent should not be used as the
maximum antifreeze protection is already reached. An even higher concentration once reduces antifreeze
protection and impairs heat dissipation. Reduced heat dissipation can lead to damage to components in the
cooling system or damage to the engine.
Water
Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always the
contents of dissolved substances in the water may be of significance for the occurrence of corrosion. If in doubt,
analyze the water.
For fresh water specifications refer to MB Specifications for Operating Fluids.
Period of use
The maximum permissible period of use of the coolant can be taken from the maintenance booklet; from the
applicable service/ maintenance sheet or the MB-Specifications for Operating Fluids respectively.
For the period of use for a varying coolant composition for CV engines, refer to MB Specifications for
Operating Fluids
Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the event of high
pollution or oil fouling levels, clean the cooling system, otherwise damage can occur to the components of the
cooling system.
Disposing of coolants
Pay attention to legal provisions and local wastewater regulations.
For workshops located in the Federal Republic of Germany refer to: "Environmental Protection Manual for
Automotive Repair Workshops"
Publisher: Association of Automotive Industry e.V. (VDA)
60625 Frankfurt am Main, Westendstrab 61
NOTES ON COOLANT LEVEL - AH20.00-P-1142-01GZB
Model 164
The coolant level must, on a cold engine, reach up to the marking (arrow) in the coolant expansion reservoir.
When the coolant is warm the coolant level in the coolant expansion reservoir is about 1 cm above the
marking (arrow).
Fig. 1: Locating Coolant Level Marking In Coolant Expansion Reservoir (Model 164)
Model 251
The coolant level must, on a cold engine, reach up to the marking (arrow) in the coolant expansion reservoir.
When the coolant is warm the coolant level in the coolant expansion reservoir is about 1 cm above the
marking (arrow).
Fig. 2: Locating Coolant Level Marking In Coolant Expansion Reservoir (Model 251)
BASIC KNOWLEDGE
HEATING SYSTEM SHUTOFF VALVE, COMPONENT DESCRIPTION - GF20.00-P-2200
Heating system shutoff valve, component description - GF20.00-P-2200AMG
Location
The shutoff valve is located at the rear on the right cylinder head.
Fig. 3: Identifying Heating System Shutoff Valve

Task
To warm up the engine quickly following a cold start, the shutoff valve can close off the coolant circuit to the
heating system.
Design
The shutoff valve consists of a solenoid with a coil resistance of around 12 ohms at 25°C.
Function
The heating system shutoff valve is actuated by the ME-SFI control unit (N3/10) via a ground signal if required.
The shutoff valve is opened without a current.
If the vehicle heater is switched on, the shutoff valve is always open (not actuated).
Component description for the heating system shutoff valve - GF20.00-P-2200V


Fig. 4: Identifying Heating System Shutoff Valve

Location
The heating system shutoff valve is located behind the left cylinder bank at the coolant outlet of the engine.
Fig. 5: Identifying Heating System Shutoff Valve Location

Task
To rapidly warm up the engine following a cold start, locks the coolant circuit to the heat exchangers. When the
vehicle heater is switched on, the valve is always open.
Function
The heating system shutoff valve is actuated by the ME control unit via a ground signal. The valve is opened
without a current. The coil resistance at room temperature is approx. 12 ohms.
COMPONENT DESCRIPTION FOR THE THREE-DISK THERMOSTAT VALVE - GF20.10-P-3160V


Location
The three-disk thermostat valve is located at the front of the engine.
Fig. 6: Identifying Three-Disk Thermostat Valve Location

Task
To control the coolant temperature in the range of approx. 80°C to 100°C. From approx. 110°C, to fully open
independently of the control.
Function
Voltage supply to terminal 87, actuation of the heating element on the ground side of the ME control unit. The
opening cross-section is set via the operating time.
COMPONENT DESCRIPTION FOR THE TWO DISC THERMOSTAT HEATER ELEMENT -

GF20.10-P-3161AMG

Location
The heating element is located on two-disk thermostat housing.
Fig. 7: Identifying Two-Disk Thermostat And Two-Disk Thermostat Element

Task
The heating element regulates the engine coolant temperature within the range from approx. 85°C to 105°C.
From a coolant temperature of about 105°C the coolant thermostat opens independently of actuation (limp-
home function).
By regulating the coolant temperature the following benefits result:
 Operating temperature is reached faster

 Reducing exhaust gas emissions
 Improved heat comfort.
Function
Actuation of the heating element takes via a PWM signal (pulse width modulated signal) from the ME-SFI
[ME] control unit (N3/10). The voltage is supplied through "terminal 87 M2e".
The open cross-section of the two-disk thermostat is determined via the duty cycle (frequency of the PWM
signal).
The limp-home function ensures that the two-disk thermostat is completely opened above around 105°C,
irrespective of actuation.
Function of two-disk thermostat, schematic

Fig. 8: Identifying Two-Disk Thermostat Function

Short-circuit operation position (A)
Heating element de-energized Coolant temperature < 100°C
Heating element energized Coolant temperature < 60°C
Mixed fuel operation position (C)
Heating element de-energized Coolant temperature 100 to 115°C
Heating element energized Coolant temperature 60 to 100°C
Radiator operation position (C)
Heating element de-energized Coolant temperature > 115°C
Heating element energized Coolant temperature > 100°C
Above about a 115°C coolant temperature the two-disk thermostat is fully open independently of energization
(limp-home function).
COMPONENT DESCRIPTION FOR THE ENGINE COOLANT CIRCULATION PUMP - GF20.10-P-

3200AMG
Location for model 164
The engine coolant circulation pump is located on the right next to the engine radiator.
Location on model 251
The engine coolant circulation pump is located on the outer right behind the bumper.
Fig. 9: Identifying Engine Coolant Circulation Pump

Location on model 216, 221
The engine coolant circulation pump is located on the lower right next to the engine radiator.
Fig. 10: Identifying Engine Coolant Circulation Pump, Engine Oil Heat Exchanger And Electric Air
Pump
Task
The engine coolant circulation pump ensures circulation of coolant through the engine oil heat exchanger.
Actuation for model 164, 251 (shown is the engine compartment at the right)
The engine coolant circulation pump is actuated for an excessively high engine oil temperature by the ME-SFI
[ME] control unit (N3/10) via the coolant circulation pump relay.
Fig. 11: Identifying Air Pump Relay, Starter Relay, Engine Compartment Fuse And Relay Box
Actuation for model 216, 221 (shown is the engine compartment at the front middle)
The engine coolant circulation pump is actuated for an excessively high engine oil temperature by the ME-SFI
[ME] control unit (N3/10) via the circulation pump relay.
Fig. 12: Identifying Circulation Pump Relay And Rear SAM Control Unit
TRANSMISSION OIL COOLER CIRCULATION PUMP, COMPONENT DESCRIPTION - GF20.10-

P-3201GZ
MODEL 164.120 /122 /822, 251.020 /022 /122 with TRANSMISSION 722.9
Shows model 164.1
Location
The transmission oil cooler circulation is located the front right on the longitudinal member and is connected to
the transmission oil cooler via an additional coolant circuit.
Fig. 13: Identifying Check Valve And Transmission Oil Cooler Circulation Pump
Task
The electrically operated transmission oil cooler circulation pump guarantees sufficient cooling of the
transmission oil when the coolant thermostat is closed or open slightly. It is actuated by the CDI control unit
(N3/9) according to the following parameters:
 transmission oil temperature > 85°C

 coolant temperature < 94°C
The electric engine and AC fan with integrated control (M4/7) is also actuated by the CDI control unit via pulse
width modulation (PWM) according to the following transmission oil temperature values:
 transmission oil temperature < or = 95°C, PWM signal = 10 %

 transmission oil temperature < or = 98°C, PWM signal = 25 %
 transmission oil temperature > 95°C and < 98°C, the PWM signal increases in a linear fashion by 5% at a
transmission oil temperature increase of 1°C
So that the coolant flow quantity through the engine radiator is not reduced at high engine
temperatures, whereby the cooling output would fall, a check valve is built into the additional coolant circuit.
SAFETY PRECAUTIONS
RISK OF INJURY - AS20.00-Z-0001-01A
Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the
pressure. Do not pour coolant into beverage bottles.
Wear protective gloves, protective clothing and eye protection.
Possible hazards
Risk of injury
When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a
risk of scalding from hot coolant which splashes out.
Danger of poisoning
If coolant is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach
pain, respiratory paralysis, unconsciousness, vomiting and cramps.
Safety precautions/instructions
 Allow cooling system to cool down to a coolant temperature of less than 90 °C.
 Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a
screwed coolant cap approx. 1/2 turn and release the pressure.
Wear protective gloves, protective clothing and eye protection.
Do not pour coolant into beverage bottles.
First aid measures
 Rinse affected skin with large quantities of cold water and cover with sterile bandages.
 Allow the person affected to drink plenty of water with the addition of medicinal charcoal.
 If the person has suffered severe burns or has swallowed coolant, contact a doctor.
TESTING & REPAIR

INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010
Inspect cooling system for leaks - AR20.00-P-1010GZ
Shown on model 164 with engine 113

Fig. 14: Identifying Coolant Expansion Reservoir, Tester Cap And Pressure Pump
Checking
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning caused by 0001-01A
swallowing
Wear protective gloves, protective
clothing and safety glasses.
Unscrew the cap of the coolant expansion Unscrew cap slowly and
1
reservoir (1) relieve excess pressure.
If the antifreeze share of the
Check engine coolant level and antifreeze coolant is too small, either antifreeze
2
content of coolant and correct if necessary must be added or the coolant must be
replaced: ?
AR20.00-P-
Drain coolant, fill.
1142GZ
BB00.40-P-
Coolant specifications Sheet 310.1
0310-01A
Anticorrosion/antifreeze agents (Sheet BB00.40-P-
Sheet 325.0
325.0) 0325-00A
Screw test cap (2) onto coolant expansion
3 Fig. 15
reservoir (1).
4 Connect pressure pump (3) at test cap (2) Fig. 16
To prevent damage to cooling *BE20.30-
5 Apply test pressure to cooling system system, do not exceed stated test
P-1005-01A
pressure.
Check hose clamps for condition and Tighten hose clamps as
6
seating necessary; replace if necessary.
Check coolant hoses and heater hoses and

Replace coolant hoses and
7 their connecting points for condition and
heater hoses if required.
coolant loss
Unscrew test cap (2) at coolant expansion Unscrew test cap (2) slowly
8
reservoir (1). and relieve excess pressure.
Remove pressure pump (3) from test cap
9
(2)
Screw cap onto coolant expansion reservoir
10
(1)
RADIATOR OR EXPANSION RESERVOIR CAP

Number Designation 2-stage cap
BE20.30-P-1005-01A Test pressure for pressure-testing cooling system bar gage 1.4
Fig. 15: Identifying Test Cap (210 589 00 91 00)

Fig. 16: Identifying Pressure Pump (124 589 24 21 00)

Inspect cooling system for leaks - AR20.00-P-1010GZS

Fig. 17: Identifying Coolant Expansion Reservoir, Tester Cap And Pressure Pump
Checking
Risk of injury to skin and eyes caused by Open cap slowly and release the
AS20.00-Z-
scalding from contact with hot coolant spray. pressure. Do not pour coolant into
0001-01A
Risk of poisoning from swallowing coolant. beverage containers.
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Turn the cap slowly and
2 Open cap of coolant expansion reservoir (1) release the excess pressure, then
unscrew the cap.
If the antifreeze share of
Check coolant level and antifreeze content the coolant is too small, either
3
coolant. antifreeze must be added or the
coolant must be replaced: ?
AR20.00-P-
Drain, fill system with coolant.
1142GZS
AH20.00-N-
Notes on coolant All engines
2080-01A
AH20.00-P-
Note on coolant level
1142-01GZB
BB00.40-P-
0310-01A
Sheet 325.0
325.0) 0325-00A
Screw test cap (2) onto coolant expansion
4 Test cap Fig. 15
reservoir (1).
5 Connect up pressure pump (3) at test cap (2) Pressure pump Fig. 16
To prevent damage to the
6 Discharge cooling system with test pressure cooling system, do not exceed the
stated test pressure
Test pressure for pressure-testing *BE20.30-P-
cooling system 1005-01A
Retighten or replace hose
7 Check hose clamps for condition and seating
clamp as required.
Hose clamp pliers Fig. 20
*WH58.30-
6 mm socket hexagon Z-1001-06A
*WH58.30-
Check coolant hoses and heater hoses and
Replace coolant hoses and heater
8 their connecting points for condition and
hoses if required.
coolant loss
Unscrew test cap (2) at coolant expansion Slowly unscrew test cap (2)
9
reservoir (1). and reduce the excess pressure.
10 Remove pressure pump (3) at test cap (2)
Screw on the cap of the coolant expansion
11
reservoir (1)
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
CAP FOR RADIATOR OR EXPANSION RESERVOIR

BE20.30-P-1005-01A Test pressure for pressure-testing cooling system bar gage 1.4


Fig. 20: Identifying Hose Clamp Pliers (003 589 03 37 00)


Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive
DRAIN/FILL IN COOLANT - AR20.00-P-1142
Drain/fill in coolant - AR20.00-P-1142GZ

Fig. 21: Identifying Radiator Drain Plug And Crankcase Drain Plug
MODIFICATION NOTES
26.1.06 Cooling system *BF20.00-P-1001-02X
Drain
smoking.
Risk of poisoning and caustic burns caused by
Wear acid-resistant gloves, AS54.10-Z-
swallowing battery acid. Risk of injury caused
clothing and glasses. Only pour 0001-01A
by burns to skin and eyes from battery acid or
when handling damaged lead-acid batteries
Do not open cooling system
unless coolant temperature is
below 90°C. Open cap slowly
Risk of injury to skin and eyes caused by and release the pressure. Do not
AS20.00-Z-
scalding from contact with hot coolant spray. pour coolant into beverage
0001-01A
Risk of poisoning caused by swallowing coolant. containers.
protective clothing and safety
glasses.
Unscrew cooling
Unscrew cooling system cap at coolant expansion
1 system cap slowly and relieve
reservoir
excess pressure.
AR61.20-P-
2 Remove bottom engine compartment paneling Model 164
1105GZ
Model 251
AR61.20-P-
1105RT
Drain coolant from radiator
Slide collector siphon hose onto fitting (2) at The fitting (2) is located
3
radiator at the bottom left of the radiator.
Loosen siphon hose (1) at radiator and drain Observe regulations for
4
coolant. disposal of coolant.
Drain coolant at crankcase
When draining coolant at right
5 Disconnect ground cable for battery
drain plug (4) on crankcase
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
Notes on battery
0001-01A
Loosen left or right drain plug (3, 4) at crankcase
6
until it can be turned manually
Push drain hose on left or right drain plug (3, 4)
7
onto crankcase
Loosen left or right drain plug (3, 4) on crankcase Follow regulations for
8
further by hand and drain off coolant disposal of coolant.
Filling
Tighten drain plug (1) at radiator and detach After coolant has been drained at
9.1
siphon hose from fitting (2) radiator
Detach drain hose and tighten crankcase drain After coolant has been drained at
9.2
plug at left and right (3, 4) crankcase
*BA20.00-
P-1001-02B
AR20.00-P-
10 Pour in coolant and bleed cooling system Reuse clean coolant. 1142-04A
Fig. 15
Fig. 26
AH20.00-P-
Notes on coolant level 1142-
01GZB
AH20.00-N-
Notes on coolant
2080-01A
BB00.40-P-
0310-01A
BB00.40-P-
Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0
0325-00A
*BF20.00-
Model 164 P-1001-02K
*BF20.00-
Model 251 P-1001-02X

AR20.00-P-
11 Inspecting cooling system for leaks
1010GZ
After tightening crankcase drain
12 Attach ground lead to battery
plug on right (4).
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
After disconnecting ground line
on battery
Stored faults which may
Connect STAR DIAGNOSIS and read fault be caused by disconnecting
13
memory cables or by simulation during
test operations, must be erased
in the fault memory after
AR61.20-P-
14 Install lower engine compartment paneling Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
Unscrew cooling
Screw cooling system cap onto coolant expansion
15 system cap slowly and relieve
reservoir
excess pressure.
ENGINE COOLING, GENERAL

Number Designation Engine 112,
113.940/941/942/943/944/945/946/948/960/961/963/964/965/966/967/968/971/980/981
Coolant
BA20.00-
drain
P-1001- Nm 12
plug to
02B
crankcase
COOLING SYSTEM
Number Designation Engine 113.964 in
model 164
Total filling capacity Liters approx. 10.00
Capacity of anticorrosion/antifreeze agent
Liters approx. 5.00
down to -37°C
BF20.00-P- Cooling
Filling capacity of anticorrosion/antifreeze
1001-02K system Liters approx. 5.5
down to -45°C
Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM
Number Designation Model 251 with
engine 113
Total filling capacity Liters 6.6
Liters 3.3
down to -37°C
BF20.00-P- Cooling Liters 3.6
down to -45°C
1001-02X system
BB00.40-P-0310-
Sheet
01A
Service specifications
BB00.40-P-0325-
Sheet
00A

Fig. 23: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Pour in coolant and bleed cooling system - AR20.00-P-1142-04A

Fig. 24: Identifying Tester Cap (169 589 00 91 00)


Usage test cap:
Test cap 169 589 00 91 00 for model 168
Test cap 210 589 00 91 00 for all except model 168
Only vent cooling system for a cold engine.
1. Unscrew cooling system closure cap (10) and screw on test cap (2) at coolant expansion reservoir (1).
2. Attach control unit (3) to test cap (2).
3. Attach venturi nozzle (9) to control unit (3).

4. Close drain valve (8) and feed valve (7).
Fig. 27: Identifying Drain Valve, Venturi Nozzle, Control Unit, Feed Valve And Coolant Expansion
Reservoir
5. Attach feed hose (4) of the coolant to coolant reservoir (4a).
To avoid suctioning in of air put at least 2 l more coolant in the coolant reservoir (4a) than the
maximum filling capacity of the cooling system.
6. Guide waste air hose (5) into an empty container (5a).

7. Connect compressed-air hose (6) to venturi nozzle (9) and apply pressure.
8. Open the drain valve (8).
A vacuum is created in cooling system.
9. Open feed valve (7) until feed hose (4) has filled with coolant.
10. Close drain valve (8) if display of the control unit (3) is in the green area.
11. Detach compressed air hose (6) from the venturi nozzle (9) and monitor whether vacuum remains stable
for 30 seconds.
If this is not the case, check hoses and connections and if necessary, repair and create a new
vacuum.
12. Open feed valve (7).
The cooling system is filled.
13. Open drain valve (8) if coolant is no longer suctioned.

14. Remove control unit (3) along with all connections and test cap (2).
15. Fill coolant up to bottom edge of filler neck of coolant expansion reservoir (1).
16. Screw cooling system closure cap (10) onto coolant expansion reservoir (1).
Drain/fill in coolant - AR20.00-P-1142GZS
Fig. 28: Identifying Radiator Drain Plug And Crankcase Drain Plug
Drain
Keep body parts and limbs well AS00.00-Z-
or crushed when removing, installing or aligning
clear of moving parts. 0011-01A
hoods, doors, trunk lids, tailgates or sliding roof.
Align vehicle between columns

Risk of death caused by vehicle slipping or of lifting platform and position AS00.00-Z-
toppling off the lifting platform. four support plates at lifting 0010-01A
platform support points
specified by vehicle
manufacturer.
below 90°C. Open cap slowly
Risk of injury to skin and eyes caused by and release the pressure. Do not
AS20.00-Z-
scalding from contact with hot coolant spray. pour coolant into beverage
0001-01A
Risk of poisoning from swallowing coolant. containers.
glasses.
AS54.10-Z-
swallowing battery acid. Risk of injury caused clothing and glasses. Only pour
0001-01A
by burns to skin and eyes from battery acid or battery acid into suitable and
when handling damaged lead-acid batteries appropriately marked
containers.
AH54.10-P-
0001-01A
When draining the
1 Disconnect ground line from battery coolant at the right drain plug
(4) on the crankcase
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Unscrew cap slowly
3 Open cap on coolant expansion reservoir and release excess pressure,
then screw down cap.
AR61.20-P-
4 Remove engine compartment paneling Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
Drain coolant from radiator
Slide collector siphon hose onto fitting (2) at The fitting (2) is
5 located at the bottom left of the
radiator
radiator.
Catch coolant with
Loosen siphon hose (1) at radiator and drain suitable vessel.
6
coolant. Observe regulations for
disposal of coolant.
Drain coolant at crankcase

AR88.10-P-
7 Remove fender liner on the right and left Model 164
1300GZ
AR88.10-P-
Model 251
1300RT
Only loosen drain
Loosen crankcase drain plug on the left (3) and
8 screws until these can be turned
crankcase drain plug on the right (4)
by hand.
9 Push drain hose onto crankcase drain screws
Catch coolant with
Continue to loosen crankcase drain screws by suitable vessel.
10
hand and drain of coolant Observe regulations for
disposal of coolant.
Filling
Tighten drain plug (1) at radiator and detach After the coolant is drained at
11
siphon hose from fitting (2) the radiator
After the coolant is drained at
12 Detach drain hose from crankcase drain screws
the radiator
Tighten crankcase drain plug on the left (3) and *BA03.20-P-
13
crankcase drain plug on the right (4) 1009-01J
Reuse the clean AR20.00-P-
14 Pour in coolant and bleed cooling system
coolant. 1142-04A
AH20.00-N-
2080-01A
AH20.00-P-
Notes on coolant level
1142-01GZB
BB00.40-P-
0310-01A
BB00.40-P-
0325-00A
*BF20.00-P-
Cooling system 1001-02U
Test cap Fig. 15
Pressure pump Fig. 16
Cooler vacuum filling Fig. 26
device
15 Screw cap onto coolant expansion reservoir
AR20.00-P-
16 Inspect cooling system for leaks
1010GZS
*WH58.30-
7 mm socket hexagon *WH58.30-
Z-1002-06A
AR61.20-P-
17 Install lower engine compartment paneling
1105GZ
After tightening the
18 Connect ground lead to battery crankcase drain plug on the
right (4).
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
Only if the ground lead
19 Perform basic programming of the battery was
disconnected.
AR00.19-P-
Model 164
0200GZ
AR00.19-P-
Model 251
0200RT
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT

BA03.20-P-1009-01J Drain plug for coolant Nm 15
COOLING SYSTEM
Number Designation Engine 156 in model
164, 251
Total filling capacity approx.Liters 7.5
Up to -37°C 50/50
BF20.00-P-1001- Cooling Antifreeze/water
Up to -45°C 55/45
02U system
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A




Number Designation
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM - AR20.00-Z-
9113AB
ENGINE 113
Inspect cooling system for leaks ENGINES 113, 272, 273 AR20.00-P-1010GZ
in MODEL 164
Inspect cooling system for leaks ENGINE 111, 112, 113, AR20.00-P-1010HA
120, 137, 271, 275, 285,
601, 602, 603, 604, 605,
606, 611, 612, 613, 628,
646, 647, 648...
Inspect cooling system for leaks ENGINE 111, 112, 113, AR20.00-P-1010P
271, 611, 612, 646...
Inspecting the cooling system for ENGINE 272.967 in AR20.00-P-1010RT
leaks MODELS 251.065 /165
ENGINE 113.971 in
MODELS 251.075/175
Inspect cooling system for leaks ENGINE 112, 113... AR20.00-P-
1010RVK
Inspect cooling system for leaks ENGINE 272.964 in AR20.00-P-1010TX
MODEL 219.356
ENGINE 113.967 in
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Drain/fill in coolant ENGINE 113, 272, 273 AR20.00-P-1142GZ
in MODEL 164
Drain/fill in coolant ENGINE 112, 113, 137... AR20.00-P-1142HA
Drain/fill in coolant ENGINE 112, 113... AR20.00-P-1142PV
Drain/fill in coolant ENGINE 272.967 in AR20.00-P-1142RT
MODELS 251.065 /165
ENGINE 113.971 in
MODELS 251.075/175
Drain/fill in coolant ENGINE 112, 113... AR20.00-P-
1142RVK
Drain/fill in coolant ENGINE 113.967 in AR20.00-P-1142TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Venting air from the low ENGINE 112, 113... AR20.00-P-
temperature circuit 1145RVK
Remove/install coolant pump ENGINE 112, 113... AR20.10-P-1271B
Remove/install coolant pump ENGINE 113.964 in AR20.10-P-1271GZ
MODEL 164.175
Remove/install coolant pump ENGINE 112, 113... AR20.10-P-1271R
Remove/install coolant pump ENGINE 113.971 in AR20.10-P-1271RT
MODELS 251.075 /175
Remove/install coolant pump ENGINE 113... AR20.10-P-

1271RVK
Remove/install coolant pump ENGINE 113.967 in AR20.10-P-1271TY
MODEL 219.375
Remove, install coolant pump ENGINE 113.990 in AR20.10-P-1271TZ
MODEL 219.376
Testing coolant thermostat ENGINE 112, 113... AR20.10-P-2455AV
Test coolant thermostat ENGINE 113.964 in AR20.10-P-2455GZ
MODEL 164.175
Test coolant thermostat ENGINE 113.971 in AR20.10-P-2455RT
MODEL 251.075/175
Testing coolant thermostat ENGINE 113.995 in AR20.10-P-
MODEL 230.472 2455RVK
Test coolant thermostat ENGINE 113.967 in AR20.10-P-2455TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Test coolant thermostat ENGINE 113.989 in AR20.10-P-2455VT
MODEL 171.473
Remove/install coolant thermostat ENGINE 112, 113... AR20.10-P-2460B
Remove/install coolant thermostat ENGINE 113.964 in AR20.10-P-2460GZ
MODEL 164.175
Remove/install coolant thermostat ENGINE 113.971 in AR20.10-P-2460RT
MODEL 251.075/175
Remove/install coolant thermostat ENGINE 113... AR20.10-P-
2460RVK
Remove/install coolant thermostat ENGINE 113.967 in AR20.10-P-2460TY
MODEL 219.375
Remove/install coolant thermostat ENGINE 113.990 in AR20.10-P-2460TZ
MODEL 219.376
Remove/install radiator ENGINE 112, 113... AR20.20-P-3865AB
Remove/install radiator ENGINES 112, 113 in AR20.20-P-3865AV
MODEL 129
Remove/install radiator ENGINE 113.964 in AR20.20-P-3865GZ
MODEL 164.175
Remove/install the radiator ENGINE 112, 113... AR20.20-P-3865HC
Remove/install radiator ENGINE 112 in AR20.20-P-3865HD
MODELS 210, 208, 202
ENGINE 113 in
MODELS 210, 208, 202
Removing/installing the radiator ENGINE 112, 113... AR20.20-P-3865PV
Remove/install radiator ENGINE 112, 113, 275... AR20.20-P-3865R
Remove/install radiator ENGINE 272.967 in AR20.20-P-3865RT
MODEL 251.065/165
ENGINE 113.971 in
MODEL 251.075/175
Remove/install radiator ENGINE 112, 113, 628... AR20.20-P-3865TV
Remove/install radiator ENGINE 113.967 in AR20.20-P-3865TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Test cooling system cap ENGINE 112, 113... AR20.30-P-4300FV
Testing the cooling system cap ENGINE 113.964 in AR20.30-P-4300GZ
MODEL 164.175
ENGINE 272.967 in
MODEL 164.186
Check cooling system cap ENGINE 111, 112, 113, AR20.30-P-4300P
271, 611, 612, 613, 628,
642...
Testing the cooling system cap ENGINE 272.967 in AR20.30-P-4300RT
MODELS 251.065 /165
ENGINE 113.971 in
MODELS 251.075/175
Test coolant gage ENGINE 111, 112, 113, AR20.30-P-4460A
156...
Testing the coolant gage ENGINE 113.964 in AR20.30-P-4460GZ
MODEL 164.175
ENGINE 272.967 in
MODEL 164.186
Test coolant gage ENGINE 113.971 in AR20.30-P-4460RT
MODEL 251.075/175
Remove/install expansion ENGINES 113, 272, 273 AR20.30-P-4950GZ
reservoir in MODEL 164
Remove/install expansion ENGINE 113, 156, 272, AR20.30-P-4950RT
reservoir 642 in MODEL 251
Remove/install expansion ENGINE 113.967 in AR20.30-P-4950TY
reservoir MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
Remove/install electric fan ENGINE 113.988 in AR20.40-P-5000AC
MODELS 203.076 /276
with TRANSMISSION
722.636
Remove/install electric fan ENGINE 113.965 in AR20.40-P-5000GH
MODEL 163.175
ENGINE 113.981 in
MODEL 163.174
Remove/install electric fan ENGINE 113.964 in AR20.40-P-5000GZ

MODEL 164.175
Remove/install electric fan ENGINE 112, 113... AR20.40-P-5000PV
Remove/install electric fan ENGINE 113.971 in AR20.40-P-5000RT
MODEL 251.075/175
Remove/install electric fan ENGINE 112, 113, 646, AR20.40-P-5000T
647, 648...
Remove/install electric fan ENGINE 113.967 in AR20.40-P-5000TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install electric fan ENGINE 113, 271, 272... AR20.40-P-5000V
Disassemble/reassemble fan ENGINE 111, 112, 113, AR20.40-P-5100PQ
271, 611, 612, 646...
Disassemble fan and reassemble ENGINE 113.967 in AR20.40-P-5100TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install viscous fan clutch ENGINE 112, 113... AR20.40-P-5660C
Remove/install fan shroud ENGINE 112, 113... AR20.40-P-6800AB
Remove/install fan shroud ENGINE 112, 113... AR20.40-P-6800TB
Remove, install fan shroud ENGINE 113.990 in AR20.40-P-6800TC
MODEL 211.076/276
ENGINE 156.983 in
MODEL 211.077/277
Removing and installing the fan ENGINE 113.967 in AR20.40-P-6800TY
shroud MODEL 219.375
Remove/install fan shroud ENGINE 113.990 in AR20.40-P-6800TZ
MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
Remove/install fan shroud ENGINE 113.989 in AR20.40-P-6800VT
MODEL 171.473
9156AB
ENGINE 156
Inspect cooling system ENGINE 156 in MODEL AR20.00-P-1010GZS

for leaks 164, 251
Checking cooling system ENGINE 156.984 in AR20.00-P-1010SMG
for leaks MODEL 216.377,
221.077 /177
Inspect cooling system ENGINE 156, 272, 273, AR20.00-P-1010SX

for leaks 275, 642 in MODEL 221
ENGINE 156, 273, 275
in MODEL 216
Inspect cooling system ENGINE 156.982 in AR20.00-P-1010TMG
for leaks MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Drain/fill in coolant ENGINE 156 in MODEL AR20.00-P-1142GZS
164, 251
Drain/fill in coolant ENGINE 156 in MODEL AR20.00-P-1142SMG
216, 221
Drain/fill in coolant ENGINE 156.982 in AR20.00-P-1142TMG
MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Remove/install coolant ENGINE 156 in MODEL AR20.10-P-1271GZS
pump 164, 251
Remove/install coolant ENGINE 156 in MODEL AR20.10-P-1271SMG
pump 216, 221
Remove/install coolant ENGINE 156.982 in AR20.10-P-1271TMG
pump MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Test coolant thermostat ENGINE 156 in MODEL AR20.10-P-2455GZS
164, 251
Test coolant thermostat ENGINE 156 in MODEL AR20.10-P-2455SMG
216, 221
Test coolant thermostat ENGINE 156.982 in AR20.10-P-2455TMG
MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Remove/install coolant ENGINE 156 in MODEL AR20.10-P-2460GZS
thermostat 164, 251
Remove/install coolant ENGINE 156 in MODEL AR20.10-P-2460SMG
thermostat 216, 221
Remove/install coolant ENGINE 156.982 in AR20.10-P-2460TMG
thermostat MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install radiator ENGINE 156 in MODEL AR20.20-P-3865GZS

164, 251
Remove/install radiator ENGINE 156.982 in AR20.20-P-3865QBS
MODEL 209.377 with
CODE (P98) Black
Series
Remove/install radiator ENGINE 156, 272, 273 AR20.20-P-3865SX
in MODEL 221
ENGINE 156, 273 in
MODEL 216
Remove/install radiator ENGINE 156 ... AR20.20-P-3865TMG
Testing cooling system ENGINE 156 in MODEL AR20.30-P-4300GZS
cap 164, 251
Remove/install coolant ENGINE 272, 642 in AR20.30-P-4392PI
level switch MODEL 203 ENGINE
156, 272, 273, 642 in
MODEL 209
Test coolant gage ENGINE 111, 112, 113, AR20.30-P-4460A
156 ...
Remove/install expansion ENGINE 156 in MODEL AR20.30-P-4950GZS
reservoir 164
Remove/install expansion ENGINE 272, 642 in AR20.30-P-4950PI
reservoir MODEL 203 ENGINE
156, 272, 642 in MODEL
209
reservoir 273, 642 in MODEL 251
Remove/install expansion ENGINE 156, 272, 273, AR20.30-P-4950SX
ENGINE 156, 273, 275
in MODEL 216
Remove/install expansion ENGINE 272, 273 in AR20.30-P-4950TS
reservoir MODELS 211, 219
ENGINE 156 in MODEL
211
Remove/install expansion ENGINE 113.967 in AR20.30-P-4950TY
ENGINE 113.990 in
MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
Remove/install electric ENGINE 156 in MODEL AR20.40-P-5000GZS
fan 164, 251
Remove/install electric ENGINE 156, 272, AR20.40-P-5000QB
fan 273 ...
Remove/install electric ENGINE 156 in MODEL AR20.40-P-5000SMG

fan 216, 221
Remove/install fan unit ENGINE 156.982 in AR20.40-P-5050QBS
MODEL 209.377 with
CODE (P98) Black
Series With electrical
radiator fan
Remove, install fan ENGINE 113.990 in AR20.40-P-6800TC
shroud MODEL 211.076 /276
ENGINE 156.983 in
MODEL 211.077 /277
Remove/install fan ENGINE 113.990 in AR20.40-P-6800TZ
shroud MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
9272AB
ENGINE 272
Inspect cooling system for ENGINE 271, 272, AR20.00-P-1010CW

leaks 642, 646 in MODEL
204
Inspect cooling system for ENGINE 272, 273 in AR20.00-P-1010GZC
leaks MODEL 164, 251
Inspect cooling system for ENGINE 272, 273 ... AR20.00-P-1010QB
leaks
Inspect cooling system for ENGINE 272, 273 in AR20.00-P-1010RX
leaks MODEL 230
Inspect cooling system for ENGINE 156, 272, AR20.00-P-1010SX
leaks 273, 275, 642 in
MODEL 221 ENGINE
156, 273, 275 in
MODEL 216
Inspect cooling system for ENGINE 272, 273 in AR20.00-P-1010TS
Inspect cooling system for ENGINE 272.964 in AR20.00-P-1010TX
leaks MODEL 219.356
ENGINE 113.967 in
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Inspect cooling system for ENGINE 272.942, AR20.00-P-1010V
leaks 271.944, 272.963 in
MODEL 171
Drain/fill in coolant ENGINE 271, 272, AR20.00-P-1142CW
642, 646 in MODEL
204
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142GZC
MODEL 164, 251
Drain/fill in coolant ENGINE 272, 273 ... AR20.00-P-1142QB
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142RX
MODEL 230
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142SX
MODEL 221 ENGINE
273 in MODEL 216
Drain, fill coolant ENGINE 272, 273 in AR20.00-P-1142TS
MODEL 211, 219
Drain/fill in coolant ENGINE 272.964 in AR20.00-P-1142TX
MODEL 219.356
Drain/fill in coolant ENGINE 272.942 in AR20.00-P-1142VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install coolant pump ENGINE 272 in AR20.10-P-1271CV
MODEL 204
Remove/install coolant pump ENGINE 272, 273 in AR20.10-P-1271GZA
MODEL 164, 251
Remove, install coolant pump ENGINE 272, 273 ... AR20.10-P-1271QB
Remove/install coolant pump ENGINES 272, 273 in AR20.10-P-1271RX
MODEL 230
Remove/install coolant pump ENGINE 272, 273 in AR20.10-P-1271SX
MODEL 221 ENGINE
273 in MODEL 216
Remove, install coolant pump ENGINE 272, 273 in AR20.10-P-1271TS
MODEL 211, 219
Remove/install coolant pump ENGINE 272.942 in AR20.10-P-1271VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Test coolant thermostat ENGINE 272 in AR20.10-P-2455CV
MODEL 204
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455GZA
MODEL 164, 251
Test coolant thermostat ENGINE 272, 273 ... AR20.10-P-2455QB
Testing coolant thermostat ENGINE 272, 273 in AR20.10-P-2455RX
MODEL 230
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455SX
MODEL 221 ENGINE

273 in MODEL 216
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455TS
MODEL 211, 219
Test coolant thermostat ENGINE 272.942 in AR20.10-P-2455VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install coolant ENGINE 272 in AR20.10-P-2460CV
thermostat MODEL 204
Remove/install coolant ENGINE 272, 273 in AR20.10-P-2460GZA
thermostat MODEL 164, 251
Remove, install coolant ENGINE 272, 273 ... AR20.10-P-2460QB
thermostat
Remove/install coolant ENGINE 272, 273 in AR20.10-P-2460RX
Remove/install coolant ENGINE 272, 273 in AR20.10-P-2460SX
thermostat MODEL 221 ENGINE
273 in MODEL 216
Remove, install coolant ENGINE 272, 273 in AR20.10-P-2460TS
Remove/install coolant ENGINE 272.942 /963 AR20.10-P-2460VA
thermostat in MODEL 171 Three-
disk thermostat
Remove/install radiator ENGINE 271, 272, AR20.20-P-3865CW
642, 646 in MODEL
204
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865GZA
MODEL 164
Remove/install radiator ENGINE 272, 273 ... AR20.20-P-3865QB
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865RTC
MODEL 251
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865RX
MODEL 230
in MODEL 221
ENGINE 156, 273 in
MODEL 216
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865TS
MODEL 211, 219
Remove/install radiator ENGINE 272.964 in AR20.20-P-3865TX
MODEL 219.356
Remove/install radiator ENGINE 272.942 /963 AR20.20-P-3865VA
in MODEL 171
Testing the cooling system cap ENGINE 113.964 in AR20.30-P-4300GZ

MODEL 164.175
ENGINE 272.967 in
MODEL 164.186
Test cooling system cap ENGINES 271.9, 272.9 AR20.30-P-4300V
in MODEL 171.4
ENGINE 155 in
MODEL 199
Remove/install coolant level ENGINE 272, 642 in AR20.30-P-4392PI
switch MODEL 203 ENGINE
156, 272, 273, 642 in
MODEL 209
Remove/install coolant level ENGINE 272, 273, AR20.30-P-4392SXI
switch 275, 642, 629 in
MODEL 221 ENGINE
275 in MODEL 216
Removing/installing coolant ENGINE 271.9, 272.9 AR20.30-P-4392V
level switch in MODEL 171.4
Remove/install expansion ENGINE 113, 272, 273 AR20.30-P-4950GZ
Remove/install expansion ENGINE 272, 642 in AR20.30-P-4950PI
reservoir MODEL 203 ENGINE
156, 272, 642 in
MODEL 209
Remove/install expansion ENGINE 113, 156, AR20.30-P-4950RT
reservoir 272, 273, 642 in
MODEL 251
Remove/install expansion ENGINE 272, 273 in AR20.30-P-4950RX
reservoir MODEL 230
Remove/install expansion ENGINE 156, 272, AR20.30-P-4950SX
reservoir 273, 275 in MODEL
221 ENGINE 156, 273,
275 in MODEL 216
ENGINE 156 in
MODEL 211
Remove/install expansion ENGINE 272.964 in AR20.30-P-4950TX
Removing/installing expansion ENGINE 271.9, 272.9 AR20.30-P-4950V
reservoir in MODEL 171.4
Remove/install electric fan ENGINE 272, 273 in AR20.40-P-5000GZA
MODEL 164
Remove/install electric fan ENGINE 156, 272, AR20.40-P-5000QB
273 ...
Remove/install electric fan ENGINE 272, 273 in AR20.40-P-5000RTA

MODEL 251
Remove/install electric fan ENGINE 272, 273 in AR20.40-P-5000SX
MODEL 221 ENGINE
273 in MODEL 216
Remove/install electric fan ENGINE 113, 271, AR20.40-P-5000V
272 ...
Remove/install fan unit ENGINE 271, 272, AR20.40-P-5050CW
642, 646 in MODEL
204
Remove/install fan shroud ENGINES 272, 273 in AR20.40-P-6800RX
MODEL 230
Remove/install fan shroud ENGINE 272, 273 in AR20.40-P-6800SX
MODEL 221 ENGINE
273 in MODEL 216
Remove/install fan shroud ENGINE 272, 273 in AR20.40-P-6800TS
MODEL 211, 219
Remove/install fan shroud ENGINE 272.964 in AR20.40-P-6800TX
MODEL 219.356
Remove/install fan shroud ENGINE 272.942 in AR20.40-P-6800VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
9273AB
ENGINE 273
Inspect cooling system ENGINE 272, 273 in AR20.00-P-1010GZC

for leaks MODEL 164, 251
Inspect cooling system ENGINE 272, 273 ... AR20.00-P-1010QB
for leaks
Inspect cooling system ENGINE 272, 273 in AR20.00-P-1010RX
for leaks MODEL 230
Inspect cooling system ENGINE 156, 272, 273, AR20.00-P-1010SX
for leaks 275, 642 in MODEL 221
ENGINE 156, 273, 275
in MODEL 216
Inspect cooling system ENGINE 272, 273 in AR20.00-P-1010TS
for leaks MODEL 211, 219
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142GZC
MODEL 164, 251
Drain/fill in coolant ENGINE 272, 273 ... AR20.00-P-1142QB
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142RX

MODEL 230
Drain/fill in coolant ENGINE 272, 273 in AR20.00-P-1142SX
MODEL 221 ENGINE
273 in MODEL 216
Drain, fill coolant ENGINE 272, 273 in AR20.00-P-1142TS
MODEL 211, 219
pump MODEL 164, 251
pump
Remove/install coolant ENGINES 272, 273 in AR20.10-P-1271RX
pump MODEL 230
pump MODEL 221 ENGINE
273 in MODEL 216
pump MODEL 211, 219
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455GZA
MODEL 164, 251
Test coolant thermostat ENGINE 272, 273 ... AR20.10-P-2455QB
Testing coolant ENGINE 272, 273 in AR20.10-P-2455RX
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455SX
MODEL 221 ENGINE
273 in MODEL 216
Test coolant thermostat ENGINE 272, 273 in AR20.10-P-2455TS
MODEL 211, 219
thermostat
Remove/install coolant ENGINE 272, 273 in AR20.10-P-2460RX
thermostat MODEL 221 ENGINE
273 in MODEL 216
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865GZA
MODEL 164
Remove/install radiator ENGINE 272, 273 ... AR20.20-P-3865QB
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865RTC
MODEL 251
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865RX

MODEL 230
in MODEL 221
ENGINE 156, 273 in
MODEL 216
Remove/install radiator ENGINE 272, 273 in AR20.20-P-3865TS
MODEL 211, 219
Remove/install coolant ENGINE 272, 642 in AR20.30-P-4392PI
level switch MODEL 203 ENGINE
156, 272, 273, 642 in
MODEL 209
Remove/install coolant ENGINE 272, 273, 275, AR20.30-P-4392SXI
level switch 642, 629 in MODEL 221
ENGINE 275 in MODEL
216
Remove/install expansion ENGINE 113, 272, 273 AR20.30-P-4950GZ
reservoir 273, 642 in MODEL 251
Remove/install expansion ENGINE 272, 273 in AR20.30-P-4950RX
reservoir MODEL 230
Remove/install expansion ENGINE 156, 272, 273, AR20.30-P-4950SX
ENGINE 156, 273, 275
in MODEL 216
ENGINE 156 in MODEL
211
Remove/install electric ENGINE 272, 273 in AR20.40-P-5000GZA
fan MODEL 164
Remove/install electric ENGINE 156, 272, AR20.40-P-5000QB
fan 273 ...
Remove/install electric ENGINE 272, 273 in AR20.40-P-5000RTA
fan MODEL 251
Remove/install electric ENGINE 272, 273 in AR20.40-P-5000SX
fan MODEL 221 ENGINE
273 in MODEL 216
Remove/install fan ENGINES 272, 273 in AR20.40-P-6800RX
shroud MODEL 230
Remove/install fan ENGINE 272, 273 in AR20.40-P-6800SX
shroud MODEL 221 ENGINE
273 in MODEL 216
Remove/install fan ENGINE 272, 273 in AR20.40-P-6800TS
shroud MODEL 211, 219
REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271
Remove/install coolant pump - AR20.10-P-1271GZ
Fig. 33: Identifying Coolant Pump Components

Fig. 34: Identifying Poly-V Belt And Alternator

Remove/install

manufacturer.
swallowing coolant.
Switch ignition off, remove ignition key switched off.
1
(transmitter key) Remove the Keyless Go transmitter
card or transmitter key from vehicle
and store beyond reach of the
AR88.40-P-
2 Open engine hood
1000GZ
AR01.10-P-
3 Unclip cover on engine firewall side
2405GZ
AR00.60-P-
1000GZ
Remove bottom engine compartment AR61.20-P-
5
paneling 1105GZ
AR20.00-P-
6 Drain coolant at radiator
1142GZ
AH20.00-
Notes on coolant All engines N-2080-
01A
BB00.40-P-
0310-01A
Sheet 325.0
325.0) 0325-00A
*BF20.00-
Coolant P-1001-02K
Test cap Fig. 15
Cooler vacuum filling device Fig. 26
Place to the side with lines

7 Detach bracket (1)
still connected.
Use a screwdriver to press out
8 Remove coolant temperature sensor (B11/4) retaining clamp (11).
Installation: Replace O-ring.
*BA20.10-
9 Slacken bolts (2) of belt pulley (3)
P-1002-01C
AR13.22-P-
1202GZ
Detach belt pulley (3) from coolant pump Installation: Screw in screws
11
(4) (2) only by hand, do not tighten.
Detach guide pulley (6) for coolant pump Pry off the cover (6a) using a
12
(4) screwdriver and undo the screw (4h).
*BA20.10-
P-1008-01C
Inspect condition of coolant
hoses and hose clamps, replace if
Dismount coolant hose (7, 8) from coolant necessary. 6 mm socket hexagon on
13 flexible shaft for hose clamps with
pump (4)
worm drive 7 mm socket hexagon on
flexible shaft for hose clamps with
worm drive
Inspect condition of coolant
Disconnect coolant hose (9) from oil/water
14 hose and hose clamp, replace if
heat exchanger
necessary.
*BA15.40-
15 Unscrew bolt (12) for alternator (G2).
P-1003-01N
*BA15.40-
P-1005-01N
Place alternator to the side
16 Unscrew bolt (13) for alternator (G2).
with lines connected.
*BA15.40-
P-1003-01N
*BA15.40-
P-1005-01N
Detach and remove coolant pump (4) from Installation: Replace gasket
17
timing case cover (4a).
Installation: Observe bolt AR20.10-P-
diagram. 1271-03GZ
*BA20.10-
P-1001-01C
AR20.00-P-
19 Inspecting cooling system for leaks 1010GZ

Tester cap Fig. 15
Conduct engine test run and check the and eliminate cause, otherwise
engine for leaks
may occur.

113.964/971
Thread not
M6 Nm 14
pretapped
Thread not
M8 Nm 35
BA20.10-P-1001- Self-tapping screw connecting coolant pretapped
01C pump to timing case Thread pre-
M6 Nm 10
tapped
Thread pre-
M8 Nm 25
tapped
BA20.10-P-1002-
Belt pulley on coolant pump Nm 10
01C
BA20.10-P-1003-
Bolt, coolant thermostat housing M6 Nm 10
01C
BA20.10-P-1008-
Bolt, guide pulley to coolant pump housing M8 Nm 20
01C
ALTERNATOR
164, 251
BA15.40-P-1003-
Alternator mounting screw Nm 42
01N
Thread not
BA15.40-P-1005- Self-tapping screw, alternator to Nm 60
pretapped
01N timing case
Thread pre-tapped Nm 45
COOLING SYSTEM
model 164
Total filling capacity Liters approx.10.00
Liters approx.5.00
down to -37°C
BF20.00-P- Cooling
1001-02K system Liters approx.5.5
down to -45°C
Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A



Bolt diagram of coolant pump - AR20.10-P-1271-03GZ

113.964/971
Thread not
M6 Nm 14
pretapped
BA20.10-P-1001- Self-tapping bolt of coolant pump to Thread not
M8 Nm 35
01C timing case pretapped
Thread pretapped M6 Nm 10
Thread pretapped M8 Nm 25
Bolt assignment of coolant pump
Fig. 39: Identifying Coolant Pump Bolts

Remove/install coolant pump - AR20.10-P-1271GZA
ENGINE 272, 273 in MODEL 164, 251
Shown on engine 272
Fig. 40: Identifying Retaining Clamp And Coolant Pump

Remove/install
scalding from contact with hot coolant spray. AS20.00-Z-
Risk of poisoning caused by swallowing 0001-01A
coolant.
AH20.00-N-
Notes on coolant
2080-01A
AR20.40-P-
1 Remove electric fan Model 164 with engine 273
5000GZA
AR20.00-P-
1142GZC
AR13.20-P-
3 Remove poly-V belt and both guide pulleys
0001GZA
Pry off electrical feed line retaining clamp (4)
4
from coolant pump (5)
Dismount coolant hose from coolant pump Installation: Replace O-
5
(5) ring on coolant hose.
Installation: Observe bolt AR20.10-P-

6 Unscrew bolts for coolant pump (5)
diagram. 1271-03VA
*BA20.10-
P-1001-01U
*BA20.10-
P-1002-01U
Remove coolant pump (5) from timing case Installation: Replace
7
cover gasket (5a).
Clean
Clean sealing surfaces on coolant pump (5)
8
and timing case cover with a rag
AR20.00-P-
1010GZC
AS00.00-Z-
0005-01A
11 Check for leaks with engine running

272 273
BA20.10-P-1001- Self-tapping bolt connecting coolant pump to timing
M7 Nm 25 25
01U case cover
BA20.10-P-1002-
Bolt, coolant pump to crankcase M8 Nm 20 20
01U
Bolt diagram for coolant pump - AR20.10-P-1271-03VA

BA20.10-P-1001- Self-tapping bolt M7 Nm 25 25
01U for coolant pump
on timing case
cover
BA20.10-P-1002- Bolt for coolant M8 Nm 20 20
01U pump on
crankcase
Bolt assignments for coolant pump
Bolts A: Coolant pump on timing case cover.

Bolts B and C: Coolant pump on crankcase.
The tightening sequence given in the following table must be followed to ensure that there are no leaks in the
coolant pump.
Fig. 41: Identifying Bolt Assignments For Coolant Pump

TIGHTENING SEQUENCE AND BOLT LENGTH

Tightening sequence Bolts
1 1A to 8A (M7_28), tighten in numerically ascending
order
2 B (M8x75)
3 C (M8x110)
Remove/install coolant pump - AR20.10-P-1271GZS

Fig. 42: Identifying Coolant Pump Components

MODIFICATION NOTES
6.2.07 Bolt, coolant pump to timing case cover and crankcase Engine 156 *BA20.10-P-1001-01V
Remove/install
installing or aligning hoods, doors, moving parts. 0011-01A
trunk lids, tailgates or sliding roof.
platform.
by scalding from contact with hot slowly and release the pressure. Do not AS20.00-Z-
coolant spray. Risk of poisoning pour coolant into beverage containers. 0001-01A
caused by swallowing coolant. Wear protective gloves, protective clothing
and safety glasses.
Switch ignition off, remove ignition repeatedly until ignition is switched off.
1
key (transmitter key). Remove keyless go transmitter card or
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Do not tilt front engine cover, but lift
3 Remove front engine cover upwards vertically otherwise the retaining
lugs can break off.
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
Remove bottom engine compartment Installation: Only install lower AR61.20-P-
5 engine compartment paneling after leak
paneling 1105GZ
test.
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR20.00-P-
6 Drain coolant from radiator
1142GZS
AH20.00-
N-2080-01A
*BF20.00-
Coolant P-1001-02U
Test cap Fig. 15
AR20.40-P-
5000GZS
8
condenser
WF58.50-
Radiator guard plate/ condenser
P-0110-01A
*BA13.25-
9 Loosen bolts of belt pulley (2)
P-1002-01U
AR13.22-P-
10 Remove poly-V belt (3)
1202GZS
Detach the belt pulley (2) from coolant Installation: Only screw in bolts
11
pump (1) by hand, do not tighten.
Remove guide pulley (4, 5) from *BA13.25-
12
coolant pump (1) P-1003-01U
*BA13.25-
P-1004-01U
Remove guide pulley (6) from timing *BA13.25-
13
case cover P-1005-01U
Dismount coolant hose (9) on coolant Inspect condition of coolant hoses
14 pump (1) and hose clamps, replace if necessary.

*BA20.10-
15 Remove bolts (7)
P-1001-01V
*BA20.10-
16 Remove bolts (8)
P-1001-01V
Detach and remove coolant pump (1)
17 Installation: Install new gasket
from the timing case cover
Installation: Clean sealing surface
Clean sealing surface on timing case
18 with clean rags otherwise leakage can
cover
occur.
Clean sealing surface on coolant pump Only when reusing coolant pump
19
(1) (1).
AR20.00-P-
1010GZS
Tester cap Fig. 15
In the event of oil loss determine and
Conduct engine test run and check eliminate cause, otherwise malfunctions,
22
engine for leaks transmission damage, and serious
environmental pollution may occur.

M6x30 Nm 9
M6x80 Nm 9
BA20.10-P-1001-01V Bolt, coolant pump to timing case cover and crankcase
M8x80 Nm 20
M8x100 Nm 20

156
BA13.25-P-
Bolt, pulley to coolant pump M6 Nm 8.5
1002-01U
BA13.25-P- Guide pulley on coolant pump housing (between power steering pump
Nm 20
1003-01U and guide pulley with grooved channel profile)
BA13.25-P- Guide pulley to coolant pump housing (between alternator and smooth
Nm 20
1004-01U guide pulley)
BA13.25-P-
Guide pulley (between poly-V belt tensioning device and coolant pump) Nm 20
1005-01U
COOLING SYSTEM
164, 251
Up to -37°C 50/50
BF20.00-P-1001- Cooling Antifreeze/water
Up to -45°C 55/45
02U system



TEST COOLANT THERMOSTAT - AR20.10-P-2455
Test coolant thermostat - AR20.10-P-2455GZ
Fig. 47: Identifying Coolant Thermostat And Valve

Remove/install

Risk of injury to skin and eyes caused by coolant temperature is below 90°C. Open
scalding from contact with hot coolant cap slowly and release the pressure. Do
spray. Risk of poisoning from swallowing not pour coolant into beverage containers. AS20.00-Z-
coolant. Wear protective gloves, protective 0001-01A
Installation: Install new sealing
ring.
The coolant thermostat (1) must AR20.10-P-
1 Remove coolant thermostat (1) not be removed from the housing. 2460GZ
Otherwise it will be destroyed. The
housing is supplied together with the
coolant thermostat (1) for repair purposes.
Checking
Suspend coolant thermostat (1)
from a wire in a vessel filled with water
and heat the water.
2 Heat coolant thermostat (1) For heating up under no circumstance
use a welding torch or a soldering torch,
otherwise the sudden heat penetration
modifies the metal structure!
The heating-up rate should be not
more than 1 to 2°C / minute from about 8°
3 Measure temperature of water
C below the start of opening of the
coolant thermostat (1).
*WH58.30-
Z-1002-08A
Warm up water to full opening temperature
If the test values are not
4 of the valve (2) and then measure the hub of
achieved, replace coolant thermostat (1).
the valve (2)
*BE20.10-P-
Start of opening
1001-02A
*BE20.10-P-
Minimum stroke
1002-02A
AR20.00-P-
1010GZ
Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving
off by itself when engine is running. Risk of by itself.
AS00.00-Z-
0005-01A
Conduct engine test run and check the eliminate cause, otherwise malfunctions,
7
COOLANT THERMOSTAT
Number Designation Engine 112, Engine
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/971/980
BE20.10-
Start of
P-1001- °C 85...89
opening
02A
BE20.10-
Minimum °C 102
P-1002-
stroke mm
02A

Number Designation
WH58.30-Z-1002-08A Digital temperature measuring instrument (measuring range -20° to +70°)
Test coolant thermostat - AR20.10-P-2455GZA
ENGINE 272, 273 in MODEL 164, 251
Shown on engine 272
Fig. 48: Identifying Multimeter, Electrical Connector And Three-Disk Thermostat Valve
Remove/install
AH54.00-P-
damage to electronic components
0001-01A
AR13.20-P-
0001GZA
2 (4) at three disc thermostat valve
(Y110)
Check
Connect multimeter (3) with
3 adapter cable (1) to three disc Fig. 49
thermostat valve (Y110)
If resistance does not comply with preset
4 Measure resistance data, the three disc thermostat valve (Y110) must be
replaced: ?
AR20.10-P-
Remove coolant thermostat
2460GZA
*BE20.10-P-
Resistor
1003-02C
Connect STAR DIAGNOSIS and disconnecting cables or by simulation during test
6
read fault memory operations, must be erased in the fault memory after
CHECK VALUES FOR COOLANT THERMOSTAT

BE20.10-P-1003-02C Resistor at 20°C ohms 15.2 (± 1.5) 15.2 (± 1.5)

Test coolant thermostat - AR20.10-P-2455GZS

Fig. 50: Identifying Coolant Thermostat And Valve

Remove/install

coolant temperature is below 90°C. Open
cap slowly and release the pressure. Do
not pour coolant into beverage
containers.
coolant.
ring.
The coolant thermostat (1) must
not be removed from the housing. AR20.10-P-
1 Remove coolant thermostat (1)
Otherwise it will be destroyed. The 2460GZS
housing is supplied together with a
coolant thermostat (1) for repair
purposes.
Checking
Suspend coolant thermostat (1)
from a wire in a vessel filled with water
and heat water.
2 Heat coolant thermostat (1) For heating up under no circumstance
use a welding torch or a soldering torch,
otherwise sudden heat penetration
modifies the metal structure!
The heating-up rate should be
not more than 1 to 2°C / minute from
3 Measure temperature of water
about 8°C below start of opening of
coolant thermostat (1).
*WH58.30-
Digital temperature measuring unit Z-1002-08A
Heat water to the fully open temperature of If the check values are not
4
thermostat (2) and then measure stroke of achieved, replace coolant thermostat (1).
valve (2)
*BE20.10-P-
Start of opening
1001-02D
*BE20.10-P-
Minimum stroke
1002-02D
AR20.00-P-
1010GZS
AS00.00-Z-
0005-01A
Conduct engine test run and check engine eliminate cause, otherwise malfunctions,
7
for leaks transmission damage, and serious
COOLANT THERMOSTAT
Conventional °C 98 to 102
BE20.10-P-1001-02D Start of opening
Electrical °C 65
Conventional °C 115
Electrical °C 100
BE20.10-P-1002-02D Minimum stroke
Conventional mm 5
Electrical mm 8

Number Designation
WH58.30-Z-1002-08A Digital temperature measuring instrument (measuring range -20° to +70°)
REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P-2460
Remove/install coolant thermostat - AR20.10-P-2460GZ

Fig. 51: Identifying Coolant Thermostat Components

Remove/Install

Risk of injury to skin and eyes caused by temperature is below 90°C. Open cap slowly
scalding from contact with hot coolant and release the pressure. Do not pour coolant AS20.00-Z-
spray. Risk of poisoning from into beverage bottles. 0001-01A
and eye protection.
AR20.00-P-
1 Drain the coolant from radiator
1142GZ
2 Unclip cover on engine firewall side See ?
AR09.10-P-
Remove air filter housing
1150GZ
Inspect condition of coolant hose
3 Dismount coolant hose (5)
(5) and hose clamp (4), replace if necessary.
*WH58.30-
*WH58.30-
The coolant thermostat must not be
removed from the housing. If this is done it
will be destroyed. Re-installation is not
Unscrew bolts (3), remove coolant
possible. The housing is supplied together
4 thermostat housing (1) with coolant
with the coolant thermostat for repair
thermostat
purposes.
ring (2).
*BA20.10-P-
1003-01C

AR20.00-P-
1010GZ
starting off by itself when engine is Secure vehicle to prevent it from moving.
AS00.00-Z-
running. Risk of injury caused by Wear closed and snug-fitting work clothes.
0005-01A
contusions and burns during starting Do not grasp hot or rotating parts.
procedure or when working near engine
Conduct engine test run and check the eliminate cause, otherwise malfunctions,
7

BA20.10-P-1003-01C Bolt of coolant thermostat housing M6 Nm 10


Number Designation
Remove/install coolant thermostat - AR20.10-P-2460GZA
ENGINE 272, 273 in MODEL 164, 251


Shown on engine 272
Remove/install

Risk of injury to skin and eyes caused by coolant temperature is below 90°C. Open
scalding from contact with hot coolant spray. cap slowly and release the pressure. Do AS20.00-Z-
Risk of poisoning caused by swallowing not pour coolant into beverage containers. 0001-01A
coolant. Wear protective gloves, protective
AH20.00-N-
Notes on coolant
2080-01A
AH54.00-P-
0001-01A
discharge
AR20.00-P-
1142GZC
Detach upper coolant hose (1) from coolant
Installation: Replace O-ring AR09.41-P-
2 thermostat housing (2) and place it on the
(1a). 1311-01AL
side
AR13.20-P-
3 Remove poly-V belt and guide pulley (3)
0001GZA
Unlatch electrical connector at three-disk
4
thermostat valve (Y110) and disconnect
*BA20.10-
5 Remove bolts (2a, 2 pieces)
P-1003-01U
The coolant thermostat and coolant

thermostat housing (2) are a single unit.
The coolant thermostat must not be taken
Pull out coolant thermostat housing (2) with
6 out of coolant thermostat housing (2) as it
coolant thermostat from timing case cover
can get damaged in the process.
Installation: Replace gasket (2b)
and O-ring (2c).
Checking
AS00.00-Z-
0005-01A
8
engine for leaks
Connect STAR DIAGNOSIS and read fault caused by disconnecting cables or by
9 simulation during test operations, must be
memory
erased in the fault memory after

BA20.10-P-1003-01U Bolt, coolant thermostat housing at timing case cover Nm 25 25
Remove/install coolant thermostat - AR20.10-P-2460GZS

Remove/install


cap slowly and release the pressure. Do
not pour coolant into beverage containers.
coolant.
Risk of death caused by vehicle slipping or platform and position four support plates AS00.00-Z-
toppling off the lifting platform. at lifting platform support points specified 0010-01A
AH20.00-N-
2080-01A
All models
Keyless Go: Press keyless go start/stop
1 Turn key in ignition switch to position "0".
switched off
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
3 Remove front engine cover upwards vertically otherwise retaining
lugs can break off.
4 Remove the right and left intake air duct
AR14.30-P-
5 Remove switchover valve
7255GZS
Loosen expansion reservoir for steering and AR46.25-P-
6
place to one side 1000GZS
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT
AR20.00-P-
1142GZS
Detach upper coolant hose (1) from coolant

thermostat housing (2) and place it to one

10 Installation: Install new O-ring.
side
Remove overflow line from coolant
11 thermostat housing (2) to coolant expansion
reservoir and set aside
Unlatch electrical connector at three-disk Also disconnect connector on
12
thermostat valve (Y110) and disconnect underside of thermostat housing.
*BA20.10-
13 Remove bolts (2a)
P-1002-01V
The coolant thermostat and coolant
thermostat housing (2) are a single unit.
The coolant thermostat must not be taken
Pull out coolant thermostat housing (2) with
14 out of coolant thermostat housing (2) as it
coolant thermostat from timing case cover
can get damaged in the process.
Installation: Install new O-ring
and seal.
AR20.00-P-
1010GZS
Checking
AS00.00-Z-
0005-01A

M6x25 Nm 8.5
BA20.10-P-1002-01V Bolt, thermostat on timing case cover
M8x80 Nm 20
REMOVE/INSTALL RADIATOR - AR20.20-P-3865
Remove/install radiator - AR20.20-P-3865GZ

Fig. 55: Identifying Radiator Components (1 Of 3)



Remove/install
coolant.
AH20.00-N-
2080-01A
Risk of injury to skin or eyes caused by Depressurize the hydraulic system
hydraulic fluid spraying out under high completely before starting any work AS00.00-Z-
pressure. Risk of poisoning caused by on the system. Wear protective 0013-01A
swallowing hydraulic fluid. clothing and safety glasses.
AR88.40-P-
1 Open engine hood
1000GZ
AR00.60-P-
1000GZ
AR01.10-P-
2405GZ
4 Remove left and right suction fan duct
AR62.30-P-
2300GZ
AR20.40-P-
6 Remove fan shroud together with electric fan
5000GZ
Installation: Install engine AR61.20-P-
7 Remove engine compartment paneling compartment paneling only after 1105GZ
engine test run.
AR20.00-P-
8 Drain coolant at radiator (1)
1142GZ
*BF20.00-P-
1001-02K
BB00.40-P-
0310-01A
BB00.40-P-
0325-00A
Installation: Check
Remove coolant line (2) from coolant condition of coolant line and replace
9 if necessary. Replace seal. Ensure
expansion reservoir at engine radiator (1)
coolant line (2) is fitted correctly on
radiator (1)
Installation: Check
Detach coolant lines of coolant pump to condition of coolant lines and
10 connection fitting (10) on radiator (1) and replace if necessary. Install new
place to one side seals. Ensure coolant lines are fitted
correctly at radiator.
Seal all connections immediately
using stop plugs, otherwise the
automatic transmission may be
damaged due to contamination.
Detach automatic transmission oil line (13)
11 Installation: Replace
on connection (12) from radiator (1)
sealing rings.
Ensure the oil lines of the automatic
transmission are fitted correctly to
the radiator.
Detach power steering oil line (14) on 6 mm socket hexagon on flexible *WH58.30-
12 shaft for hose clamps with worm
connection (12) Z-1001-06A
drive
7 mm socket hexagon on flexible *WH58.30-
shaft for hose clamps with worm Z-1002-06A
drive
13 Undo bolt (4) on air ducting (3) from radiator AR88.20-P-
(1) 2000GZ
Remove front section of fender liner in left AR88.10-P-
14
front fender 1310GZ
AR88.20-P-
15 Partially remove left bumper
2000GZ
To ease access to bolt (6),
Undo bolt (6) for refrigerant line mounting
16 pull partially removed bumper
on radiator (1)
somewhat to front, see (arrow).
Lift radiator (1) with condenser of air
This improves accessibility
17 conditioning upwards out of rubber mount
to the air ducting (3) bolt (5).
(9), slide towards the engine and put down
18 Remove bolt (5) from air ducting (3)
19 Remove air ducting (3)
Unclip condenser for air conditioning from Place air conditioning
20 top mount (7) and pull condenser upwards condenser down in front of radiator
out of bottom mount (8) (1).
Installation:
 Ensure correct seating of

rubber mounts (9) in bottom
Take out the radiator (1) in the upward mounts on radiator (1).
21
direction
 Ensure air conditioning
condenser lower support (8) is
correctly seated in radiator
(1).
Check oil level in automatic transmission and AR27.00-P-
23
correct if necessary 0100W
24 Check power steering oil level
AP46.00-P-
Check and correct power steering fluid level
4611GZ
AR20.00-P-
1010GZ
Test cap Fig. 15
system Z-1048-13A
off by itself when engine is running. Risk of moving by itself. AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work 0005-01A

for leaks whilst it is running
may occur.
COOLING SYSTEM
model 164
Total filling capacity Liters approx.10.00
Liters approx.5.00
down to -37°C
BF20.00-P- Cooling
1001-02K system Liters approx.5.5
down to -45°C
Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A




Number Designation
Remove/install radiator - AR20.20-P-3865GZA

Fig. 62: Identifying Radiator Components - Shown On Engine 272 (1 Of 3)

Shown on engine 272
Shown on engine 272

Shown on engine 272


MODIFICATION NOTES
13.1.06 Disconnect ground line from battery - removed
Remove/install

coolant.
hydraulic fluid spraying out under high completely before starting any work on AS00.00-Z-
pressure. Risk of poisoning caused by the system. Wear protective clothing 0013-01A
swallowing hydraulic fluid and safety glasses.
AH20.00-
Notes on coolant N-2080-
01A
2 Remove left and right engine intake air ducts
AR62.30-P-
3 Remove upper radiator crossmember Engine 273
2300GZ
AR20.40-P-
5000GZA
5 Remove engine compartment paneling compartment paneling only after engine
1105GZ
test run.
AR20.00-P-
1142GZC
AH20.00-
01A
Installation: Check condition
7 Take off coolant hose (2) at radiator (1) of coolant hose (2) and replace if
necessary. Ensure coolant hose (2) is
fitted correctly on radiator (1)
Fig. 20
Detach coolant hoses from connection fitting of coolant hoses; replace if necessary.
8
(10) on radiator (1) and place to one side Ensure that coolant hoses are correctly
fitted to radiator (1).
Fig. 20
Seal connections (12) using stop
plugs to prevent dirt from entering.
Detach automatic transmission oil lines (13) Installation: Replace sealing
9 rings.
from connections (12) on radiator (1)
Make sure that automatic transmission
oil lines (13) are correctly fitted to
radiator (1).
Fig. 46
Detach power steering oil lines (14) from Seal connections (11) using stop
10
connections (11) on radiator (1) plugs to prevent dirt from entering.
Fig. 46
Remove bolts (4) to air ducting (3) from
11
radiator (1)
Remove front section of fender liner in left AR88.10-P-
12 Model 164 except 164.177
front fender 1310GZ
AR88.20-P-
13 Partially remove left bumper
2000GZ
To ease access to bolt (6), pull
Undo bolt (6) of refrigerant line mounting on
14 partially removed bumper somewhat to
radiator (1)
front, see arrow.
This provides access to the
15 conditioning system upwards out of rubber
mounts (9), push towards engine and put down bolts (5) of the air ducting (3).
16 Undo bolts (5) from air ducting (3)
17 Remove air ducting (3)
Unclip condenser of air conditioning from
upper supports (7) on radiator (1) and pull Place air conditioning
18
condenser upwards and out of lower supports condenser down in front of radiator (1).
(8)

correct seating of rubber mount (9).
19 Take out radiator (1) in an upward direction Ensure air conditioning condenser's
lower supports (8) are correctly seated
in radiator (1).
Check oil level in automatic transmission, AR27.00-P-
21
correct if necessary 0100W
22 Check power steering oil level
AP46.00-P-
Check and correct power steering fluid level
4611GZ
AR20.00-P-
1010GZC
Connect STAR DIAGNOSIS and read fault
memory
by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
0005-01A
25
leaks whilst it is running


Remove/install radiator - AR20.20-P-3865GZS




Remove/install
manufacturer.
hydraulic fluid spraying out under high completely before starting any work on AS00.00-Z-
pressure. Risk of poisoning caused by the system. Wear protective clothing 0013-01A
swallowing hydraulic fluid. and safety glasses.
swallowing coolant.
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
2 Remove front engine cover upwards vertically otherwise the
AR62.30-P-
4 Remove upper radiator crossmember Model 164
2300GZ
AR62.30-P-
Model 251
2300RT
AR20.40-P-
5000GZS
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
7 Remove engine compartment paneling compartment paneling only after engine
test run.
AR61.20-P-
Model 164 1105GZ

AR61.20-P-
Model 251
1105RT
AR20.00-P-
1142GZS
AH20.00-N-
2080-01A
AH20.00-P-
Notes on coolant level 1142-
01GZB
*BF20.00-
Cooling system P-1001-02U
Remove coolant line (2) from coolant of coolant line and replace if necessary.
9
expansion reservoir at engine radiator (1) Replace seal. Ensure coolant line (2) is
fitted correctly on radiator (1)
Remove coolant hoses at connection
10 fittings (10) on engine radiator (1) and of coolant hoses; replace if necessary.
Install new seals. Ensure coolant hoses
place to one side
are fitted correctly on radiator.
Seal all connections immediately
Detach automatic transmission oil line using stop plugs, otherwise the AR27.10-P-
11
(13) on connection (12) from radiator (1) automatic transmission may be 0501-03RT
damaged due to contamination.
AR88.20-P-
12 Remove bumper Model 164
2000GZ
AR88.20-P-
Model 251
2000RT
Unclip power steering oil line at the side
13
on engine radiator (1)
Undo bolt (4) on air ducting (3) from
14
radiator (1)
Undo bolt (6) for refrigerant line
15
mounting on radiator (1)
This improves accessibility to
16 conditioning upwards out of rubber mount
the air ducting (3) bolt (5).
(9), slide towards the engine and put down
17 Remove bolt (5) from air ducting (3)
Loosen bolt on carrier frame (A) for
18 Model 251
power steering lines
Unclip carrier frame (A) on cooler (1) and
19 remove Model 251

Unclip condenser for air conditioning
Place air conditioning
20 from top mount (7) and pull condenser
upwards out of bottom mount (8) condenser down in front of radiator (1).
Installation:
 Ensure correct seating of rubber

Take out the radiator (1) in the upward mounts (9) in bottom mounts of
21 radiator (1).
direction
 Ensure air conditioning condenser
lower supports (8) are correctly
seated in radiator (1).
Check oil level in automatic transmission AR27.00-P-
23
and correct if necessary 0100W
AR20.00-P-
1010GZS
Test cap Fig. 15
moving by itself.
clothes.
eliminate cause, otherwise
25 malfunctions, transmission damage, and
engine for leaks
serious environmental pollution may
occur.
COOLING SYSTEM
164, 251
Up to -37°C 50/50
Antifreeze/water
Up to -45°C 55/45
BF20.00-P-1001- Cooling
02U system Sheet
Specifications for Operating BB00.40-P-0310-01A
Fluids
Sheet
BB00.40-P-0325-00A



TESTING COOLING SYSTEM CAP - AR20.30-P-4300
Testing the cooling system cap - AR20.30-P-4300GZ
Fig. 75: Identifying Cooling System Cap, Adapter And Pressure Pump
Check
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
Risk of injury to skin and eyes caused by temperature is below 90°C. Open cap slowly
scalding from contact with hot coolant and release the pressure. Do not pour coolant AS20.00-Z-
spray. Risk of poisoning from into beverage bottles. 0001-01A
and eye protection.
AH20.00-N-
2080-01A
AR88.40-P-
1 Open engine hood
1000GZ
Rotate the cooling system cap (1)
halfway through in the anti-clockwise
2 Screw down coolant system cap (1)
direction and release the excess pressure.
Then screw down the cooling system cap.
Fix the adapter (2) to the pressure pump
3 Pressure pump Fig. 16
(3)
Adapter Fig. 76
Screw on cooling system cap (1) at
4 Adapter Fig. 76
adapter (2)
Establish opening pressure of
Check pressure relief valve in cooling
5 pressure relief valve by pumping and replace
system cap (1)
cooling system cap (1) if necessary.
*BE20.30-P-
Cap code number
1001-01A
*BE20.30-P-
Pressure relief valve opens
1004-01A
Changeover the pressure pump (3)
Check vacuum valve in cooling system and determine the opening pressure of the
6
cap (1) vacuum valve by pumping. If necessary,
replace the cooling system cap (1).
*BE20.30-P-
Cap code number
1001-01A
*BE20.30-P-
Vacuum valve opens (reference value)
1003-01A
Close coolant expansion reservoir using
7
cooling system cap (1)
AR88.40-P-
8 Close engine hood
1000GZ

BE20.30-P-1001-01A Cap code number 140/200
BE20.30-P-1003-01A Vacuum valve opens (reference value) bar vacuum 0.1
bar gage 1.4 ± 1
1st stage
Coolant temp. > or = 130/134
BE20.30-P-1004-01A Pressure relief valve opens
bar gage 2.0 ± 1
2nd stage


Testing cooling system cap - AR20.30-P-4300GZS
Fig. 78: Identifying Cooling System Cap, Adapter And Pressure Pump
Checking
Risk of injury to skin and eyes caused temperature is below 90°C. Open cap slowly
by scalding from contact with hot coolant and release the pressure. Do not pour coolant AS20.00-Z-
spray. Risk of poisoning caused by into beverage containers. 0001-01A
and safety glasses.
AH20.00-N-
2080-01A
AR88.40-P-
1 Open engine hood Model 164 1000GZ

AR88.40-P-
Model 251
1000RT
Rotate the cooling system cap (1)
halfway through in the anti-clockwise
2 Screw down coolant system cap (1)
direction and release the excess pressure.
Then screw down cooling system cap (1).
Fix the adapter (2) to the pressure pump
3 Pressure pump Fig. 16
(3)
Adapter Fig. 76
Screw on cooling system cap (1) at
4 Adapter Fig. 76
adapter (2)
Establish opening pressure of
Check pressure relief valve in cooling
5 pressure relief valve by pumping and replace
system cap (1)
cooling system cap (1) if necessary.
*BE20.30-P-
Cap code number
1001-01A
*BE20.30-P-
Pressure relief valve opens
1004-01A
Changeover the pressure pump (3)
Check vacuum valve in cooling system and determine the opening pressure of the
6
cap (1) vacuum valve by pumping. If necessary,
replace the cooling system cap (1).
*BE20.30-P-
Cap code number
1001-01A
*BE20.30-P-
Vacuum valve opens (reference value)
1003-01A
Close coolant expansion reservoir using
7
cooling system cap (1)
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT

BE20.30-P-1001-01A Cap code number 140/200
BE20.30-P-1003-01A Vacuum valve opens (reference value) bar vacuum 0.1
bar gage 1,4 ± 1
Stage 1
BE20.30-P-1004-01A Pressure relief valve opens
bar gage 2,0 ± 1
Stage 2


REMOVE/INSTALL EXPANSION RESERVOIR - AR20.30-P-4950
Remove/install expansion reservoir - AR20.30-P-4950GZ
ENGINE 113, 272, 273 in MODEL 164
Shown on engine 272

Fig. 81: Identifying Expansion Reservoir Components - Shown On Engine 272

MODIFICATION NOTES
Drain off coolant at engine radiator replaced by suction off coolant from expansion Step
17.10.05
reservoir 2
Remove/install

Risk of injury to skin and eyes caused by temperature is below 90°C. Open cap
scalding from contact with hot coolant slowly and release the pressure. Do not pour AS20.00-Z-
spray. Risk of poisoning caused by coolant into beverage containers. 0001-01A
and safety glasses.
Suction coolant out of coolant expansion
1 Fig. 82
reservoir (4)
Disconnect electrical connector (2) at
2
coolant level indicator switch (S41)
Remove vent hose (1) on coolant
3
expansion reservoir (4)
4 Unscrew nut (3)
Detach coolant hoses (5, 6) with
5 Detach coolant hoses (5, 6)
expansion reservoir raised (4).
Lift coolant expansion reservoir (4)
6
upwards out of rubber mounts
7 Take out coolant expansion reservoir (4)
Checking
Check coolant level and correct if
9
necessary
AH20.00-P-
1142-01GZB
AR20.00-P-
10 Inspecting cooling system for leaks Engine 113
1010GZ
AR20.00-P-
Engine 272, 273
1010GZC

Remove/install expansion reservoir - AR20.30-P-4950GZS
Fig. 83: Identifying Expansion Reservoir Components

Remove/install
below 90°C. Open cap slowly and
release the pressure. Do not pour AS20.00-Z-
scalding from contact with hot coolant spray.
coolant into beverage containers. 0001-01A
Risk of poisoning from swallowing coolant.
glasses.
pinched or crushed when removing, installing Keep body parts and limbs well AS00.00-Z-
or aligning hoods, doors, trunk lids, tailgates or clear of moving parts. 0011-01A
sliding roof.
AR88.40-P-
1 Open engine hood
1000GZ
Screw down cap on coolant expansion reservoir
2 Hand pump Fig. 82
(4) and suction off coolant
AH20.00-N-
2080-01A
BB00.40-P-
0310-01A
BB00.40-P-
0325-00A
Disconnect electrical connector (2) at coolant
3
level indicator switch (S41)
Remove overflow hose (1) on coolant (4)
4
expansion reservoir
5 Screw down nut (3)
Detach coolant hose (5,
6 Detach coolant hose (5, 6) 6) with expansion reservoir raised
(4).
*WH58.30-
Hose clamp pliers Z-1019-02A
Lift coolant expansion
7 Remove coolant (4) expansion reservoir reservoir (4) upwards out of
rubber mounts
Checking
*BF20.00-P-
9 Check coolant level and correct if necessary. Cooling system 1001-02U
AH20.00-P-
1142-01GZB
AR20.00-P-
1010GZS
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting
0005-01A
starting procedure or when working near the work clothes.
In the event of oil loss
determine and eliminate cause,
Conduct engine test run and check the engine otherwise malfunctions,
11
environmental pollution may
occur.
COOLING SYSTEM
164, 251
Up to -37°C 50/50
Antifreeze/water
Up to -45°C 55/45
BF20.00-P-1001- Cooling
02U system Sheet
Specifications for Operating BB00.40-P-0310-01A
Fluids
Sheet
BB00.40-P-0325-00A


Number Designation
WH58.30-Z-1019-02A Hose clamp pliers (length 210 mm, clamping range 80 mm)
REMOVE/INSTALL ELECTRIC FAN - AR20.40-P-5000
Remove/install electric fan - AR20.40-P-5000GZ

Fig. 85: Identifying Electric Fan Components

Remove/install

installing or aligning hoods, doors, trunk lids, moving parts. 0011-01A
1
position 1000GZ
AR01.10-P-
2405GZ
AR62.30-P-
2300GZ
Disconnect electrical connector (3) at fan
5
shroud (1)
The automatic transmission oil line
Lift out automatic transmission oil line (6) (6) must not get deformed during the
6 from oil line mount (5) at radiator and turn it process otherwise, its optimal seating in
outwards the oil line mount (5) at the radiator
will not be ensured.
7 Unscrew bolt (2)
Lift fan shroud (1) with electric fan out of retaining lugs for fan shroud are
8
mounts (4) and guide it upwards inserted in mounts (4) at bottom of
radiator.

*WH58.30-
Z-1048-13A
AS00.00-Z-
0005-01A

Number Designation
Remove/install electric fan - AR20.40-P-5000GZA
Shown on engine 272
Fig. 86: Identifying Electric Fan Components - Shown On Engine 272

MODIFICATION NOTES
17.10.05 Disconnect ground line from battery - removed
Remove/install
Notes on self-locking nuts AH00.00-N-

and bolts 0001-01A
Remove left and right
1
engine intake air duct (1)
Remove upper radiator AR62.30-P-
2 Engine 273
crossmember 2300GZ
Unplug electrical
3 connection (2) on fan
shroud (3)
Unscrew bolts (4) at fan
4
shroud (3)
Remove fan shroud (3)
5 from lower mounts (5) on When removing fan shroud (3) observe that none
of attached lines are damaged on radiator (5).
radiator
Connect STAR
7 DIAGNOSIS and read fault disconnecting cables or by simulation during test
operations, must be erased in the fault memory after
memory
Remove/install electric fan - AR20.40-P-5000GZS
Fig. 87: Identifying Electric Fan Components

Remove/install

pinched or crushed when removing, installing Keep body parts and limbs well clear of AS00.00-Z-
or aligning hoods, doors, trunk lids, tailgates or moving parts. 0011-01A
sliding roof.
manufacturer.
AR88.40-
P-1000GZ
AR88.40-P-
Model 251
1000RT
2 Remove front engine cover upwards vertically otherwise the
AR62.30-
P-2300GZ
AR62.30-P-
Model 251
2300RT
AR00.60-
P-1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-
P-1105GZ
AR61.20-P-
Model 251
1105RT
AR20.00-
7 Drain coolant from radiator P-
1142GZS
Remove coolant hose at top left at engine
8 Hose clamp pliers Fig. 20
radiator
Disconnect electrical connector (3) on electrical
9
fan (1)
10 Unscrew bolt (2)
Installation: Ensure that the
Lift electrical fan (1) out of mounts (4) and lead retaining lug for the electrical fan (1) is
11
upwards led into the mounts (4) at the bottom of
the engine radiator.
by itself when engine is running. Risk of injury moving by itself. AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting work 0005-01A
procedure or when working near the engine as it clothes.


TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ENGINE COOLING SYSTEM - BE20.00-
Z-9999AZ
MODEL all
Coolant thermostat ENGINE 103, 104, 111, BE20.10-P-1000-02A

112, 113, 119, 120, 155,
271...
Coolant thermostat ENGINE 601, BE20.10-P-1000-02B
602.91 /96,
603.91 /96 /97, 604, 605
Coolant thermostat ENGINE 272, 273 BE20.10-P-1000-02C
Coolant thermostat ENGINE 156 BE20.10-P-1000-02D
Fan/fan shroud ENGINE 111, 604, 605, BE20.20-P-1000-01A
606
Fan/fan shroud ENGINE 103, 104, 119 BE20.20-P-1000-01B
Fan/fan shroud ENGINE 104, 119, 120, BE20.20-P-1000-01C
603
Test values for cooling ENGINE all BE20.30-P-1000-01A
system cap
Fan, fan clutch ENGINE 120 BE20.40-P-1000-01A
COOLANT THERMOSTAT - BE20.10-P-1000
Coolant thermostat - BE20.10-P-1000-02A

Engine 103, 104, 111, 112, 113, 119, 120, 155
COOLANT THERMOSTAT
Number Designation Engine Engine 112, Engine
103, 113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/96
104,
111,
120
BE20.10- Start of °C 85...89 85...89
P-1001- opening
02A
BE20.10- Minimum °C 102 102
P-1002- stroke
02A mm 8 8
BE20.10- Thermostat mm 43 -
P-1003- bypass
02A valve dia.
COOLANT THERMOSTAT
BE20.10-P- Start of opening °C 82...86 85...89 88...92
1001-02A
BE20.10-P- Minimum stroke °C - 102 105
1002-02A mm - 8 8
BE20.10-P- Thermostat bypass valve mm 29 - -
1003-02A dia.
Coolant thermostat - BE20.10-P-1000-02C
Engine 272, 273
TEST VALUES FOR COOLANT THERMOSTAT

BE20.10-P- Start of opening Main valve °C 65 65
1001-02C Shutoff valve °C 40 -
BE20.10-P- Minimum stroke Main valve °C 100 100
1002-02C Shutoff valve °C - -
mm 8 -
BE20.10-P- Resistor at 20°C ohms 15.2 (±1.5) 15.2 (±1.5)
1003-02C
TEST VALUES FOR COOLING SYSTEM CAP - BE20.30-P-1000-01A
All engines
CAP OF RADIATOR OR EXPANSION RESERVOIR

Number Designation Cap 2-stage cap 1-stage cap
on model
163
BE20.30-P- Cap code number 140 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar overpressure 1.4 (+0.1) - 1.4 (+0.1)
1002-01A valve opens Used bar overpressure 1.4 (-0.1) - 1.4 (+0.1)
BE20.30-P- Vacuum valve opens bar vacuum 0.1 0.1 0.5
1003-01A (reference value)
BE20.30-P- Pressure relief Stage 1 bar overpressure - 1.4 (± 1) -
1004-01A valve opens Coolant temp. - > or = -
130/134
Stage 2 bar overpressure - 2.0 (±1) -
Coolant temp. - > or = -
137/143
BE20.30-P- Test pressure for pressure- bar overpressure 1.4 1.4 -
1005-01A testing cooling system

Number Designation 2-stage cap 2-stage Engines
for engine closing cover 160.921 / 923
113.968 in on model in model
model 209 211 452.3/4
BE20.30-P- Cap code number 140/200 - 160
1001-01A
BE20.30-P- Pressure relief New bar overpressure - 1.5 (-0.2) 1.6
1002-01A valve opens Used bar overpressure - 1.5 (-0.2) -
BE20.30-P- Pressure relief Stage 1 bar overpressure 1.4 (±1) 1.5 (-0.2) -
1004-01A valve opens Coolant temp. > or = 135 (+5) -
130/134
Stage 2 bar overpressure 2.0 (±1) 1.5 (-0.2) -
Coolant temp. > or = 145 (+5) -
137/143
BE20.30-P- Test pressure for pressure- bar overpressure 1.4 1.4 1.6

Number Designation Engine Engine Engine
160.922 in 160.910 in 160.920 in
model model model
452.3/4 450.3/4 450.3/4
BE20.30-P- Cap code number 160 160 160

1001-01A
BE20.30-P- Pressure relief New bar overpressure 1.6 1.6 1.6
1002-01A valve opens Used bar overpressure - - -
BE20.30-P- Pressure relief Stage 1 bar overpressure - - -
1004-01A valve opens Coolant temp. - - -
Stage 2 bar overpressure - - -
Coolant temp. - - -
BE20.30-P- Test pressure for pressure- bar overpressure 1.6 1.6 1.6
MAINTENANCE
REPLACE COOLANT - AP20.00-P-2080GZ
ENGINE 113, 156, 272, 273 in MODEL 164
Fig. 89: Identifying Coolant Expansion Reservoir And Cap

Checking
Risk of poisoning caused release the pressure. Do
by swallowing coolant. not pour coolant into
safety glasses.
1 Switch off ignition
2 Unscrew cap (1) on If fluid loss is
expansion reservoir (2) not due to normal
for coolant and check consumption, against
coolant level separate order: ?
Inspect cooling system
for leaks:
Engine 113 in model 164 AR20.00-P-1010GZ
Engines 272, 273 in AR20.00-P-1010GZC
model 164
Engine 156 in model 164, AR20.00-P-1010GZS
251
Engine 156 in model 209 AR20.00-P-1010TMG
Notes on coolant level Model 164, 251 AH20.00-P-1142-
01GZB
Model 209 AH20.00-P-1142-01PI
3 Drain coolant
Drain/fill in coolant Engine 113 in model 164 AR20.00-P-1142GZ
model 164
251
Notes on coolant AH20.00-N-2080-01A
4 Pour in new coolant Use only
approved anticorrosion
and antifreeze agents.
Drain/fill in coolant Engine 113 in model 164 AR20.00-P-1142GZ
model 164
251
Mixture ratio for *BF20.00-P-1001-04A
coolant
MIXTURE RATIO FOR COOLANT

Number Designation Engine all
BF20.00-P-1001- Mixture ratio for Antifreeze/water Up to -37°C 50/50
04A coolant Up to -45°C 55/45
Specifications for service Sheet BB00.40-P-0310-
products 01A
Sheet BB00.40-P-0325-
00A
CAPACITIES & SPECIFICATIONS

COOLING SYSTEM - BF20.00-P-1000
Cooling system - BF20.00-P-1000-02K
Engines 112, 113
COOLING SYSTEM
Number Designation Engine Engines Engines
112 in 112.910/920 112.911/921/941
model 170 in models in model 210
202, 112.940
in model 208
BF20.00- Cooling Total filling capacity Liters approx. 8 approx. 9.5 approx. 10.0
P-1001- system Capacity of Liters approx. 4 approx. 4.75 approx. 5.0
02K anticorrosion/antifreeze
agent down to -37°C
Filling capacity of Liters approx. approx. 5.25 approx. 5.5
anticorrosion/antifreeze 4.5
down to -45°C
Specifications for Sheet BB00.40- BB00.40-P- BB00.40-P-0310-
Operating Fluids P-0310- 0310-01A 01A
01A
Sheet BB00.40- BB00.40-P- BB00.40-P-0325-
P-0325- 0325-00A 00A
00A
COOLING SYSTEM
112.912/946 112.912/946/955 112.913/917/949/954
in model in model 209 in model 211
203
BF20.00- Cooling Total filling capacity Liters 10.5 10.5 9.5

P-1001- system Capacity of Liters approx. 5.25 approx. 5.25 approx. 4.75
Filling capacity of Liters approx. 5.75 approx. 5.75 approx. 5.25
anticorrosion/antifreeze
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-0310-
Operating Fluids 0310-01A 0310-01A 01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0325-
0325-00A 0325-00A 00A
COOLING SYSTEM
112.916/953 112.922/944/972 112.923/943
in model 220 in model 129
BF20.00- Cooling Total filling capacity Liters approx. 10.0 approx. 10.5 approx. 11.75
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P-0310- BB00.40-P-
Operating Fluids 0310-01A 01A 0310-01A
Sheet BB00.40-P- BB00.40-P-0325- BB00.40-P-
0325-00A 00A 0325-00A
COOLING SYSTEM
Number Designation Engine Engine 112.945 in models Engines
112.942 in 463.209/232/233/244/245/250 112.951/976
models 163, in model
113.940/980 639 without
in models code H13
210, or HZ7
113.943/984
in models
208,
113.944 in
model 202

down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P-0310-01A BB00.40-P-
Operating Fluids 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P-0325-00A BB00.40-P-
0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engines Engine Engine
112.951/976 112.960 in 112.961 in
in model 639 model models
with code 170.466 203.065/265
H13 or HZ7 AMG AMG
BF20.00- Cooling Total filling capacity Liters approx. 9.9 approx. approx. 10.5
P-1001- system 8.0
02K Capacity of Liters approx. 5 - -
Filling capacity of Liters approx. 5.5 - -
down to -45°C
Specifications for Operating Sheet BB00.40-P- - -
Fluids 0310-01A
Sheet BB00.40-P- - -
0325-00A
COOLING SYSTEM
Number Designation Engines Engine Engine
112.970 112.973 in 112.975 in
113.965 in model model 220
model 163 230.467
BF20.00-P- Cooling Total filling capacity Liters approx. 12.0 approx. 10.8 approx. 10.4
1001-02K system Capacity of Liters approx. 6.0 approx. 5.4 approx. 5.2
anticorrosion/antifreeze agent
down to -37°C
Filling capacity of Liters approx. 6.75 approx. 6 approx. 5.7
anticorrosion/antifreeze down
to -45°C
Specifications for Operating Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Fluids 0310-01A 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0310-01A 0310-01A
COOLING SYSTEM
113.941/960 113.942/981 113.948/966
in model 220 in model 163 in model 220
Filling capacity of Liters 6.25 approx. 6.25 6.4
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0310-01A 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine Engine Engine 113.962 in models
113.960/986 113.961 463.206/240/241/247/248/249/254
in model in model
215 129
BF20.00- Cooling Total filling capacity Liters approx. 11.5 approx. approx. 12
P-1001- system 12.75
02K Capacity of Liters approx. 5.75 approx. approx. 6
Filling capacity of Liters approx. 6.25 approx. approx. 6.6
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40- BB00.40-P-0310-01A
Operating Fluids 0310-01A P-0310-
01A
Sheet BB00.40-P- BB00.40- BB00.40-P-0325-00A
0325-00A P-0325-
00A
COOLING SYSTEM
113.963 in 113.964 in 113.967/969 in
model model 164 model 211
230.475
BF20.00-P- Cooling Total filling capacity Liters approx. approx. approx. 10.75
1001-02K system 11.5 10.00
Capacity of Liters approx. 5.8 approx. approx. 5.25
down to -45°C
Specifications for Operating Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Fluids 0310-01A 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine Engine Engine 113.982 in
113.967 in 113.968 in models
model 219 model 209, 463.241/243/246
211
Engine
113.969 in
model 211
BF20.00- Cooling Total filling capacity Liters approx. approx. approx. 11.9
P-1001- system 10.65 11.5
02K Capacity of anticorrosion/ Liters approx. approx. approx. 5.95
antifreeze agent down to - 5.65 5.75
37°C
Filling capacity of Liters approx. 6.0 approx. approx. 6.55
down to -45°C
Specifications for Sheet BB00.40- BB00.40- BB00.40-P-0310-
Operating Fluids P-0310- P-0310- 01A
01A 01A
Sheet BB00.40- BB00.40- BB00.40-P-0325-
P-0325- P-0325- 00A
00A 00A
COOLING SYSTEM
113.986/991 in 113.987/988 113.989 in
model 220 model 171
BF20.00-P- Cooling Total filling Liters approx. 13.5 approx. 11.5 approx. 11.5
1001-02K system capacity
Capacity of Liters approx. 6.8 approx. 5.8 approx. 5.55
anticorrosion/
antifreeze agent
down to -37°C
anticorrosion/
antifreeze down to
-45°C
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
113.990 113.991 in 113.992/995 in
model 215 model 230
BF20.00-P- Cooling Total filling Liters approx. 13.2 approx. 14.5 approx. 13.0
1001-02K system capacity
Capacity of Liters approx. 6.6 approx. 7.3 approx. 6.5
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx. 7.3 approx. 8 approx. 7.3
anticorrosion/
antifreeze down to
-45°C
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
model
463.270/271
BF20.00-P-1001- Cooling system Total filling capacity Liters approx. 13.0
02K Capacity of anticorrosion/antifreeze Liters approx. 6.5
Filling capacity of Liters approx. 7.3
anticorrosion/antifreeze down to -
45°C
Specifications for Operating Fluids Sheet BB00.40-P-0310-
01A
Sheet BB00.40-P-0325-
00A
Cooling system - BF20.00-P-1000-02U
Engine 156, 272, 273

MODIFICATION NOTES
6.3.06 Cooling system Engine 272, 273
COOLING SYSTEM
Number Designation Engine 156 in Engine 156 in
model 164, model 209,
251 211, 219
BF20.00-P- Cooling Total filling capacity approx. Liters 7.5 8
1001-02U system Antifreeze/water Up to -37°C 50/50 50/50
Up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P- BB00.40-P-
Sheet BB00.40-P- BB00.40-P-
0325-00A 0325-00A
COOLING SYSTEM
model 216, model 204
221
BF20.00-P- Cooling Total filling capacity approx. Liters 10 5
Up to -45°C 55/45 55/45
0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine 272 Engine 272 in model
in model 164, 171, 209, Engine
211, 251, 272.920/940/941 in
Engine model 203
272.964 in
model 219
Up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P- BB00.40-P-0310-01A
Operating Fluids 0310-01A
Sheet BB00.40-P- BB00.40-P-0325-00A
0325-00A
COOLING SYSTEM

model 230 model 221
Engine Engine
272.960/970 in 272.985 in
model 203 model 219
Up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P-0310- BB00.40-P-
Operating Fluids 01A 0310-01A
Sheet BB00.40-P-0325- BB00.40-P-
00A 0325-00A
COOLING SYSTEM
Number Designation Engine 273 in
model 164, 251
BF20.00-P-1001- Cooling system Total filling capacity approx. Liters 6.5
02U Antifreeze/water Up to -37°C 50/50
Up to -45°C 55/45
Specifications for Sheet BB00.40-P-0310-
Sheet BB00.40-P-0325-
00A
COOLING SYSTEM
Number Designation ENGINE 273 Engine 273 in
in model 211, model 209
219
BF20.00-P- Cooling Total filling capacity approx. Liters 7 7.5
Up to -45°C 55/45 55/45
0325-00A 0325-00A
COOLING SYSTEM
model 230 model 216,
221
BF20.00-P- Cooling Total filling capacity approx. Liters 8 8.5
Up to -45°C 55/45 55/45

0325-00A 0325-00A
CAPACITIES: PASSENGER CARS: ENGINE COOLING SYSTEM - BF20.00-Z-9999AZ
MODEL all
Cooling system ENGINE 104... BF20.00-P-1000-02A

Cooling system ENGINE 119 BF20.00-P-1000-02B
Cooling system ENGINE 120 BF20.00-P-1000-02C
Cooling system ENGINE 601, 602, 603 BF20.00-P-1000-02D
Cooling system ENGINE 604, 605, 606, BF20.00-P-1000-02E
611, 612, 613, 628, 647,
648...
Cooling system ENGINE 111... BF20.00-P-1000-02F
Cooling system ENGINE 112, 113... BF20.00-P-1000-02K
Cooling system ENGINE 166... BF20.00-P-1000-02L
Cooling system ENGINE 137.970 BF20.00-P-1000-02M
Cooling system ENGINE 668... BF20.00-P-1000-02N
Cooling system ENGINE 271 BF20.00-P-1000-02P
Cooling system ENGINE 275, 285... BF20.00-P-1000-02Q
Cooling system ENGINE 155.980 BF20.00-P-1000-02S
Cooling system ENGINE 156, 272, 273... BF20.00-P-1000-02U
Cooling system ENGINE 266, 640... BF20.00-P-1000-02V
Cooling system ENGINE 642 in MODEL BF20.00-P-1000-02W
164, 203, 204, 209, 211,
219, 221, 251 ENGINE
642 in MODEL 463
Cooling system MODEL 251 with BF20.00-P-1000-02X
ENGINE 113
Cooling system ENGINE 629 in MODEL BF20.00-P-1000-02Y
164, 221, 211
Mixture ratio for coolant ENGINE all BF20.00-P-1000-04A
ENGINE COOLING, GENERAL - BA20.00-P-1000
Coolant preheater - BA20.00-P-1000-01A
Engine 111, 112, 113, 119, 155, 271

COOLANT PREHEATER
Number Designation Engine 111 Engine 112, 113 Engine 119
BA20.00-P-1001- Coolant preheater Nm 70 35 70
01A in engine block
COOLANT PREHEATER
BA20.00-P-1001- Coolant preheater in Nm - 70
01A engine block
Engine cooling, general - BA20.00-P-1000-02B
Engines 111, 112, 113, 155

Number Designation Engine Engines 112, Engine Engine 155
111.951/ 113.940/941/ 113.989
955/981 942/943/944/
945/946/948/
960/961/963/
964/965/966/
967/968/971/
980/981/984/
986/987/988/
990/991/992/ 995
BA20.00-P- Coolant drain Nm 40 12 12 -
1001-02B plug to
crankcase
Engine cooling, general - BA20.00-P-1000-02E
Engine 272, 273

BA20.00-P-1001- Coolant drain plug to Nm 12 12
02E crankcase
TIGHTENING TORQUES: PASSENGER CARS: ENGINE COOLING SYSTEM - BA20.00-Z-9999AZ
MODEL all
Coolant preheater ENGINE 111, 112/, 113/, 119, 155.980, BA20.00-P-1000-

271 01A
Coolant preheater ENGINE 602, 603, 604, 605, 606, 611, BA20.00-P-1000-
612, 613 01B

Engine cooling, ENGINE 611, 612, 613, 628, 646, 647, BA20.00-P-1000-
general 648... 02A
Engine cooling, ENGINE 111, 112, 113, 155... BA20.00-P-1000-
general 02B
Engine cooling, ENGINE 271 BA20.00-P-1000-
general 02C
Engine cooling, ENGINE BA20.00-P-1000-
general 275.950 /951 /952 /953 /954 /980 /981 /982, 02D
285.950 /980
Engine cooling, ENGINE 272, 273 BA20.00-P-1000-
general 02E
Engine cooling, ENGINE 640 BA20.00-P-1000-
general 02F
Engine coolant pump, ENGINE 601 /, 602 //982 /983 BA20.10-N-1000-
engine coolant 01B
thermostat
Coolant pump, ENGINE 601, 602, 603, 604, 605, 606, BA20.10-P-1000-
coolant thermostat 611, 612, 613, 647... 01A
Engine coolant pump, ENGINE 103/, 104/, 111, 119, 120 BA20.10-P-1000-
engine coolant 01B
thermostat
Coolant pump, ENGINE 113, 137, 155, 275, 285... BA20.10-P-1000-
coolant thermostat 01C
Coolant pump, ENGINE 166.940/960/961/990/991/995 BA20.10-P-1000-
coolant thermostat 01D
Coolant pump, ENGINE 668.914/940/941/942 BA20.10-P-1000-
coolant thermostat 01E
Coolant pump, ENGINE 628.960/961/962/963,629 BA20.10-P-1000-
coolant thermostat 01F
Coolant pump, ENGINE 646.951/8/961/962/963/966, 647, BA20.10-P-1000-
coolant thermostat 648 01G
Coolant pump, ENGINE 271 BA20.10-P-1000-01I
coolant thermostat
Coolant pump, ENGINE 113.987/988/989/990/991, 155 BA20.10-P-1000-
coolant thermostat 01L
Coolant pump, ENGINE 112... BA20.10-P-1000-
coolant thermostat 01M
Coolant pump, ENGINE 266.920/940/960/980 BA20.10-P-1000-
coolant thermostat 01P
Coolant pump, ENGINE 640 BA20.10-P-1000-
coolant thermostat 01Q
Coolant pump, ENGINE 642/ BA20.10-P-1000-
coolant thermostat 01S
Coolant pump, ENGINE 272, 273 BA20.10-P-1000-

coolant thermostat 01U
Coolant pump, ENGINE 156 BA20.10-P-1000-
coolant thermostat 01V
Radiator, coolant ENGINE 601, 602, 646... BA20.20-N-1000-
hoses 01B
Radiator, coolant ENGINE 103, 111, 112, 113, 119, 137, BA20.20-P-1000-
hoses 155, 272, 273, 275... 01A
Radiator, coolant ENGINE 166.940/960/961/990/991/995 BA20.20-P-1000-
hoses 01C
Radiator, radiator ENGINE 611.960/961 BA20.20-P-1000-
hoses 01D
Radiator, radiator ENGINE 120 BA20.20-P-1000-
hoses 01F
Radiator, coolant ENGINES 668.914/940/941/942 BA20.20-P-1000-
hoses 01G
Radiator, radiator ENGINE 601, 602, 603, 604, 605, 606, 613 BA20.20-P-1000-
hoses 01H
Radiator, coolant ENGINE 628.963/961 BA20.20-P-1000-01I
hoses
Radiator, coolant ENGINE BA20.20-P-1000-
hoses 271.940/941/942/943/944/946/948/955/956 01K
Radiator, coolant ENGINE 612.963 in MODEL 163.113 BA20.20-P-1000-
hoses ENGINE 628.963 in MODEL 163.128 01L
Radiator, coolant ENGINE 266.920/940/960/980 BA20.20-P-1000-
hoses 01M
Radiator, coolant ENGINE 640 BA20.20-P-1000-
hoses 01N
Fan, fan clutch ENGINE 103, 104, 111, 119, 120, 601, BA20.40-P-1000-
602, 603, 604, 605, 606, 612, 613... 01A
Fan, fan clutch ENGINE 112, 113, 155... BA20.40-P-1000-
01B
Fan shroud ENGINE 285.950 BA20.40-P-1000-
03A
Fan shroud ENGINE 111, 112, 113, 271, 272, 273, BA20.40-P-1000-
611, 612, 646... 03B
Fan shroud ENGINE 113.967/990 in MODEL 219 BA20.40-P-1000-
03C
Heat exchanger ENGINE 271 BA20.50-P-1000-
01A
COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P-1000
Coolant pump, coolant thermostat - BA20.10-P-1000-01C

Engines 113, 137, 155, 275, 285
Coolant pump, coolant thermostat

Number Designation Engines 113.940/941/ Engines Engines
942/943/944/ 945/946/948/ 113.964/971 137, 275
960/961/962/ 963/965/966/
967/968/969/ 980/981/982/
984/986/992 993/995
Thread
not pre- M6 Nm 14 14 -
tapped
Thread
Self-tapping not pre- M8 Nm 35 35 -
BA20.10- tapped
screw for
P-1001-
coolant pump Thread
01C
to timing case pre- M6 Nm 10 10 -
tapped
Thread
pre- M8 Nm 25 25 -
tapped
BA20.10-
P-1002- Belt pulley to coolant pump Nm 10 10 8
01C
BA20.10-
Bolt for coolant
P-1003- M6 Nm 10 10 15
thermostat housing
01C
BA20.10-
Coolant pump at the
P-1004- M7 Nm 10 10 14
timing case
01C
BA20.10- Bolt, coolant line to
P-1005- housing of coolant M6 Nm - - 8
01C thermostat
BA20.10-
Bolt, coolant line to
P-1006- M6 Nm - - 8
cylinder head
01C
BA20.10-
Bolt, coolant thermostat
P-1007- M6 Nm - - 8
housing to cylinder head
01C
BA20.10-
Bolt, guide pulley to
P-1008- M8 Nm - 20 -
coolant pump housing
01C
Coolant pump, coolant thermostat

155 285
Thread not pre-

M6 Nm - -
tapped
Thread not pre-
M8 Nm --
BA20.10-P-1001- Self-tapping screw for coolant pump tapped
01C to timing case Thread pre-
M6 Nm - -
tapped
Thread pre-
M8 Nm - -
tapped
BA20.10-P-1002-
Belt pulley to coolant pump Nm - 8
01C
BA20.10-P-1003-
Bolt for coolant thermostat housing M6 Nm 9 15
01C
BA20.10-P-1004-
Coolant pump at the timing case M7 Nm - 14
01C
BA20.10-P-1005-
Bolt, coolant line to housing of coolant thermostat M6 Nm - 8
01C
BA20.10-P-1006-
Bolt, coolant line to cylinder head M6 Nm - 8
01C
BA20.10-P-1007-
Bolt, coolant thermostat housing to cylinder head M6 Nm - -
01C
BA20.10-P-1008-
Bolt, guide pulley to coolant pump housing M8 Nm - -
01C
Coolant pump, coolant thermostat - BA20.10-P-1000-01U
Engine 272, 273

BA20.10-P-1001- Self-tapping bolt of coolant pump to M7 Nm 25 25
01U timing case cover
BA20.10-P-1002- Bolt connecting coolant pump to M8 Nm 20 20
01U crankcase
BA20.10-P-1003- Bolt connecting coolant thermostat housing Nm 25 25
01U to timing case cover
BA20.10-P-1004- Bolt connecting poly-V-belt guide pulley to Nm 35 35
01U coolant pump
BA20.10-P-1005- Bolt connecting coolant pipe to coolant Nm - 9
01U thermostat housing
BA20.10-P-1006- Bolt connecting coolant pipe to cylinder Nm - 9
01U head front cover
Coolant pump, coolant thermostat - BA20.10-P-1000-01V

Engine 156
MODIFICATION NOTES
6.2.07 Bolt, coolant pump to Engine 156
timing case cover and
crankcase

BA20.10-P-1001- Bolt, coolant pump M6x30 Nm 9
01V to timing case M6x80 Nm 9
cover and M8x80 Nm 20
crankcase
M8x100 Nm 20
BA20.10-P-1002- Bolt, thermostat to M6x25 Nm 8.5
01V timing case cover M8x80 Nm 20
BA20.10-P-1003- Bolt, shutoff valve M6x16 Nm 8.5
01V to cylinder head at
the right rear
BA20.10-P-1004- Heating water pipe M8x12 Nm 20
01V to crankcase for
shutoff valve for
hot water hose
BA20.10-P-1005- Bolt, preheater M6x40 Nm 10
01V
FAN, FAN CLUTCH/SHROUD - BA20.40-P-1000
Fan, fan clutch - BA20.40-P-1000-01B
Engine 112, 113, 155
FAN, FAN CLUTCH

Number Designation Engine Engine 113 Engine 155
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
BA20.40-P-1001- Fan to viscous Nm 10 10 -
01B clutch
BA20.40-P-1002- Viscous clutch Nm 45 45 -
01B to bearing body
Fan shroud - BA20.40-P-1000-03B
Engine 111, 112, 113, 271, 272, 273, 611, 612, 646
FAN SHROUD
Number Designation Engine Engine Engines Engine
111.951 112.912/916/946/953/961 112. in 113.968/987 in
955/981 in in Model 203 model 209 model 209
Model 203
BA20.40-P- Bolt, fan Nm 6 6 6 6
1001-03B wheel to fan
motor
BA20.40-P- Bolt, fan Nm 8 8 8 8
1002-03B wheel to
notch
BA20.40-P- Bolt, Nm 3 3 3 3
1003-03B electronics to
notch
BA20.40-P- Bolt, fan Nm - - - -
1004-03B motor to fan
shroud
FAN SHROUD
Number Designation Engine Engine Engine Engine 271
113.988 in 113.989 in 271.921/940/942/946/948 in model
model model 171 in model 203 209
203.076/276
BA20.40-P- Bolt, fan Nm 6 6 6 6
1001-03B wheel to fan
motor
BA20.40-P- Bolt, fan Nm 8 - 8 8
1002-03B wheel to
notch
BA20.40-P- Bolt, Nm 3 - 3 3
notch
BA20.40-P- Bolt, fan Nm - 8 - -
1004-03B motor to fan
shroud
FAN SHROUD
Number Designation Engine 271 in Engine 272 in Engine 272 in Engine 272
model 171 model 164 model 171 in model 203
BA20.40-P- Bolt, fan wheel Nm 6 6 6 6
1001-03B to fan motor
BA20.40-P- Bolt, fan wheel Nm - - - -
1002-03B to notch
BA20.40-P- Bolt, Nm - 8 - -
notch
BA20.40-P- Bolt, fan motor Nm 8 - 8 8
1004-03B to fan shroud
FAN SHROUD
Number Designation Engine 272 in Engine 272 in Engine 272, 273
model 209 model 251 in model 221
BA20.40-P-1001- Bolt, fan wheel to Nm 6 6 6
03B fan motor
BA20.40-P-1002- Bolt, fan wheel to Nm - - -
03B notch
BA20.40-P-1003- Bolt, electronics Nm - 8 -
03B to notch
BA20.40-P-1004- Bolt, fan motor to Nm 8 - 8
03B fan shroud
FAN SHROUD
Number Designation Engine 611.962 Engine 612.967 Engine 646.962
612.962 in in model 209 in model 203
Model 203
03B fan motor
03B notch
BA20.40-P-1003- Bolt, electronics Nm 3 3 3
03B to notch
BA20.40-P-1004- Bolt, fan motor to Nm - - -
03B fan shroud
2006-2008 ENGINE Electrical System - Engine - 164 Chassis
2006-2008 ENGINE
Electrical System - Engine - 164 Chassis
GENERAL INFORMATION
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01D
Engine 104, 111, 112, 113, 119, 120, 156, 271
 To avoid damage to control unit connect and disconnect the two connectors on control unit only when
 Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as anti-theft protection.
 Install only original ignition system components.
 Do not operate ignition system at starting speed unless all of the ignition cables are connected.
 No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or
pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is
running.
 Every high voltage circuit must be loaded with at least 2 kohms (spark plug connector).
 If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with
a spark plug at a cylinder ignition cable. Ensure that the spark plug has good contact to ground.
 Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect
connector "2" from control unit.
Engine 120 has two fuel injection and ignition systems.
Use of testers
 Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
 If the shot-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not
possible to conduct the test with this test instrument.
 Do not connect test lamp to ignition coil terminals 1 and 15.
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01V
Engine 272, 273
 Before disconnecting the connector (R) at the ME-SFI [ME] control unit (N3/10), turn the key in the
ignition switch (EIS [EZS] control unit) to the "0" position.
 Disconnect the battery before disconnecting the connector (L) at the ME-SFI [ME] control unit (N3/10).
 Install only original ignition system components.
Shown on engine 272

Fig. 1: Identifying ME-SFI [ME] Control Unit And Connectors - Shown On Engine 272
Fig. 2: Identifying Spark Plug Connector And Ignition Coils - Shown On Engine 272
 Do not run the ignition system without fully connected lines or without the spark plug connector (a).
 Do not disconnect the connectors at the ignition coils (T1/1 to T1/8) at starting speed or when the engine
is running.
 Do not take off the ignition coils (T1/1 to T1/8) from the spark plugs at starting speed or when the engine
is running.
 Before working at starting speed, for example, check the compression pressure, turn the key in the EIS
[EZS] control unit to the "0" position.
BASIC KNOWLEDGE
COMPONENT DESCRIPTION FOR SPARK PLUGS - GF15.10-P-2000AMG

Location
On each cylinder, a spark plug is inserted from the top of the cylinder head to centrally in the combustion
chamber.
Fig. 3: Identifying Spark Plug And Ignition Coil Cylinder 8

Task
The spark plugs ignite the suctioned and compressed fuel-air mixture due to arcing between the electrodes.
Function
The ignition voltage flows from the ignition lines of the directly plugged in ignition coils to the spark plugs and
causes arcing in the air gap between the central electrode and ground electrode.
All the spark plug characteristics are defined by the type symbols provided by the manufacturer (e.g. heat
rating, seat shape, thread, width across flats, electrode material, spark position).
SPARK PLUGS, DESCRIPTION OF COMPONENTS - GF15.10-P-2000BK
Location
Two spark plugs per cylinder are fitted in the cylinder head
Fig. 4: Identifying Spark Plugs

Task
The spark plugs ignite the suctioned and compressed fuel-air mixture due to arcing between the electrodes.
Function
The ignition voltage flows from the ignition lines of the ignition coils to the spark plugs and causes arcing in the
air gap between the central electrode and ground electrode.
All spark plug characteristics are defined in the model formula for the specific manufacturer (e.g. heat rating,
seat shape, thread, width across flats, electrode material, spark location).
COMPONENT DESCRIPTION FOR SPARK PLUGS - GF15.10-P-2000V

Location
In the cylinder head, each cylinder has a spark plug located in the center between the engine valves.
Task
The compressed fuel-air mixture is combusted by sparks between the electrodes according to the actuation from
the ME control unit.
Design
In the manufacturer's specific type symbols, all the spark plug features are assigned (e. g. heat rating, shape of
seating, thread, width across flats, electrode material, spark position).
Fig. 5: Identifying Spark Plugs - Engine 272.920/940/941

Function
The ignition voltage flows from the ignition lines of the directly plugged in ignition coils to the spark plugs and
causes arcing in the air gap between the central electrode and ground electrode.
Spark plug table, see IS, Group 15.
IGNITION COIL, COMPONENT DESCRIPTION - GF15.10-P-2100AMG
Location
A dedicated ignition coil is plugged straight onto the spark plug (R4) for each cylinder.
Fig. 6: Identifying Ignition Coil, Component Location

Task
The ignition coils provide sufficient ignition energy under all operating conditions for the respective ignition
circuit.
Design (ignition coil with integrated output stage)
Fig. 7: Identifying Ignition Coil With Integrated Output Stage Design

Function
An output stage is located in each ignition coil for the ignition coil primary circuit. The ME-SFI control unit
(N3/10) actuates the ignition coil primary circuit between connection (2) and (4). The current flow in the
primary coil (P) causes a magnetic field to form. The dwell angle control determines the operating time of the
ignition coil primary circuit and thus the magnetic saturation of the ferrous core of the ignition coil.
The primary current flow is interrupted at the moment of ignition timing point. The sudden collapse of the
magnetic field generates the ignition voltage in the secondary coil (S), which is fed directly to the spark plugs
(R4).
The diode (D) is fitted to suppress an additional ignition spark when the primary current is switched on.
Because of the diode it is not possible to measure the resistance of the secondary coil.
For diagnosis of the ignition coils, the primary current is measured. The capacitive tap is used to connect
measuring equipment.
COMPONENT DESCRIPTION OF IGNITION COIL - GF15.10-P-2100BK
Location
For each cylinder, a double ignition coil is located at the cylinder head cover.
Fig. 8: Identifying Ignition Coil

Task
The ignition coils provide sufficient ignition energy under all operating conditions for the respective ignition
circuit.
Design
Two spark plugs per cylinder, controlled by a double ignition coil.
The double ignition coils have two separate ignition circuits, two ignition cable connections and a 3-pole plug
Fig. 9: Identifying Ignition Coils Cylinders

Function
Fig. 10: Ignition Coils Function Diagram

The ME control unit simultaneously actuates both primary windings of the double ignition coils at circuits 1a
and 1b to ground.
The primary current flow is interrupted at the moment of ignition timing point. As a result of the sudden
collapse of the magnetic field the ignition voltage is generated in the secondary windings.
The respective ignition voltage is sent via high-voltage terminals 4a and 4b via short ignition lines and spark
plug connectors to the spark plugs.
The voltage supply for the double ignition coils is provided via "circuit 15".
Diodes are built-in to the secondary ignition circuit to suppress additional ignition sparks when the primary
current is switched on.
Because of the diodes, it is not possible to measure the resistance in the secondary windings.
COMPONENT DESCRIPTION FOR AN IGNITION COIL - GF15.10-P-2100V

Shown on ENGINE 272
Fig. 11: Identifying Ignition Coil Cylinder 1 To 6 - Shown On Engine 272

Location
For each cylinder, a dedicated ignition coil is plugged directly onto the spark plugs.
Task
Supplying adequate ignition energy in all operating conditions for the particular ignition circuit.
Shown on engine 272
Fig. 12: Identifying Ignition Coils - Shown On Engine 272

Shown on engine 273
Fig. 13: Identifying Ignition Coils - Shown On Engine 273

Design
Shown on engine 272
Fig. 14: Ignition Coil Design - Shown On Engine 272

The ignition output stages are integrated in the ignition coils.
Internal circuitry of ignition coils with integral output stage
Shown on engine 272
Fig. 15: Circuit Diagram Of Ignition Coils With Integral Output Stage - Shown On Engine 272
Function
An output stage is located in each ignition coil for the primary circuit. The ME control unit actuated the ignition
coil primary circuit between terminals 2 and 4. The current flow in the primary coil (L1) causes a magnetic field
to form. The dwell angle control determines the operating time of the ignition coil primary circuit and thus the
magnetic saturation of the ferrous core of the ignition coil.
The primary current flow is interrupted at the moment of ignition timing point. The sudden collapse of the
magnetic field generates the ignition voltage in the secondary coil (L2) which is fed directly to the spark plugs.
The voltage supply of the ignition coils is protected at circuit 87 M1
A diode is integrated in each ignition coil for suppressing additional ignition sparks when the output stage is
switched off.
Because of the diodes, it is not possible to measure the resistance in the secondary windings. For diagnosis
of the ignition coils, the primary current is measured. The capacitive tap is used to connect measuring
equipment.
ME-SFI IGNITION SYSTEM - FUNCTION - GF15.12-P-0001BK

Fig. 16: ME-SFI Ignition System Function Diagram

When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor by the teeth
of the driven plate.
During this operation, each tooth generates an alternating voltage signal. No voltage is generated as a result of
the gap created by 2 missing teeth. The ME-SFI control unit detects the TDC position of the crankshaft with the
2nd negative slope after the gap.
If the signal from the camshaft Hall sensor is at 0 V ("low") at this moment, the ME control unit processes this
in order to detect ignition TDC. This is used for actuating the ignition coils and fuel injection valves.
The ME control unit actuates the ignition coils. When the ignition coil primary circuit is turned off, high-
voltage is generated via induction.
High-voltage is distributed statically and directly from ignition coils to spark plugs.
Advantages are
 Essentially lower electromagnetic base noise (no naked sparks)

 no rotating parts
 Noise reduction
 no high voltage connections.
The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
 Engine load
 Engine speed
 Crankshaft position
 Camshaft position
 Coolant temperature sensor
 Knock signals
 Throttle valve position
 intake air temperature.
The ignition angle can only be tested with the STAR DIAGNOSIS.
The engine torque can be changed rapidly via the ignition angle.
The following functions require adaptation of ignition timing.
Catalytic converter heating-up
To bring the catalytic convertor quickly to operating temperature, the ignition angle is constantly adjusted for
approx. 20 seconds to "Late" when the coolant temperature at start is between 15°C and 40°C and when with
automatic transmission, selector lever position P or N is selected.
Idling
To assist the idle speed control, the ignition angle can be retarded by as much as 36° crank angle or advanced by
as much as 20° crank angle.
Inertia fuel shutoff
The ignition angle is briefly retarded when combustion is resumed (fuel injection valves actuated) in order to
prevent a sudden increase in torque.
AC system
Shortly before the coolant compressor is switched on, the engine torque increases. In doing so, the ignition
angle is adjusted for a short time to "Early" to support idle speed control.
Transmission overload protection
In order to protect the shift elements of the automatic transmission from excessive thermal stresses during
powershifts, the ignition angle is briefly retarded during the gearshift and the engine torque is thus reduced.
The ME control unit is supplied with a signal for this purpose by the transmission control unit over the CAN
databus.
ESP control mode

In order to reduce the engine torque as rapidly as possible in the ESP/ASR control mode, the ignition angle is
retarded by the throttle valve actuator (opening angle reduced) before the commencement of the control cycle.
The information flows from the ESP/ASR control unit over the CAN databus to the ME control unit.
Intake air temperature/coolant temperature
To prevent the knock angle at an air intake temperature over approx. 35°C or a coolant temperature over
approx. 105°C, the ignition angle is adjusted to "Late" under load.
Anti-knock control (AKC)
During uncontrolled combustion (knocking) at one or several cylinders, the ignition angle is adjusted to "Late"
at the knocking cylinders.
Component description for the engine electronics control unit GF07.61-P-6000BK

Component description for the knock sensor GF07.04-P-6030BK
Component description for the crankshaft position sensor GF07.04-P-6010BK
Component description for the camshaft Hall sensor GF07.04-P-6020BK
Component description for the coolant temperature sensor GF07.04-P-6040BK
Component description for the hot film MAF sensor GF07.07-P-6000BK
Component description for the spark plugs GF15.10-P-2000BK
Component description for the ignition coil GF15.10-P-2100BK
ME-SFI synchronization of fuel injection and firing order - function GF07.61-P-4009BK
ME engine speed signal - function GF07.61-P-3017BK
Anti-knock control - function GF15.12-P-4024BK
ME-SFI IGNITION SYSTEM, FUNCTION - GF15.12-P-0001V

Shown on engine 272 in model 171

Fig. 17: ME-SFI Ignition System Function Diagram - Shown On Engine 272 In Model 171
Cylinder arrangement and ignition firing order
Fig. 18: Identifying Cylinder Arrangement And Ignition Firing Order

The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
 Air mass
 Position and rpm of crankshaft
 Positions of intake camshafts
 Positions of exhaust camshafts

 Intake air temperature
 Knock sensor signals
 Intake manifold air pressure
 Engine torque requests
The ME-SFI [ME] control unit interrupts the respective ignition coil at the moment of the ignition timing of the
primary circuit to "terminal 1".
Ignition angle adaptation
For the following partial functions an ignition angle adjustment in the direction "retarded" or "advanced" can
take place:
 Catalytic converter heating-up

 Overheating / knock protection
 Deceleration fuel shutoff
 Transmission overload protection (with automatic transmission 722.9)
 Anti-knock control [AKC]
 Engine torque requests
The ignition angle can only be checked using the DAS.

for the ME-SFI [ME]
control unit
for the knock sensor
for the pressure sensor
sensor
for the camshaft Hall
sensor
for the coolant
temperature sensor

flow sensor
for spark plugs
for ignition coils
sensor
actuator
ANTI-KNOCK CONTROL - FUNCTION - GF15.12-P-4024BK
Fig. 19: Anti-Knock Control Function Diagram

The task of the anti-knock control is to ensure knock-free operation of the engine with different fuels and in all
operating conditions from idling speed up to maximum engine speed. For this purpose, if uncontrolled
combustion (knocking) occurs, the ignition angle at the relevant cylinder or cylinders is retarded.
The anti-knock control (AKC) function is integrated in the ME-SFI control unit.
Input signals:
 Recognition of knocking over knocking sensors

 Engine speed from crankshaft position sensor
 Camshaft position (ignition circuit identification) by means of camshaft Hall sensor
 Engine temperature from coolant temperature sensor
 Air mass from hot film MAF sensor
 Engine load by means of accelerator pedal sensor
 Presetting (programming) by means of STAR DIAGNOSIS.
Output signals:
 Ignition angle correction for specific cylinder to the map value calculated by the ME control unit
 The emergency running ignition angle for a detected fault on the knock sensors.
The anti-knock control is active from engine start. If knocking is detected at a cylinder, the electronic mapped
ignition angle of this cylinder is retarded from the next ignition. If knocking continues the ignition angle will be
adjusted step by step towards "retard" until the maximum retarding of the ignition timing depending in the
engine speed is achieved.
If knocking-free combustion exists, the retardation is reduced in stages after a few ignitions (depending on
engine speed) until the original performance map value is achieved or knocking once again occurs.
If the anti-knock control specifies retardation of the ignition angle for a lengthy period, the engine control
system reduces the engine power output as a protection of the engine.
Faults if knocking detected
If no signals are received from the knock sensor, the ignition angle of all cylinders is retarded by as much as a
15° crank angle for safety reasons, depending on engine speed and temperature. The anti-knock control and the
adaptation are blocked and a fault is stored in the fault memory.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active as of a coolant temperature of approx. 50°C. Any corrections
required to the ignition angle because of knocking combustion are constantly detected for the specific cylinder
and stored together with the relevant operating state of the engine (engine load/speed range).
The stored adaptation value is taken into account in the output of the individual cylinder angles so that each
cylinder is immediately operated with the optimal ignition angle.
During an abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect
adaptation values.
A default setting for the RON correction can be programmed using the STAR DIAGNOSIS.
The ignition angle corrections of the overheating and pinging protection, intake air temperature correction and
anti-knock control are added together on the basis of the performance map.

Component description for the camshaft Hall sensor GF07.04-P-6020BK
Component description for the knock sensor GF07.04-P-6030BK
Component description for the hot film MAF sensor GF07.07-P-6000BK
Component description for the ignition coil GF15.10-P-2100BK
THE ANTI-KNOCK CONTROL FUNCTION - GF15.12-P-4024V


Fig. 20: Anti-Knock Control Function Diagram - Shown On Engine 272.963 In Model 171
The task of the anti-knock control AKC is to ensure knock-free operation of the engine with different fuels and
in all operating conditions from idling speed up to maximum engine speed.
For this purpose, if uncontrolled combustion (knocking) occurs, the ignition angle at the knocking cylinders is
retarded.
The anti-knock control (AKR) is integrated in the ME-SFI [ME] control unit.
Input signals:
 Motor speed (crankshaft Hall sensor)

 Camshaft position (camshaft Hall sensor)
 Recognition of knocking over 2 knocking sensors
 Engine temperature (coolant temperature sensor)
 Engine load (hot film mass air flow sensor)
 Accelerator pedal position (accelerator pedal sensor)
 Precontrol by means of automatic RON switch (internal)
 RON correction with STAR DIAGNOSIS.
Output signals:
 Ignition angle correction for specific cylinder to the map value calculated by the ME control unit
 Ignition angle emergency mode if fault identified.
The anti-knock control is active from a coolant temperature of 40°C. If cylinder knocking is recognized above
an engine load of about 40%, its ignition angle is adjusted to retarded by about a 3.0° crank angle after the next
ignition. If knocking continues to be detected, the ignition angle is continuously retarded in steps of a 3° crank
angle until the maximum retardation is reached (approx. a 10 -15° crank angle, depending on the engine speed).
The automatic RON switch also influences the maximum retarding of the ignition timing - the higher the
selected RON stage, the less is the maximum retarding of the ignition timing.
If knocking-free combustion exists, the retardation is reduced in steps of approx. 0.75° crank angle after a few
ignitions (depending on the engine speed) until the map value is achieved, or knocking occurs again.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active from a coolant temperature of approx. 75°C. Any corrections
required to the ignition angle because of knocking combustion are constantly detected for the specific cylinder
and stored together with the relevant operating state of the engine (engine load/speed range).
The stored adaptation value is taken into account in the output of the individual cylinder angles so that each
cylinder is immediately operated with the optimal ignition angle.
During abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect adaptation
values.
Faults if knocking is detected
If no signals are received from the knock sensors, the ignition angle of all cylinders is retarded by as much as a
11° crank angle for safety reasons, depending on engine speed and temperature. The anti-knock control and the
adaptation are deactivated and a fault is stored.
Automatic RON switch
In addition to the RON correction using STAR DIAGNOSIS, the antiknock control features an automatic RON
switch. This detects a persistent high knocking tendency of the engine and assists the anti-knock control by
means of an appropriate pre-control.
This is done by analyzing the stored adaptation values, the ignition angles of all the cylinders and the number of
control interventions in certain engine load and speed ranges. Depending on the threshold which has been
exceeded, the RON value is adjusted by one or several stages. The value is retained until the engine is switched
off.
After engine start, only the RON correction which is carried out by means of STAR DIAGNOSIS is at first
active.

for the ME-SFI [ME]
control unit
for a knock sensor
sensor
for the camshaft Hall
sensor
for the coolant
temperature sensor
for the hot film MAF
sensor
sensor
ME-SFI synchronization GF07.61-P-4009V
of fuel injection and firing
order function
CDI GLOW FUNCTION - GF15.20-P-3004P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 251.0 /1
The preglow system warms up the engine combustion chamber to the temperature required for ignition of the
fuel-air mixture. For preheating, one differentiates between the following conditions:
 Preglowing
 Start-ready glowing
 Start-glowing
 Afterglowing
 Diagnostic glowing
 Diesel particulate filter (DPF) preheating
 Emergency glowing
Preglowing
For vehicles except model 461 the CDI control unit (N3/9) receives the message "terminal 15 ON" via the
Control Area Network bus Class C (engine compartment) (CAN-C) from the EIS [EZS] control unit (N73).
For model 461 the CDI control unit receives the signal "terminal 15 ON" discretely via the ignition/starter
switch (S2/1). The CDI control unit reads the coolant temperature over the coolant temperature sensor (B11/4)
and actuates the glow time output stage (N14/3) and the preglow indicator lamp (A1e16) over the local
interconnect network (LIN) in response depending on the coolant temperature. The glow time output stage then
actuates the glow plugs (R9) on the plus side. The preglow indicator lamp goes out after preglowing has
finished.
If an error occurs in the preglow system, at the glow plugs or on the lines then this is shown by the preglow
indicator lamp and also stored in the CDI control unit.
Start-ready glowing (except model 461)
Once the preglow indicator lamp goes out then an adequately high temperature has been secured for certain
running of the engine. If the CDI control unit receives the information "Circuit 50 ON" over CAN-C from the
EIS [EZS] control unit it will continue to actuate the glow time output stage for a certain time irrespective of the
coolant temperature which in turn actuates the glow plugs.
Start-ready glowing (model 461)
Once the preglow indicator lamp goes out then an adequately high temperature has been secured for certain
running of the engine. If CDI control unit receives the signal "terminal 50 ON" discretely via the ignition/starter
switch, it will continue to actuate the glow time output stage for a certain amount of time irrespective of the
coolant temperature, which in turn actuates the glow plugs.
Start-up glowing (except model 461)
Start-up glowing is used to stabilize the cold start engine speed.
If the CDI control unit receives the information "Circuit 61 ON" over CAN-C from the EIS [EZS] control unit
then the glow time output stage will be actuated over LIN. The glow time output stage reacts by actuating the
glow plugs. In this way the first engine cycles and the eventual running of the engine are supported.
Start-up glowing (model 461)
If the CDI control unit receives the information "terminal 61 ON" discretely via the ignition/starter switch then
the glow time output stage will be actuated over LIN. The glow time output stage reacts by actuating the glow
plugs. In this way the first engine cycles and the eventual running of the engine are supported.
Afterglowing
Afterglowing improves engine running after a cold start and improves the engine warm-up.
After a successful engine start, the CDI control unit reads in the coolant temperature through the coolant
temperature sensor and actuates the glow plugs over the glow output stage according to the coolant temperature.
Diagnostic glowing
This function ensures that the preglow indicator lamp is actuated in the instrument cluster (A1) if a fault occurs
in the preheating system.
DPF glow function with code (474) Particulate filter (except model 461)
The DPF glow function is used for increasing the load and for combustion stabilization and thus supports
regeneration of the DPF.
The CDI control unit receives the message "Circuit 50 ON" over the CAN-C from the EIS [EZS] control unit.
The CDI control unit reacts by actuating the Glow time output stage.
DPF glow function with code (474) Particulate filter (model 461)
The DPF glow function is used for increasing the load and for combustion stabilization and thus supports
regeneration of the DPF.
To do this CDI control unit receives the signal "terminal 50 ON" via the ignition/starter switch. The CDI control
unit reacts by actuating the Glow time output stage.
Emergency glowing
If a problem in communication occurs between the CDI control unit and the glow time output stage so that the
glow time output stage does not recognize any activity 2 seconds after activation through terminal 87, the
emergency glowing function is actuated for 180 seconds. If communication is missing during a glowing process
for more than 250 ms then the glowing process will be continued for 180 s.
If no new glow demand is received from the CDI control unit then emergency glowing stops after 180 s.
Coolant temperature sensor, GF07.04-P-

B11/4
component description 6040P
Component description for CDI Model 203, 209 GF07.16-P-
control unit N3/9 6000P
Model 211, 219 GF07.16-P-
N3/9 6000T
Model 164, 463 GF07.16-P-
N3/9 6000GZ
N3/9 6000RT
N3/9 6000GX
Model 164.1/8, 203.0/2, 209.3/4, 211.0/2/6,
Component description for the glow GF15.20-P-
219.3, 251.0/1, 463
time output stage 4010P
N14/3
N14/3 4010GX
Model 164.1/8, 203.0/2, 209.3/4, 251.0/1, 461,
463
Engine 642.920 in model 211.020/220/620,
219.322
Component description for glow Engine 642.921 in model 211.084/089/ 284/289 GF15.20-P-
plugs Engine 642.920 in model 211.022 except code 4020P
(494) USA version
Engine 642.920 in model 211.022/222 except
code (498) Japan version
R9
Engine 642.920 in model 211.022 with code
(494) USA version
Engine 642.920 in model 211.022/222 with code GF15.20-P-
(498) Japan version 4020TU
Engine 642.920 in model 211.024
R9
COMPONENT DESCRIPTION FOR THE GLOW TIME OUTPUT STAGE - GF15.20-P-4010P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1
Shown except code (494) USA version
Fig. 21: Identifying Glow Time Output Stage

Location
The glow time output stage is located on the engine at the front next to the vacuum pump.
Task
The glow time output stage has the task, for "terminal 87 ON" and for a coolant temperature < 40°C to initiate
the glowing process. The CDI control unit (N3/9) transmits control signals over the local interconnect network
(LIN) which the glow time output stage concerts into a performance map dependent glow plug voltage. The
glow heating is interrupted if no data transfer takes place with the CDI control unit. The glow time output stage
reports the current operating condition (preheat "ON" or "OFF") continuously to the CDI control unit. A system
error is also sent to the CDI control unit.
For a glowing process of the glow time output stage one differentiates between the following types of glowing:
 Preglowing
Enables the temperature of the glow plugs (R9) to be reached rapidly, which is necessary for starting the
engine.
 Start-readiness glowing
Provides an adequately high temperature after preglowing until the engine starts.
 Start-glowing
Supports the first working cycles and running up of the engine on starting.
 Afterglowing
Map-controlled achievement of temperature to support combustion.
 Diagnosis glowing
Energizing of glow plugs to a certain temperature level.
Diagnosis glowing is used for troubleshooting in the workshop in order to diagnose individual glow
power circuits using STAR DIAGNOSIS. Diagnosis glowing is a fault recognition function.
 Diesel particulate filter (DPF) glowing
Energizing of glow plugs up to a certain temperature level, which supports regeneration of the diesel
particulate filter (DPF). A glow plug temperature of about 850°C is set.
 Emergency glowing
If a problem occurs with communication after "terminal 87 ON" then emergency glowing is initiated after
2 s. If communication is missing during a glowing process for more than 250 ms then emergency glowing
is initiated for a maximum of 180 seconds.
COMPONENT DESCRIPTION FOR GLOW PLUGS - GF15.20-P-4020P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 221.0 /1, 251.0 /1
ENGINE 642.920 in MODEL 211.022 except CODE (494) USA version
ENGINE 642.920 in MODEL 211.022 /222 except CODE (498) Japan version
ENGINE 642.921 in MODEL 211.084 /089 /284 /289
ENGINE 642.920 in MODEL 211.020 /220 /620, 219.322
Fig. 22: Identifying Glow Plugs

Location
The glow plugs are screwed on under the rail on the left and right in the cylinder heads.
Task
The glow plugs warm the combustion chamber in order to reach and secure the required ignition temperature of
the fuel-air mixture under all operating conditions.
Body
Fig. 23: Identifying Glow Plugs Components

The glow plugs consist of a heater tube which is pressed firmly and gas-tight into the plug housing. The heater
tube consists of a hot gas and corrosion-resistant pipe which carries on the inside a glow coil embedded in
compressed magnesium oxide powder. The glow coil consists of 2 series resistors.
The sensor coil housed in the tip of the glow pipe consists of a material with a positive temperature coefficient.
The heating coil consists of a virtually temperature-independent resistance. The heating coil is welded for
contacting at the ground end in the round end of the glow tube. The sensor coil is contacted at a plug connector
over which connection is made to the on-board electrical system.
These are:
 The sensor coil

 The heating coil
Function
Application of the voltage to the glow plugs initially causes the majority of the electrical energy to be converted
into heat in the heating coil. The temperature of the plug tip increases steeply. The temperature of the sensor
coil also increases after some delay and thus also the resistance. The power consumption and thus the overall
performance of the glow plugs come close to the balanced condition.
Fig. 24: Glow Plugs Voltage Graph

COMPONENT DESCRIPTION FOR THE STARTER RELAY - GF15.30-P-2010BK
Shows model 219
Fig. 25: Identifying Starter Relay Components (Shows Model 219)

Location
 Model 219 In the driver-side SAM control unit with fuse and relay module
 Models 164.1, 251 In the engine compartment fuse and relay box.
Function
The starter relay is operated by the ME-SFI control unit through an output stage by means of a GND signal. The
voltage supply of the starter relay (coil) is performed via rely circuit 15.
The voltage supply to the starter (circuit 50) is fused.
A suppressor diode in integrated in the starter relay.
Task
To actuate the circuit (terminal 50) to the starter solenoid switch until the engine start speed is reached or the
maximum start time has expired.
STARTER CONTROL, FUNCTION - GF15.30-P-3000AMG
Fig. 26: Identifying Starter Control Components

The starter control which is integrated in the ME control unit takes over the actuation of the starter and the
deactivation of the starter after reaching the engine starting speed.
Starting prerequisites
Actuation of the starter only takes place for "start enable" (drive authorization) from EIS [EZS] control unit and
by recognition of engaged drive position "P" or "N" by the electronic selector lever module control unit (for
model 209, 211, 219) or by the intelligent servo module for DIRECT SELECT (for model 164, 216, 221, 251).
Starting
Through actuation of ignition in the start position, the ME control unit receives the "tml. 50 signal" from the
EIS control unit via the CAN data bus. Start control is carried out automatically by the ME control unit (touch
start). It actuates the starter relay with a ground signal. The power contact on the starter relay closes and the
starter solenoid switch is supplied at "terminal 50" with voltage from "terminal 15 unfused".
Ending start
When reaching an engine starting speed of 400 up to 700 rpm and a starting time of approx. 5 to 40 seconds
(dependent on the coolant temperature), the ME control unit interrupts the negative activation to the starter relay
and therefore ends the starting procedure.
Once the start operation is initiated, switching off "Terminal 50" (ignition/starter switch) has no further
influence on the starting procedure.
Component description B11/4 GF07.04-P-6040AMG

for the coolant
temperature sensor,
sensor
for the ME-SFI [ME]
control unit
STARTER CONTROL - FUNCTION - GF15.30-P-3000BK

Fig. 27: Starter Control Function Diagram

Starter control actuates the starter and interrupts the circuit (terminal 50) to the starter solenoid switch (starter
disconnection) when the engine speed is achieved.
By operating the ignition start switch on the EIS control unit, from position "2" (ignition ON) to position
"3" (START), the ME control unit detects the start
The solenoid switch of the starter is actuated by the ME control unit via the starter relay.
The voltage for the starter relay (coil) is supplied through circuit 15. The starter relay is actuated by the ME
control unit by a ground signal.
If the starting procedure has started, the actuation of the ignition starter switch from position "3" back into
position "2" no longer has any influence (touch start).
When reaching the engine start speed of 400 up to 700 rpm or a starting time of approx. 5 to 40 seconds
(dependent on the engine temperature), the ME control unit interrupts the negative activation to the starter relay

Component description for the starter relay GF15.30-P-2010BK
STARTER CONTROL, FUNCTION - GF15.30-P-3000GZ
ENGINE 642 in MODEL 164.1 /8, 251.0 /1

Starting the engine is only possible if the DIRECT SELECT gear selector switch (S16/13) is switched into
position "P" or "N". The CDI control unit (N3/9) receives the message "P" or "N" via the Controller Area
Network bus Class C (engine compartment) (CANC) from the intelligent servo module for DIRECT SELECT
(A80) control unit. Also the CDI control unit receives the message "terminal 50 ON" over the CAN-C from the
EIS [EZS] control unit (N73). he CDI control unit actuates the starter (M1) over the integral starter relay
(F58kI) in the SAM control unit at the rear (N10/8).
The CDI control unit detects engine running via the crankshaft position sensor (B70) and the "tml. 61 ON"
message, and the end of the starting procedure through the "tml. 50 OFF" message. The CDI control unit reacts
by interrupting actuation of the starter.
If there is a repeat start after the end of starting procedure, a cut-off period of about 1.5 to 3 seconds is
applied. This occurs so that the rotating pinion of the starter is prevented from meshing with the toothing on the
engine clutch plate (ring gear protection).
Component description for the crankshaft Hall sensor B70 GF07.04-P-6220P

Component description for the coolant temperature sensor B11/4 GF07.04-P-6040P
Model 164
Component description for the CDI control unit GF07.16-P-6000GZ
N3/9
Model 251
GF07.16-P-6000RT
N3/9
THE STARTER CONTROL FUNCTION - GF15.30-P-3000V
ENGINES 272.942 /963 in MODEL 171 with TRANSMISSION 716.6 with manual transmission
ENGINES 272.920 /940 /960 in MODEL 203 with TRANSMISSION 716.6 with manual transmission
ENGINES 272.940 /960 in MODEL 209 with TRANSMISSION 716.6 with manual transmission
ENGINE 272.943 in MODEL 211 with TRANSMISSION 716.6 with manual transmission
Fig. 28: Starter Control Function Diagram - Engines 272.920 /940 /960 In Model 203 With Transmission
716.6 With Manual Transmission
Starter control takes over actuation of the starter and interrupts the circuit (terminal 50) to the starter solenoid
switch once the engine speed is achieved (starter disconnection).
The solenoid switch of the starter is actuated by the ME control unit via the starter relay.
The voltage supply of the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the
ME control unit with a ground signal.
When reaching the engine start speed of 400 up to 700 rpm or a starting time of approx. 5 to 40 seconds
The starter control is only enabled when the clutch pedal is operated. When the clutch pedal is depressed, the
clutch pedal switch is operated with start enable.

for the ME-SFI [ME]
control unit
Voltage supply for the Models 171, 211, 219 GF07.61-P-5001V
ME-SFI control unit
function
Model 164.1 GF07.61-P-5001VA
Model 203, 209 GF07.61-P-5001VB

sensor
for the coolant
temperature sensor
for the clutch pedal
switch
STARTER CONTROL, FUNCTION - GF15.30-P-3000VA
ENGINE 272.920 in MODEL 203 with automatic transmission 722.9

Shown on Engine 272.963 in Model 171
Fig. 29: Starter Control Function Diagram - Shown On Engine 272.963 In Model 171
Starter control actuates the starter and provides the circuit (terminal 50) when the engine speed is achieved to
the starter solenoid switch (starter disconnection).
The solenoid switch of the starter is actuated by the ME-SFI control unit via the starter relay.
The voltage supply of the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the
ME-SFI control unit with a ground signal.
If the starting procedure has started, the actuation of the ignition starter switch from position "3" back into
position "2" no longer has any influence (touch start).
When reaching the engine cranking speed of 400 up to 700 rpm or a starting time of approx. 5 to 40 seconds

for the ME-SFI [ME]
control unit
Voltage supply of ME- Model 171, 211, 219 GF07.61-P-5001V
SFI control unit, function
Model 164, 251 GF07.61-P-5001VA
Model 203, 209 GF07.61-P-5001VB
Model 216, 221 GF07.61-P-5001VC
Model 230 GF07.61-P-5001VD
sensor
for the coolant
temperature sensor
POWER SUPPLY FOR ON-BOARD ELECTRICAL SYSTEM, LOCATION OF COMPONENTS -

GF15.40-P-0001-02AA
Shown on model 211 with 642

Fig. 30: Identifying Power Supply For On-Board Electrical System, Location
ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY LOCATION OF COMPONENTS - GF15.40-

P-0001-02AB
Fig. 31: Identifying On-Board Electrical System Power Supply Components Location (Shown On Model
Shown on model 164 with 272
POWER SUPPLY FOR ON-BOARD ELECTRICAL SYSTEM, FUNCTION - GF15.40-P-0001A
ENGINE 112, 113 in MODEL 203, 209, 211, 220, 230 only valid with engine control unit variant ME 2.8
ENGINE 113 in MODEL 164, 171, 215, 219, 251 only valid with engine control unit variant ME 2.8
ENGINE 155 in MODEL 199 only valid with engine control unit variant ME 2.8
ENGINE 646 in MODEL 211 only valid with engine control unit variant CDI 3
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3
Networking
Fig. 32: Identifying Power Supply For On-Board Electrical System, Location - Shown On Model 211
With Engine 113
Networking
Fig. 33: Identifying Power Supply For On-Board Electrical System, Location - Shown On Model 211
With Engine 647
General
When the engine is running, the alternator supplies the on-board electrical system with electrical energy and
charges the battery. For this purpose, the alternator generates three-phase current which is rectified.
Function
The alternator is driven by a poly-V-belt. When the engine is started, the driver-side SAM control unit with fuse
and relay module energizes the alternator. The alternator produces its pre-excitation current or excitation current
automatically and supplies current via terminal B+ of the alternator to the battery and to the on-board electrical
system.
The alternator is regulated by the multifunction regulator according to:
 the alternator speed (determined internally)

 the on-board power supply voltage
The on-board power supply voltage is measured and evaluated internally by the electronics of the alternator.
The DFM connection outputs a signal which indicates the capacity utilization of the alternator.
This signal is used for electrical control of the engine's heater booster. In model series 211, the AAC [KLA]
control and operating unit evaluates the signal and regulates the heater booster according to the alternator load
condition.
Networking
The driver-side SAM control unit with fuse and relay module energizes the alternator. If the charging function
is working properly, the alternator supplies a voltage signal along the same line. This signal is evaluated by the
driver-side SAM control unit with fuse and relay module and is sent as a message on the Controller Area
Network bus class B to the instrument cluster.
Engine speed
Depending on the variant, the pulses from the crankshaft position sensor are read in by the ME-SFI [ME]
control unit or CDI control unit.
The control unit places the engine speed message (in rpm) on the Controller Area Network bus class C.
Alternator monitor
If there is an alternator fault, the "battery symbol" and the "Visit workshop" message are shown in the
multifunction display in the instrument cluster.
The message/symbol appears if the alternator is not operating correctly although the engine speed is higher than
200 rpm. There is no message when the engine is OFF.
This fault message in the multifunction display of the instrument cluster can also be triggered by information
from the following control units:
 battery control unit (N82)

 EIS [EZS] control unit (N73)
Diagnosis
The alternator with multifunction regulator without interface cannot be checked using Star Diagnosis (DAS).
The appropriate work instructions in the workshop information system (WIS) apply.
Depending on the vehicle variant, the alternators have a load response.
There are two types:
 Starting load response
This function prevents the alternator from supplying current while and immediately after the engine is
started. As a result, the starting procedure is not impeded or prolonged by the retarding torque of the
alternator.
 Driving load response
This function prevents the rise in torque produced by the alternator in the case of a positive change in
electrical load from being passed directly on to the engine. The power output is increased continuously by
means of a ramp function. The load is connected smoothly.
Power supply for on- GF15.40-P-0001-02AA

board electrical system,
location of components
Alternator, component GF15.40-P-2000A
description
ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY, FUNCTION - GF15.40-P-0001C
ENGINE 266 in MODEL 169, 245 only valid with engine control unit variant SIM 266
ENGINE 272 in MODEL 164, 171, 203, 209, 211, 219, 221, 230, 251 only valid with engine control unit
variant ME 9.7
ENGINE 273 in MODEL 211, 219, 221, 230 only valid with engine control unit variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.7.2
ENGINE 629 in MODEL 164, 211, 221 only valid with engine control unit variant CDI 5
ENGINE 640 in MODEL 169, 245 only valid with engine control unit variant CDI A
ENGINE 642 in MODEL 164, 203, 209, 211, 219, 221, 251 only valid with engine control unit variant CDI
4
ENGINE 646 in MODEL 211 only valid with engine control unit variant CDI D
Networking
Fig. 34: On-Board Electrical System Power Supply Function Diagram - Shown On Model 211 With
Engine 272
Networking
Fig. 35: On-Board Electrical System Power Supply Function Diagram - Shown On Model 211 With
Engine 642
General
When the engine is running, the alternator supplies the on-board electrical system with electrical energy and
charges the battery. For this purpose, the alternator generates three-phase current which is rectified. A local
interconnect network is used as the alternator interface between the engine control unit and the alternator.
The LIN bus is a bidirectional single-wire interface with a maximum transfer rate of 20 kbit/s.
Function and task
Messages between the engine control unit and the alternator are exchanged via the alternator interface. This
follows the master-slave principle. The engine control unit is the master and the alternator acts as the slave. The
alternator only sends when it is requested to do so by the master. The following tasks are performed:
 Switching on of the alternator after the engine has been started, and regulation of the alternator according
to the information stored in the engine control unit. To do this, the control voltage is preset by the engine
control unit.
 Delayed adaptation of the regulation voltage in the case of a major change in alternator load.
 Protects the generator against overheating.
 Protects the generator against overheating.
 Generation of terminal 61 (information "alternator is turning") in the engine control unit.
The alternator constantly performs self-diagnosis and sends the results when requested to the engine control
unit. The engine control unit compares them with other signals (e.g. engine speed, battery voltage and time after
engine start) and detects the following faults:
 Electrical and mechanical faults at the alternator (regulator or diodes defective, stator interruption or short
circuit, exciter interruption, regulation voltage and charging current may not be achieved, regulation
voltage too high, cracked or loose poly-V belt).
 Line for the alternator interface interrupted between engine control unit and alternator. With this fault, the
alternator operates using its fixed parameters. A regulation voltage of approx. 14.3 V is predefined.
 Short circuit or open circuit at output terminal 61 of engine control unit.
Networking
The engine control unit uses the alternator interface to control the control response of the alternator in order to
reduce, in idle, the generator torque which is produced at a high power output. As a result of the reduced engine
load, less fuel is injected and the exhaust characteristics are optimized.
Terminal 61 in the engine control unit is simulated using information which the engine control unit receives via
the alternator interface. This information is supplied to the driver-side SAM control unit with fuse and relay
module via Controller Area Network bus class C or via a signal line.
The driver-side SAM control unit with fuse and relay module conditions the signal and makes it available to the
instrument cluster via Controller Area Network bus class B.
The upper limit value of the regulation voltage can be up to approx. 15 V.
Engine speed
Pulses from the Hall sensor or position sensor to the crankshaft are read in by the engine control unit.
The engine control unit delivers the message engine speed (in rpm) to the Controller Area Network bus Class C.
Diagnosis
The following faults are detected after "ignition ON" and may be stored as a fault entry in the engine control
unit:
 Alternator interface defective.

 Line interruption (tml. 30)
The following faults are detected after "Engine start" and may be stored as a fault entry in the engine control
unit:
 Electrical fault at alternator

 Mechanical fault at alternator
 Line interruption (tml. 30)
 Undervoltage and defective alternator interface
The "battery symbol" and the "Visit workshop" message also appear in the multifunction display in the
instrument cluster.
This fault message in the multifunction display in the instrument cluster can also be triggered by information
from the following control units:
 Battery control unit

 EIS [EZS] control unit
Test prerequisites for the alternator test are listed in the diagnosis assistance system (DAS) and must always
be observed. The test itself is a test routine and is menu-assisted.
Emergency running
If communication between the alternator and engine control unit is interrupted, the alternator continues to run at
its fixed default parameters during normal engine operation.
Emergency start
The alternator has an emergency start function. If the communication between the alternator and engine control
unit is interrupted, the alternator can build up a voltage via the residual magnetism depending on the rotational
speed. If, on the basis of the voltage and frequency, the regulator detects that the alternator is rotating, it
automatically begins energizing of the field and enters regulation mode.
Limitations:
 The command "Regulation Off" from the engine control unit interrupts this limp-home.
 Precise specification of the starting speed for the emergency start function is not possible.
On-board electrical Engine 272 in model 171, GF15.40-P-0001-02AA

system power supply 203, 209, 211, 219, 221,
Location of components 230 only valid with
engine control unit
variant ME 9.7
Engine 273 in model 211,
219, 221, 230 only valid
with engine control unit
variant ME 9.7
221, 230 only valid with
engine control unit
variants ME 2.7.1, ME
2.7.2
221 only valid with

engine control unit
variant CDI 5
209, 211, 219, 221 only
valid with engine control
unit variants CDI 4
only valid with engine
control unit variant CDI
D
Engine 272 in model 164, GF15.40-P-0001-02AB
251 only valid with
engine control unit
variant ME 9.7
control unit variant CDI 5
251 only valid with
engine control unit
variant CDI 4
Engine 266 in model 169, GF15.40-P-0001-02AC
245 only valid with
engine control unit
variant SIM 266
245 only valid with
engine control unit
variant CDI A
Component description GF15.40-P-2000A
for the alternator
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION ON-BOARD ELECTRICAL SYSTEM

POWER SUPPLY - GF15.40-P-0999A
ENGINE 271 in MODEL 171, 203, 209, 211 only valid with engine control unit variant SIM 4
variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.7.1, ME 2.7.2
ENGINE 285 in MODEL 240 only valid with engine control unit variant ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control unit variant CDI V1
4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control unit variant CDI 3, CDI 3 (UP),
CDI D
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3, CDI 3 (UP)
On-board electrical Alternator with GF15.40-P-0001A

system power supply, multifunction regulator
function (MFR) without interface:
Engine 112, 113 in model
203, 209, 211, 220, 230
control unit variant ME
2.8
171, 215, 219, 251 only
valid with engine control
unit variants CDI 2.8
2.8

220 only valid with
engine control unit
variant CDI 3
Alternator with bit GF15.40-P-0001B
synchronous data
interface (BSS)
211, 203, 209 only valid
variant SIM 4
engine control unit
variant ME 2.7.1
control unit variant ME
2.7.1
engine control unit
variant CDI V1
engine control unit
variant CDI 3 (UP)
220 only valid with
engine control unit
variant CDI 3 (UP)
Alternators with local GF15.40-P-0001C
interconnect network
(LIN) interface:
245 only valid with
engine control unit
variant SIM 266
171, 203, 209, 211, 219,
221, 230, 251 only valid
variant ME 9.7

219, 221, 230 only valid
variant ME 9.7
engine control unit
variant ME 2.7.2
engine control unit
variant CDI 5
245 only valid with
engine control unit
variant CDI A
203, 209, 211, 219, 221,
251 only valid with
engine control unit
variant CDI 4
D
On-board electrical Engine 112, 113 in model GF15.40-P-0001-02AA
system power supply 203, 209, 211, 220, 230
Location of components
215, 219
203, 209, 211
203, 209, 211, 219, 221,
230
219, 221, 230
221, 230
211, 220
221
209, 211, 219, 221
209, 211
220
Engine 113 in model 164, GF15.40-P-0001-02AB
251 only valid with
engine control unit
variant ME 2.8
251 only valid with
engine control unit
variant ME 9.7
251 only valid with
engine control unit
variant CDI 4
Engine 266 in model 169, GF15.40-P-0001-02AC
245 only valid with
engine control unit
variant SIM 266
245 only valid with
engine control unit
variant CDI A
Overview of system GF15.40-P-9999A
components On-board
electrical system power
supply
COMPONENT DESCRIPTION FOR THE ALTERNATOR - GF15.40-P-2000A
ENGINE 271 in MODEL 203, 209, 211, 171 only valid with engine control unit variant SIM 4
variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.7.1, ME 2.7.2
ENGINE 285 in MODEL 240 only valid with engine control unit variant ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control unit variant CDI V1
4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control unit variant CDI 3, CDI 3 (UP),
CDI D
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3, CDI 3 (UP)
Fig. 36: Identifying Alternator Components

Assignment of connection for signal lines
Connector on alternator, pin 1:
 Alternator with multifunctional regulator without interface: Connection for alternator (G2) to driver-side
SAM control unit with fuse and relay module (N10/1)
 Alternators with bit synchronous data interface (BSS): Connection for alternator to engine control unit
ME (N3/10) or CDI (N3/9)
 Alternators with local interconnect network interface (LIN): Connection for alternator to engine control
unit ME or CDI
Connector on alternator, pin 2:
 This is a Dynamo Field Monitor (DFM) signal. It provides information about the load condition of the
alternator.
This signal is used for electrical control of the engine heater booster. In model series 211 the AAC [KLA]
control and operating unit (N22) evaluates the signal and regulates the heater booster (R22/3) depending
on the alternator load.
Pre-excitation power circuit
Alternators receive the pre-or excitation current directly from the battery (G1), via circuit B+ at the alternator.
The switch-on signal at Pin 1 of the alternator takes place:
 for multifunction regulator without interface with a discrete signal from the driver-side SAM control unit
with fuse and relay module
 for BSS or LIN interface with a valid message from the engine control unit
Excitation power circuit
Alternator are self-exciting power generators. The excitation current builds up the magnetic field in the
excitation coil of the rotor. It is branched off from the current flowing in the three-phase AC winding.
Charge power circuit
The charge power circuit supplies the on-board electrical system with electrical energy.
Control
Regulation of alternator with multifunction regulator takes place by integral electronics depending on the
rotational speed and on-board power supply voltage.
For alternators with BSS or a LIN interface the engine management intervenes in the regulation.
Overview of system GF15.40-P-9999A

components On-board
electrical system power
supply
OVERVIEW OF SYSTEM COMPONENTS ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY -

GF15.40-P-9999A
ENGINE 113 in MODEL 164, 171, 215, 219, 251 only valid with engine control unit variant ME 2.8 ME
2.8
ENGINE 155 in MODEL 199 only valid with engine control unit variant ME 2.8 ME 2.8
ENGINE 266 in MODEL 169, 245 only valid with engine control unit variant ME 2.8 SIM 266
ENGINE 271 in MODEL 203, 209, 211, 171 only valid with engine control unit variant ME 2.8 SIM 4
variant ME 2.8 ME 9.7
ENGINE 273 in MODEL 211, 219, 221, 230 only valid with engine control unit variant ME 2.8 ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.8 ME 2.7.1, ME
2.7.2
ENGINE 285 in MODEL 240 only valid with engine control unit variant ME 2.8 ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control unit variant ME 2.8 CDI V1
ENGINE 629 in MODEL 164, 211, 221 only valid with engine control unit variant ME 2.8 CDI 5
ENGINE 640 in MODEL 169, 245 only valid with engine control unit variant ME 2.8 CDI A
ENGINE 642 in MODEL 164, 203, 209, 211, 219, 221, 251 only valid with engine control unit variant ME
2.8 CDI 4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control unit variant ME 2.8 CDI 3, CDI 3
(UP), CDI D
ENGINE 647 in MODEL 211 only valid with engine control unit variant ME 2.8 CDI 3
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant ME 2.8 CDI 3, CDI 3 (UP)

Component description GF15.40-P-2000A

for the alternator
Table of contents for GF15.40-P-0999A
function description
Onboard electrical system
power supply
SAFETY PRECAUTIONS
RISK OF DEATH CAUSED BY CONTACT WITH PARTS CONDUCTING HIGH VOLTAGES. -
AS15.10-Z-0001-01A
Do not touch parts which conduct high voltages. Persons who wear electronic implants (e.g. heart
pacemakers) must not carry out work on the ignition system
Risk of death caused by high voltages in the ignition system
Electronic ignition systems operate within a hazardous power range both on the low voltage side (primary
circuit) as well as on the high voltage side (secondary circuit). Contacts with such parts can result in burns,
heart flutter or cardiac arrest.
Fig. 37: High Voltage Warning

 Persons with heart pacemakers must not perform any work on the ignition system.
 Switch ignition off before commencing any work on the ignition system.
 Do not touch or dismantle components of ignition system when working on running or rotating engine
with cranking speed.
 Wear safety shoes (with rubber soles).
 Detach the crankshaft position sensor connection either at the control unit or at the position sensor.
 Do not install any electrically conducting, un-insulated adapters or installation sensors into the ignition
cable.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
AR15.00-Z-9113AB
ENGINE 113
Remove, install camshaft Hall ENGINE 112, 113... AR15.10-P-2000A

sensor
Remove/install camshaft Hall ENGINE 113.988 in AR15.10-P-2000AC
sensor MODEL 203.076/276
ENGINE 113.989 in
MODEL 171.473
Remove/install camshaft Hall ENGINE 113.964 in AR15.10-P-2000GZ
sensor MODEL 164.175
Remove/install camshaft Hall ENGINE 113.971 in AR15.10-P-2000RT
sensor MODELS 251.075 /175
Remove/install camshaft Hall ENGINE 113.990 in AR15.10-P-2000RVK
sensor MODELS 211.076 /276
ENGINE 113.991 in
MODELS 215.374,
220.074/174
Remove/install camshaft Hall ENGINE 113.967 in AR15.10-P-2000TY
sensor MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Test rotorless high voltage ENGINE 112, 113... AR15.10-P-3000WA
distribution
Remove/install spark plugs ENGINE 113.964 in AR15.12-P-1010GZ
MODEL 164.175
Remove/install spark plugs ENGINE 113.971 in AR15.12-P-1010RT
MODELS 251.075/175
Remove/install ignition lines ENGINE 113.964 in AR15.12-P-1312GZ
MODEL 164.175
Remove/install ignition lines ENGINE 113.971 in AR15.12-P-1312RT
MODELS 251.075/175
Remove/install ignition coils ENGINE 112, 113... AR15.12-P-2003A
Remove/install ignition coils ENGINE 113.964 in AR15.12-P-2003GZ
MODEL 164.175
Remove/install ignition coils ENGINE 113.971 in AR15.12-P-2003RT
MODELS 251.075/175
Remove/install ignition coils ENGINE 113.967 in AR15.12-P-2003TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install crankshaft ENGINE 112, 113... AR15.12-P-2133A

position sensor
Remove/install crankshaft ENGINE 113.964 in AR15.12-P-2133GZ
position sensor MODEL 164.175
Remove/install crankshaft ENGINE 112, 113... AR15.12-P-2133Q
position sensor
Remove/install crankshaft ENGINE 113.971 in AR15.12-P-2133RT
position sensor MODEL 251.075/175
Remove/install knock sensors ENGINE 112, 113... AR15.12-P-2184A
Remove/install knock sensors ENGINE 113.964 in AR15.12-P-2184GZ
MODEL 164.175
Remove/install knock sensors ENGINE 113.971 in AR15.12-P-2184RT
MODELS 251.075/175
Remove starter, install ENGINE 112, 113... AR15.30-P-7100CS
Remove starter, install ENGINE 112, 113... AR15.30-P-7100ED
Removing/installing the ENGINE 112, 113... AR15.30-P-7100FF
starter
Remove and installing the ENGINE 112, 113... AR15.30-P-7100GH
starter
Removing/installing the ENGINE 113.964 in AR15.30-P-7100GZ
starter MODEL 164.175
Remove starter, install ENGINE 112, 113... AR15.30-P-7100I
Removing and installing the ENGINE 111, 112, 113... AR15.30-P-7100P
starter
Remove/install starter ENGINE 112, AR15.30-P-7100PW
113,272,273...
Remove/install starter ENGINE 112, 113... AR15.30-P-7100R
Removing and installing ENGINE 113.971 in AR15.30-P-7100RT
starter MODELS 251.075/175
Removing and installing the ENGINE 113.967 in AR15.30-P-7100TY
starter MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove starter, install ENGINE 113.989 in AR15.30-P-7100VT
MODEL 171.473
Prerequisites for testing ENGINE 103, 104, 112, AR15.40-P-5009C
alternator 113, 119, 120 in MODEL
129
Prerequisites for testing ENGINE 104, 111, 112, AR15.40-P-5009EA
alternator 113, 601, 604, 605, 611...
Prerequisites for testing ENGINE 104, 111, 112, AR15.40-P-5009F
alternator 113, 119, 602, 604, 605,
606, 611, 612, 613...
Prerequisites for testing ENGINE 111.977, AR15.40-P-5009GH
generator 112.942/970,
113.942/965 /981,
612.963, 628.963 in
MODEL 163
Prerequisites for testing the ENGINE 113 in MODEL AR15.40-P-5009GZ
alternator 164, 251
Prerequisites for testing ENGINE 112, 113, 137, AR15.40-P-5009I
alternator 275...
Prerequisites for testing the ENGINE 111, 112, 113, AR15.40-P-5009P
alternator 611, 612, 646...
Prerequisites for testing the ENGINE 112, 113, 275 in AR15.40-P-5009R
alternator MODEL 230
Prerequisites for testing the ENGINE 112, 113, 628, AR15.40-P-5009T
alternator 646.### ## up to 709556,
647 in MODEL 211
ENGINE 113 in MODEL
219
Checking regulation voltage ENGINES 103, 104, 112, AR15.40-P-5010C
of alternator 113, 119, 120 in MODEL
129
Checking regulation voltage ENGINE 104, 111, 112, AR15.40-P-5010EA
of alternator 113, 601, 604, 605, 611...
Checking regulation voltage ENGINE 104, 111, 112, AR15.40-P-5010F
of alternator 113, 119, 602, 604, 605,
606, 611, 612, 613...
Checking regulation voltage ENGINES 111.977, AR15.40-P-5010GH
of alternator 112.942/970,
113.942/965 /981,
612.963, 628.963 in
MODEL 163
Checking regulation voltage ENGINE 113 in MODELS AR15.40-P-5010GZ
of alternator 164, 251
Checking regulation voltage ENGINE 112, 113, 137, AR15.40-P-5010I
of alternator 275...
Checking regulation voltage ENGINE 111, 112, 113, AR15.40-P-5010P
of alternator 611, 612...
Check regulation voltage of ENGINE 112, 113, 275 in AR15.40-P-5010R
Check regulation voltage of ENGINE 112, 113, 628, AR15.40-P-5010T
alternator 646, 647...
Testing alternator charging ENGINES 103, 104, 112, AR15.40-P-5011C
current 113, 119, 120 in MODEL
129
Checking charging current of ENGINE 104, 111, 112, AR15.40-P-5011EA
alternator 113, 601, 604, 605, 611...
Checking charging current of ENGINE 104, 111, 112, AR15.40-P-5011F

alternator 113, 119, 602, 604, 605,
606, 611, 612, 613...
Checking charging current of ENGINES 111.977, AR15.40-P-5011GH
alternator 112.942/970,
113.942/965 /981,
612.963, 628.963 in
MODEL 163
Test charging current of ENGINE 113 in MODEL AR15.40-P-5011GZ
alternator 164, 251
Checking charging current of ENGINE 112, 113, 137, AR15.40-P-5011I
alternator 275...
Checking charging current of ENGINE 111, 112, 113, AR15.40-P-5011P
Test Charging current for ENGINE 112, 113, 275 in AR15.40-P-5011R
Test charging current for ENGINE 112, 113, 628, AR15.40-P-5011T
Test backup fuse for ENGINE 111, 112, 113, AR15.40-P-5012P
alternator 271, 611, 612...
Test alternator fuse ENGINE 112, 113, 271, AR15.40-P-5012T
628, 646, 647, 648...
Remove and install generator ENGINE 113.991 in AR15.40-P-5032AM
MODEL 215.374,
220.074 /174
Remove and install generator ENGINE 112, 113 in AR15.40-P-5032CT
MODEL 129
Remove and install generator ENGINE 112.910 /920 in AR15.40-P-5032EB
MODEL 202 ENGINE
112.940, 113.943/984 in
MODEL 208
Remove and install generator ENGINE 112.921 /941, AR15.40-P-5032ED
113.940/980, 119.985 in
MODEL 210
Remove and install generator ENGINE 111.977, AR15.40-P-5032GH
112.942/970,
113.942/965 /981 in
MODEL 163
Remove and installing the ENGINE 113.964 in AR15.40-P-5032GZ
alternator MODEL 164.175
Remove/install alternator ENGINE 112, 113... AR15.40-P-5032I
Remove/install alternator ENGINE 111, 112, 113... AR15.40-P-5032P
Remove, install alternator ENGINE 112, 113 in AR15.40-P-5032R
MODEL 230
Removing and installing the ENGINE 113.971 in AR15.40-P-5032RT

alternator MODELS 251.075/175
Remove/install alternator ENGINE 112, 113... AR15.40-P-5032TC
Removing/installing the ENGINE 113.967 in AR15.40-P-5032TY
ENGINE 113.990 in
MODEL 219.376
Remove/install alternator ENGINE 113.989 in AR15.40-P-5032VT
MODEL 171.473
Remove/install generator belt ENGINE 104, 111, 112, AR15.40-P-5710EA
pulley 113, 119, 601, 602, 604,
605, 606...
Remove/install generator belt ENGINE 111, 112, 113, AR15.40-P-5710GF
pulley 166...
Remove/install generator belt ENGINE 113.964 in AR15.40-P-5710GZ
pulley MODEL 164.175
Remove/install alternator belt ENGINE 112, 113, 137... AR15.40-P-5710I
pulley
Remove/install alternator belt ENGINE 111, 112, 113, AR15.40-P-5710P
pulley 271...
Removing and installing belt ENGINE 113.971 in AR15.40-P-5710RT
pulley for the alternator MODELS 251.075/175
Removing and installing ENGINE 103, 104, 119, AR15.40-P-5760CS
regulator of generator 120, 112, 113 in MODEL
129
Removing and installing ENGINE 104, 111, 112, AR15.40-P-5760EA
regulator of generator 113, 601, 604, 605, 611...
Removing and installing ENGINE 104, 111, 112, AR15.40-P-5760F
regulator of generator 113, 119, 602, 604, 605,
606, 611...
Remove/install regulator of ENGINE 111.977, AR15.40-P-5760GH
alternator 112.942/970,
113.942/965 /981 in
MODEL 163
Remove/install regulator of ENGINE 113.964 in AR15.40-P-5760GZ
generator MODEL 164.175
Removing/installing the ENGINE 112, 113... AR15.40-P-5760I
alternator regulator
Remove/install regulator for ENGINE 111, 112, 113, AR15.40-P-5760P
alternator 271...
Removing/installing the ENGINE 112, 113 in AR15.40-P-5760R
alternator regulator MODEL 230
Removing and installing the ENGINE 113.971 in AR15.40-P-5760RT
alternator regulator MODELS 251.075/175
Remove/installing regulator ENGINE 112, 113, 646, AR15.40-P-5760T

for alternator 647...
Removing/installing regulator ENGINE 113.967 in AR15.40-P-5760TY
for alternator MODEL 219.375
ENGINE 113.990 in
MODEL 219.376

AR15.00-Z-9156AB
ENGINE 156
Remove/install camshaft ENGINE 156 in MODEL AR15.10-P-2000GZS

Hall sensor 164, 251
Remove/install camshaft ENGINE 156 in MODEL AR15.10-P-2000SMG
Hall sensor 221, 216
Remove/install camshaft ENGINE 156.983 in AR15.10-P-2000TMG
Hall sensor MODEL 211.077 /277,
219.377 ENGINE
156.982 in MODEL
209.377/477
Remove/install spark ENGINE 156 in MODEL AR15.12-P-1010GZS
plugs 164, 251
Remove/install spark ENGINE 156 in MODEL AR15.12-P-1010SMG
plugs 221, 216
Remove/install spark ENGINE 156.983 in AR15.12-P-1010TMG
plugs MODELS 211.077 /277,
219.377 ENGINE
156.982 in MODELS
209.377 /477
Remove/install ignition ENGINE 156 in MODEL AR15.12-P-2003GZS
coils 164, 251
Remove/install ignition ENGINE 156 in MODEL AR15.12-P-2003SMG
coils 216, 221
Remove/install ignition ENGINE 156.983 in AR15.12-P-2003TMG
coils MODEL 211.077 /277,
219.377 ENGINE
156.982 in MODEL
209.377 /477
Remove/install ENGINE 156 in MODEL AR15.12-P-2133GZS
crankshaft position sensor 164, 251
Remove/install ENGINE 156.982 in AR15.12-P-2133QMG
crankshaft position sensor MODELS 209.377 /477
crankshaft position sensor 221, 216
Remove/install ENGINE 156.983 in AR15.12-P-2133TMG

crankshaft position sensor MODELS 211.077 /277,
219.377
Remove/install knock ENGINE 156 in MODEL AR15.12-P-2184GZS
sensors 164, 251
Remove/install knock ENGINE 156 in MODEL AR15.12-P-2184SMG
sensors 216, 221
Remove/install knock ENGINE 156.982 in AR15.12-P-2184TMG
sensors MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install starter ENGINE 156 in MODEL AR15.30-P-7100GZS
164, 251
Remove/install starter ENGINE 156.982 in AR15.30-P-7100QMG
MODEL 209.377 /477
Remove/install starter ENGINE 156 in MODEL AR15.30-P-7100SMG
216, 221
Remove/install starter ENGINE 156.983 in AR15.30-P-7100TMG
MODEL 211.077 /277,
219.377
Checking regulator and ENGINE 156, 272, 273, AR15.40-P-5000SX
221 ENGINE 156, 273,
275 in MODEL 216
Checking the alternator ENGINE 156, 271, 272, AR15.40-P-5000T
and regulator 273, 629, 642, 646,
648 ...
Prerequisites for testing ENGINE 156 in MODEL AR15.40-P-5009GZS
Alternator 164, 251
Test charging current for ENGINE 156 in MODEL AR15.40-P-5011GZS
alternator 164, 251
Test Charging current for ENGINE 156.982 in AR15.40-P-5011QMG
alternator MODEL 209.377 /477
Test charging current for ENGINE 156, 272, 273, AR15.40-P-5011SX
221 ENGINE 156, 273,
275 in MODEL 216
Test charging current for ENGINE 156, 271, 272, AR15.40-P-5011TS
alternator 273, 629, 642, 646,
648 ...
Testing backup fuse of ENGINE 156, 272, AR15.40-P-5012QB
alternator 273 ...
Testing backup fuse of ENGINE 156, 272, 273 AR15.40-P-5012TS
alternator in MODEL 211, 219
Remove/install alternator ENGINE 156 in MODEL AR15.40-P-5032GZS

164, 251
Remove/install alternator ENGINE 156 in MODEL AR15.40-P-5032SMG
216, 221
Remove/install alternator ENGINE 156.982 in AR15.40-P-5032TMG
MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install regulator ENGINE 156 in MODEL AR15.40-P-5760GZS
for alternator 164, 251
Remove/install regulator ENGINE 156 in MODEL AR15.40-P-5760SMG
Remove/install regulator ENGINE 156.982 in AR15.40-P-5760TMG
for alternator MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Remove/install ENGINE 156 in MODEL AR15.60-P-3000GZS
temperature sensor 164, 251
temperature sensor 216, 221
Remove/install ENGINE 156.982 in AR15.60-P-3000TMG
temperature sensor MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377

AR15.00-Z-9272AB
ENGINE 272
Remove/install camshaft Hall ENGINE 272, 273 in AR15.10-P-2000GZA

sensor MODEL 164, 251
Remove/install camshaft Hall ENGINE 272, 273 ... AR15.10-P-2000QB
sensor
Remove/install camshaft Hall ENGINE 272, 273 in AR15.10-P-2000RX
sensor MODEL 230
Remove/install camshaft Hall ENGINE 272, 273 in AR15.10-P-2000SX
sensor MODEL 221 ENGINE
273 in MODEL 216
Remove, install camshaft Hall ENGINE 272, 273 in AR15.10-P-2000TS
sensor MODEL 211, 219
Remove/install camshaft Hall ENGINE 272.942 /963 in AR15.10-P-2000VA
sensor MODEL 171

Removing/installing spark ENGINE 271.944 in AR15.12-P-1010V
plugs MODEL 171.442
ENGINE 272.942 in
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install ignition coils ENGINE 272 in MODEL AR15.12-P-2003CV
204
Remove/install ignition coils ENGINE 272, 273 in AR15.12-P-2003GZA
MODEL 164, 251
Remove/install ignition coils ENGINE 272, 273 ... AR15.12-P-2003QB
Remove/install ignition coils ENGINE 272, 273 in AR15.12-P-2003RX
MODEL 230
Remove/install ignition coils ENGINE 272, 273 in AR15.12-P-2003SX
MODEL 221 ENGINE
273 in MODEL 216
Remove, install ignition coils ENGINE 272, 273 in AR15.12-P-2003TS
MODEL 211, 219
Remove/install ignition coils ENGINE 272.942 in AR15.12-P-2003VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install crankshaft ENGINE 272, 273 in AR15.12-P-2133GZA
position sensor MODEL 164
Remove/install crankshaft ENGINE 272, 273 ... AR15.12-P-2133QB
position sensor
Remove/install crankshaft ENGINE 272, 273 in AR15.12-P-2133RTA
Remove/install crankshaft ENGINE 272, 273 in AR15.12-P-2133RX
Remove/install crankshaft ENGINE 272, 273 in AR15.12-P-2133SX
position sensor MODEL 221 ENGINE
273 in MODEL 216
Remove, install crankshaft ENGINE 272, 273 in AR15.12-P-2133TS
position sensor MODEL 211, 219
Remove/install crankshaft ENGINE 272.942 in AR15.12-P-2133VA
position sensor MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install crankshaft ENGINE 272 in MODEL AR15.12-P-2136CV
Hall sensor 204
Remove/install knock sensors ENGINE 272 in MODEL AR15.12-P-2184CV
204
Remove/install knock sensors ENGINE 272, 273 in AR15.12-P-2184GZA

MODEL 164, 251
Remove/install knock sensors ENGINE 272, 273 ... AR15.12-P-2184QB
Remove/install knock sensors ENGINE 272, 273 in AR15.12-P-2184RX
MODEL 230
Remove/install knock sensors ENGINE 272, 273 in AR15.12-P-2184SX
MODEL 221 ENGINE
273 in MODEL 216
Remove, install knock sensors ENGINE 272, 273 in AR15.12-P-2184TS
MODEL 211, 219
Removing/installing knock ENGINE 272.942 in AR15.12-P-2184VA
sensors MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install starter ENGINE 272 in MODEL AR15.30-P-7100CV
204
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100GZA
MODEL 164
Remove/install starter ENGINE 112, 113, 272, AR15.30-P-7100PW
273 ...
Remove/install starter ENGINE 272, 273 ... AR15.30-P-7100QB
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100RTA
MODEL 251
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100RX
MODEL 230
Remove/install starter ENGINE AR15.30-P-7100SX
272.946 /965 /975 in
MODEL 221 ENGINE
273 in MODEL 216, 221
Remove, install starter ENGINE 272 (except AR15.30-P-7100TS
272.944 /972) in MODEL
211 ENGINE 272 in
MODEL 219
Remove/install starter ENGINE 272.942 in AR15.30-P-7100VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Check regulator and ENGINE 271, 272, 642, AR15.40-P-5000CW
alternator. 646 in MODEL 204
Checking regulator and ENGINE 272, 273, 642 in AR15.40-P-5000GZ
alternator MODEL 164 ENGINE
272, 273, 642 in MODEL
251 ENGINE 629 in
MODEL 164
Test alternator and regulator ENGINE 271, 272, 642, AR15.40-P-5000P
646 in MODEL 203, 209

ENGINE 273 in MODEL
209
Test alternator and regulator ENGINES 272, 273 in AR15.40-P-5000RX
MODEL 230
Checking regulator and ENGINE 156, 272, 273, AR15.40-P-5000SX
221 ENGINE 156, 273,
275 in MODEL 216
Checking the alternator and ENGINE 156, 271, 272, AR15.40-P-5000T
regulator 273, 629, 642, 646, 648 ...
Checking the regulator and ENGINES 271, 272 in AR15.40-P-5000V
Test charging current for ENGINE 271, 272, 642, AR15.40-P-5011CW
alternator 646 in MODEL 204
Test charging current for ENGINE 272, 273, 642, AR15.40-P-5011GA
alternator 629 in MODEL 164
ENGINE 272, 273, 642 in
MODEL 251
Test charging current for ENGINE 271, 272, 642, AR15.40-P-5011PI
alternator 646 in MODEL 203, 209
ENGINE 273 in MODEL
209
Test Charging current for ENGINE 272, 273 in AR15.40-P-5011RX
Test charging current for ENGINE 156, 272, 273, AR15.40-P-5011SX
221 ENGINE 156, 273,
275 in MODEL 216
Test charging current for ENGINE 156, 271, 272, AR15.40-P-5011TS
alternator 273, 629, 642, 646, 648 ...
Test charging current for ENGINE 271, 272 in AR15.40-P-5011V
Testing backup fuse of ENGINE 156, 272, 273 ... AR15.40-P-5012QB
alternator
Testing backup fuse of ENGINE 156, 272, 273 in AR15.40-P-5012TS
alternator MODEL 211, 219
Testing backup fuse for ENGINES 271.944, AR15.40-P-5012V
alternator 272.942 /963 in MODEL
171.4
Remove/install alternator ENGINE 272 in MODEL AR15.40-P-5032CV
204
Remove/install alternator ENGINE 272, 273 in AR15.40-P-5032GZA
MODEL 164
Remove/install alternator ENGINE 272, 273 ... AR15.40-P-5032QB
Remove/install alternator ENGINE 272, 273 in AR15.40-P-5032RTA

MODEL 251
Remove/install alternator ENGINE 272, 273 in AR15.40-P-5032RX
MODEL 230
Remove/install alternator ENGINE AR15.40-P-5032SX
272.946 /965 /975 in
MODEL 221 ENGINE
273 in MODEL 216, 221
Remove, install alternator ENGINE 272, 273 in AR15.40-P-5032TS
MODEL 211, 219
Remove/install alternator ENGINE 272.942 in AR15.40-P-5032VA
MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install alternator belt ENGINE 271, 272, 646 in AR15.40-P-5710CW
pulley MODEL 204
Remove/install alternator belt ENGINE 272, 273 in AR15.40-P-5710GZA
pulley MODEL 164, 251
Remove/install alternator belt ENGINE 272, 273 ... AR15.40-P-5710QB
pulley
Remove/install alternator belt ENGINE 272, 273 in AR15.40-P-5710RX
pulley MODEL 230
Remove/install alternator belt ENGINE 272, 273 in AR15.40-P-5710SX
pulley MODEL 221 ENGINE
273 in MODEL 216
Remove, install alternator belt ENGINE 272, 273 in AR15.40-P-5710TS
pulley MODEL 211, 219
Remove/install alternator belt ENGINE 272.942 in AR15.40-P-5710VA
pulley MODEL 171.454
ENGINE 272.963 in
MODEL 171.456
Remove/install regulator for ENGINE 272 in MODEL AR15.40-P-5760CV
alternator 204
Remove/install regulator for ENGINE 272, 273 in AR15.40-P-5760GZA
Remove/install regulator for ENGINE 272, 273 ... AR15.40-P-5760QB
alternator
Remove/install regulator for ENGINE 272, 273 in AR15.40-P-5760RX
Remove/install regulator for ENGINE AR15.40-P-5760SXA
alternator 272.946 /965 /975 in
MODEL 221
Remove, install governor for ENGINE 272, 273 in AR15.40-P-5760TS
Remove/install regulator for ENGINE 272.942 in AR15.40-P-5760VA

ENGINE 272.963 in
MODEL 171.456
Remove/install temperature ENGINE 272 in MODEL AR15.60-P-3000CV
sensor 204
Remove/install temperature ENGINE 272, 273 in AR15.60-P-3000GZA
sensor MODEL 164 Coolant
temperature sensor
Remove/install temperature ENGINE 272, 273 ... AR15.60-P-3000QB
sensor
Remove/install temperature ENGINE 272, 273 in AR15.60-P-3000RTA
temperature sensor
Remove/install temperature ENGINE 272, 273 in AR15.60-P-3000RX
temperature sensor
Remove/install temperature ENGINE 272, 273 ... AR15.60-P-3000SX
sensor
Remove, install temperature ENGINE 272 273 in AR15.60-P-3000TS
sensor MODEL 211, 219 Coolant
temperature sensor
Remove/install temperature ENGINE 272 ... AR15.60-P-3000VA
sensor

AR15.00-Z-9273AB
\\\\ENGINE 273
Remove/install camshaft ENGINE 272, 273 in AR15.10-P-2000GZA

Hall sensor MODEL 164, 251
Remove/install camshaft ENGINE 272, 273 ... AR15.10-P-2000QB
Hall sensor
Remove/install camshaft ENGINE 272, 273 in AR15.10-P-2000RX
Hall sensor MODEL 230
Remove/install camshaft ENGINE 272, 273 in AR15.10-P-2000SX
Hall sensor MODEL 221 ENGINE 273
in MODEL 216
camshaft Hall sensor MODEL 211, 219
Remove/install ignition ENGINE 272, 273 in AR15.12-P-2003GZA
coils MODEL 164, 251
Remove/install ignition ENGINE 272, 273 ... AR15.12-P-2003QB
coils
Remove/install ignition ENGINE 272, 273 in AR15.12-P-2003RX

coils MODEL 230
Remove/install ignition ENGINE 272, 273 in AR15.12-P-2003SX
coils MODEL 221 ENGINE 273
in MODEL 216
Remove, install ignition ENGINE 272, 273 in AR15.12-P-2003TS
coils MODEL 211, 219
crankshaft position MODEL 164
sensor
crankshaft position
sensor
Remove/install ENGINE 272, 273 in AR15.12-P-2133RTA
sensor
sensor
crankshaft position MODEL 221 ENGINE 273
sensor in MODEL 216
crankshaft position MODEL 211, 219
sensor
Remove/install knock ENGINE 272, 273 in AR15.12-P-2184GZA
sensors MODEL 164, 251
Remove/install knock ENGINE 272, 273 ... AR15.12-P-2184QB
sensors
Remove/install knock ENGINE 272, 273 in AR15.12-P-2184RX
sensors MODEL 230
Remove/install knock ENGINE 272, 273 in AR15.12-P-2184SX
sensors MODEL 221 ENGINE 273
in MODEL 216
Remove, install knock ENGINE 272, 273 in AR15.12-P-2184TS
sensors MODEL 211, 219
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100GZA
MODEL 164
Remove/install starter ENGINE 112, 113, 272, AR15.30-P-7100PW
273 ...
Remove/install starter ENGINE 272, 273 ... AR15.30-P-7100QB
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100RTA
MODEL 251
Remove/install starter ENGINE 272, 273 in AR15.30-P-7100RX
MODEL 230
Remove/install starter ENGINE 272.946 /965 /975 AR15.30-P-7100SX
in MODEL 221 ENGINE
273 in MODEL 216, 221
Remove, install starter ENGINE 273 in MODEL AR15.30-P-7100TX
219 ENGINE 273 (except
273.962) in MODEL 211
Checking regulator and ENGINE 272, 273, 642 in AR15.40-P-5000GZ
alternator MODEL 164 ENGINE 272,
273, 642 in MODEL 251
ENGINE 629 in MODEL
164
Test alternator and ENGINE 271, 272, 642, 646 AR15.40-P-5000P
regulator in MODEL 203, 209
ENGINE 273 in MODEL
209
Test alternator and ENGINES 272, 273 in AR15.40-P-5000RX
regulator MODEL 230
Checking regulator and ENGINE 156, 272, 273, 275, AR15.40-P-5000SX
alternator 629, 642 in MODEL 221
ENGINE 156, 273, 275 in
MODEL 216
Checking the alternator ENGINE 156, 271, 272, 273, AR15.40-P-5000T
and regulator 629, 642, 646, 648 ...
Test charging current for ENGINE 272, 273, 642, 629 AR15.40-P-5011GA
alternator in MODEL 164 ENGINE
272, 273, 642 in MODEL
251
Test charging current for ENGINE 271, 272, 642, 646 AR15.40-P-5011PI
alternator in MODEL 203, 209
ENGINE 273 in MODEL
209
Test Charging current ENGINE 272, 273 in AR15.40-P-5011RX
for alternator MODEL 230
Test charging current for ENGINE 156, 272, 273, 275, AR15.40-P-5011SX
alternator 629, 642 in MODEL 221
ENGINE 156, 273, 275 in
MODEL 216
Test charging current for ENGINE 156, 271, 272, 273, AR15.40-P-5011TS
alternator 629, 642, 646, 648 ...
Testing backup fuse of ENGINE 156, 272, 273 ... AR15.40-P-5012QB
alternator
Testing backup fuse of ENGINE 156, 272, 273 in AR15.40-P-5012TS

alternator
Remove/install ENGINE 272.946 /965 /975 AR15.40-P-5032SX
alternator in MODEL 221 ENGINE
273 in MODEL 216, 221
alternator belt pulley MODEL 164, 251
alternator belt pulley
alternator belt pulley MODEL 230
alternator belt pulley MODEL 221 ENGINE 273
in MODEL 216
alternator belt pulley MODEL 211, 219
Remove/install regulator ENGINE 272, 273 in AR15.40-P-5760GZA
for alternator MODEL 164, 251
Remove/install regulator ENGINE 272, 273 ... AR15.40-P-5760QB
for alternator
Remove/install regulator ENGINE 272, 273 in AR15.40-P-5760RX
for alternator MODEL 230
Remove/install regulator ENGINE 273 in MODEL AR15.40-P-5760SX
governor for alternator MODEL 211, 219
temperature sensor MODEL 164 Coolant
temperature sensor
temperature sensor
temperature sensor
temperature sensor
Remove/install ENGINE 272, 273 ... AR15.60-P-3000SX

temperature sensor
Remove, install ENGINE 272 273 in AR15.60-P-3000TS
temperature sensor MODEL 211, 219 Coolant
temperature sensor
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000GZ
Fig. 38: Identifying Camshaft Hall Sensor And Bolts

Remove/install

installing or aligning hoods, doors, trunk lid/ within the operating range of 0011-01A
1
position 1000GZ
AH54.00-P-
0001-01A
discharge
Disconnect electrical connector at camshaft
2
Hall sensor (B6/1)
*BA15.10-P-
3 Remove screw (1)
1002-03A
Pull camshaft Hall sensor (B6/1) out of Installation: Install new O-
4
cylinder head ring.
POSITION SENSOR
Number Designation Engines 113.940/941/ 942/943/944/ 948/960/961/
962/963/964/ 965/966/967/ 968/969/971/ 980/981/982/
984/986/992/ 993/995
BA15.10-P- Camshaft Hall sensor

Nm 8
1002-03A on cylinder head
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 39: Identifying Camshaft Hall Sensor Remove/Install Components

Remove/install
Wear safety gloves, protective

Risk of injury to skin and eyes caused by AS00.00-Z-
clothing and safety glasses, if
handling hot or glowing objects. 0002-01A
necessary.
Remove left and right engine intake air duct
2
(2)
Remove bolts (4), detach power steering
pump expansion reservoir (3) from front When removing the left exhaust
3
cover on cylinder head and swivel with camshaft Hall sensor (B6/6).
attached lines to the side
Disconnect plug from each camshaft Hall
4
sensor.
Undo bolt (5) and remove each camshaft
Installation: Replace sealing
5 Hall sensor from front cover on cylinder
ring.
head
*BA15.10-
P-1002-03E
Connect STAR DIAGNOSIS and read fault
7 simulation during test operations,
memory
AS00.00-Z-
0005-01A
8 Check for oil leaks with engine running
POSITION SENSOR
272 273
BA15.10-P-1002- Bolt, camshaft Hall sensor to front cover on cylinder
Nm 8 8
03E head
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000GZS
Fig. 40: Identifying Camshaft Hall Sensor Remove/Install Components

Remove/install

or crushed when removing, installing or Keep body parts and limbs well AS00.00-Z-
aligning hoods, doors, trunk lids, tailgates or clear of moving parts. 0011-01A
sliding roof.
AR88.40-P-
1 Open engine hood and raise to vertical position Model 164
1000GZ
AR88.40-P-
Model 251
1000RT
Depending on which Hall
2 Remove left or right suction fan duct
sensor must be removed
Remove air pump hose at power steering pump Only when removing right
3.1
expansion reservoir Hall sensor.
Unhook power steering pump feed line from oil Only when removing left
3.2
filter housing Hall sensor.
When disconnecting the
Disconnect connector (2) from respective upper camshaft Hall sensor the
4
camshaft Hall sensor cable tie must be disconnected at
lower camshaft Hall sensor.
Undo bolt (1) and remove respective camshaft Installation: Replace sealing
5
Hall sensor from front cover on cylinder head ring.
*BA15.10-
P-1001-02C
moving by itself.
is running
parts.
Conduct engine test run and check the engine for
7
leaks
KNOCK SENSORS
BA15.10-P-1001-02C Bolt, knock sensor to crankcase Nm 20
REMOVE/INSTALL SPARK PLUGS - AR15.12-P-1010GZ
Shown on right cylinder bank

Fig. 41: Identifying Spark Plugs Remove/Install Components (Shown On Right Cylinder Bank)
Remove/install
Do not touch parts which conduct

high voltages. Persons who wear
Risk of death caused by contact with parts AS15.10-Z-
electronic implants (e.g. heart
conducting high voltages. 0001-01A
pacemakers) must not carry out
work on the ignition system
necessary.
AH54.00-P-
0001-01A
discharge
AH15.10-P-
Notes on avoiding damage to ignition system
0002-01D
1
position 1000GZ
AR09.10-P-
1150GZ
AR15.12-P-
3 Remove ignition coils
2003GZ
*BA15.10-
P-1001-04A
Installation: Observe the
Pry off spark plug connector (1) over the assignment markings "a" and "b" on
cylinder head cover from the spark plugs the ignition coils and cylinder head
4 (R4) cover when plugging on the spark
plug connector (1).
Double open-ended wrench Fig. 44
Remove spark plugs (R4) from cylinder *BA15.10-
5
heads P-1001-01A
Spark plug wrench Fig. 42
Checking
AS00.00-Z-
0005-01A
IGNITION COIL
BA15.10-P-1001-04A Bolt for ignition coil on cylinder head cover Nm 8
SPARK PLUGS
Number Designation Engines 104, 110, 111, 113.940/941/942/943/ 944/948/960/961/962/
963/964/965/966/967/ 968/969/971/980/981/ 982/984/986/992/993/ 995,
115, 117, 119, 120
BA15.10-P- Spark
Nm 28
1001-01A plugs
Fig. 42: Identifying Spark Plug Wrench (112 589 01 09 00)


Fig. 44: Identifying Double Open-End Wrench (110 589 01 01 00)

REMOVE/INSTALL SPARK PLUGS - AR15.12-P-1010GZS
Shown on the right cylinder bank
Fig. 45: Identifying Spark Plugs (Shown On Right Cylinder Bank)

Remove/install

pacemakers) should never perform
any work on the ignition system
necessary.
All models
Notes on avoiding damage to ignition AH15.10-P-
system 0002-01D
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
1 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
Remove the partition wall between the AR62.30-P-
2 Only model 251.
wheelhouses 2400RT
AR09.10-P-
1150GZS
AR15.12-P-
2003GZS
*BA15.10-P-
1001-04B
Remove spark plugs (R4) from cylinder *BA15.10-P-
5
heads 1001-01H
*WH58.30-
Spark plug wrench Z-1073-06A
Checking
AS00.00-Z-
0005-01A
IGNITION COIL

BA15.10-P-1001-04B Bolt, ignition coil to cylinder head cover Nm 8
SPARK PLUGS
BA15.10-P-1001-01H Spark plug to cylinder head Nm 20

Number Designation
WH58.30-Z-1073-06A Spark plug wrench
REMOVE/INSTALL IGNITION LINES - AR15.12-P-1312GZ
Shown on right cylinder bank
Fig. 46: Identifying Ignition Lines Remove/Install Components (Shown On Right Cylinder Bank)
Remove/install

pacemakers) must not carry out
work on the ignition system
Risk of injury to skin and eyes caused by clothing and safety glasses, if AS00.00-Z-
handling hot or glowing objects. necessary. 0002-01A
AH54.00-P-
0001-01A
discharge
AH15.10-P-
Notes on avoiding damage to ignition system
0002-01D
1
position 1000GZ
AR09.10-P-
1150GZ
AR15.12-P-
2003GZ
*BA15.10-
P-1001-04A
Installation: Observe assignment
Pry off spark plug connector (2) over the markings "a" and "b" on ignition
4
cylinder head covers from spark plugs coils and cylinder head covers when
mounting spark plug connector (2).
Checking
AS00.00-Z-
0005-01A
IGNITION COIL

REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003GZ
Fig. 48: Identifying Ignition Coils Remove/Install Components

Remove/install

Risk of death caused by contact with AS15.10-Z-
implants (e.g. heart pacemakers) must
parts conducting high voltages. 0001-01A
not carry out work on the ignition
system.
Risk of injury to skin and eyes caused by Wear safety gloves, protective clothing AS00.00-Z-
handling hot or glowing objects. and safety glasses, if necessary. 0002-01A
Information on preventing damage to AH54.00-P-
All models
electronic components due to electrostatic 0001-01A
discharge
system 0002-01D
1
position 1000GZ
AR09.10-P-
1150GZ
Detach electrical feed lines from cylinder
3 1 ignition coil to cylinder 8 ignition coil Installation: replace tie straps (1).
(T1/1-T1/8) at ignition coil
Unlock electrical connectors (2) for
4 cylinder 1 ignition coil to cylinder 8
ignition coil (T1/1-T1/8) and detach
*BA15.10-
5 Remove screw (3)
P-1001-04A
Installation: Observe assignment
Remove cylinder 1 ignition coil to marks "a" and "b" on cylinder 1
cylinder 8 ignition coil (T1/1-T1/8) and ignition coil to cylinder 8 ignition coil
6
also pry off spark plug connector (4) over (T1/1-T1/8) and on cylinder head cover
cylinder head covers from spark plugs when mounting the spark plug
connector.
moving by itself.
clothes.
running engine
IGNITION COIL

REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003GZA
ENGINE 272, 273 in MODEL 164, 251
Engine 272
Fig. 50: Identifying Ignition Coils Remove/Install Components (Engine 272)

Engine 273
Fig. 51: Identifying Ignition Coils Remove/Install Components (Engine 273)

Remove/install

Risk of death caused by contact
voltages. Persons who wear electronic implants AS15.10-Z-
with parts conducting high
(e.g. heart pacemakers) should never perform 0001-01A
voltages.
caused by handling hot or
glowing objects.
AH54.00-P-
0001-01A
Notes on avoiding damage to AH15.10-P-
ignition system 0002-01V
AR09.10-P-
1150GZA
Remove bolts (1) for ignition
*BA15.10-P-
2 coils (T1/1 to T1/6 and T1/1 to
1001-04A
T1/8)
Pull ignition coils (T1/1 to T1/6
3 and T1/1 to T1/8) with spark plug
connectors (a) upwards and out
4 of ignition coils (T1/1 to T1/6
and T1/1 to T1/8)
Connect STAR DIAGNOSIS and disconnecting cables or by simulation during
6
read fault memory test operations, must be erased in the fault
IGNITION COIL
BA15.10-P-1001-04A Bolt, ignition coil to cylinder head cover Nm 9 9
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003GZS

Fig. 52: Identifying Ignition Coils Remove/Install Components

Remove/install
Do not come into contact with parts

that are under high voltage. Persons
Risk of death caused by contact with parts who wear electronic implants (e.g. AS15.10-Z-
conducting high voltages. heart pacemakers) should never 0001-01A
perform any work on the ignition
system.
necessary.
All models
All models
system 0002-01D
1 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
2 Only model 251.
wheelhouses 2400RT
AR09.10-P-
1150GZS
4 Detach electrical feed lines from cylinder 1
Install: Install new cable ties.
ignition coil through to cylinder 8 ignition
coil (T1/1 up to T1/8) on the ignition coil

Unlock electrical connector (2) for cylinder
5 1 ignition coil through to cylinder 8 ignition
coil (T1/1 up to T1/8) and detach
*BA15.10-
6 Remove bolts (3)
P-1001-04B
Remove cylinder 1 ignition coil to cylinder
7
8 ignition coils (T1/1 to T1/8)
AS00.00-Z-
0005-01A
IGNITION COIL
BA15.10-P-1001-04B Bolt, ignition coil to cylinder head cover Nm 8
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133GZ
ENGINES 113.964 in MODEL 164.175
Fig. 53: Identifying Crankshaft Position Sensor Remove/Install Components

Remove/install

lids, liftgates or sliding roof
the lifting platform and position the
AR88.40-P-
1 Open engine hood
1000GZ
AR00.60-P-
1000GZ
AR09.10-P-
1150GZ
Remove catalytic convertor on the AR49.10-P-
4 Remove catalytic converter
left side. 5500GZN
*BA49.10-
P-1001-01S
*BA49.10-
P-1002-01S
*BA49.10-
P-1004-01S
*BA62.30-
P-1003-01E
*BA62.30-
P-1004-01E
*BR00.45-
Paste
Z-1005-06A
*BA27.40-
5 Remove bolt (1)
P-1001-01E
6 Remove shield (2)
Detach the electrical connector of the
7
crankshaft position sensor (L5)
*BA15.10-
8 Remove screw (3)
P-1001-03A
9 Remove crankshaft position sensor (L5)
11
necessary
system
AS00.00-Z-
0005-01A
POSITION SENSOR
962/963/964/ 965/966/967/ 968/969/971/ 980/981/982/
984/986/992/ 993/995
BA15.10-P- Crankshaft position
Nm 8
1001-03A sensor to engine block
HOUSING
Number Designation Transmission 722.9 in model 164
BA27.40-P-1001-01E Bolt, automatic transmission to crankcase Nm 39
EXHAUST SYSTEM
Number Designation Engines 113.964 in model
164.1
BA49.10-P-1001- Bolt, catalytic converter bracket to catalytic
Nm 20
01S convertor
BA49.10-P-1002- Bolt, flange connection to exhaust pipe/exhaust
Nm 20
01S manifold
BA49.10-P-1004- Bolt, center muffler flange connection to catalytic
Nm 35
01S converter
CROSSMEMBER AND FRONT REINFORCEMENT

BA62.30-P-1003-01E Bolt, left bracket to engine crossmember M10 Nm 45
BA62.30-P-1004-01E Bolt, left bracket to transmission tunnel M10 Nm 45
REPAIR MATERIALS
BR00.45-Z-1005-06A Paste A 000 989 76 51
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133GZA

Fig. 54: Identifying Crankshaft Position Sensor And Bolts

Remove/install

necessary.
AH54.00-P-
0001-01A
discharge
AH00.00-N-
0001-01A
AR09.10-P-
1150GZA
Remove shield on crankshaft Hall sensor *BA27.40-P-
2
(B70) 1008-01A
3
connector at crankshaft Hall sensor (B70)
Unscrew bolt (1) and pull crankshaft Hall *BA15.10-P-
4
sensor (B70) out of the crankcase 1001-03E
Only when replacing.
Menu guidance:
Connect STAR DIAGNOSIS and then
6 perform default initialization of sensor  Engine control module
rotor adaptation
 Adaptations
 Learning processes
HOUSING

M10X40 Nm 38
BA27.40-P-1008-01A Bolt, automatic transmission to engine M10X90 Nm 38
M12 Nm -
POSITION SENSOR
BA15.10-P-1001-03E Bolt, crankshaft Hall sensor to crankcase Nm 8 8
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133GZS
Fig. 55: Identifying Crankshaft Position Sensor Remove/Install Components

Remove/install
Risk of injury caused by fingers being pinched or Keep body parts and
AS00.00-Z-
crushed when removing, installing or aligning hoods, limbs well clear of
0011-01A
doors, trunk lids, tailgates or sliding roof. moving parts.
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR62.30-P-
2 Remove the partition wall between the wheelhouses Only model 251
2400RT
AR09.10-P-
3 Remove air filter housing (1).
1150GZS
Push shielding (2)
4 Push shielding (2) upwards upwards until the
electrical connector (3) is
accessible.
Disconnect electrical connector (3) from crankshaft
5
position sensor (L5)
*BA15.12-P-
6 Unscrew bolt (4)
1001-01K
7 Remove crankshaft position sensor (L5)
STAR DIAGNOSIS *WH58.30-Z-
diagnosis system 1048-13A
memory 2000-04A
Secure vehicle to prevent
Risk of accident caused by vehicle starting off by it from moving by itself.
itself when engine is running. Risk of injury caused Wear closed and snug- AS00.00-Z-
by contusions and burns during starting procedure or fitting work clothes. 0005-01A
when working near the engine as it is running Do not touch hot or
rotating parts.
ECI IGNITION SYSTEM

BA15.12-P-1001-01K Crankshaft position sensor on crankshaft housing M6 Nm 8

Number Designation
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184GZ

Fig. 56: Identifying Knock Sensors Remove/Install Components

Remove/install
Risk of injury caused by fingers being jammed When moving components,

or pinched when removing, installing or ensure that no body parts or AS00.00-Z-
aligning hoods, doors, trunk lid/rear-end door or limbs are within the operating 0011-01A
sliding roof. range of moving parts.
AR88.40-P-
1 Open engine hood
1000GZ
AR09.10-P-
1150GZ
The intake manifold must AR09.20-P-
3 Remove intake manifold
not be disassembled. 1310GZ
Disconnect electrical connector at right knock
4
sensor 1 (A16/1) and left knock sensor 2 (A16/2)
*BA15.10-P-
5 Remove bolts (1)
1001-02A
Remove right knock sensor 1, (A16/1) and left
6
knock sensor 2 (A16/2)
system Z-1048-13A
Risk of accident caused by vehicle starting off Secure vehicle to prevent it

AS00.00-Z-
by itself when engine is running. Risk of injury from moving by itself.
0005-01A
caused by contusions and burns during starting Wear closed and snug-fitting
procedure or when working near the running work clothes.
engine Do not grasp hot or rotating

parts.
KNOCK SENSORS
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/971/
Bolt
securing
BA15.10- knock
P-1001- sensor Nm 20
02A to
cylinder
block

Number Designation
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184GZA
ENGINE 272, 273 in MODEL 164, 251

Remove/install
AH54.00-P-
0001-01A
AR09.10-P-
1150GZA
2
manifold 1961GZA

3 at right knock sensor 1 (A16/1)
or left knock sensor 2 (A16/2)
Remove bolt (1) and take out
*BA15.10-P-
4 right knock sensor 1 (A16/1) or
1001-02B
left knock sensor 2 (A16/2)
Connect STAR DIAGNOSIS disconnecting cables or by simulation during
6
and read fault memory test operations, must be erased in the fault
KNOCK SENSORS
BA15.10-P-1001-02B Bolt, knock sensor to crankcase Nm 20 20
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184GZS

Remove/install
Risk of injury caused by fingers being Keep body parts and limbs well AS00.00-Z-
pinched or crushed when removing, clear of moving parts. 0011-01A
installing or aligning hoods, doors, trunk lids,

platform support points specified
All models
caused by swallowing battery acid. Risk of Wear acid-resistant gloves, AS54.10-Z-
injury caused by burns to skin and eyes from clothing and glasses. Only pour 0001-01A
battery acid or when handling damaged lead- battery acid into suitable and
acid batteries appropriately marked containers.
Only when removing right
knock sensor 1 (A16/1) is
necessary.
Insulate ground line clamp
as a protection against
unintentional contact of
dismounted ground line with
1 Disconnect ground line from battery
ground point of battery.
Keyless Go:
Switch engine off, remove
Keyless-Go cards from the vehicle
and store outside of transmitter
range.
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR62.30-P-
3 Remove partition wall between wheelhouses Only model 251. 2400RT
Do not tilt front engine
4 Remove air filter housing cover, but lift upwards vertically AR09.10-P-
otherwise the retaining lugs can 1150GZS
break off.
5 Mount engine hoist Model 164 AR33.10-P-
0100-01GZ
AR33.10-P-
Model 251
0100-01RT
Engine supporting frame *WE58.40-
basic frame side piece (M/S-class) Z-1027-11A
Model 251: ?
Engine lifting device side *WH58.30-
adapter for model 251 Z-1019-07A
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT
Only model 251 when removing
8 Disconnect electrical connections at alternator
right knock sensor (A16/1).
Depending on which knock
Remove engine mount with front engine AR22.10-P-
9 sensor, on the right or left, should
support on the appropriate side 1260GZS
be removed.
Unlock and remove the electrical connector
10 sensor, on the right or left, should
(1, 3).
be removed.
11 Undo bolt (2, 4) sensor, on the right or left, should
be removed.
*BA15.10-P-
1001-02C
Remove right knock sensor 1, (A16/1) or left
12
knock sensor 2 (A16/2)
AR00.19-P-
0200GZ
AR00.19-P-
Model 251
0200RT
system Z-1048-13A

injury caused by contusions and burns during Wear closed and snug-fitting work 0005-01A

KNOCK SENSORS
BA15.10-P-1001-02C Bolt, knock sensor to crankcase Nm 20

Number Designation
WH58.30-Z-1019- Side adapter for engine lifting device, Company BlitzRotary GmbH D-78199 Br
07A unlingen
WH58.30-Z-1048-
STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
13A
WORKSHOP EQUIPMENT
WE58.40-Z-1027-11A Engine support frame
REMOVING/INSTALLING THE STARTER - AR15.30-P-7100GZ
Fig. 59: Identifying Starter Remove/Install Components

Removing/installing
Risk of injury caused by fingers being When moving components,

jammed or pinched when removing, installing ensure that no body parts or

AS00.00-Z-
or aligning hoods, doors, trunk lid/ rear-end door limbs are within the operating
0011-01A
or sliding roof. range of moving parts.
AR88.40-P-
1 Open engine hood
1000GZ
AS54.10-Z-
swallowing battery acid. Risk of injury caused clothing and safety glasses. Only
0001-01A
by burns to skin and eyes from battery acid or pour battery acid into suitable
when handling damaged lead-acid batteries and appropriately marked
containers.
Insulate clamp of
ground line as a protection AR54.10-P-
2 Disconnect ground cable from battery against unintentional contact of 0003GZ
AH54.10-P-
0001-01A
Align vehicle between the
columns of the hydraulic hoist
Risk of death caused by vehicle slipping or and position the four support AS00.00-Z-
toppling off the lifting platform. plates below the hoist support 0010-01A
points specified by the vehicle
manufacturer.
AR00.60-P-
1000GZ
AR61.20-P-
4 Remove bottom engine compartment paneling
1105GZ
AR49.10-P-
5 Remove complete exhaust system
7000GZ
Remove protection against electrical contact for
6 electrical line circuit 30 (1) from starter motor
(M1)
Detach the electrical line for circuit 30(1) on Nut for terminal 30 *BA15.30-P-
7
starter motor (M1) connection 1001-01A
Detach the electrical line for circuit 50 (2) on Nut for terminal 50 *BA15.30-P-
8
starter motor(M1) connection 1002-01A
9 Screw down nut (3) on mounting clamp (5)
Unhook shield (4) out of the mounting clamp (5)
10
upwards and remove
*BA15.30-P-
11 Unscrew bolts (7) from starter motor (M1) Bolt for starter on crankcase 1003-01A
12 Lead starter motor (M1) downwards Pull starter motor out of the
crankcase and turn anti-
clockwise by about 45°.

When replacing the starter
motor (M1).
Check ring gear on the drive plate for wear and
13.1 Rotate engine at the center
damage
Bolt for the crankshaft in the
direction of rotation.
system Z-1048-13A
STARTER
BA15.30-P-1001-01A Nut for connection of circuit 30 Nm 14
BA15.30-P-1002-01A Nut for connection of circuit 50 Nm 6
BA15.30-P-1003-01A Bolt for starter on crankcase Nm 40

Number Designation
REMOVE/INSTALL STARTER - AR15.30-P-7100GZA

Fig. 60: Identifying Starter Remove/Install Components - Shown On Model 164.1 (1 Of 2)

Fig. 61: Identifying Starter Remove/Install Components - Shown On Model 164.1 (2 Of 2)

Remove/install

vehicle lift and position four
AH00.00-N-
0001-01A

AS54.10-Z-
swallowing battery acid. Risk of injury caused clothing and glasses. Only pour
0001-01A
by burns to skin and eyes from battery acid or battery acid into suitable and
when handling damaged lead-acid batteries appropriately marked containers.
Insulate ground line
clamp as a protection against AR54.10-P-
1 Disconnect ground cable of battery unintentional contact of 0003GZ
AH54.10-P-
Notes on battery
0001-01A
AR61.20-P-
2 Remove bottom engine compartment paneling
1105GZ
AR49.10-P-
3 Remove right catalytic converter Engine 272
7100GZA
Unhook nuts (5m), heat shield (5) from bracket
4
(5h) and take off
Pry off cable holder (1a) from transmission
5
bracket
*BA15.30-
6 Undo bolts (4) from starter (M1)
P-1003-01J
First lower starter with
Move starter (M1) out of transmission bell attached lines to the rear, then to
7 the front out of the transmission
housing
bell housing until the electrical
connections are accessible.
Pull out protective cap (1) and remove electrical *BA15.30-
8
connections circuit 30 (2), 50 (3) at starter (M1) P-1001-01J
*BA15.30-
P-1002-01J
9 Take starter (M1) down and out
Checking
Rotate engine at center bolt of
Check ring gear on drive plate for wear and
10 crankshaft in the direction of
damage
rotation.
STARTER
BA15.30-P-1001-01J Nut, connection for circuit 30 Nm 15
BA15.30-P-1002-01J Nut, connection for circuit 50 Nm 8
BA15.30-P-1003-01J Bolt connecting starter to crankcase Nm 40
REMOVE/INSTALL STARTER - AR15.30-P-7100GZS
Fig. 62: Identifying Starter Remove/Install Components

Remove/install

Risk of poisoning and caustic burns caused smoking.
by swallowing battery acid. Risk of injury Wear acid-resistant gloves, AS54.10-Z-
caused by burns to skin and eyes from battery clothing and glasses. Only pour 0001-01A
acid or when handling damaged lead-acid battery acid into suitable and
Insulate ground line
clamp as a protection against
1 Disconnect ground line from battery unintentional contact of
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR62.30-P-
3 Remove partition wall between wheelhouses Only model 251. 2400RT
Do not tilt front engine
4 Remove air filter housing cover, but lift upwards vertically AR09.10-P-
otherwise the retaining lugs can 1150GZS
break off.
AR33.10-P-
5 Mount engine hoist Model 164
0100-01GZ
AR33.10-P-
Model 251
0100-01RT
Engine supporting frame *WE58.40-
basic frame side piece (M/S-class) Z-1027-11A
Model 251: ?
Engine lifting device side *WH58.30-
adapter for model 251 Z-1019-07A
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
7 Remove bottom engine compartment paneling Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
Do not completely remove
Remove exhaust system up to rear flange exhaust system, instead separate
8
connection at rear flange connection.
Model 164: ?
Remove/install exhaust system
AR49.10-P-
complete
7000GZ
Model 251: ?
Remove/install exhaust system AR49.10-P-
complete 7000RT
Remove engine mount with engine support at AR22.10-P-
9
right front 1260GZS
Remove protection against accidental contact

10 for electrical line for circuit 30 (1) on starter
(M1)
Dismount electrical line for circuit 30 (1) at *BA15.30-P-
11
starter (M1) 1001-01O
Remove circuit 50 (2) electrical line on starter *BA15.30-P-
12
(M1) 1002-01O
Detach bracket for automatic oil lines at oil *BA01.45-P-
13
pan 1005-01R
*BA15.30-P-
14 Unscrew bolts (7) of starter (M1)
1003-01O
15 Lead starter (M1) down and out
When replacing starter (M1)
Check ring gear on the drive plate for wear and
16 Rotate engine at center bolt,
damage
crankshaft in direction of rotation.
AR00.19-P-
0200GZ
AR00.19-P-
Model 251
0200RT
STARTER
BA15.30-P-1001-01O Nut for connection of circuit 30 Nm 15
BA15.30-P-1002-01O Nut for connection of circuit 50 Nm 8
BA15.30-P-1003-01O Bolt connecting starter to crankcase Nm 40
OIL PAN
BA01.45-P-1005-01R Bracket, oil lines to oil pan M6 Nm 5

Number Designation
07A Uunlingen
WORKSHOP EQUIPMENT
CHECKING REGULATOR AND ALTERNATOR - AR15.40-P-5000GZ
ENGINE 272, 273, 642 in MODEL 164

ENGINE 272, 273, 642 in MODEL 251
Fig. 63: Identifying Star Diagnosis And Data Link Connector

Check
smoking.
clothing and glasses. Only pour 0001-01A
AH54.00-
Information on preventing damage to electronic
P-0001-
components due to electrostatic discharge
01A
AH54.10-
01A
Assess the results, replace
1 Check status of batteries
battery if required.
AR54.10-
Model 164
P-1129GZ
AR54.10-P-
Model 251
1129RT
Connect up STAR DIAGNOSIS (0100) to data
2
link connector (X11/4)
Risk of accident caused by vehicle starting off by moving by itself. AS00.00-Z-
itself when engine is running. Risk of injury Wear closed and snug-fitting 0005-01A
caused by contusions and burns during starting work clothes.
procedure or when working near the engine as it Do not touch hot or rotating
is running parts.
Only perform tests when
engine at its normal operating
temperature.
Checking is menu-assisted:
3 Test alternator using STAR DIAGNOSIS (0100)
 Engine control unit
 actuations
 alternator diagnosis
4 Disconnect STAR DIAGNOSIS (0100).
CHECKING THE ALTERNATOR AND REGULATOR - AR15.40-P-5000T
ENGINE 271, 629, 646.### ## as of 709557, 648 in MODEL 211
ENGINE 272, 273, 642 in MODEL 211, 219
ENGINE 156 in MODELS 164, 209, 211, 219, 251
Fig. 64: Identifying Star Diagnosis And Data Link Connector

Check
by oxyhydrogen gas. flames or smoking.
Risk of poisoning and Wear acid-resistant
caustic burns caused by gloves, clothing and
swallowing battery acid. glasses. Only pour battery
Risk of injury caused by acid into suitable and

burns to skin and eyes appropriately marked
from battery acid or when containers.
handling damaged lead-
acid batteries
damage to electronic
components due to
Notes on battery AH54.10-P-0001-01A
1 Check battery for Model 164 AR54.10-P-1129GZ
condition
Model 209 AR54.10-P-1129P
Model 211, 219 AR54.10-P-1129TX
Model 251 AR54.10-P-1129RT
Observe notes about
absorbent glass mat
battery, see: ?
Notes on AGM battery AH54.10-P-0002-01A
Dispose of battery OS54.10-P-0001-01Z
Assess the results,
replace battery if
required.
Midtronics MCR *WH58.30-Z-1008-09A
717 battery tester and
analyzer
2 Connect up STAR
DIAGNOSIS (0100) to
data link connector
(X11/4).
DIAGNOSIS and read
out fault memory
diagnosis system
procedure or when
as it is running
3 Check alternator using Only perform tests
STAR DIAGNOSIS when engine at its normal

(0100) operating temperature.
Checking is menu-
assisted
Engine control unit
Actuations
Alternator diagnosis
diagnosis system
4 Disconnect STAR
DIAGNOSIS (0100).

Number Designation
WH58.30-Z-1008-09A Battery tester and analyzer
PREREQUISITES FOR TESTING THE ALTERNATOR - AR15.40-P-5009GZ
Connection diagram
Fig. 65: Alternator Connection Diagram

Check

smoking.
Wear acid-resistant gloves,
clothing and goggles. Only pour AS54.10-Z-
swallowing battery acid. Risk of injury caused by
battery acid into suitable and 0001-01A
burns to skin and eyes from battery acid or when
appropriately marked
handling damaged lead-acid batteries
containers.
AH54.10-
01A
AR88.40-
P-1000GZ
AR88.40-P-
Model 251
1000RT
2 Inspect poly-V-belt
AP13.22-P-
Check poly-V-belt in visible area for wear Model 164
1352GZ
AP13.22-P-
Model 251
1352RT
AR61.20-
P-1105GZ
AR61.20-P-
Model 251
1105RT
Tight seating and proper
Check the electrical lines at the battery (G1),
4 condition of the cables must be
alternator (G2) and starter (M1)
guaranteed.
5 Check ground strap between engine and body condition of the cables must be
guaranteed.
AR61.20-
P-1105GZ
AR61.20-P-
Model 251
1105RT
AR88.40-
P-1000GZ
AR88.40-P-
Model 251
1000RT
PREREQUISITES FOR TESTING ALTERNATOR - AR15.40-P-5009GZS
Connection diagram
Fig. 66: Alternator Connection Diagram

Check
AS54.10-Z-
swallowing battery acid. Risk of injury caused by clothing and goggles. Only pour
0001-01A
burns to skin and eyes from battery acid or when battery acid into suitable and
handling damaged lead-acid batteries appropriately marked
containers.
AH54.10-
01A
AR88.40-
P-1000GZ
AR88.40-P-
Model 251
1000RT
2 Inspect poly-V-belt
AP13.22-P-
Check poly-V-belt in visible range for wear
1352GZ
AR61.20-
3 Remove lower engine compartment paneling
P-1105GZ
guaranteed.
5 Check ground strap between engine and body condition of the cables must be
guaranteed.
AR61.20-
P-1105GZ
AR61.20-P-
Model 251
1105RT
AR88.40-
P-1000GZ
AR88.40-P-
Model 251
1000RT
CHECKING REGULATION VOLTAGE OF ALTERNATOR - AR15.40-P-5010GZ
ENGINE 113 in MODELS 164, 251
Connection diagram
Fig. 67: Alternator Regulation Voltage Connection Diagram

Checking
caused by burns to skin and eyes from battery clothing and goggles. Only pour 0001-01A
AH54.10-P-
Notes on battery
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR54.10-P-
2 Check condition of battery (G1) Model 164
1129GZ
AR54.10-P-
Model 251
1129RT
Check whether preconditions for alternator AR15.40-P-
3
testing have been fulfilled 5009GZ
Attach volt ampere tester (079) according to Volt ampere tester with *WH58.30-
4
connection plan load resistance Z-1002-09A
Volt ampere tester ETT *WH58.30-
011.00 Z-1003-09A
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting
0005-01A
starting procedure or when working near the work clothes.
5 Start engine
Check function of charge indicator lamp when In case of correct charging
voltage, no fault message is
6 engine is idling and with increasing engine
speed (up to 3000 rpm) shown in the display of the
instrument cluster.
Load battery (G1) using a permanent consumer *BE15.40-P-
7
and check regulation voltage of alternator (G2) 1001-02A
Volt ampere tester with *WH58.30-
load resistance Z-1002-09A
Volt ampere tester ETT
011.00
*WH58.30-
Regulation voltage > 15.0 V: ? Z-1003-09A
 Replace regulator
AR15.40-P-
Model 164
5760GZ
Model 251 AR15.40-P-
Regulation voltage < 13.0 V: ? 5760RT
 Check electrical
connections for charging
system for transition
resistances; repair if
necessary.
Electrical connections OK: ?
 Check alternator (G2) AR15.40-P-

diodes 9301-02GZ
Current measurement *WH58.30-
pliers Z-1016-09A
Engine tester with oscilloscope
If diodes are faulty: ? *WH58.30-
Z-1046-13A
 Replace alternator (G2)
AR15.40-P-
Model 164
5032GZ
AR15.40-P-
Model 251
5032RT
8 Turn off engine
9 Disconnect volt ampere tester (079)
011.00 Z-1003-09A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
CHECK VALUES FOR REGULATOR

Number Designation Engines 103, 104, 111, 112, 113,
119, 120, 137, 155, 166, 275
Loading: only on
V 13 to 15
BE15.40-P- Regulating voltage permanent consumer
1001-02A (at battery) Engine speed rpm 3000
measured after min approx. 2

Number Designation
WH58.30-Z-1002-09A Volt-amp(s) tester with load resistance (no longer available)
WH58.30-Z-1016-09A Clamp-on probe
WH58.30-Z-1046-13A Engine tester with oscilloscope
TEST CHARGING CURRENT FOR ALTERNATOR - AR15.40-P-5011GA
ENGINE 272, 273, 642, 629 in MODEL 164
ENGINE 272, 273, 642 in MODEL 251
Connection scheme
Fig. 68: Alternator Charging Current Connection Diagram

Checking
AS54.10-Z-
swallowing battery acid. Risk of injury goggles. Only pour battery acid into
0001-01A
caused by burns to skin and eyes from suitable and appropriately marked
battery acid or when handling damaged containers.
lead-acid batteries
AH54.10-P-
Notes on battery
0001-01A
1 Check tension of poly-V belt
2 Check poly-V belt for wear
Check visible area of poly-V belt for Model 164.1 with engine 272.9, 164.8 with AP13.22-P-
wear engine 273.9 1352GZC
AP13.22-P-
Model 251.065/165
1352RTC
AP13.22-P-
Model 164 with engine 629
1352GZE
AP13.22-P-
1352GZD
Model 251.020/022/122
AP13.22-P-
Model 164.1 with engine 273.9, 251.026/
1352RTD
054/056/072/126/154/156/172
Check electrical lines at battery (G1), Tight seating and proper condition of
3
alternator (G2) and starter (M1) the cables must be guaranteed.
4.1 paneling Model 164 with engine 272, 273 1105GZ

AR61.20-P-
Model 251 with engine 272, 273
1105RT
4.2 Model 164 with engine 629, 642
soundproofing 5300GZ
AR94.30-P-
5300RT
Check ground strap between engine
5 and body for tight seating and proper
condition
Connect volt-ampere tester (079) with
6 current clamp (065) according to the
connection diagram
7 Start engine
Vary load resistance long enough until
Load battery (G1) with volt ampere
tester (079) and check charging current maximum load current is achieved; when
8 this is done, the regulating voltage must not
of alternator (G2) with increased
drop below 12.7 V.
engine speed
Engine 272, 273
Charge current for alternator *BE15.40-
Engine 629 P-1001-01I
Charge current for alternator *BE15.40-
Engine 642 P-1001-01J
*BE15.40-
Charge current for alternator
P-1001-
Charging current below desired value: ?
01H
Check diodes of alternator.
AR15.40-P-
If diodes are faulty: ? 9301-02GZ
Remove/install alternator
AR15.40-P-
5032GZA
AR15.40-P-
5032RTA
AR15.40-P-
5032GZD
AR15.40-P-
Model 164, 251 with engine 642
5032GZB
9 Turn off engine
Disconnect volt ampere tester (079)
10 with current clamp (065)

Install lower engine compartment AR61.20-P-
paneling 1105GZ
AR61.20-P-
1105RT
Install bottom sections of AR94.30-P-
soundproofing 5300GZ
AR94.30-P-
5300RT
CHECK VALUES FOR ALTERNATOR

Number Designation Engine 629 in model 164, 211, 221
max. A 220
min. A 170
BE15.40-P-1001-01J Charge current for alternator
Engine speed rpm 2000
Ratio i= 2.93

Number Designation Engine 642 in model 164, Engine 642 in model
203, 209, 211, 251, Valeo 164, 221, 251, Bosch
max. A 180 220
min. A 140 170
BE15.40-P- Charge current for
1001-01H alternator Engine
rpm 2200 2000
speed
Ratio i= 2.82 2.93

Number Designation Engine 272 in model 164, Engine 273 in model 164, 209,
211, 219, 230, 251 Engine 211, 219, 230, 251 Engine 273
272 in model 221 without in model 216, 221 without code
code 910 910
max. A 180 180
Charge min. A 140 140
BE15.40-P-
current for Engine
1001-01I rpm 2000 2000
alternator speed
Ratio i= 2.93 2.93
TEST CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011GZ
Connection diagram

Checking
injury caused by burns to skin and eyes from and goggles. Only pour battery acid 0001-01A
battery acid or when handling damaged lead- into suitable and appropriately
acid batteries marked containers.
AH54.10-P-
0001-01A
AR15.40-P-
1 Test regulation voltage of alternator (G2)
5010GZ
Connect volt ampere tester (079) with current Volt ampere tester with load *WH58.30-
2
clamp (065) according to connection diagram resistance Z-1002-09A
011.00 Z-1003-09A
AS00.00-Z-
0005-01A
3 Start engine
Vary load resistance long
Load battery (G1) with volt ampere tester enough until the maximum load *BE15.40-P-
4 (079) and check charging current of alternator current is achieved; when this is
1001-01K
(G2) with increased engine speed done, the regulating voltage must
not drop below 12.7 V.
Volt ampere tester with load *WH58.30-

resistance Z-1002-09A
Volt ampere tester ETT
011.00 *WH58.30-
Charging current below desired Z-1003-09A
value: ?
 Check diodes for alternator AR15.40-P-
(G2). 9301-02GZ
*WH58.30-
Current measurement pliers Z-1016-09A
Engine tester with oscilloscope
If diodes are faulty: ? *WH58.30-
Z-1046-13A
 Replace alternator (G2)
AR15.40-P-
Model 164
5032GZ
AR15.40-P-
Model 251
5032RT
5 Turn off engine
Disconnect volt ampere tester (079) with Volt ampere tester with load *WH58.30-
6
current clamp (065) resistance Z-1002-09A
011.00 Z-1003-09A
TEST VALUES FOR ALTERNATOR

Number Designation Engine 113 in models 164, 251, 211.076/276,
215.374, 219.376, 220.074/174, 230.472/474 Bosch
max. A 180
min A 140
BE15.40-P- Charging current
1001-01K of alternator Engine
rpm 2000
speed
Ratio I= 2.93

Number Designation
TEST CHARGING CURRENT FOR ALTERNATOR - AR15.40-P-5011GZS

Connection diagram

MODIFICATION NOTES
Charge current for Engine 156 in model 164, 204, 209, 211, 219, *BE15.40-P-1001-
21.6.06
alternator 230, 251 01I
Checking
smoking.
clothing and goggles. Only pour 0001-01A
AH54.10-P-
Notes on battery
0001-01A
1 Check tension of poly-V-belt
2 Check poly-V-belt for wear
AP13.22-P-
Check poly-V-belt in visible range for wear
1352GZ
guaranteed.
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT
Check ground strap between engine and body

5
for tight seating and proper condition
Connect volt ampere tester (079) with current Volt ampere tester with *WH58.30-
6
clamp (065) according to connection diagram load resistance Z-1002-09A
Volt ampere Tester ETT *WH58.30-
011.00 Z-1003-09A
pliers Z-1016-09A
moving by itself.
is running
parts.
7 Start engine
Vary load resistance until
Load battery (G1) with volt ampere tester (079)
8 and check charging current of alternator (G2) maximum charging current is
reached; the regulation voltage
with increased engine speed
must not fall below 12.7 V.
*BE15.40-P-
Charge current for alternator
1001-01I
Volt ampere Tester ETT
011.00 *WH58.30-
Charging current below Z-1003-09A
desired value: ?
 Check diodes for AR15.40-P-
alternator (G2). 9301-02GZ
pliers Z-1016-09A
Engine tester with oscilloscope *WH58.30-
If diodes are faulty: ? Z-1046-13A
AR15.40-P-
 Replace alternator (G2).
5032GZS
9 Turn off engine
Disconnect volt ampere tester (079) with current
10
clamp (065)
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT

Number Designation Engine 156 in model 164, 209, 211,

219, 251
max. A 180
min. A 140
BE15.40-P-1001- Charge current for
01I alternator Engine
rpm 2000
speed
Ratio I= 2.93

Number Designation
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032GZ
Fig. 71: Identifying Alternator Remove/Install Components

Remove/install

sliding roof.
AR88.40-P-
1000GZ

by swallowing battery acid. Risk of injury Wear acid-resistant gloves,
AS54.10-Z-
caused by burns to skin and eyes from battery clothing and glasses. Only pour
0001-01A
Insulate clamping device
of the ground line in order to AR54.10-P-
prevent inadvertent contact with 0003GZ
the ground point of the battery.
AH54.10-P-
0001-01A
AR00.60-P-
1000GZ
AR01.10-P-
2405GZ
AR13.22-P-
6 Partly remove poly-V belt
1202GZ
Remove protection against accidental contact
*BA15.40-
7 (4) and dismount circuit B+ (1) from alternator Nut, circuit B+ to alternator P-1001-01N
(G2)
Detach electrical connector (2) from alternator
8
(G2)
9 Remove bolts (3) Self-grooving screw, alternator *BA15.40-
to timing case P-1005-01N
10 Take alternator (G2) down and out
memory 2000-04A
system
ALTERNATOR
Number Designation Engine 113 in Model
164, 251
BA15.40-P-1001-
Nut, circuit B+ to alternator Nm 18
01N
Thread not pre-

tapped
01N timing case

REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032GZA

Remove/install

Insulate ground line clamp
as a protection against AR54.10-P-
1 Disconnect ground cable of battery
unintentional contact of 0003GZ

AH54.10-P-
Notes on battery
0001-01A
3 Remove left and right engine intake air ducts
AR13.20-P-
0001GZA
Remove cap (1) and disconnect circuit 30
*BA15.40-
5 electrical line (B+) (3) from alternator (G2) by
P-1002-01F
unscrewing nut (2).
Remove electrical line plug of tml. 61 (D+) (4)
6
from alternator (G2)
Unscrew bottom bolts (5) of the alternator *BA15.40-
7
(G2) P-1001-01F
*BA15.40-
8 Unscrew top bolts (6) of the alternator (G2)
P-1001-01F
9 Take alternator (G2) down and out
caused by disconnecting cables or
Connect STAR DIAGNOSIS and read fault by simulation during test
11
memory operations, must be erased in the
fault memory after completing the
work.
ALTERNATOR
BA15.40-P-1001-01F Bolt, alternator to timing case Nm 20 20
BA15.40-P-1002-01F Nut of circuit B+ to generator Nm 15 15
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032GZS


Remove/install

sliding roof.
Insulate clamp of ground
line as a protection against
unintentional contact of
1 Disconnect ground line from battery ground point of battery.
code 889: Switch engine off,
remove Keyless-Go cards from
the vehicle and store outside of
the transmitter range.

AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
Notes on battery
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Do not tilt front engine cover,
3 Remove front engine cover but lift upwards vertically
otherwise the retaining lugs can
break off.
4 Remove right and left intake air duct
Unclip engine wiring harness clip on alternator
5
(G2)
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT
AR13.22-P-
8 Remove poly-V-belt
1202GZS
AR20.00-P-
1142GZS
For model 251 the coolant hose
10 Remove lower coolant hose on water pump must also be disconnected from
the expansion reservoir.
Disconnect oil heat exchanger oil line at flange
11 Check engine oil level.
connection
Remove cap (1) and disconnect circuit 30
*BA15.40-
12 electrical line (B+) (3) at alternator (G2) by
P-1002-01P
unscrewing nut (2).
Remove electrical line plug of circuit 61 (D+)
13
(4) from the alternator (G2)
Installation: Screw ground
14 Remove bolts (5) on alternator (G2)
strap back on again.
*BA15.40-
P-1001-01P
15 Take generator (G2) down and out

AR00.19-P-
0200GZ
AR00.19-P-
Model 251
0200RT
ALTERNATOR
BA15.40-P-1001-01P Bolt, alternator to timing case M8X90 Nm 20
BA15.40-P-1002-01P Nut, circuit B+ to alternator Nm 18
REMOVE/INSTALL ALTERNATOR BELT PULLEY - AR15.40-P-5710GZ
Fig. 75: Identifying Collar Nut, Shaft And Belt Pulley

Fig. 76: Identifying Double Hexagon Wrench

Remove/install

Keep body parts and limbs AS00.00-Z-
well clear of moving parts. 0011-01A
AR88.40-P-
1 Open engine hood
1000GZ
AS54.10-Z-
swallowing battery acid. Risk of injury caused by clothing and glasses. Only
0001-01A
burns to skin and eyes from battery acid or when pour battery acid into suitable
containers.
AR54.10-P-
0003GZ
AH54.10-P-
0001-01A
AR15.40-P-
3 Remove alternator
5032GZ
*BA15.40-
P-1001-01N
*BA15.40-
P-1002-01N
*BA15.40-
P-1003-01N
*BA15.40-
P-1005-01N
To hold shaft (2) tight,
insert screwdriver bit through

4 Unscrew collar nut (1)
double hexagon wrench (4).
WF58.50-P-
Double hexagon wrench to remove pulley
1540-01I
*BA15.40-
P-1004-01N
Screwdriver bit Fig. 77
5 Detach belt pulley (3) from shaft (2)
memory 2000-04A
system
Risk of accident caused by vehicle starting off by
from moving by itself.
itself when engine is running. Risk of injury
procedure or when working near the engine as it is
running
parts.
ALTERNATOR
164, 251
BA15.40-P-1001-
01N
BA15.40-P-1002-
Nut, circuit D+ to alternator Nm 5
01N
BA15.40-P-1003-
01N
BA15.40-P-1004-
Collar nut on poly-V belt pulley Nm 80
01N
Thread not pre-
tapped
01N timing case
Fig. 77: Identifying Screwdriver Bit (601 589 00 10 00)

REMOVE/INSTALL ALTERNATOR BELT PULLEY - AR15.40-P-5710GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 78: Identifying Alternator Belt Pulley Remove/Install Components

Remove/install
Remove front engine

1 Pull out front engine cover (1) from mounts.
cover (1)
AR13.20-P-
0001GZA
At the same time counterhold alternator shaft
Dismantle belt pulley (4) with a multitooth nut.
3
using box wrench In case of any repairs to alternators after
mileage in excess of 100,000 km, also replace the
belt pulley (4).

*BA15.40-P-
1004-01F
ALTERNATOR
BA15.40-P-1004-01F Collar nut connecting belt pulley to alternator Nm 80 80
REMOVE/INSTALL REGULATOR FOR ALTERNATOR - AR15.40-P-5760GZ
Fig. 79: Identifying Alternator Regulator Remove/Install Components

Remove/install

Keep body parts and limbs AS00.00-Z-
well clear of moving parts. 0011-01A
AR88.40-P-
1 Open engine hood
1000GZ
Risk of explosion caused by oxyhydrogen gas. smoking. AS54.10-Z-
Risk of poisoning and caustic burns caused by Wear acid-resistant gloves, 0001-01A

containers.
AR54.10-P-
0003GZ
AH54.10-P-
0001-01A
*BA15.40-
3 Screw down alternator nuts (1) (G2)
P-1001-01N
*BA15.40-
P-1002-01N
4 Remove bolt (2)
6 Unscrew bolts (4) at regulator (5)
Installation: When
inserting the regulator (5),
7 Take out regulator (5)
ensure that the ground lug is
making contact.
memory 2000-04A
system
Risk of accident caused by vehicle starting off by
from moving by itself.
itself when engine is running. Risk of injury
procedure or when working near the engine as it is
running
parts.
ALTERNATOR
Number Designation Engine 113 in Model 164, 251
BA15.40-P-1001-01N Nut, circuit B+ to alternator Nm 18
BA15.40-P-1002-01N Nut, circuit D+ to alternator Nm 5
REMOVE/INSTALL REGULATOR FOR ALTERNATOR - AR15.40-P-5760GZA
ENGINE 272, 273 in MODEL 164, 251


MODIFICATION NOTES
7.12.05 Bolt connecting regulator to alternator Engine 272 *BA15.40-P-1005-01F
Bolt connecting cover to alternator *BA15.40-P-1008-01F
Remove/install

AS54.10-Z-
0001-01A
containers.
AR61.20-P-
1 Dismount lower engine compartment paneling Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR15.40-P-
2 Remove alternator Model 164.8
5032GZA
Model 251 with engine 272 AR15.40-P-
without 4MATIC 5032RTA
*BA15.40-
3 Unscrew collar nut (2)
P-1007-01F
*BA15.40-
4 Unscrew nut (1)
P-1006-01F
*BA15.40-
5 Remove screw (3)
P-1008-01F
*BA15.40-
7 Remove bolts (5, 7) from regulator (6)
P-1005-01F
Installation: Do not
8 Remove regulator (6) from the side damage sliding brushes during
installation!
ALTERNATOR
M4X19 Nm 3 3
BA15.40-P-1005-01F Bolt connecting regulator to alternator
M4X13 Nm 22
BA15.40-P-1006-01F Nut connecting cover to alternator Nm 12 12
BA15.40-P-1007-01F Collar nut connecting cover to alternator Nm 30 30
BA15.40-P-1008-01F Bolt connecting cover to alternator Nm 3 3
REMOVE/INSTALL REGULATOR FOR ALTERNATOR - AR15.40-P-5760GZS

Remove/install

platform support points specified
injury caused by burns to skin and eyes from and glasses. Only pour battery acid 0001-01A
battery acid or when handling damaged lead- into suitable and appropriately
acid batteries marked containers.
AR54.10-P-
0003GZ
AH54.10-P-
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
AR61.20-P-
1105GZ
AR61.20-P-
Model 251
1105RT
*BA15.40-
5 Unscrew bolts (4) at regulator (5)
P-1006-01P
Installation: When assembling
6 Take out regulator (5) the regulator (5) ensure that the
carbon brushes are not damaged!
AR00.19-P-
0200GZ
AR00.19-P-
Model 251
0200RT
injury caused by contusions and burns during Wear closed and snug-fitting work 0005-01A

ALTERNATOR
Nm 2,8
BA15.40-P-1006-01P Bolt connecting regulator to alternator M4X13 Nm 1.2
M4X19 Nm 2.5
TEST ALTERNATOR DIODES - AR15.40-P-9301-02GZ
Connection diagram
Fig. 82: Alternator Diodes Connection Diagram

In this test it is not possible to assess the exciter diodes.
1. Connect the engine tester with oscilloscope (030).

2. Start engine.
3. Switch on low beams.
4. Assess diode harmonics at 3000 rpm (engine speed).
Example: Diode harmonics in order (voltage spikes possible, but not significant)
Fig. 83: Waveform Display - Diode Harmonics In Order

Example: Zero line, in the event of a line interruption or a defective fuse.
Fig. 84: Waveform Display - Zero Line In Event Of Line Interruption Or Defective Fuse
Example: Harmonics, if a positive diode is defective.
Fig. 85: Waveform Display - Harmonics if positive diode defective

Example: Harmonics, if a negative diode is defective.

Fig. 86: Waveform Display - Harmonics If Negative Diode Defective

REMOVE/INSTALL TEMPERATURE SENSOR - AR15.60-P-3000GZA
Coolant temperature sensor
Fig. 87: Identifying Coolant Temperature Sensor Remove/Install Components

Remove/install

Risk of injury to skin and eyes caused
by scalding from contact with hot
cap slowly and release the pressure. Do AS20.00-Z-
coolant spray.
not pour coolant into beverage containers. 0001-01A
swallowing coolant.

AH54.00-P-
0001-01A
AR09.10-P-
1 Remove air filter housing (3).
1150GZA
Reduce pressure in the engine cooling
The coolant temperature should be
system, to do this, slowly open the cap
2 approx. 40°C.
(1) at the expansion reservoir (2) for
the coolant and close again Do not drain off coolant.
Disconnect electrical connector on
3
crankshaft Hall sensor (B70)
Unlatch the electrical connector at the
4 coolant temperature sensor (B11/4) and
disconnect
Remove bolt (4) and remove clamping *BA15.60-P-
5
plate (5) 1001-01A
Fit new O-ring (6) to new coolant
6
Pull coolant temperature sensor
(B11/4) out of cylinder head and
7
immediately insert new coolant
Pour in coolant and bleed cooling AR20.00-P-
9
system 1142GZC
disconnecting cables or by simulation
Connect STAR DIAGNOSIS and read
10 during test operations, must be erased in
fault memory
the fault memory after completing the
work.
TEMPERATURE SENSOR
272 273
BA15.60-P-1001- Bolt, clamping plate for coolant temperature sensor to
Nm 8 8
01A cylinder head
REMOVE/INSTALL TEMPERATURE SENSOR - AR15.60-P-3000GZS

Fig. 88: Identifying Coolant Temperature Sensor Remove/Install Components

Remove/install

Risk of injury to skin and eyes caused
by scalding from contact with hot
cap slowly and release the pressure. Do AS20.00-Z-
coolant spray.
not pour coolant into beverage containers. 0001-01A
swallowing coolant.
AS00.00-Z-
slipping or toppling off of the lifting support plates at the lifting platform
0010-01A
manufacturer.
AH54.00-P-
components due to electrostatic All models
0001-01A
discharge
889:
Switch ignition off, remove ignition Press Keyless Go start/stop button
1
key (transmitter key). repeatedly until ignition is switched off.
Remove keyless go transmitter card or

AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
Remove the left and right intake air
3
duct
Detach air hose (3) from air shutoff
5
valves
Unclip air hose (3) on steering
6 expansion reservoir (1) and place to
one side
AR14.30-P-
7 Remove switchover valve (2)
7255GZS
Detach steering expansion reservoir (1) AR46.25-P-
8
and place to one side 1000GZS
Remove guide pulley (5) from coolant *BA13.25-
10
pump P-1004-01U
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
Remove bottom engine compartment Installation: Only install lower engine
12
paneling compartment paneling after leak test.
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR20.00-P-
1142GZS
AH20.00-N-
2080-01A
*BF20.00-P-
Coolant 1001-02U
Unlock and disconnect electrical
14 connector (6) on coolant temperature
sensor (B11/4)
Remove coolant temperature sensor
15 Installation: Replace sealing ring.
(B11/4) from cylinder head
*BA15.60-
P-1002-01C
Pour in coolant and bleed cooling AR20.00-P-
17
system 1142GZS
18
engine for leaks
TEMPERATURE SENSOR
BA15.60-P-1002-01C Coolant temperature temperature sensor on cylinder head Nm 21

156
BA13.25-P-1004- Guide pulley on coolant pump housing (between alternator and
Nm 20
01U smooth guide pulley)
COOLING SYSTEM
Number Designation Engine 156 in model 164,
251
approx.
Total filling capacity 7.5
Liters
BF20.00-P-1001- Cooling Up to -37°C 50/50
Antifreeze/water
02U system Up to -45°C 55/45

TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
BE15.00-Z-9999AZ
MODEL all
Spark plugs ENGINE all BE15.10-P-1000-01A

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

Number Designation All engines
BE15.10-P-1001-01A Electrode gap mm 0.8
CHECK VALUES FOR ALTERNATOR - BE15.40-P-1000-01I
Engine 156, 266, 271, 272, 273, 275, 285
MODIFICATION NOTES
21.6.06 Charge current for Engine 156 in model 164,
alternator 204, 209, 211, 219, 230,
251
Charge current for Engine 156 in model 216,

alternator 221
10.8.06 Charging current for Engine 271 in model 171,
alternator, engine speed 203, 209 Valeo
and gear ratio

Number Designation Engine 156 Engine 156 Engine
in model 164, in model 216, 266.920/940
209, 211, 219, 221 without code
251 910 in model
169, 245
BE15.40-P- Charge current max. A 180 220 90
1001-01I for alternator min. A 140 170 70
Engine speed rpm 2000 2000 2000
Ratio I= 2.93 2.93 2.77

Number Designation Engine Engine 271 in
266.920/940 with model 171, 203,
code 910 engine 209 Bosch
266.960/980 in
model 169, 245
BE15.40-P-1001- Charge current max. A 115 120
01I for alternator min. A 90 90
Engine speed rpm 2000 2000
Ratio I= 2.77 2.93

Number Designation Engine 271 in Engine 271 in Engine 272 in
model 171, model 211 model 171,
203, 209 Bosch 203, 209
Valeo
Ratio I= 2.93 2.93 2.93

model 164, 211, model 221 with
219, 230, 251 code 910
Engine 272 in
model 221
without code
910
Ratio I= 2.93 2.93

Number Designation Engine 273 in Engine 273 in Engine 275 in
model 164, model 216, model 216,
209, 211, 219, 221 with code 221, Bosch
230, 251 910
Engine 273 in
model 216,
221 without
code 910
Ratio I= 2.93 2.93 2.93

model 215, 220, model 240,
230, Bosch Bosch
Ratio I= 2.93 2.56
TEST VALUES FOR ALTERNATOR - BE15.40-P-1000-01K
Engine 112, 113

Number Designation Engine 112 Engine 112 Engine 112 in
in model 129 in model 220, model 163, 170,
Bosch 230, in model 202, 203, 208,
210 with 209, in model
code 978, in 210 without
model 211 code 978, in
with code model 211
910, Bosch without code
910,
Bosch/Valeo
1001-01K of generator min A 90 120 90
Ratio I= 2.93 2.93 2.93

Number Designation Engine 113 Engine 113 in Engine 113 in
in model model 163, 171, model 164, 251,
129, 202 203, 208, 209, 211.076/276,
Bosch 210, 211, 215, 215.374,
219, 220, 230 219.376,
except model 220.074/174,
211.076/276, 230.472/474
215.374, Bosch
219.376,
220.074/174,
230.472/474
Bosch
1001-01K of generator min A 120 120 140
Ratio I= 2.93 2.93 2.93
GOVERNOR - BE15.40-P-1000-02A
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155, 166, 275
CHECK VALUES FOR REGULATOR

Number Designation Engines 103, 104,
111, 112, 113, 119,
120, 137, 155, 166,
275
BE15.40-P-1001- Regulating voltage Loading: only on V 13 to 15
02A (at battery) permanent consumer
Engine speed rpm 3000
measured after min approx. 2
MAINTENANCE
REPLACE SPARK PLUGS - AP15.10-P-1580GZ

Fig. 89: Identifying Spark Plug And Ignition Coil Cylinder

MODIFICATION NOTES
damage through
contamination and
Remove/install and
replace
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if
necessary.
Risk of death caused by Do not touch parts which AS15.10-Z-0001-01A
contact with parts conduct high voltages.
conducting high voltages. Persons who wear
electronic implants (e.g.
heart pacemakers) should
never perform any work
on the ignition system
Notes on avoiding AH15.10-P-0002-01D
damage to ignition system

damage through
contamination and foreign
objects
1 Open engine hood
AR88.40-P-1000GZ
moving to upright
position and closing
Remove/install air filter AR09.10-P-1150GZ
housing
3 Remove hot film mass air
flow sensor with air
intake pipe
Remove/install hot film
mass air flow sensor
together with air intake
pipe AR07.07-P-1454GZ
4 Remove cylinder 1
ignition coil to cylinder 8
ignition coil (T1/1 to
T1/8)
Remove/install ignition
coils AR15.12-P-2003GZ
5 Use double open-end Double open-ended Fig. 44
wrench to pry off spark wrench
plug connectors above
cylinder head cover
Checking
6 Check spark plug Check for damage,
connectors, ignition coil deformation and crack
connectors and ignition formation, replace if
lines necessary.
7 Unscrew spark plugs (R4) Spark plugs *BA15.10-P-1001-01A
from the cylinder heads Spark plug wrench Fig. 42
SPARK PLUGS
Engine 104, 110, 111,
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/
Number Designation 115, 117, 119, 120
BA15.10- Spark Nm 28
P-1001- plugs
01A

Fig. 91: Identifying Open-End Wrench, Double (110 589 01 09 00)

REPLACE SPARK PLUGS - AP15.10-P-1580GZC
Fig. 92: Identifying Spark Plugs And Spark Plug Wrench

MODIFICATION NOTES

parts conducting high voltages 0001-01A
system
Risk of injury to skin and eyes caused Wear safety gloves, protective clothing AS00.00-Z-
by handling hot or glowing objects. and safety glasses, if necessary. 0002-01A
system 0002-01V
1 Turn key in ignition switch to position 0
2 Open engine hood
Opening engine hood, moving to upright AR88.40-P-
position and closing 1000GZ
AR09.10-P-
1150GZA
AR15.12-P-
Remove/install ignition coils
2003GZA
Checking
Check spark plug connectors, ignition Check for damage, deformation and
5
coil connectors and feed lines crack formation, replace if necessary.
Remove spark plugs (R4) with spark *BA15.10-
6 Spark plug to cylinder head
plug wrenches (01) from cylinder heads P-1001-01C
Spark plug wrench Fig. 42
SPARK PLUGS
BA15.10-P-1001-01C Spark plug on cylinder head Nm 23 23

TIGHTENING TORQUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - BA15.00-Z-
9999AZ
MODEL all
Ignition system ENGINE 102, 103, 104, 110, 111, BA15.10-P-1000-01A

112, 113, 115, 117, 119, 120, 137,
155, 166...
Ignition system ENGINE 271, 272, 273, 275, 285 BA15.10-P-1000-01C
Ignition system ENGINE 266 BA15.10-P-1000-01E
Ignition system ENGINE 266.920 /940 /960 /980 BA15.10-P-1000-01F
Ignition system ENGINE 113.971 in MODEL 251 BA15.10-P-1000-01G
Ignition system ENGINE 156 BA15.10-P-1000-01H
Knock sensors ENGINE 111, 112, 113, 119, 120, BA15.10-P-1000-02A
271...
Knock sensors ENGINE 272, 273, 275, 285 BA15.10-P-1000-02B
Knock sensors ENGINE 156 BA15.10-P-1000-02C
Knock sensors ENGINE 646.8 BA15.10-P-1000-02D
Position sensor ENGINE 111, 112, 113, 155... BA15.10-P-1000-03A
Position sensor ENGINE 137 BA15.10-P-1000-03B
Position sensor ENGINE BA15.10-P-1000-03C
612.962 /963 /965 /966 /967 /990,
628, 629, 646, 647.961 /981, 648
Position sensor ENGINE 271, 275, 285 BA15.10-P-1000-03D
Position sensor ENGINE 272, 273 BA15.10-P-1000-03E
Position sensor ENGINE 640 BA15.10-P-1000-03F
Position sensor ENGINE 642 / BA15.10-P-1000-03G
Ignition coil ENGINE 112 / /, 113 /, 155, 272, BA15.10-P-1000-04A
273
Ignition coil ENGINE 156 BA15.10-P-1000-04B
Ground strap MODEL 163 with ENGINE 111, BA15.10-P-1000-05A

112, 113, 612, 628
Ground strap ENGINE 266.920 /940 /960 /980 BA15.10-P-1000-05B
Distributor ignition (DI ENGINE BA15.12-P-1000-01A
[EZL]) system 166.940 /960 /961 /990 /991 /995
ECI ignition system ENGINE 668.914 /940 /941 /942 BA15.12-P-1000-01B
DI ignition system ENGINE 120 BA15.12-P-1000-01C
Distributor ignition (DI ENGINE 137, 275, 285 BA15.12-P-1000-01D
[EZL]) system
Distributor ignition (DI ENGINE 111.951 /955 /981 BA15.12-P-1000-01E
[EZL]) system
Distributor ignition (DI ENGINE 271 BA15.12-P-1000-01F
[EZL]) system
Distributor ignition (DI ENGINE 266.920 /940 /960 /980 BA15.12-P-1000-01J
[EZL]) system
Distributor ignition (DI ENGINE 156 BA15.12-P-1000-01K
[EZL]) system
ECI ignition system ENGINE 275, 285 BA15.15-P-1000-01A
Engine wiring harness ENGINE 628.960 /961, 629 BA15.18-P-1000-01A
Engine wiring harness ENGINE 272, 273 BA15.18-P-1000-01B
Engine wiring harness ENGINE 646.8 BA15.18-P-1000-01C
Preglow system ENGINE 601, 602, 603, 604, 605, BA15.20-P-1000-01A
606, 611, 612, 613, 628, 629, 646,
647, 648...
Preglow system ENGINE 668.914 /940 /941 /942 BA15.20-P-1000-01B
Preglow system ENGINE 640 BA15.20-P-1000-01E
Preglow system ENGINE 642 / BA15.20-P-1000-01F
Starter ENGINE 611, 612, 613, 642, 646, BA15.30-N-1000-01G
647, 648...
Starter ENGINE 103, 104, 111, 112, 113, BA15.30-P-1000-01A
119, 120, 271...
Starter ENGINE BA15.30-P-1000-01B
166.940 /960 /961 /990 /995 /991
Starter ENGINE 601, 602, 604, 605, 606, BA15.30-P-1000-01C
611, 628, 629...
Starter ENGINE 668.914 /940 /941 /942 BA15.30-P-1000-01
Starter ENGINE 137, 275, 285.950 BA15.30-P-1000-01G
Starter ENGINE 155.980 BA15.30-P-1000-01H
Starter ENGINE 272, 273 BA15.30-P-1000-01J
Starter ENGINE 640 BA15.30-P-1000-01K
Starter ENGINE 266.920 /940 /960 /980 BA15.30-P-1000-01L
Starter ENGINE 113 in MODEL 219 BA15.30-P-1000-01M
Starter ENGINE 642 ENGINE 642 in BA15.30-P-1000-01N

MODEL 463
Starter ENGINE 156 BA15.30-P-1000-01O
Generator ENGINE 601.942 /943 /970, BA15.40-N-1000-01I
602.980 /982 /984 /985
Alternator ENGINE 103, 104, 111, 112, 113, BA15.40-P-1000-01A
119, 120, 137, 155...
Generator ENGINE BA15.40-P-1000-01B
166.940 /960 /961 /990 /991 /995
Generator ENGINE 668.914 /940 /941 /942 BA15.40-P-1000-01C
Alternator ENGINE 611, 612, 613, 628, 629, BA15.40-P-1000-01D
642, 646, 647, 648...
Generator ENGINE 601, 602, 603, 604, 605, BA15.40-P-1000-01E
606, 612.966
Generator ENGINE 271, 272, 273 BA15.40-P-1000-01F
Alternator ENGINE 275, 285... BA15.40-P-1000-01I
Alternator ENGINE 266.920 /940 /960 /980, BA15.40-P-1000-01K
640
Alternator ENGINE 113.967 /990 in MODEL BA15.40-P-1000-01M
219
Alternator ENGINE 113.964 in MODEL BA15.40-P-1000-01N
164.1 ENGINE 113.971 in
MODEL 251.075 /175
Alternator ENGINE 156 BA15.40-P-1000-01P
Temperature sensor ENGINE 272, 273 BA15.60-P-1000-01A
Temperature sensor ENGINE 156 BA15.60-P-1000-01C
IGNITION SYSTEM - BA15.10-P-1000-01A
Engines 102, 103, 104, 110, 111, 112, 113, 115, 117, 119, 120, 137, 155, 166
SPARK PLUGS
Number Designation Engine Engine Engines 104, 110, 111,
102 103 113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/96
115, 117, 119, 120
BA15.10- Spark Nm 20 20 28
P-1001- plugs
01A
SPARK PLUGS
Number Designation Engine Engine Engine Engine Engine Engine
113.987/988/990/991 113.989 137 155 166.940/960/990/995 166.961/991
BA15.10- Spark Nm 25 25 28 25 25 25
P-1001- plugs
01A
IGNITION SYSTEM - BA15.10-P-1000-01C
Engine 271, 272, 273, 275, 285
MODIFICATION NOTES
21.4.04 Value changed from 25 Value in series 1001
Nm to 28 Nm modified on engine 271
SPARK PLUGS
Number Designation Engine 271 Engine 272 Engine 273 Engine 275,
285
BA15.10-P- Spark plug at Nm 28 23 23 25
1001-01C the cylinder
head
IGNITION SYSTEM - BA15.10-P-1000-01H
Engine 156
SPARK PLUGS
BA15.10-P-1001-01H Spark plug to cylinder Nm 20
head
KNOCK SENSORS - BA15.10-P-1000-02A
Engines 111, 112, 113, 119, 120, 271
KNOCK SENSORS
111.951/955/958/983 112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/
BA15.10- Bolt Nm 20 20
P-1001- securing
02A knock
sensor
to
cylinder
block
KNOCK SENSORS
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/971/
BA15.10- Bolt Nm 20
P-1001- securing
02A knock
sensor
to
cylinder
block
KNOCK SENSORS - BA15.10-P-1000-02B
Engines 272, 273, 275, 285
KNOCK SENSORS
Number Designation Engine 272 Engine 273 Engines 275,
285
BA15.10-P-1001- Bolt, knock Nm 20 20 20
02B sensor to
crankcase
BA15.10-P-1002- Bolt, heat shield Nm - - 8
02B of knock sensor
to crankcase
KNOCK SENSORS - BA15.10-P-1000-02C
Engine 156
KNOCK SENSORS
BA15.10-P-1001-02C Bolt of knock sensor to Nm 20
crankcase
BA15.10-P-1002-02C Bolt heat shield of knock Nm 20
sensor to crankcase
POSITION SENSOR - BA15.10-P-1000-03A
Engines 111, 112, 113, 155
POSITION SENSOR
111.951/955/958/983 112.910/911/912/913/914/915/916/917/920/921/922/923/940/94
BA15.10- Crankshaft Nm 8 8
P-1001- position
03A sensor on
engine
block
BA15.10- Camshaft Nm - 8
P-1002- Hall
03A sensor on
cylinder
head
BA15.10- Camshaft Nm 8 -
P-1003- position
03A sensor on
cylinder
head cover
BA15.10- Camshaft Nm - -
P-1004- position
03A sensor on
cylinder
head
POSITION SENSOR
Number Designation Engine 113.989 Engine 155
BA15.10-P-1001- Crankshaft position Nm 7 8
03A sensor on engine
block
BA15.10-P-1002- Camshaft Hall sensor Nm 8 -
03A on cylinder head
BA15.10-P-1003- Camshaft position Nm 8 -
03A sensor on cylinder
head cover
BA15.10-P-1004- Camshaft position Nm - 8
03A sensor on cylinder
head
POSITION SENSOR - BA15.10-P-1000-03E
Engine 272, 273
POSITION SENSOR
BA15.10-P-1001- Bolt of crankshaft Nm 8 8
03E Hall sensor to
crankcase
BA15.10-P-1002- Bolt of camshaft Hall Nm 8 8
03E sensor to front cover
on the cylinder head
BA15.10-P-1003- Bolt of camshaft Nm 8 8
03E solenoid to front

cover on the cylinder
head
IGNITION COIL - BA15.10-P-1000-04A
Engines 112, 113, 155, 272, 273
IGNITION COIL
Number Designation Engines 112, Engine 155 Engine 272
113
BA15.10-P-1001- Bolt, ignition Nm 8 8 9
04A coil to cylinder
head cover
IGNITION COIL
BA15.10-P-1001-04A Bolt, ignition coil to Nm 9
cylinder head cover
IGNITION COIL - BA15.10-P-1000-04B
Engine 156 B
IGNITION COIL
BA15.10-P-1001-04B Bolt for ignition coil on Nm 8
cylinder head cover
DISTRIBUTOR IGNITION (DI [EZL]) SYSTEM - BA15.12-P-1000-01K
Engine 156
ECI IGNITION SYSTEM

BA15.12-P-1001- Crankshaft position M6 Nm 8
01K sensor on crankshaft
housing
ENGINE WIRING HARNESS - BA15.18-P-1000-01B
Engine 272, 273
ENGINE WIRING HARNESS


BA15.18-P-1001- Bolt of supply cable Nm 8 8
01B to resonance intake
manifold
BA15.18-P-1002- Bolt of feed line duct Nm 8 8
01B to cylinder head
cover
BA15.18-P-1003- Bolt of feed line duct Nm 8 8
01B to motor suspension
lug
STARTER - BA15.30-P-1000-01A
Engines 103, 104, 111, 112, 113, 119, 120, 271
STARTER
Number Designation Engines Engine 112 Engines Engine Engine
103, 104, except 112.951/976 113.964 in 113.971 in
111, 120 112.951, model 164 model
113.94/96/98 251.075/175
BA15.30-P- Nut for Nm 14 14 14 14 14
1001-01A connection
of circuit 30
BA15.30-P- Nut for Nm 6 6 6 6 6
1002-01A connection
of circuit 50
BA15.30-P- Bolt, starter Nm 42 42 40 40 40
1003-01A to crankcase
STARTER
Number Designation Engine Engine Engine Engine
113.987 in 113.988 in 113.989 in 113.990/991/993
model 209 model 203 model 171
BA15.30-P- Nut for Nm 14 14 14 14
1001-01A connection of
circuit 30
BA15.30-P- Nut for Nm 6 6 6 6
circuit 50
BA15.30-P- Bolt, starter to Nm 40 40 40 40
1003-01A crankcase
STARTER
Number Designation Engine Engines Engine 119 Engine 271
113.963 in 113.992/995 in
model 230 model 230
BA15.30-P- Nut for Nm 14 14 14 14
circuit 30
BA15.30-P- Nut for Nm 6 6 6 6
circuit 50
BA15.30-P- Bolt, starter to Nm 40 40 58 40
1003-01A crankcase
STARTER - BA15.30-P-1000-01J
Engine 272, 273
STARTER
BA15.30-P-1001-01J Nut of connection of Nm 15
circuit 30
BA15.30-P-1002-01J Nut of connection circuit Nm 8
50
BA15.30-P-1003-01J Bolt connecting starter to Nm 40
crankcase
STARTER - BA15.30-P-1000-01O
Engine 156
STARTER
BA15.30-P-1001- Nut for connection Nm 15
01O of circuit 30
BA15.30-P-1002- Nut for connection Nm 8
01O of circuit 50
BA15.30-P-1003- Bolt connecting Nm 40
01O starter to crankcase
BA15.30-P-1004- Bracket on starter M6 Nm 9
01O
BA15.30-P-1005- Shield on bracket M6 Nm 9
01O
ALTERNATOR - BA15.40-P-1000-01A
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155
ALTERNATOR
103 104 111 112.91/92/94/953/954/955/96/97,113.94/96/98
except 112.976
BA15.40- Nut, circuit B+ to Nm 15 15 15 18
P-1001- alternator
01A
BA15.40- Nut, circuit D+ to Nm 4 4 4 5
P-1002- alternator
01A
BA15.40- Bolt for alternator Nm 42 42 42 42
P-1003-
01A
BA15.40- Collar nut on Nm 80 80 80 80
P-1004- poly-V-pulley
01A
BA15.40- Self- Thread Nm - - - 57
P-1005- grooving not
01A screw, pre-
alternator tapped
to timing Thread Nm - - - 45
case pre-
tapped
BA15.40- Bolt for Nm - - - -
P-1006- alternator to
01A cooling housing
BA15.40- Bolt, M7 Nm - - - -
P-1007- cooler
01A housing
for
alternator M8 Nm - - - -
to
crankcase
ALTERNATOR
112.951/976 113.963 in 113.987 in 113.988 in
model 230 model 209 model 203
BA15.40-P- Nut, circuit B+ to Nm 14 14 18 18
1001-01A alternator
BA15.40-P- Nut, circuit D+ to Nm - - 5 5
1002-01A alternator
BA15.40-P- Bolt for alternator Nm - - - -
1003-01A
BA15.40-P- Collar nut on poly-V- Nm 80 - 80 80
1004-01A pulley
BA15.40-P- Self- Thread not Nm 57 57 57 57
1005-01A grooving pre-tapped
screw,
alternator to Thread pre- Nm 45 45 45 45
timing case tapped
BA15.40-P- Bolt, alternator to cooling Nm - - - -
1006-01A housing
BA15.40-P- Bolt, cooler M7 Nm - - - -
1007-01A housing of
alternator to M8 Nm - - - -
crankcase
ALTERNATOR
in model 171 in model 211
BA15.40-P-1001- Nut, circuit B+ to alternator Nm 18 14
01A
BA15.40-P-1002- Nut, circuit D+ to alternator Nm 5 -
01A
BA15.40-P-1003- Bolt for alternator Nm - -
01A
BA15.40-P-1004- Collar nut on poly-V-pulley Nm 80 80
01A
BA15.40-P-1005- Self-grooving Thread not pre- Nm 57 57
01A screw, alternator tapped
to timing case Thread pre- Nm 45 45
tapped
BA15.40-P-1006- Bolt, alternator to cooling housing Nm - -
01A
BA15.40-P-1007- Bolt, cooler M7 Nm - -
01A housing of
alternator to M8 Nm - -
crankcase
ALTERNATOR
Number Designation Engine Engine Engine Engine 119
113.991 in 113.992/995 113.993
models 215, in model 230 AMG in
220 model 463
BA15.40-P- Nut, circuit B+ to Nm 14 18 18 15
1001-01A alternator
BA15.40-P- Nut, circuit D+ to Nm - - - 4
1002-01A alternator
BA15.40-P- Bolt for alternator Nm - 42 42 42

1003-01A
BA15.40-P- Collar nut to poly-V-pulley Nm 80 - - 80
1004-01A
BA15.40-P- Self- Thread not Nm 57 57 57 -
1005-01A grooving pretapped
screw,
alternator to Thread pre- Nm 45 45 45 -
timing case tapped
BA15.40-P- Bolt, alternator on cooling Nm - - - -
1006-01A housing
BA15.40-P- Bolt, cooler M7 Nm - - - -
1007-01A housing of
alternator to M8 Nm - - - -
crankcase
ALTERNATOR
BA15.40-P- Nut, circuit B+ to alternator Nm 15 15 15
1001-01A
BA15.40-P- Nut, circuit D+ to alternator Nm 4 - -
1002-01A
BA15.40-P- Bolt for alternator Nm 42 - 30
1003-01A
BA15.40-P- Collar nut on poly-V-pulley Nm 80 80 -
1004-01A
BA15.40-P- Self-grooving Thread not Nm - - -
1005-01A screw, pre-tapped
alternator to Thread pre- Nm - - -
timing case tapped
BA15.40-P- Bolt, alternator to cooling Nm - 8 -
1006-01A housing
BA15.40-P- Bolt, cooler M7 Nm - 14 -
1007-01A housing of
alternator to M8 Nm - 20 -
crankcase
GENERATOR - BA15.40-P-1000-01F
Engine 271, 272, 273
MODIFICATION NOTES
7.12.05 Bolt of regulator to Engine 272
generator
Bolt of cover to generator
ALTERNATOR
BA15.40-P- Bolt of Nm 20 20 20
1001-01F alternator to
timing case
BA15.40-P- Nut of circuit Nm 15 15 15
1002-01F B+ to generator
BA15.40-P- Nut of circuit Nm 4 - -
1003-01F D+ to generator
BA15.40-P- Collar nut of Nm 80 80 80
1004-01F belt pulley to
generator
BA15.40-P- Bolt of M4 x 19 Nm 3 3 3
1005-01F regulator to
generator M4 x 13 Nm 2 2 2
BA15.40-P- Nut of cover to Nm 12 12 12
1006-01F generator
BA15.40-P- Collar nut of Nm 30 30 30
1007-01F cover to
generator
BA15.40-P- Bolt of cover to Nm 3 3 3
1008-01F generator
BA15.40-P- Bolt of Nm 3 3 3
1009-01F regulator to
generator
ALTERNATOR - BA15.40-P-1000-01N
Engine 113 in Model 164, 251
ALTERNATOR
164, 251
BA15.40-P-1001-
01N
BA15.40-P-1002-
Nut, circuit D+ to alternator Nm 5
01N
BA15.40-P-1003-
01N
BA15.40-P-1004-
Collar nut on poly-V belt pulley Nm 80
01N
Thread not pre-
BA15.40-P-1005- Self-tapping screw, alternator to tapped Nm 60

01N timing case Thread pre-tapped Nm 45
ALTERNATOR - BA15.40-P-1000-01P
Engine 156
ALTERNATOR
BA15.40-P-1001- Bolt, alternator to M8x90 Nm 20
01P timing case
BA15.40-P-1002- Nut of circuit B+ to Nm 18
01P alternator
BA15.40-P-1003- Nut, circuit D+ to Nm 5
01P alternator
BA15.40-P-1004- Nut of cover to Nm 12
01P alternator
BA15.40-P-1005- Collar nut, cover to Nm 30
01P alternator
BA15.40-P-1006- Bolt, regulator to Nm 2.8
01P alternator M4x13 Nm 1.2
M4x19 Nm 2.5
TEMPERATURE SENSOR - BA15.60-P-1000-01A
Engine 272, 273
TEMPERATURE SENSOR
BA15.60-P-1001- Bolt of clamping plate Nm 8 8
01A for coolant
temperature sensor to
cylinder head
TEMPERATURE SENSOR - BA15.60-P-1000-01C
Engine 156
TEMPERATURE SENSOR
BA15.60-P-1001-01C Oil temperature Nm 21
temperature sensor on
crankcase
BA15.60-P-1002-01C Coolant temperature Nm 21
cylinder head
2006-2008 ENGINE Complete engine - General Information - 164 Chassis
2006-2008 ENGINE
Complete engine - General Information - 164 Chassis
GENERAL INFORMATION
DETERMINE LOSS OF PRESSURE AT CYLINDER - AH01.00-N-1300-02A
All engines
If an increased pressure loss was found with the cylinder leaktightness tester, inspect engine by listening at
cylinder head gasket, air intake area, exhaust, oil filler opening and prechamber or spark plug bores of the
adjacent cylinder or cylinders. Check the coolant in the coolant expansion reservoir for the formation of air
bubbles.
Possible causes for the pressure loss are:
1. Outlet of air through prechamber or spark plug bore of adjacent cylinder or cylinders, air bubbles
in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area: For inspecting by listening, open throttle valve pressure loss at
inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening: pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the relevant cylinder by spraying with engine oil. Engine
oil seals off the gap between piston and cylinder briefly.
If a reduced pressure loss now occurs for a short time, the cause is very likely to be at the pistons, piston
rings or cylinder contact surface of the relevant cylinder.
Determining the cause can be falsified by the position of the piston ring joints. If suspicion exists that the
loss of pressure is caused by the piston ring joints being positioned directly one above the other, fit parts
to engine and repeat test after running engine for a short time.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A
Engine 112, 113, 122, 134, 135, 137, 166, 275, 285, 611, 612, 613, 628, 629, 639, 642, 646, 647, 648
Pressure gloss marks, smoothings

Individual blank points, e.g. in the middle of the cylinder barrel or around the cylinder head bolts.
The crankcase can be reused.
Fig. 1: Identifying Pressure Gloss Marks On Cylinder Walls

Visible mottling, friction marks
Starting from reverse area of the upper piston ring tapering down.
Traces of dry rubbing which cannot be felt, caused by oil film being washed off by fuel, for example from many
cold starts when driving for short distances.
These traces of friction occurring mainly around the cylinder head bolts and on the pressure side are not a
problem provided that they are smoothed out.
The piston rings are not damaged.

Fig. 2: Identifying Visible Mottling And Friction Marks On Cylinder Walls

Ring shaped imprints
Visible imprints on cylinder barrel in the upper and lower reverse area of piston rings are not a cause for
complaint.
Fig. 3: Identifying Visible Imprints On Cylinder Barrel

Rotary bright, specular, polished upper surfaces of cylinder

Starting from the reverse area of the upper piston ring with measurable, partial cylinder wear.
The cylinder barrel is unusable.
Fig. 4: Identifying Cylinder Wear

Roughened mottling, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Progressive signs
of friction lead to friction score marks.
Where these signs of friction are perceptible, the cylinder barrel is unusable.
The piston rings may be damaged.

Fig. 5: Identifying Friction Score Marks

Continuous individual traces of scratch
Caused by dirt, for example, through back pulsation of soot particles from the exhaust.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length.
Material deposits and perceptible scoring marks on cylinder wall and at piston skirt.
The cylinder barrel is unusable.
Brown coloring of cylinder upper surface.
A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been
driven at a high temperature level.
The crankcase can be reused if no impermissible cylinder warping is visible
Oil varnish above piston ring zone is normal and is not a reason for complaint.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01AMG
1. Pressure gloss marks, smooth spots

Individual blank points, e.g. in middle of cylinder or in area of cylinder head bolts.
Reuse crankcase.
Fig. 6: Identifying Pressure Gloss Marks On Cylinder Walls

2. Visible mottling, friction marks
Starting from first piston ring, tapering to an end after about 30 mm. Traces of dry friction marks which
cannot be felt, caused by oil film being washed off by fuel, e.g. during frequent cold starts associated with
short-distance driving. These traces of friction marks which occur principally in area of cylinder head
bolts and on pressure side are not a problem provided they are smoothed. The piston rings are not
damaged.
Reuse crankcase.
Fig. 7: Identifying Visible Mottling And Friction Marks On Cylinder Walls

3. Ring shaped imprints
Visible imprints in the upper and lower piston ring reversal range are not a reason for complaint.
Reuse crankcase.
Fig. 8: Identifying Ring Shaped Imprints On Cylinder Walls

4. Rotary bright, specular, polished upper surfaces of cylinder

Usually starting from the first piston ring, in the upper area of cylinder, with measurable partial cylinder
wear.
Cylinder wall unusable.
Fig. 9: Identifying Rotary Bright, Specular, Polished Upper Surfaces On Cylinder Walls
5. Roughened mottling, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Traces of
rubbing as described in item 2, which have advanced to signs of seizure. Piston rings may be damaged.
If damage can be felt, cylinder wall unusable.

Fig. 10: Identifying Roughened Mottling, Friction Scoring On Cylinder Walls

6. Continuous individual traces of scratch
Caused by contamination, e.g. through reverse pulsation of soot particles out of exhaust.
Reuse crankcase.
7. Piston seizure
Most of cylinder wall perceptibly roughened over the entire length. Material deposits and perceptible
scoring marks on cylinder wall and at piston skirt.
8. Brown coloring of cylinder upper surface.
Oil varnish is over large areas of cylinder contact surface and indicates, that engine was driven at high
temperature level. Reuse crankcase provided no impermissible cylinder distortion is present. Oil varnish
above piston ring zone is normal and is not a reason for complaint.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01VA
1. Pressure gloss marks, smoothings
Individual blank locations, for example in the middle of the cylinder or in the area of the cylinder head
bolt.
Reuse crankcase.
Fig. 11: Identifying Pressure Gloss Marks, Smoothings

2. Visible stripes, friction marks
Starting from first piston ring, tapering to an end after about 30 mm. Traces of dry rubbing which cannot
be felt, caused by oil film being washed off by fuel, e.g. during frequent cold starts in short-distance
driving. These traces of rubbing which occur principally in the area of the cylinder head bolts and on the
pressure side are not a problem provided they are smoothed. The piston rings are not damaged.
Reuse crankcase.
Fig. 12: Identifying Visible Stripes, Friction Marks

3. Ring shaped imprints
Visible depressions in the upper and lower reversal range of piston rings, are not a reason for complaint.
Reuse crankcase.
Fig. 13: Identifying Ring Shaped Imprints

4. Rotary bright, reflecting, polished upper surfaces of cylinder
Usually starting from the first piston ring, in the upper area of cylinder, with a measurable partial cylinder
wear.
Fig. 14: Identifying Rotary Bright, Reflecting, Polished Upper Surfaces Of Cylinder
5. Roughened streaks, rubbing seizures

Starting from the first and second piston ring, tapering to an end only in bottom part of cylinder. Traces of
rubbing as described in item 2, which have advanced to signs of seizure. Piston rings may be damaged.
If damage can be felt, cylinder wall is unusable.
Fig. 15: Identifying Roughened Streaks, Rubbing Seizures

6. Continuous individual traces of scratch
Caused by contamination, e.g. through reverse pulsation of soot particles out of the exhaust.
Reuse crankcase.
7. Piston seizure
Cylinder wall usually perceptibly roughened over the entire length. Material deposits and perceptible
traces of seizure on cylinder wall and piston skirt.
8. Brown coloring of cylinder upper surface.
Oil varnish over large areas of the cylinder contact surface which indicates that the engine was driven at
high temperature level. Reuse crankcase provided no impermissible cylinder distortion is present. Oil
varnish above the piston ring zone is normal and should not be considered a fault.
NOTES ON APPLICATION OF SEALANT TO FRONT COVER OF THE CYLINDER HEAD -

AH01.30-P-1000-02V
Application of sealant to the right front cover

The line (A) identifies the sealant run.
The sealing compound must only be applied along the line (A) in the form of a bead with a height and width
of 1.0 mm (+0.5 mm).
The sealing compound must be applied within 10 minutes.
The sealing compound bead must not be spread. Only the approved sealant may be used.
Fig. 16: Identifying Application Area Of Sealant To Right Front Cover

Application of sealant to the left front cover
Fig. 17: Identifying Application Area Of Sealant To Left Front Cover

NOTES ON APPLICATION OF SEALANT TO CYLINDER HEAD GASKET - AH01.30-P-1000-04V
Engine 113
Engine 113
Before installing the left cylinder head, it is necessary to apply sealant to the cylinder head gasket in the area
of the timing case cover because of porous areas in the left cylinder head.
Repair note
The sealant must be applied only in the manner shown, with a bead of 2.0 mm ± 0.5mm.
The sealant must be used within 10 min.
The silicone bead must not be spread.
Fig. 18: Identifying Application Of Sealant To Cylinder Head Gasket

INFORMATION ON CYLINDER HEAD CONTACT SURFACE - AH01.30-P-1000-05A
Engine 112, 113
The cylinder head contact surface must only be machined if mechanically damaged points are present.
The cylinder head contact surface must not be re-worked (face-ground) if a variation exists in the flatness of the
cylinder head contact surface in the longitudinal direction and transverse direction (distortion).
When the cylinder head is fitted on again, the distortion is compensated for by tightening the cylinder head
bolts.
Stock removal on the cylinder head and at the crankcase of an engine must together be not more than 0.3 mm.
The valve seats must be re-set if the cylinder head separating surface is machined.
INFORMATION FOR ASSIGNING THE CYLINDER HEAD GASKETS - AH01.30-P-1000-06V
Engines 112, 113
The assignment of the applicable cylinder head gasket on the left and right to the matching engine can be
verified when the cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particularly at high idling speeds, as the pistons touch the projecting cylinder head gasket. If a complaint exists,
replace cylinder head gasket.
Illustration shows M112/113
Fig. 19: Information For Assigning Cylinder Head Gaskets (1 Of 2)

The assignment of the applicable cylinder head gasket on the left and right to the matching engine can be
verified when the cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particularly at high idling speeds, as the pistons touch the projecting cylinder head gasket. If a complaint exists,
replace cylinder head gasket.
Illustration shows M112/113
Fig. 20: Information For Assigning Cylinder Head Gaskets (2 Of 2)

NOTES ON THE APPLICATION OF SEALING COMPOUND TO THE CYLINDER HEAD COVER -

AH01.30-P-1000-08SX
Sealing compound beads on the right cylinder head cover
The lines (A) identify the sealing compound beads.
The sealing surface must be cleaned. The sealing compound must only be applied to the specified surface in
the form of a bead and a height and width of 1.0 mm (± 0.2 mm).
The sealing compound bead must not be spread. Only the approved sealant may be used.
Fig. 21: Identifying Sealing Compound Beads On Right Cylinder Head Cover
Sealing compound beads on the left cylinder head cover
Fig. 22: Identifying Sealing Compound Beads On Left Cylinder Head Cover
NOTES ON THE COURSE OF THE APPLICATION OF SEALING COMPOUND ON A CYLINDER

HEAD COVER - AH01.30-P-1000-08V
Courses of sealing compound on the right hand cylinder head cover
The lines (A) mark the courses of sealing compound.
The sealing compound should only be applied along the specified lines (A) in the form of a bead of sealing
compound of 1.0 mm ± 0.2 mm.

The sealing compound bead must not be spread. Only the approved sealing compound may be used.
Fig. 23: Identifying Sealing Compound Application Area On Right Hand Cylinder Head Cover
Courses of sealing compound on the left hand cylinder head cover
The lines (A) mark the courses of sealing compound.
The sealing compound should only be applied along the specified lines (A) in the form of a bead of sealing
compound of 1.0 mm ± 0.2 mm.
The sealing compound bead must not be spread. Only the approved sealing compound may be used.
Fig. 24: Identifying Sealing Compound Application Area On Left Hand Cylinder Head Cover
NOTES ON APPLICATION OF SEALANT TO TIMING CASE COVER - AH01.40-P-1000-01AMG
The lines (1) identify the application of the sealant.
The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of
a bead and to a height and width of 1.5 mm (± 0.5 mm). The sealant must be applied within 10 min. The sealant
bead must not be spread. Use only sealant listed in the Repair Products.
Fig. 25: Identifying Sealant Application Lines

NOTES ON APPLICATION OF SEALANT TIMING CASE COVER - AH01.40-P-1000-01B
Engine 112, 113
Application of sealant to timing case cover
The timing case cover is sealed with a silicone sealant at points A, C, D.
No sealant must be applied to the timing case cover at points B , pressure oil galleries to crankcase, with the
exception around the bolt hole G . Sealant which is applied to the points B , is entrained by the oil flow and
blocks the oil supply drillings of: Main bearings, camshaft bearings, rocker arms and oil spray nozzles.
Fig. 26: Identifying Application Of Sealant Timing Case Cover

Clean sealing surfaces
Apply sealant only to the specified surfaces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.
NOTES ON APPLICATION OF SEALANT TO TIMING CASE COVER - AH01.40-P-1000-01VA
The broken lines (1) identify the application of the sealing compound.
The sealing surface must be cleaned. The sealing compound may only be coated on the specified surface in
the form of a bead with a height and width of 1.5 mm ± 0.5 mm. The sealing compound must be applied within
10 min. The sealing compound bead must not be spread. Only the sealing compound listed in the section Repair
products may be used.
Fig. 27: Identifying Sealant Application Area To Timing Case Cover

NOTES APPLICATION OF SEALANT TO END COVER WITH RADIAL SHAFT SEAL - AH01.40-P-
1000-06A
Engine 112, 113
Application of sealant to end cover
The lines drawn G, E and the arrow D mark the application of sealant.
Clean sealing surfaces, apply sealant only to the specified surfaces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.
Fig. 28: Identifying Application Of Sealant To End Cover With Radial Shaft Seal
NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01GZ
Engine 113.964/971, 156.980
Application of sealant on the oil pan top section
The line drawn (F) identifies the course of application of sealant.
The sealant must only be applied to the specified surfaces in the form of a sealant bead 2.0 mm (± 0.5 mm)
diameter.
The sealant must be applied within 10 min. The sealant bead must not be spread. Use only sealant listed in
the Repair Products.
Fig. 29: Identifying Application Of Sealant On Oil Pan Top Section

Application of sealant to bottom part of oil pan
The line drawn (F) identifies the course of application of sealant.
The sealant must only be applied to specified surfaces in the form of a sealant bead 2.0 mm (± 0.5 mm)
diameter.
The sealant must be applied within 10 min. The sealant bead must not be spread. Use only sealant listed in
the Repair Products.
Fig. 30: Identifying Application Of Sealant To Bottom Part Of Oil Pan

NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01GZA
MODIFICATION NOTES
Sealant path for oil pan top section adapted to specifications of the Development Engine
3.3.06
Department 272
Sealant application on oil pan bottom section
The line (A) identifies the sealant run.
The sealing surface must be cleaned.
The sealant must only be applied to the specified surface in the form of a bead and a height and width of 2.0
mm (± 0.5 mm).
The sealant must be applied within 10 min.

The sealant bead must not be spread. Only the sealant listed in the Repair Products may be used.
Fig. 31: Identifying Sealant Application On Oil Pan Bottom Section

Application of sealant to oil pan top section
The lines (A) identify application of the sealant.
a bead and a height and width of 2.0 mm (± 0.5 mm).
The sealant must be applied within 10 min.
The sealant bead must not be spread. Only the sealant listed in the Repair Products may be used.
Fig. 32: Identifying Application Of Sealant To Oil Pan Top Section

NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01SX
MODIFICATION NOTES
28.2.06 Sealant path for adapted Engine 273
to specifications of the
Development Department
Oil pan with front sump
the line (A) identifies the sealant run.
mm (±0.5 mm).
The sealant must be applied within 10 min. The sealant bead must not be spread. Only the sealant listed in the
Repair Products may be used.
Fig. 33: Identifying Sealant Application Areas On Oil Pan - Front Sump
Oil pan with rear sump
Fig. 34: Identifying Sealant Application Areas On Oil Pan - Rear Sump
Oil pan with middle sump

Fig. 35: Identifying Sealant Application Areas On Oil Pan - Middle Sump
NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-P-0001-01SY
Application of sealant to oil pan bottom section for engine with front sump
The line (1)identifies the sealant run.
mm (±0.5 mm).
The sealant must be applied within 10 min. The sealant bead must not be spread. Only sealant listed in the
Fig. 36: Identifying Sealant Application Bottom Section Area On Oil Pan - Front Sump
Application of sealant to oil pan bottom section for engine with middle sump
Fig. 37: Identifying Sealant Application Bottom Section Area On Oil Pan - Middle Sump
Application of sealant to oil pan bottom section for engine with rear sump
Fig. 38: Identifying Sealant Application Bottom Section Area On Oil Pan - Rear Sump
NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01VB
MODIFICATION NOTES
28.2.06 Sealant path for adapted to Engine 272
specifications of the
Development Department
Oil pan with rear sump
The lines (A) identify the sealant beads.
a bead and a height and width of 2.0 mm (±0.5 mm).
The sealant must be applied within 10 min. The sealant bead must not be spread. Only the sealant listed in the
Fig. 39: Identifying Sealant Beads - Oil Pan With Rear Sump
Oil pan with front sump
Fig. 40: Identifying Sealant Beads - Oil Pan With Front Sump
Oil pan with middle sump

Fig. 41: Identifying Sealant Beads - Oil Pan With Middle Sump
2006-2008 ENGINE Engine Lubrication, Engine Oil Cooling - 164 Chassis
2006-2008 ENGINE
Engine Lubrication, Engine Oil Cooling - 164 Chassis
GENERAL INFORMATION
NOTES CONCERNING EXTENSION OF THE OIL CHANGE INTERVAL - AH18.00-P-0102-01A
All engines
When using engine oil conforming to Specifications for Operating Fluids, sheet 229.5, the oil change
interval can be extended.
Vehicles without ASSYST or without ASSYST PLUS
 On vehicles without ASSYST or without ASSYST PLUS the oil change interval increases from 15.000
km to 20.000 km.
Observes entries in the maintenance booklet.
Vehicles with ASSYST
 In vehicles with ASSYST, the interval can be extended by a factor of 1.3 using the STAR DIAGNOSIS
diagnosis system.
 As of model refinement, extension of the interval is also possible with the instrument cluster.
Vehicles with ASSYST PLUS
 For vehicles with ASSYST PLUS the intervals can be extended by a factor of 1.3 through the instrument
cluster.
 Alternatively, the intervals can also be extended using the STAR DIAGNOSIS system.
If this is not done, the shorter oil change interval will be stored automatically.
BASIC KNOWLEDGE
OIL TEMPERATURE SENSOR, COMPONENT DESCRIPTION - GF18.30-P-2010AMG

Location
The oil temperature sensor is located at the front at the left side of the crankcase.
Fig. 1: Identifying Oil Temperature Sensor Location - ENGINE 156.980

Function
The NTC resistor integrated in the oil temperature sensor alters its electrical resistance according to the oil
temperature. The ME-SFI control unit (N3/10) evaluates the corresponding voltage signal for the oil
temperature.
NTC means "N egative T emperature C oefficient", which means:
The electrical resistance falls as the temperature rises (heat conductor).
Oil temperature Resistance value Voltage signal

20°C 3123 ohms 0,312 V
60°C 632 ohms 0,063 V
120°C 101 ohms 0,010 V
OIL TEMPERATURE SENSOR, COMPONENT DESCRIPTION - GF18.30-P-2010P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1

Fig. 2: Identifying Oil Temperature Sensor Location - ENGINE 642

Location
The oil temperature sensor is located on the small oil pan at the middle front.
Task
The oil temperature sensor detects the current oil temperature and supplies a matching voltage signal to the CDI
control unit (N3/9).
Design
The oil temperature sensor possesses an integral measuring resistor with a negative temperature coefficient
(NTC).
Function
The NTC measuring resistor alters its electrical resistance in line with the oil temperature. Electrical resistance
decreases as temperature increases.
Faults in the oil temperature sensor are detected by the CDI control unit and entered in the fault
memory.
PART DESCRIPTION FOR OIL SENSOR - GF18.40-P-2000BK

Location
The oil sensor is located in the oil pan.
Task
The oil sensor detects the following values:
 Oil level
 Oil temperature
 Oil quality.
Fig. 3: Identifying Oil Sensor - ENGINE 113.964

Design
Fig. 4: Identifying Oil Sensor Design With Measuring Range

Fig. 5: Identifying Temperature Sensor, Oil Sensor And Oil Sensor Measuring Range
Function
Oil level and oil quality are detected on the basis of the capacitance of the engine oil (dielectric). The oil
temperature is detected by the temperature sensor. All the signals are processed in the electronics to form a
PWM signal and transferred to the engine control unit. The data is passed on by the engine control unit over
CAN to the instrument cluster and used there to calculate the individual service intervals. Oil top-ups are
automatically recognized and extend the service interval. The data can be displayed on the instrument cluster.
Overfilling of engine oil, error messages, overheating of engine oil and an upcoming oil change are
automatically displayed.
The dielectric constant of the engine oil is determined by the lower condenser, which is always full of oil
( approx. 2.3 to 4.0).
The fill level is then determined by the upper condenser using the dielectric constant. The capacitance of the
upper condenser is calculated on the basis of its parallel connection with two condensers which have air and
engine oil as a dielectric material.
The measuring principle of the oil sensor is a capacitance measurement, whereby the capacitance is dependent
upon the oil level. The measuring system consists of two cylinder condensers which possess a metal pipe as a
common external electrode. Both other electrodes are arranged over each other as an inner pipe.
The condensers are located in a plastic housing which serves as a damping cup. The engine oil flows through
the feed bore holes into the housing between the condensers.
The measuring range for the oil level is 80 mm (Normal level ± 40 mm), measurement accuracy approx. ± 3
mm.
The voltage for the oil sensor (approx. 5 V) is supplied by the engine control unit.
Oil sensor signal assignment
Fig. 6: Oil Sensor Signals Graph

Each information block consists of three successive square-wave signals, This is followed by a short pause.
A measured variable is assigned to each square-wave signal. The quantisizing in each case is based on the
on/off ratio of approx. 20 to 80 %.
Because oil level and oil quality (capacitance of the engine oil) are dependent of each other, this information is
first compensated for in the engine control unit, before it is transmitted via CAN databus to instrument cluster.
The following faults at the oil sensor are detected by the engine control unit and entered in the fault
memory:
 Duty cycle of a signal less than 17 % or more than 83 %

 Dielectric constant of the engine oil longer than 100 s greater than 5.8 (e.g. due to excessive water in the
engine oil).
COMPONENT DESCRIPTION OF THE OIL LEVEL CHECK SWITCH - GF18.40-P-4114AMG
Location for an engine with front sump

(Engine 156.980 in model 164, 251)
The oil level check switch is located at the right front in the oil pan top section.
The connector for the oil level check switch is located at the right front on the oil pan top section.
Fig. 7: Identifying Oil Level Check Switch Location For Engine With Front Sump
Location for engine with rear sump
(engine 156.982/83/84 in model 209, 211, 216, 219, 221)
The oil level check switch is located at the rear front in the oil pan top section.
The connector for the oil level check switch is located at the rear front below the oil pan top section.
Fig. 8: Identifying Oil Level Check Switch Location For Engine With Rear Sump
Task
The oil level check switch recognizes the minimum oil level in the engine oil pan and reports going below the
minimum oil level to the ME-SFI [ME] control unit (N3/10).
Body (shown with sufficient engine oil level)
Fig. 9: Sectional View Of Oil Level Check Switch - Body (Shown With Sufficient Engine Oil Level)
Function
The engine oil from the engine oil pan reaches the oil level switch via 2 bore holes in the switch housing. The
float is moved according to the oil level. The dry-reed contact is closed for an adequate engine oil level by the
magnetic field from ring magnets. If the engine oil level becomes too low the dry-reed contact opens and the
connection to the ground contact is interrupted. This recognized by the ME-SFI [ME] control unit and a suitable
warning signal is sent via the CAN data bus to the instrument cluster (A1).
Short-term fluctuations in level are compensated for by to the size of the oil volume and the 2 bores in
the switch housing (e.g. during braking or for cornering) which avoids unnecessary warning signals.
COMPONENT DESCRIPTION OF THE OIL LEVEL CHECK SWITCH - GF18.40-P-4114P
ENGINE 642 in MODEL 164.1 /8, 203.0 /2, 209.3 /4, 211.0 /2 /6, 219.3, 221.0 /1, 251.0 /1

Fig. 10: Identifying Oil Level Check Switch

Location
The oil level check switch is located on the underside of the engine and is fastened with the base plate on the
inside on the large oil pan. The jack for the oil level check switch is located on the output side at the lower left.
Task
The oil level check switch has the task to record the oil level and forward this over a discrete line to the CDI
control unit (N3/9).
Body
Shown on engine oil level greater than "Min"
Fig. 11: Identifying Oil Level Check Switch Components

Function
The engine oil levels in the oil level check switch and oil pan balance out over the feed and drain bore. The float
is moved according to the oil level. The dry-reed contact is opened off for an engine oil level less than "Min"
and closed for an engine oil level greater than "Min" by the magnetic field of the ring magnets. If the dry-reed
contact is opened then the connection to ground contact is interrupted and a warning message appears in the
multifunction display (A1p13) in the Instrument cluster (A1) concerning an unacceptably low oil level.
The volume of the housing and size of the drain bore on the oil level check switch compensate for
short-term level fluctuations and thus unnecessary warning messages. Level fluctuations can occur, for
example, during cornering.
COMPONENT DESCRIPTION FOR THE OIL LEVEL CHECK SWITCH - GF18.40-P-4114V

Fig. 12: Identifying Oil Level Check Switch - Engines 272.940/941

Fig. 13: Identifying Oil Level Check Switch And Connector - Engines 272.940/941
The oil level check switch is in the oil pan; the outer connector is located on the oil pan.
Task
To recognize reaching a minimum oil level in the oil pan.
Design
In the oil pan there is a dry-reed contact mounted in the float chamber and a float with ring magnet. A short line
leads to the connector on the side on the oil pan.
Function
When the oil level is adequate the contact to engine ground is closed. If the switch opens due to oil starvation
then this is recognized by the ME-SFI [ME] control unit and a message sent over the CAN to the instrument
cluster.
TESTING & REPAIR

READ OUT OIL CONSUMPTION WITH STAR DIAGNOSIS - AR18.00-P-0025-04CB
For evaluating the actual values, the vehicle must be at the starting point of the measuring trip for example at
the location of the oil change otherwise errors could occur while evaluating the actual values
Read out data for calculation of oil consumption with STAR DIAGNOSIS
1. In the case of the function main groups open menu point "Body".
2. In the case of the function main group Body open "KI (instrument cluster)".
3. In the case of the functions instrument cluster open menu point "Actual values".
4. In the case of the actual values of the instrument cluster open "Active service system since last oil
change".
5. In the active service system menu point "Driven travel distance since last oil change" read off travel
distance and note.
Example mileage: 1123 km
6. In the active service system menu point "Quantity of oil added during oil change", read off oil quantity
and note.
Example of added oil quantity: 6.3 liters
7. In the active service system menu point "Last and second last detected oil quantity in engine with engine
operation", read off last quantity of oil detected and note.
Example of detected oil quantity: 5.6 liters

Calculation of oil consumption
Added oil quantity 6.3 liters Minus last detected oil quantity: 5.6 liters = Differential quantity 0.7 l
If engine oil had been refilled during the measuring trip, the refill quantity has to be added when
calculating the filled oil quantity
Oil consumption = Quantity difference x 1000/Test course
= 0.7 l x 1000/1123 Km
= 0.62 l/1000 km
DETERMINE OIL CONSUMPTION - AR18.00-P-0025-05QB
Weigh engine oil
1. Allow engine oil to drain in the oil reservoir provided.
When oil filler cap is opened and engine is at operating temperature.
2. Place oil reservoir on a balance and weigh.

3. Note oil mass in kg and kilometer reading for the vehicle.
4. Fill up the engine with the prescribed quantity of engine oil.
5. Fit remaining parts to vehicle
Determine oil consumption
1. Weigh engine oil.

3. Perform measurement run.
4. Weigh engine oil again.
To prevent measurement errors, the new measurement must be carried out at the place of the first oil
measurement!

6. Determine differential mass and measurement distance.
Oil consumption over 1000 km:
Fig. 14: Oil Consumption Calculation Over 1000 KM

Calculated oil consumption in liters (l) per 1000 km.
MEASURE OIL CONSUMPTION - AR18.00-P-0025GZ
ENGINE 113.964 in MODEL 164.175 Oil consumption measurement with STAR-DIAGNOSIS
Check
Seal off non leak-tight parts, otherwise
Check outside of ENGINE
1 malfunctions, engine damage and environmental
for oil leakage
pollution may occur.
In order to avoid false measurements, for
example through fuel in engine oil, the engine oil has
Carry out engine oil and to be changed before each oil consumption measuring
2.1
filter change trip.
It is not necessary to change engine oil when
driven less than 1000 km after the last oil change.
Engine oil and filter AP18.00-P-
change 0101GZ
During test drive by workshop personnel:
 Test course 250 km taking into account use of

the vehicle by the customer
Conduct oil consumption
3
measuring drive
During test drive by the customer:
 Test course 1000 km

After repair or tests, e. g. through
Connect STAR
4 disconnection of connectors or through simulation,
DIAGNOSIS and read
erase retracted errors in the diagnostic trouble code
fault memory
memory.
Connect STAR
AD00.00-P-
2000-04A
fault memory
*WH58.30-Z-
1048-13A
For evaluating the actual values, the vehicle
Read out oil consumption must be at the starting point of the test run, for AR18.00-P-
5
with STAR DIAGNOSIS example at the location of the oil change, otherwise 0025-04CB
errors could occur while evaluating the actual values
If engine oil consumption After a driving performance of 1000 km, the
6 requires, refill engine oil engine oil consumption should amount to max 0.8 l. If
or conduct repair oil consumption is higher, appropriate repair
operations operations have to be conducted.

Number Designation
MEASURE OIL CONSUMPTION - AR18.00-P-0025GZS
ENGINE 156 in MODEL 164, 216, 221, 251
Checking
Risk of death caused by vehicle Align vehicle between columns of vehicle lift and AS00.00-
slipping or toppling off the lifting position four support plates at vehicle lift support Z-0010-
platform. points specified by vehicle manufacturer. 01A
Risk of injury to skin and eyes AS00.00-
Wear safety gloves, protective clothing and safety
caused by handling hot or glowing Z-0002-
glasses, if necessary.
objects. 01A
Check outside of ENGINE for oil Eliminate leaks prior to measuring oil
1
leakage consumption.
example through fuel in engine oil, the engine oil
2 Carry out engine oil and filter change has to be changed before each oil consumption
measuring trip It is not necessary to change engine
oil when driven less than 1000 km after last oil
change
Start engine and bring to operating
3
temperature
4 Turn off engine
AR18.00-
5 Weigh engine oil P-0025-
05QB
Conduct test run over a measured distance
of 250 km (if measurement carried out by
workshop personnel) or 1000 km (if measurement
6 Conduct measurement run carried out by customer). If measurements are
conducted by the workshop personnel, take into
account operating conditions of the vehicle at the
customer's.

7
temperature
8 Turn off engine
To prevent measurement errors, the new AR18.00-
Weigh engine oil again and
9 measurement must be carried out at the place of the P-0025-
determine oil consumption
first oil measurement. 05QB
If engine oil consumption requires, The oil consumption may be as much as
0.8 liter of oil over 1000 km. The corresponding
10 refill engine oil or conduct repair
repair measures must only be carried out if the oil
operations
consumption is higher than this.
MEASURE OIL CONSUMPTION - AR18.00-P-0025QB
ENGINE 272, 273
Check
Risk of death caused by vehicle AS00.00-
platform and position the four support plates at the
slipping or toppling off of the Z-0010-
lifting platform support points specified by the
lifting platform. 01A
Secure vehicle to prevent it from moving. AS00.00-
contusions and burns during
Do not grasp hot or rotating parts. 01A
starting procedure or when working
near engine
Risk of injury to skin and eyes AS00.00-
Wear safety gloves, protective clothing and safety
caused by handling hot or glowing Z-0002-
glasses, if necessary.
objects. 01A
Check outside of ENGINE for oil Eliminate leaks prior to measuring oil
1
leakage consumption.
example through fuel in engine oil, the engine oil has
Carry out engine oil and filter to be changed before each oil consumption
2.1
change measuring trip It is not necessary to change engine
oil when driven less than 1000 km after the last oil
change
3
temperature
4 Turn off engine
AR18.00-
5 Weigh engine oil P-0025-
05QB
Conduct test run over a measured distance

of 250 km (if measurement carried out by workshop

personnel) or 1000 km (if measurement carried out
6 Conduct measurement run by customer). If the measurements are conducted by
the workshop personnel, take into account operating
conditions of the vehicle at the customer's.
7
temperature
8 Turn off engine
To prevent measurement errors, the new AR18.00-
Weigh engine oil again and
9 measurement must be carried out at the place of the P-0025-
determine oil consumption
first oil measurement. 05QB
The oil consumption may be as much as 0.8
If engine oil consumption requires,
liter of oil over 1000 km. The corresponding repair
10 refill engine oil or conduct repair
measures must only be carried out if the oil
operations
consumption is higher than this.
CHECK OIL PRESSURE - AR18.00-P-1250GZ
Fig. 15: Identifying Double Union, Sealing Rings, Screw Plug And Tester
Remove/install

the and position the four support plates
below the lifting platform support
manufacturer.

jammed or pinched when removing, installing AS00.00-Z-
AR88.40-P-
1000GZ
2 Unclip cover on engine firewall side See ?
AR09.10-P-
Remove air filter housing
1150GZ
Unscrew screw plug (4) with sealing ring (5) at Installation: Replace sealing
3
timing case cover ring.
*BA18.40-
P-1001-01B
Fit double fittings (2) with a sealing ring (3) to
4 Tester Fig. 16
the crankcase cover and connect tester (1)
Double union Fig. 18
Checking
The vehicle must be positioned AR18.00-P-
5 Check engine oil level and correct if required. horizontally on the wheels, otherwise
3035-01CA
false measurements occur.
Measuring rod Fig. 19
Guide temperature sensor of the remote
thermometer through the oil dipstick guide tube
6 Remote thermometer Fig. 17
into the engine oil and read off the engine oil
temperature from the remote thermometer.
AS00.00-Z-
0005-01A
Bring engine up to operating
temperature (approx. 80°C).
*BE18.00-P-
7 Start the engine and measure oil pressure When the throttle is opened, 1001-01B
the oil pressure must rise without any
delay.
Check engine oil level and replenish oil if AR18.00-P-
9
necessary 3035-01CA
AS00.00-Z-
0005-01A


Conduct engine test run and check the engine malfunctions, transmission damage,
10
for leaks while it is running and serious environmental pollution
may occur.
TEST VALUES FOR OIL PRESSURE

Number Designation Engine 112, engine
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969
Oil bar > or =0,7
BE18.00-
pressure at at rpm
P-1001-
operating bar > or =3,0
01B
temperature at rpm 3000
OIL LEVEL/OIL PRESSURE SENSOR

BA18.40-P-1001-01B Screw plug to crankcase Nm 20
Fig. 16: Identifying Tester (103 589 00 21 00)

Fig. 17: Identifying Remote Thermometer (124 589 07 21 00)

Fig. 18: Identifying Double Union (166 589 00 63 00)

Fig. 19: Identifying Measuring Rod (120 589 07 21 00)

CHECK OIL PRESSURE - AR18.00-P-1250GZS
Fig. 20: Identifying Sealing Ring, Adapter Fitting, Pressure Gauge, Pressure Hose And Tester Cap
Remove/install

pinched or crushed when removing, installing Keep body parts and limbs well clear AS00.00-Z-
or aligning hoods, doors, trunk lids, tailgates or of moving parts. 0011-01A
sliding roof.
AS00.00-Z-
0005-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
3 Remove oil filter cover
ring.
*BA18.20-P-
1001-01V
Socket Fig. 21
Screw on test connection (1) with sealing ring Check whether there is a sealing
4 ring on test connection (1) and mount
to oil filter housing
one if not to prevent leaks.
*BA18.20-P-
1001-01V
Test cap Fig. 22
Screw adapter fitting (3) with sealing ring (2) *WH58.30-
5 Adapter fitting
onto test connection (1) Z-1011-05A
Screw pressure gauge (5) with pressure hose (4)
6 Testing unit Fig. 16
onto adapter fitting (3)
Pressure hose Fig. 24
Checking
The vehicle must be positioned
7 Check engine oil level and correct if required. horizontally on the wheels, otherwise
Guide temperature sensor of the remote
thermometer through the oil dipstick guide tube
8 Remote thermometer Fig. 17
into the engine oil and read off the engine oil
temperature from the remote thermometer.
Bring engine up to operating
temperature (approx. 80°C).
When the throttle is opened,

9 Start the engine and measure oil pressure the oil pressure must rise without any
delay.
*BE18.00-P-
Oil pressure at operating temperature
1001-01B
11 horizontally on the wheels, otherwise
necessary
for leaks while it is running
may occur.

bar > or =0.8
at rpm 560
BE18.00-P-1001-01B Oil pressure at operating temperature
bar > or =4.4
at rpm 3000
OIL FILTER
BA18.20-P-1001-01V Screw cap to oil filter housing Nm 25


Fig. 23: Identifying Testing Unit (103 589 00 21 00)




Number Designation
WH58.30-Z-1011-05A Adapter fitting M10 x 1-M12 x 1.5 for oil pressure gage 915 007 004 001 (DIN)
CHECK OIL LEVEL - AR18.00-P-3035-01CA
OIL LEVEL CHECK

113.964/971
BF18.00-P- Maximum mm 127
Oil level
1001-03U Minimum mm 101
Replenished oil
88 mm +2.9
quantity in liters
Replenished oil
90 mm +2.8
quantity in liters
Replenished oil
92 mm +2.6
quantity in liters
Replenished oil
94 mm +2.5
quantity in liters
Replenished oil
96 mm +2.4
quantity in liters
Replenished oil
98 mm +2.3
quantity in liters
Replenished oil
100 mm +2.2
quantity in liters
Replenished oil
102 mm +2.1
quantity in liters
BF18.00-P- Oil dipstick indication from 88 mm to
Replenished oil
1002-03U 124 mm (oil level too low) 104 mm +1.9
quantity in liters
Replenished oil
106 mm +1.8
quantity in liters
Replenished oil
108 mm +1.7
quantity in liters
Replenished oil
110 mm +1.5
quantity in liters
Replenished oil
112 mm +1.4
quantity in liters
Replenished oil
114 mm +1.2
quantity in liters
Replenished oil
116 mm +1.0
quantity in liters
Replenished oil
118 mm +0.9
quantity in liters
Replenished oil
120 mm +0.7
quantity in liters
Replenished oil
122 mm +0.5
quantity in liters
Replenished oil
124 mm +0.3
quantity in liters
126 mm Oil quantity in liters 0.0
BF18.00-P- Oil dipstick indication from 126 mm
1003-03U to 128 mm (oil level correct)
Extracted oil quantity
130 mm -0.3
in liters
132 mm -0.5
in liters
BF18.00-P- Oil dipstick indication from 130 mm Extracted oil quantity
134 mm -0.7
1004-03U to 138 mm (oil level too high) in liters
136 mm -0.9
in liters
138 mm -1.1
in liters
Fig. 26: Identifying Measuring Rod (120 589 07 21 00)

1. Position vehicle with warm engine on an even surface.

2. Switch off engine and maintain a waiting time of approx. 5 minutes.
3. Unplug plug (1) of oil dipstick guide tube (2).
4. Lead the dipstick (3) into the oil dipstick guide tube (2) until its tip is in the engine oil pan.
Leave there for at least a 3 seconds dwell time.
The collar of the dipstick grip end does not sit on the oil dipstick guide tube (2).
Do not bend the dipstick (3). The dipstick (3) must be pushed and guided
according to the form of the oil dipstick guide tube (2).
Fig. 27: Identifying Dipstick, Oil Dipstick Guide Tube Plug And Oil Dipstick Guide Tube
5. Read off engine oil level on dipstick (3).

6. Establish the oil replenishment quantity from the oil level table.
7. Adjust engine oil level correctly, if required.
8. Place plug (1) onto oil dipstick guide tube (2).
CHECK OIL LEVEL - AR18.00-P-3035-01GZ
OIL LEVEL CHECK

113.964/971
Oil level
Replenish oil
88 mm +2.9
quantity in liters
Replenish oil
90 mm +2.8
quantity in liters
Replenish oil
92 mm +2.6
quantity in liters
Replenish oil
94 mm +2.5
quantity in liters
Replenish oil
96 mm +2.4
quantity in liters
Replenish oil
98 mm +2,3
quantity in liters
Replenish oil
100 mm +2.2
quantity in liters
Replenish oil
102 mm +2.1
quantity in liters
Replenish oil
104 mm +1,9
quantity in liters
Replenish oil
106 mm +1.8
quantity in liters
Replenish oil
108 mm +1.7
BF18.00-P- Dipstick indication 88 mm to 124 mm quantity in liters
1002-03U (oil level too low) Replenish oil
110 mm +1.5
quantity in liters
Replenish oil
112 mm +1.4
quantity in liters
Replenish oil
114 mm +1.2
quantity in liters
Replenish oil
116 mm +1.0
quantity in liters
Replenish oil
118 mm +0.9
quantity in liters
Replenish oil
120 mm +0.7
quantity in liters
Replenish oil
122 mm +0.5
quantity in liters
Replenish oil
124 mm +0,3
quantity in liters
BF18.00-P- Oil dipstick indication 126 mm to 128
1003-03U mm (oil level correct)
Extract oil quantity
130 mm -0,3
in liters
132 mm -0.5
in liters
1004-03U mm (oil level too high) 134 mm -0.7
in liters
136 mm -0.9
in liters
138 mm in liters -1,1
Fig. 28: Identifying Dipstick (120 589 07 21 00)

1. Park vehicle on an even surface with engine at operating temperature.

2. Switch off engine and wait approx. 5 minutes.
3. Open engine hood.
4. Unplug plug (1) of oil dipstick guide tube (2).
5. Insert dipstick (3) into oil dipstick guide tube (2) until tip appears in engine oil pan.
The collar of the dipstick grip end sits close at oil dipstick guide tube (2).
6. Maintain a residence time of at least 3 s then pull dipstick (3) out of oil dipstick guide tube (2) and
read off engine oil level at dipstick (3).
Fig. 29: Identifying Dipstick, Oil Dipstick Guide Tube Plug And Oil Dipstick Guide Tube
7. Adjust engine oil level correctly, if required.

8. Place stop plug (1) onto oil dipstick guide tube (2).
9. Close engine hood.
REMOVE/INSTALL OIL SPRAY NOZZLES (PISTONS) - AR18.00-P-4000AMG
ENGINE 156
Fig. 30: Identifying Oil Spray Nozzles (Pistons) Remove/Install Components

Remove/install
toppling off of the lifting
and position four support
1.1 Remove engine with front Model 164, 251 AR01.10-P-2500GZS
axle carrier
1.2 Remove engine Model 209 AR01.10-P-2400QMG
Model 211, 219 AR01.10-P-2400TMG
Model 216, 221 AR01.10-P-2400SMG
2 Detach engine from front Model 164, 251 AR01.10-P-2510GZS
axle carrier only
3 Remove automatic Model 209, 211, 216, *BA27.10-P-1001-04E
transmission from engine 219, 221 with
transmission 722.9
Model 209, 211, 216, *BA27.10-P-1002-04E
219, 221 with
transmission 722.9
Model 216, 221 with *BA27.40-P-1001-01E
transmission 722.9
Model 216, 221 with *BA27.40-P-1002-01E
transmission 722.9
Model 164, 251 with *BA27.10-P-1001-04E
transmission 722.9
Model 164, 251 with *BA27.10-P-1002-04E
transmission 722.9
Engine 156 *BA15.30-P-1003-01O
4 Mount engine onto
assembly stand
5 Remove crankshaft AR03.20-P-4351AMG
6 Remove oil spray nozzles Installation:
(1) Ensure that injection
pipes (2) of oil spray
nozzles (1) are not bent
or damaged during
installation.
*BA18.00-P-1001-01G
Clean
7 Inspect/clean oil ducts Blow through oil
ducts in direction of flow
oil with compressed air.
Do not use any hard
ENGINE LUBRICATION, ENGINE OIL COOLING, GENERAL

BA18.00-P-1001-01G Fitted bolt, oil spray Nm 13
nozzle to crankcase
AUTOMATIC TRANSMISSION COMPLETE

BA27.10-P-1001- Bolt, automatic M10 Nm 38
04E transmission to
crankcase M12 Nm -
BA27.10-P-1002- Bolt, transmission to engine oil pan Nm 38
04E
HOUSING
Transmission 722.9 in
Number Designation Model 216, 221
BA27.40-P-1001-01E Bolt, automatic Nm 40
transmission to crankcase
BA27.40-P-1002-01E Bolt, automatic Nm 40
transmission to engine oil
pan
STARTER
BA15.30-P-1003-01O Bolt connecting starter to Nm 40
crankcase
AUTOMATIC TRANSMISSION COMPLETE

BA27.10-P-1001- Bolt, automatic M10 Nm 38
04E transmission to
crankcase M12 Nm -
BA27.10-P-1002- Bolt, transmission to engine oil pan Nm 38
04E
REMOVE/INSTALL OIL SPRAY NOZZLES (PISTONS) - AR18.00-P-4000GZ
Shown without connecting rod and pistons
Fig. 31: Identifying Torx Screws, Oil Spray Nozzles And Injection Pipe
Remove/install

Risk of death caused by vehicle slipping or and position the four support plates AS00.00-Z-
toppling off the lifting platform. below the lifting platform support points 0010-01A
Installation: Only install the AR61.20-P-

1 Remove bottom engine compartment paneling lower engine compartment after a
1105GZ
successful leak test.
AR01.45-P-
7555GZ
Installation:
 Ensure that the oil return shutoff

valve is correctly located. AR18.10-P-
3 Remove oil pump
 Clean the oil pump strainer. 6020GZ
 Fill the oil pump with engine oil
before installing, so that oil is
delivered at the initial startup.
If required, turn the crankshaft a
little at the crankshaft center bolt.
Installation:
4 Remove oil spray nozzles (1) Replace oil spray nozzle (1).
It is important to ensure that the spray
pipes (3) of the oil spray nozzles (1) are
not bent when being installed.
*BA18.00-
P-1001-01D
Clean
Note the following:
 Blow through oil galleries in

5 Inspect the oil ducts and clean if required direction of flow oil with
compressed air.
 Do not use any hard objects for
cleaning.
off by itself when engine is running. Risk ofby itself.
AS00.00-Z-
0005-01A
Conduct engine test run and check the engine eliminate cause, otherwise malfunctions,
7
for leaks while it is running transmission damage, and serious

Number Designation Engine 112 except 112.951/976,
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/971/980
Bolt, oil-
BA18.00-
spray
P-1001- Nm 15
nozzle at
01D
crankcase
REMOVE/INSTALL OIL SPRAY NOZZLES (PISTONS) - AR18.00-P-4000QB
ENGINE 272
ENGINE 273
Fig. 32: Identifying Oil Spray Nozzles And Injection Pipe - Engine 272 And 273
Remove/install
Align vehicle between the columns of the and
position the four support plates below the lifting AS00.00-Z-
slipping or toppling off the
platform support points specified by the vehicle 0010-01A
lifting platform.
manufacturer.
1 Remove oil pan
Remove the oil suction pipe *BA18.10-P-
2 Bolt for oil intake tube on oil pump
from the oil pump 1004-01B
*BA18.10-P-
Oil suction pipe to crankcase 1005-01B
Remove the oil baffle from the *BA18.10-P-
3
crankcase 1006-01B
To improve accessibility, turn the crankshaft

slightly at the belt pulley if required.

4 Remove oil spray nozzles (1) Installation: Ensure that the injection pipes
(2) of the oil spray nozzles (1) are not bent.
*BA18.00-P-
1001-01D
Clean
Blow through oil ducts in direction of flow
5 Inspect/clean oil ducts oil with compressed air. Do not use any hard objects
for cleaning.
OIL PUMP
BA18.10-P-1004-01B Bolt, oil suction pipe to oil pump. M6 x 16 Nm 9 9
BA18.10-P-1005-01B Oil suction pipe to crankcase Nm 9 9
BA18.10-P-1006-01B Bolt, oil baffle to crankcase Nm 9 9

BA18.00-P-1001-01D Bolt, oil-spray nozzle to crankcase Nm 8 8
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE LUBRICATION, ENGINE OIL
COOLING - AR18.00-Z-9113AB
ENGINE 113
Measure oil consumption ENGINE 112, 113 Only for AR18.00-P-0025AV

models without Star
Diagnosis
Measure oil consumption ENGINE 112, 113, 611, AR18.00-P-0025CB
612, 613, 628...
Measure oil consumption ENGINE 113.964 in AR18.00-P-0025GZ
MODEL 164.175 Oil
consumption measurement
with STAR-DIAGNOSIS
Measure oil consumption ENGINE 113.971 in AR18.00-P-0025RT
MODEL 251.075 /175, oil
consumption measurement
with STAR-DIAGNOSIS
Measure oil consumption ENGINE 113.967 in AR18.00-P-0025TY
113.990 in MODEL
219.376
Check oil pressure ENGINE 113.988 in AR18.00-P-1250AC

MODEL 203.076/276
ENGINE 113.989 in
MODEL 171.473
Check oil pressure ENGINE 112, 113... AR18.00-P-1250D
Check oil pressure ENGINE 112, 113... AR18.00-P-1250DA
Check oil pressure ENGINE 113.964 in AR18.00-P-1250GZ
MODEL 164.175
Check oil pressure ENGINE 113.995 in AR18.00-P-1250RKV
MODEL 230.472
Check oil pressure ENGINE 113.971 in AR18.00-P-1250RT
MODEL 251.075/175
Check oil pressure ENGINE 113.990 in AR18.00-P-1250RVK
MODELS 211.076 /276
ENGINE 113.991 in
MODELS 215.374,
220.074/174
Check oil pressure ENGINE 113.967 in AR18.00-P-1250TY
113.990 in MODEL
219.376
Remove/install oil spray ENGINE 112, 113... AR18.00-P-4000DV
nozzles (pistons)
Remove/install oil spray ENGINE 113.964 in AR18.00-P-4000GZ
nozzles (pistons) MODEL 164.175
Remove/install oil spray ENGINE 113.971 in AR18.00-P-4000RT
nozzles (pistons) MODELS 251.075/175
Remove, install oil spray ENGINE 113.995 in AR18.00-P-4000RVK
Remove/install oil spray ENGINE 113.967 in AR18.00-P-4000TY
nozzles (pistons) MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install oil spray ENGINE 113.989 in AR18.00-P-4000VT
Replace oil pump chain ENGINE 113.964 in AR18.10-P-2140GZ
MODEL 164.175
Replace the oil pump chain ENGINE 113.971 in AR18.10-P-2140RT
MODEL 251.075/175
Replace oil pump chain ENGINE 113.967 in AR18.10-P-2140TY
113.990 in MODEL
219.376
Replace the oil pump chain ENGINE 112, 113... AR18.10-P-2140V
Replace oil pump chain ENGINE 113.989 in AR18.10-P-2140VT

MODEL 171.473
Remove, install oil pressure ENGINE 112, 113... AR18.10-P-5031GV
relief valve
Remove/install oil pressure ENGINE 113.964 in AR18.10-P-5031GZ
relief valve MODEL 164.175
Remove/install oil pressure ENGINE 113.971 in AR18.10-P-5031RT
relief valve MODEL 251.075/175
Remove/install oil pressure ENGINE 113.967 in AR18.10-P-5031TY
relief valve MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install oil pressure ENGINE 113.989 in AR18.10-P-5031VT
relief valve MODEL 171.473
Remove/install oil pump ENGINE 112, 113... AR18.10-P-6020B
Remove/install oil pump ENGINE 113.964 in AR18.10-P-6020GZ
MODEL 164.175
Remove/install oil pump ENGINE 111, 112, 113... AR18.10-P-6020PV
Remove/install oil pump ENGINE 112, 113... AR18.10-P-6020PW
Remove/install oil pump ENGINE 113... AR18.10-P-6020R
Remove/install oil pump ENGINE 113.971 in AR18.10-P-6020R
MODEL 251.075/175
Remove/install oil pump ENGINE 113.967 in AR18.10-P-6020TY
113.990 in MODEL
219.376
Removing/installing the oil ENGINE 112, 113... AR18.20-P-3471B
filter housing
Remove/install oil filter ENGINE 112, 113... AR18.20-P-3471B
housing
Remove/install oil filter ENGINE 113.964 in AR18.20-P-3471GZ
housing MODEL 164.175
Remove, install oil filter ENGINE 113... AR18.20-P-3471RKV
housing
Remove/install oil filter ENGINE 113.971 in AR18.20-P-3471RT
housing MODEL 251.075/175
Remove/install oil filter ENGINE 113.967 in AR18.20-P-3471TY
Remove/install oil filter ENGINE 113.990 in AR18.20-P-3471TZ
Remove/install engine oil ENGINE 113.991 in AR18.30-P-1000M
cooler MODEL 220.074
Remove, install engine oil ENGINE 113.991 in AR18.30-P-1000RKV
cooler MODEL 215.374 ENGINE
113.992 in MODEL
230.474 ENGINE 113.995
in MODEL 230.472
Remove, install engine oil ENGINE 113... AR18.30-P-1000RKY
cooler
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1000T
cooler MODELS 211.076 /276
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1000TY
cooler MODEL 219.376
Additional oil cooler
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1000TZ
cooler MODEL 219.376 Wheel
house oil cooler
Removing/installing the ENGINE 113.989 in AR18.30-P-1000VT
engine oil cooler MODEL 171.473
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1010T
cooler fan MODEL 211.076/276
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1010TZ
cooler fan MODEL 219.376
Remove/install oil/water heat ENGINE 112, 113... AR18.30-P-3481C
exchanger at oil filter
Remove, install oil/water ENGINE 112, 113... AR18.30-P-3481CA
heat exchanger at oil filter
Remove/install oil/water heat ENGINE 113.964 in AR18.30-P-3481GZ
exchanger at oil filter MODEL 164.175
Remove/install oil/water heat ENGINE 113.971 in AR18.30-P-3481RT
exchanger at oil filter MODEL 251.075/175
Remove/install oil/water heat ENGINE 113.967 in AR18.30-P-3481TY
exchanger at oil filter MODEL 219.375
Remove/install oil dipstick ENGINE 112/, 113/(except, AR18.40-P-3510BV
guide tube 112.912/946 /961,
113.963/995)
Remove/install oil dipstick ENGINE 113.964 in AR18.40-P-3510GZ
guide tube MODEL 164.175
Remove/install oil dipstick ENGINE 113.971 in AR18.40-P-3510RT
guide tube MODELS 251.075/175
Remove, install oil dipstick ENGINE 113.995 in AR18.40-P-3510RVK
Remove oil level sensor, ENGINE 112, 113... AR18.40-P-5111A
install
Remove oil level sensor, ENGINE 111, 112, 113... AR18.40-P-5111PR
install
Remove/install oil level ENGINE 112, 113... AR18.40-P-5111PW
sensor
Remove oil level sensor, ENGINE 113.967 in AR18.40-P-5111TY

install MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install oil sensor ENGINE 113.964 in AR18.40-P-5112GZ
MODEL 164.175
Remove/install oil sensor ENGINE 112, 113... AR18.40-P-5112R
Remove/install oil sensor ENGINE 113.971 in AR18.40-P-5112RT
MODEL 251.075/175
ENGINE 156
Measure oil consumption ENGINE 156 in MODEL AR18.00-P-0025GZS

164, 216, 221, 251
Measure oil consumption ENGINE 156.982 in AR18.00-P-0025TMG
MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Check oil pressure ENGINE 156 in MODEL AR18.00-P-1250GZS
164, 251
Check oil pressure ENGINE 156 in MODEL AR18.00-P-1250SMG
216, 221
Check oil pressure ENGINE 156.982 in AR18.00-P-1250TMG
MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install oil spray ENGINE 156 AR18.00-P-4000AMG
nozzles (pistons)
Replace the oil pump ENGINE 156 in MODEL AR18.10-P-2140GZS
chain 164, 251
Replace oil pump chain ENGINE 156 in MODEL AR18.10-P-2140SMG
216, 221
Replace the oil pump ENGINE 156.982 in AR18.10-P-2140TMG
chain MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
Remove/install oil pump ENGINE 156 in MODEL AR18.10-P-6020GZS
164, 251
Remove/install oil pump ENGINE 156 in MODEL AR18.10-P-6020SMG
216, 221
Remove/install oil pump ENGINE 156.982 in AR18.10-P-6020TMG
MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install oil filter ENGINE 156 in MODEL AR18.20-P-3471GZS
housing 164, 251
Remove/install oil filter ENGINE 156 in MODEL AR18.20-P-3471SMG
housing 216, 221
Remove/install oil filter ENGINE 156.982 in AR18.20-P-3471TMG
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove, install engine ENGINE 156 in MODEL AR18.30-P-1000GZS
oil cooler 164, 251
Remove, install engine ENGINE 156 ... AR18.30-P-1000QBS
oil cooler
Remove, install engine ENGINE 156.982 in AR18.30-P-1000QSB
oil cooler MODEL 209.377 with
CODE (P98) Black
Series Wheelhouse oil
cooler on the right
Remove, install engine ENGINE 156 in MODEL AR18.30-P-1000SMG
oil cooler 216, 221
Remove, install engine ENGINE 156 ... AR18.30-P-1000TMG
oil cooler
Remove, install engine ENGINE 156 ... AR18.30-P-1000TMR
oil cooler
Remove, install oil ENGINE 156 AR18.30-P-3000AMG
temperature regulator
Remove/install oil-water ENGINE 156 in MODEL AR18.30-P-6840GZS
heat exchanger 164
Remove/install oil-water ENGINE 156 in MODEL AR18.30-P-6840RTS
heat exchanger 251
Remove/install oil ENGINE 156 in MODEL AR18.40-P-3510GZS
dipstick guide tube 164, 251
Remove/install oil ENGINE 156 in MODEL AR18.40-P-3510SMG
dipstick guide tube 216, 221
Remove/install oil ENGINE 156.982 in AR18.40-P-3510TMG
dipstick guide tube MODEL 209.377 /477
ENGINE 156.983 in
MODEL 211.077 /277,
219.377
Remove/install sensor for ENGINE 156 AR18.40-P-4123AMG

engine oil temperature
Remove/install oil level ENGINE 156 in MODEL AR18.40-P-5113GZS
check switch 164, 251
Remove/install oil level ENGINE 156 in MODEL AR18.40-P-5113SMG
check switch 216, 221
Remove/install the oil ENGINE 156.982 in AR18.40-P-5113TMG
level check switch MODELS 209.377 /477
ENGINE 156.983 in
MODELS 211.077 /277,
219.377
ENGINE 272
Measure oil consumption ENGINE 272, 273 AR18.00-P-0025QB

Checking oil pressure ENGINE 272 ENGINE AR18.00-P-1250SX
273
Remove/install oil spray ENGINE 272 ENGINE AR18.00-P-4000QB
nozzles (pistons) 273
Remove/install the tensioning ENGINE 272 ENGINE AR18.10-P-2000SX
device for the oil pump chain 273
Replace the oil pump chain ENGINE 272 ENGINE AR18.10-P-2140SX
273
Remove/install oil pump ENGINE 272 in AR18.10-P-6020CV
MODEL 204
Remove/install oil pump ENGINE 272, 273 in AR18.10-P-6020GZA
MODEL 164, 251
Remove/install oil pump ENGINE 272, 273 ... AR18.10-P-6020QB
Remove, install oil pump ENGINE 272, 273 ... AR18.10-P-6020QD
Remove/install oil pump ENGINE 272, 273 in AR18.10-P-6020RX
MODEL 230
Remove/install oil pump ENGINE 273 in AR18.10-P-6020SX
MODEL 216 ENGINE
272, 273 in MODEL
221
Remove, install oil pump ENGINE 272, 273 in AR18.10-P-6020TS
MODEL 211, 219
Vehicles with rear
sump
Remove/install oil pump ENGINE 272.942 /963 AR18.10-P-6020VA
in MODEL 171
Remove/install oil filter ENGINE 272 in AR18.20-P-3471CV

housing MODEL 204
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471GZA
Remove/install oil filter ENGINE 272, 273 ... AR18.20-P-3471QB
housing
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471RX
housing MODEL 230
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471SX
273 in MODEL 216
Remove, install oil filter ENGINE 272, 273 in AR18.20-P-3471TS
Removing/installing the oil ENGINE 272.942 /963 AR18.20-P-3471VA
filter housing in MODEL 171
Remove, install oil/water heat ENGINE 272 in AR18.30-P-3481CV
exchanger at oil filter MODEL 204
Remove/install oil-water heat ENGINE 272, 273 in AR18.30-P-3481GZA
exchanger at oil filter MODEL 164, 251
Remove, install oil/water heat ENGINE 272, 273 ... AR18.30-P-3481QB
exchanger at oil filter
Remove/install oil/water heat ENGINE 272, 273 in AR18.30-P-3481RX
exchanger at oil filter MODEL 230
Remove, install oil/water heat ENGINE 272, 273 in AR18.30-P-3481SX
exchanger at oil filter MODEL 221 ENGINE
273 in MODEL 216
Remove, install oil/water heat ENGINE 272, 273 in AR18.30-P-3481TS
exchanger at oil filter MODEL 211, 219
Removing/installing the ENGINE 272.942 in AR18.30-P-3481VA
oil/water heat exchanger at the MODEL 171.454
oil filter ENGINE 272.963 in
MODEL 171.456
Remove/install oil dipstick ENGINE 272 in AR18.40-P-3510CV
guide tube MODEL 204 Vehicle
with rear sump
Remove/install oil dipstick ENGINE 272 in AR18.40-P-3510CWX
Vehicles with middle
sump
Remove/install oil dipstick ENGINE 272, 273 in AR18.40-P-3510GZA
guide tube MODEL 164, 251
Remove/install oil dipstick ENGINE 272, 273 ... AR18.40-P-3510QB
guide tube
Remove/install oil dipstick ENGINE 272, 273 in AR18.40-P-3510RX
guide tube MODEL 230

Remove/install oil dipstick ENGINE 273, 272 in AR18.40-P-3510SW
guide tube MODEL 221.08 /18
Remove/install oil dipstick ENGINE 272.946 /965 AR18.40-P-3510SX
guide tube in MODEL 221
ENGINE 273.922 /961
in MODEL 221
ENGINE 273.961 in
MODEL 216
Remove, install oil dipstick ENGINE 272, 273 in AR18.40-P-3510TS
guide tube MODEL 211, 219
Vehicles with rear
sump
Remove/install oil dipstick ENGINE 272, 273 ... AR18.40-P-3510TW
guide tube
Remove/install oil dipstick ENGINE 272.942 /963 AR18.40-P-3510VA
guide tube in MODEL 171
Remove/install the oil level ENGINE 272 ENGINE AR18.40-P-5113SX
check switch 273
ENGINE 273
Measure oil consumption ENGINE 272, 273 AR18.00-P-0025QB

Checking oil pressure ENGINE 272 ENGINE AR18.00-P-1250SX
273
Remove/install oil spray ENGINE 272 ENGINE AR18.00-P-4000QB
nozzles (pistons) 273
Remove/install the ENGINE 272 ENGINE AR18.10-P-2000SX
tensioning device for the 273
oil pump chain
Replace the oil pump ENGINE 272 ENGINE AR18.10-P-2140SX
chain 273
Remove/install oil pump ENGINE 272, 273 in AR18.10-P-6020GZA
MODEL 164, 251
Remove/install oil pump ENGINE 272, 273 ... AR18.10-P-6020QB
Remove, install oil pump ENGINE 272, 273 ... AR18.10-P-6020QD
Remove/install oil pump ENGINE 272, 273 in AR18.10-P-6020RX
MODEL 230
Remove/install oil pump ENGINE 273 in MODEL AR18.10-P-6020SX
216 ENGINE 272, 273 in
MODEL 221
Remove, install oil pump ENGINE 272, 273 in AR18.10-P-6020TS

MODEL 211, 219
Vehicles with rear sump
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471GZA
Remove/install oil filter ENGINE 272, 273 ... AR18.20-P-3471QB
housing
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471RX
housing MODEL 230
Remove/install oil filter ENGINE 272, 273 in AR18.20-P-3471SX
273 in MODEL 216
Remove, install oil filter ENGINE 272, 273 in AR18.20-P-3471TS
Remove/install oil-water ENGINE 272, 273 in AR18.30-P-3481GZA
heat exchanger at oil MODEL 164, 251
filter
Remove, install oil/water ENGINE 272, 273 ... AR18.30-P-3481QB
heat exchanger at oil
filter
Remove/install oil/water ENGINE 272, 273 in AR18.30-P-3481RX
heat exchanger at oil MODEL 230
filter
Remove, install oil/water ENGINE 272, 273 in AR18.30-P-3481SX
heat exchanger at oil MODEL 221 ENGINE
filter 273 in MODEL 216
Remove, install oil/water ENGINE 272, 273 in AR18.30-P-3481TS
heat exchanger at oil MODEL 211, 219
filter
Remove/install oil ENGINE 272, 273 in AR18.40-P-3510GZA
dipstick guide tube MODEL 164, 251
Remove/install oil ENGINE 272, 273 ... AR18.40-P-3510QB
dipstick guide tube
Remove/install oil ENGINE 272, 273 in AR18.40-P-3510RX
dipstick guide tube MODEL 230
Remove/install oil ENGINE 273, 272 in AR18.40-P-3510SW
dipstick guide tube MODEL 221.08 /18
Remove/install oil ENGINE 272.946 /965 in AR18.40-P-3510SX
dipstick guide tube MODEL 221 ENGINE
273.922 /961 in MODEL
221 ENGINE 273.961 in
MODEL 216
Remove, install oil ENGINE 272, 273 in AR18.40-P-3510TS
dipstick guide tube MODEL 211, 219
Vehicles with rear sump
Remove/install oil ENGINE 272, 273 ... AR18.40-P-3510TW

dipstick guide tube
Remove/install the oil ENGINE 272 ENGINE AR18.40-P-5113SX
level check switch 273
SEPARATE OIL PUMP CHAIN - AR18.10-P-2140-01AMG
Fig. 33: Identifying Case (602 589 00 98 00)

Fig. 34: Identifying Thrust Spindle (271 589 10 63 00)

Fig. 35: Identifying Chain Separating Tool (602 589 02 33 00)

1. Screw the pressure screw (02) with the pressure pin (02a) into the chain separating
tool (03).
2. Fit chain separating tool (03)onto oil pump chain.
3. Screw in pressure screw (02).
Screw in the pressure screw until the pressure pin (02a)is lying against the pin (arrow) on
the oil pump chain.
4. Screw in pressure pin (02a)and press out bolt on oil pump chain.
Fig. 36: Identifying Pressure Screw, Pressure Pin And Chain Separating Tool
5. Unscrew pressure screw (02) and remove chain separating tool (03).
6. Remove bolt (1) for oil pump chain from chain separating tool (03).
Fig. 37: Identifying Pressure Screw And Chain Separating Tool

SEPARATE OIL PUMP CHAIN - AR18.10-P-2140-01V



Fig. 41: Identifying Thrust Pins (602 589 05 63 01)

1. Screw pressure screw (02) with pressure pin (02a) into chain-separating tool (03).
2. Fit chain separating tool (03) onto oil pump chain.
3. Screw in pressure screw (02) as far as necessary until the closely at the oil pump chain pin
(arrow).
4. Screw in pressure pin (02a) and press out oil pump chain pin.
Fig. 42: Identifying Pressure Screw, Pressure Pin And Chain Spring Tool
5. Unscrew pressure screw (02) and remove chain separating tool (03).
6. Remove oil pump chain pin (1) from chain separating tool (03).
Fig. 43: Identifying Pressure Screw And Chain Spring Tool

RIVET OIL PUMP CHAIN - AR18.10-P-2140-02AMG

Fig. 45: Identifying Riveting Tool (602 589 00 39 00)


Fig. 47: Identifying Assembly Link (271 589 02 40 00)

Fig. 48: Identifying Assembly Inserts (271 589 02 63 00)

1. Connect new oil pump chain (2)and old oil pump chain (1)together using an assembly link (3).
2. Slowly rotate crankshaft in the direction of engine rotation (arrowed) until it is possible to connect both
ends of new oil pump chain (2).
3. Remove assembly link (3) and old oil pump chain (1).
Fig. 49: Identifying Oil Pump Chain And Assembly Link

4. Connect ends of new oil pump chain (2) using a riveted link (4).
Insert riveted link (4) from front.
Fig. 50: Identifying Oil Pump Chain And Riveted Link

5. Place assembly insert with digit F10 into rivet press tool (arrow) and fix in place by a bolt
(28).
Fig. 51: Identifying Digit F10, Rivet Press Tool And Bolt
6. Place moveable assembly insert with digit D10 into rivet press tool (arrow).
Fig. 52: Identifying Digit D10 Into Rivet Press Tool

7. Lay outer plate into the assembly insert with digit D10 (arrow).
Fig. 53: Locating Digit D10

8. Place rivet press tool on oil pump chain.
Fit in such a way that the rollers of the riveted link (4)rest on the spacer web (arrow).
9. Tighten pressure screw (6) until a firm resistance is felt.
While turning the pressure screw (6),ensure that pin in rivet link (4) is inserted in holes in
the external mounting link (5).
10. Remove rivet press tool.

Fig. 54: Locating Spacer Web

11. Move assembly insert with digit D10 onto rivet profile (arrow).
Fig. 55: Locating Rivet Profile

12. Place rivet press tool on oil pump chain riveted link (4).
Fit the in such a way that pins for the riveted link (4) are located exactly in the center of V-type
support (arrow).
13. Tighten pressure screw (6).
The torque applied to pressure screw (6) is about 30 to 35 Nm (reference value).
14. Rivet bolts for riveted link (4) individually.

Fig. 56: Locating V-Type Support

15. Check riveted joint (arrows) for bolt; re-rivet bolt if necessary.
Fig. 57: Locating Riveted Joint

RIVET OIL PUMP CHAIN - AR18.10-P-2140-02V



Fig. 61: Identifying Assembly Links (602 589 02 40 00)

1. Connect new oil pump chain (2) and old oil pump chain (1) with assembly clip-type fastener (3)
2. Slowly rotate crankshaft in direction of rotation of engine (arrow) until it is possible to connect the ends
of the new oil pump chain (2).
3. Unhook old oil pump chain (1).
Fig. 62: Identifying Oil Pump Chain And Clip-Type Fastener

4. Connect the ends of the new oil pump chain (2) with the riveted link (4) Insert riveted link (4)
from the front.
Fig. 63: Identifying Oil Pump Chain And Riveted Link

5. Place guide piece with the digit F2 into the press-on tool (arrow) and fix with bolt (28)
Fig. 64: Locating Guide Piece With Press-On Tool

6. Place moveable thrust piece with the digit 2 (arrow) into the press-on tool.
Fig. 65: Locating Thrust Piece And Press-On Tool

7. Place outer plate into the thrust piece with the digit 2 (arrow).
Fig. 66: Locating Outer Plate And Thrust Piece

8. Fit on press-on tool in such a way, that the rollers of the riveted link (4) are resting on the distance
web (arrow).
9. Tighten spindle (6) up to solid resistance.
When turning the spindle (6) ensure, that the pins of the riveted link (4) are inserted in the
holes of the outer plate (5).
10. Remove press-on tool.

Fig. 67: Locating Rollers Of Riveted Link

11. Turn thrust piece with the digit 2 onto rivet profile (arrow).
Fig. 68: Locating Thrust Piece With Digit 2 Onto Rivet Profile
12. Fit on press-on tool in such a way, that the pin is located exactly in the middle of the V-type
support (arrow).
13. Tighten spindle (6).
The torque at the spindle (6) amounts to approx. 30-35 Nm (reference value).
14. Rivet pins of riveted link individually

Fig. 69: Locating Spindle

15. Check rivets (arrows) of pins, if necessary rivet pins again.
Fig. 70: Locating Rivets Of Pins

REPLACE OIL PUMP CHAIN - AR18.10-P-2140GZ

Fig. 71: Identifying Transmission Oil Pump, Oil Return Shutoff Valve And Oil Pump Bolts
Remove/Install

lifting platform and position the four
support plates below the hoist support
manufacturer.
AR01.45-
1 Remove oil pan bottom section (1)
P-7555GZ
AR01.45-
2 Remove oil pan
P-7500GZ
Installation:
 Ensure oil return flow check valve

(3) is correctly installed. AR18.10-
3 Remove oil pump (2)
 Clean the oil pump strainer. P-6020GZ
AR18.10-
4 Separate oil-pump chain P-2140-
01V
Case Fig. 33
Pressure screw Fig. 39
Chain separating tool Fig. 35
Thrust pins Fig. 41

AR18.10-
5 Draw in oil pump chain and rivet P-2140-
02V
Case Fig. 33
Riveting tool Fig. 45
Assembly inserts Fig. 77
Assembly links Fig. 61
Risk of accident caused by vehicle starting
Secure vehicle to prevent it from moving.
off by itself when engine is running. Risk of
Wear closed and snug-fitting work AS00.00-Z-
injury caused by contusions and burns during
clothes. 0005-01A
starting procedure or when working near
engine
7



Fig. 75: Identifying Thrust Pins (602 589 05 63 01)



Fig. 78: Identifying Assembly Links (602 589 02 40 00)

REPLACE THE OIL PUMP CHAIN - AR18.10-P-2140GZS
Fig. 79: Replacing Oil Pump Chain

Remove/install

manufacturer.
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
Installation: Only install the
2 Remove bottom engine compartment paneling lower engine compartment paneling
after the leak test.
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR01.45-P-
7555GZS
AR18.10-P-
4 Remove oil pump
6020GZS
AR18.10-P-
5 Disconnect old oil pump chain (1) 2140-
01AMG
Case Fig. 33
Chain separating tool Fig. 35
AR18.10-P-
6 Draw in new oil pump chain (2) and rivet 2140-
02AMG
Case Fig. 33
Riveting tool Fig. 45
Assembly link Fig. 47
Assembly inserts Fig. 48
AS00.00-Z-
0005-01A
8
for leaks




Fig. 84: Identifying Assembly Link (271 589 02 40 00)


REMOVE/INSTALL OIL PRESSURE RELIEF VALVE - AR18.10-P-5031GZ
Fig. 86: Identifying Oil Return Shutoff Valve, Oil Pump Bolts And Oil Pump Bottom Section
Remove/Install

lifting platform and position the four
manufacturer.
AR01.45-
1 Remove oil pan bottom section (1)
P-7555GZ
AR01.45-
2 Remove oil pan
P-7500GZ
Installation:
 Ensure oil return flow check valve

Remove oil pump with oil pressure relief (3) is correctly installed. AR18.10-
3
valve (2)  Clean the oil pump strainer. P-6020GZ
The oil pressure relief valve is
supplied together with the oil pump for
4 Replace oil pressure relief valve
repair purposes. It is therefore not
necessary to disassemble the oil pump.
Secure vehicle to prevent it from moving.
off by itself when engine is running. Risk of
Wear closed and snug-fitting work AS00.00-Z-
injury caused by contusions and burns during
clothes. 0005-01A
starting procedure or when working near
engine
6
REMOVE/INSTALL OIL PUMP - AR18.10-P-6020GZ

Fig. 87: Identifying Oil Pump Remove/Install Components

Remove/Install

1
position 1000GZ
manufacturer.
AR00.60-P-
1000GZ
AR01.45-P-
3 Remove bottom part of oil pan
7555GZ
Push back chain tensioner (5) and take oil
4
pump chain (3) off oil pump gear (4)
*BA18.10-
5 Unscrew bolts (2) of the oil pump (1)
P-1001-01B
Installation: Before installing,
fill oil pump (1) with engine oil, so that
it delivers oil immediately when first
started.
To do this, unscrew bolts (7)

7 Clean strainer of oil pump (1) and take cover and oil pipe (8) off the oil
pump (1).
*BA18.10-
P-1003-01B
Check
If the oil return shutoff valve (6)
Check oil return shutoff valve (6) for correct
8 is damaged or a malfunction detected, it
position and function.
must be replaced.
10 Check engine oil level and correct if required.
off by itself when engine is running. Risk of moving.
AS00.00-Z-
0005-01A
starting procedure or when working near clothes.
11
OIL PUMP
M8 x 30 Nm 20
BA18.10-P-1001-01B Bolt of oil pump to crankcase M7 x 40 Nm -
M6 x 16 Nm -
BA18.10-P-1003-01B Screw of oil pump cover with oil pipe to oil pump Nm 10
REMOVE/INSTALL OIL PUMP - AR18.10-P-6020GZA
ENGINE 272, 273 in MODEL 164, 251


Remove/install
1 Separate connector (3)

AR01.45-P-
7555GZA
Detach oil suction pipe (1) with bracket
The oil sensor (B40) remains
3 (2) and oil sensor (B40) from crankcase;
attached to the bracket (2).
to do so, remove bolts (4)
*BA18.10-P-
1005-01B
Remove oil pump (5) from crankcase by *BA18.10-P-
4
unscrewing bolts (6) 1008-01B
Torx bit set Fig. 89
Push back chain tensioner (7) and take
5
oil pump chain (8) off oil pump gear (9)
Installation: Before installing, fill
Remove oil pump (5) with oil suction
6 oil pump (5) with engine oil, so that it
pipe (1)
delivers oil immediately when first started.
OIL PUMP
BA18.10-P-1005-01B Oil suction pipe to crankcase Nm 9 9
Stage 1 Nm 5 5
BA18.10-P-1008-01B Bolt, oil pump to crankcase
Stage 2 Nm 20 20
Fig. 89: Identifying Torx Bit Set (000 589 01 10 00)


REMOVE/INSTALL OIL PUMP - AR18.10-P-6020GZS


Remove/install
manufacturer.
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
Installation: Only install the
Remove lower engine compartment
3 lower engine compartment paneling
paneling
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR01.45-P-
4 Remove bottom part of oil pan
7555GZS
Push back chain tensioner (5) and take oil
5
pump chain (3) off oil pump gear (4)
*BA18.10-
6 Unscrew bolts (2) for oil pump (1)
P-1001-01N
Observe the following when
installing:
 Replace seal.
 Fill oil pump prior to installation
with engine oil so that it starts
pumping oil immediately when
engine is started.
By removing bolts (6) and oil
8 Clean oil strainer for oil pump (1)
suction pipe (7) from oil pump (1).
*BA18.10-
P-1004-01N
Checking
Check oil pump gear (4) for easy
9
movement and damage
11 Check engine oil level and adjust correctly See: ?
AP18.00-P-
0101GZ
moving by itself.
clothes.
12
engine for leaks while it is running
OIL PUMP
BA18.10-P-1001-01N Fitted bolt, oil pump to crankcase Nm 20
BA18.10-P-1004-01N Bolt, oil suction pipe to oil pump. M6 x 16 Nm 8.5
BOLT PLAN FOR OIL FILTER HOUSING - AR18.20-P-3471-01AMG
OIL FILTER
BA18.20-P-1002- Bolt, oil filter M8 x 35 Nm 20

01V housing to timing m8 x 80 Nm 20
case cover M8 x 100 Nm 20
Assignment of bolts for oil filter housing
Fig. 92: Assignment Of Bolts For Oil Filter Housing

BOLT PLAN FOR THE OIL FILTER HOUSING - AR18.20-P-3471-01VA
OIL FILTER
272 273
BA18.20-P-1002- Self-tapping screw, oil filter housing at timing case
Nm 20 20
01O cover
BA18.20-P-1003-
Bolt, oil filter housing at crankcase Nm 20 20
01O
Assignment of bolts for oil filter housing

Fig. 93: Assignment Of Bolts For Oil Filter Housing

REMOVE/INSTALL OIL FILTER HOUSING - AR18.20-P-3471GZ
Fig. 94: Identifying Oil Filter Housing Remove/Install Components

Remove/Install

AR88.40-P-
1000GZ
AR09.10-P-
1150GZ
Remove cover (4) and take out oil filter *BA18.20-P-
3
element (7) 1001-01D
Unscrew bolt (9) from oil/water heat The coolant lines are not AR18.30-P-
4 detached. They remain on the oil/water 3481GZ
exchanger (3) to oil filter housing (5)
heat exchanger.
*BA18.20-P-
5 Remove screw (8)
1002-01D
Installation: Replace the
6 Remove oil filter housing (5)
sealing ring of the oil filter housing (6).
AR18.00-P-
8 Check engine oil level and correct if required.
3035-01CA
by itself when engine is running. Risk of moving.
AS00.00-Z-
0005-01A
Conduct engine test run and check the engine eliminate cause, otherwise
9 malfunctions, transmission damage, and
for leaks while it is running
serious environmental pollution may
occur.
OIL FILTER
BA18.20-P-1001-01D Screw cap at oil filter Nm 25
BA18.20-P-1002-01D Bolt of oil filter housing to timing case Nm 70
REMOVE/INSTALL OIL FILTER HOUSING - AR18.20-P-3471GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 95: Identifying Oil Filter Housing Remove/Install Components

Remove/install
AR20.00-P-
1142GZC
AH20.00-N-
Notes on coolant
2080-01A
3 Remove oil filter element from oil filter housing (5) To empty the oil
filter housing (5).
*BA18.20-P-
1001-01O
Remove poly-V belt, poly-V belt tensioning device (3) and AR13.20-P-
4
guide pulley (4) 0001GZA
Detach coolant hose (1) from coolant thermostat housing (2) Installation:
5
and place to one side Install new O-ring.
*BA20.10-P-
6 Remove coolant thermostat housing (2)
1003-01U
Installation:
7 Remove bolts (5a) Observe bolt order and
tightening torques:
?
Bolt plan for oil filter AR18.20-P-
housing 3471-01VA
*BA18.20-P-
1002-01O
*BA18.20-P-
1003-01O
8 Remove oil filter housing (5) Catch dripping
engine oil in a pan.
9 Replace seal (5b)
Check
11 Check engine oil level, correct if necessary.
Secure vehicle to
prevent it from starting
Risk of accident caused by vehicle starting off by itself
off by itself.
when engine is running. Risk of injury caused by contusions AS00.00-Z-
Wear closed and snug-
and burns from working on the vehicle as it is being started 0005-01A
fitting work clothes.
or when the engine is running
Do not touch hot or
rotating parts.
12 Conduct engine test run and check the engine for leaks

BA20.10-P-1003-01U Bolt, coolant thermostat housing to timing case cover Nm 25 25
OIL FILTER
272 273
BA18.20-P-1001-
Threaded cap to oil filter housing Nm 25 25
01O
BA18.20-P-1002- Self-tapping screw, oil filter housing to timing case
Nm 20 20
01O cover
BA18.20-P-1003-
Bolt, oil filter housing to crankcase Nm 20 20
01O
REMOVE/INSTALL OIL FILTER HOUSING - AR18.20-P-3471GZS

Fig. 96: Identifying Coolant Thermostat Housing, Oil Filter Housing And Oil Line
Remove/install

Risk of injury to skin and eyes caused by temperature is below 90°C. Open cap
scalding from contact with hot coolant slowly and release the pressure. Do not pour AS20.00-Z-
spray. Risk of poisoning caused by coolant into beverage containers. Wear 0001-01A
swallowing coolant. protective gloves, protective clothing and
safety glasses.
Risk of death caused by vehicle slipping platform and position four support plates at AS00.00-Z-
or toppling off the lifting platform. lifting platform support points specified by 0010-01A
1 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
Do not tilt front engine cover (1) but
2 Remove front engine cover instead lift it off vertically, otherwise
3 Remove intake air duct on left and right

AR20.40-P-
4 Remove electrical fan
5000GZS
AR13.22-P-
5 Remove ribbed V-belt
1202GZS
AR13.25-P-
6 Remove poly-V-belt tensioning device
3200GZS
Dismount top coolant hose from coolant
7 thermostat housing (1) and place it on the Installation: Replace O-ring.
side
Remove oil filter element from oil filter
8
housing (2)
Unhook coolant hose and oil line (3) on oil
9
filter housing (2)
Installation: Pay attention to bolt
10 Remove bolts (4) arrangement and tightening torques, see:
?
AR18.20-P-
Bolt plan for the oil filter housing 3471-
01AMG
*BA18.20-
P-1002-01V
Catch the dripping engine oil in a
11 Remove oil filter housing (2) pan.
Installation: Install new gasket
Check
Using dipstick, check engine oil level
horizontally on the wheels, otherwise false
approx. 5 minutes after switching off the
13 measurements occur.
warm engine, if required adjust to correct
level Insert dipstick fully in the dipstick
guide tube and leave for at least 3 seconds.
14
engine for leaks
TIGHTENING TORQUE SPECIFICATIONS

M8 x 35 Nm 20
BA18.20-P-1002-01V Bolt, oil filter housing to timing case cover M8 x 80 Nm 20
M8 x 100 Nm 20
REMOVE/INSTALL ENGINE OIL COOLER - AR18.30-P-1000GZS

ENGINES 156 in MODEL 164, 251
Shown on model 164
Fig. 97: Identifying Engine Oil Cooler Remove/Install Components

MODIFICATION NOTES
3.3.06 Nut connecting bracket to retaining frame Engine 156.980/983 *BA18.30-P-1007-01B
Bolt connecting oil line to oil cooler flange *BA18.30-P-1016-01B
Remove/install
or sliding roof
vehicle lift and position four
manufacturer.
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR00.60-P-
2 Raise vehicle with vehicle lift Model 164
1000GZ
AR00.60-P-
Model 251
1000RT
Installation: Only install

3 Remove lower engine compartment paneling lower engine compartment
paneling after the leak test.
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR88.20-P-
4 Remove front bumper Model 164
2000GZ
AR88.20-P-
Model 251
2000RT
*BA18.30-
5 Remove bolt (3)
P-1016-01B
6 Disconnect oil lines (4) from oil cooler (1) Collect engine oil in
reservoir.
Screw down nut (5) and take out right bracket Secure oil cooler (1)
7
(6). against falling down.
*BA18.30-
P-1007-01B
Pull oil cooler (1) with air duct housing (2)
8
out of left bracket
Unclip bottom locks (7), fold up top locks (8) When exchanging the oil
9
and remove oil cooler (1) cooler (1).
Checking
Check for wear and
Check rubber mount in left and right bracket
10 correct seating, if required: ?
(6)
Install new rubber bushing
*BR00.45-
Lubricant paste
Z-1002-06A
12 Check engine oil level and adjust correctly See: ?
AP18.00-P-
0101GZ
AS00.00-Z-
0005-01A
13
leaks while it is running
OIL COOLING SYSTEM


BA18.30-P-1007-01B Nut connecting bracket to retaining frame Nm 9
BA18.30-P-1016-01B Oil line flange bolt to oil cooler Nm 9

REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricant paste A 000 989 01 60
REMOVE, INSTALL OIL TEMPERATURE REGULATOR - AR18.30-P-3000AMG
ENGINE 156
Fig. 99: Identifying Oil Temperature Regulator Remove/Install Components

Remove/install

vehicle slipping or the columns of the lifting
toppling off of the lifting platform and position the
platform. four support plates at the
lifting platform support
points specified by the
1 Remove timing case cover AR01.40-P-8000AMG
2 Remove bolts (1)
3 Take off cover (3) The temperature
regulator (2) is installed
under pre-tension in the
crankcase.
4 Remove temperature Installation:
regulator (2). Replace sealing ring at
cover (3).
REMOVE/INSTALL OIL/WATER HEAT EXCHANGER AT OIL FILTER - AR18.30-P-3481GZ

Fig. 100: Identifying Oil/Water Heat Exchanger Remove/Install Components

Remove/Install
or aligning hoods, doors, trunk lid/rear-end within the operating range of 0011-01A
AR88.40-P-
1000GZ
AR09.10-P-
1150GZ
*BA18.20-
3 Unscrew the cap (3) of the oil filter housing (2) Screw cap at oil filter P-1001-01D
Socket wrench bit Fig. 21
Risk of injury to skin and eyes caused by Open cap slowly and release the
AS20.00-Z-
scalding from contact with hot coolant spray. pressure. Do not pour coolant into
0001-01A
Risk of poisoning from swallowing coolant. beverage bottles.
clothing and eye protection.
AR20.00-P-
4 Drain the coolant from radiator
1142GZ
AH20.00-N-
2080-01A
BB00.40-P-
Coolant specifications Sheet 310.1 0310-01A

BB00.40-P-
0325-00A
Dismount coolant line (4, 5) from oil-water
5
heat exchanger (6)
6 Remove screw (1) Oil-water heat exchanger to oil *BA18.30-
filter housing P-1001-01B
Dismount oil-water heat exchanger (6) from oil sealing rings (7) for oil filter
7
filter housing (2) housing (2) and for oil-water heat
exchanger (6).
AR20.00-P-
1010GZ
by itself when engine is running. Risk of moving.
AS00.00-Z-
0005-01A
In the event of oil loss
determine and eliminate cause,
Conduct engine test run and check the engine otherwise malfunctions,
10
environmental pollution may
occur.
OIL FILTER
OIL COOLING SYSTEM

113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/97
Oil-water
heat
BA18.30-
exchanger
P-1001- Nm 11
to oil
01B
filter
housing
Fig. 101: Identifying Socket (103 589 02 09 00)

REMOVE/INSTALL OIL-WATER HEAT EXCHANGER AT OIL FILTER - AR18.30-P-3481GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 102: Identifying Oil/Water Heat Exchanger Remove/Install Components

Remove/install
AR20.00-P-
1142GZC
AH20.00-N-
Notes on coolant
2080-01A
Remove front engine cover (2) and left engine air intake duct
2
(1)
AR46.25-P-
3 Detach power steering expansion reservoir (3) from front cover Model 164
1000GZA
AR46.25-P-
Model 251
1000RT
*BA18.30-P-
4 Remove bolts (4a)
1001-01G
Remove oil-water heat exchanger (4) from oil filter housing Installation:
5
(5) Replace seal (4b).
Check
7 Check engine oil level, correct if necessary.
Secure vehicle to
prevent it from starting
Risk of accident caused by vehicle starting off by itself when
off by itself.
engine is running. Risk of injury caused by contusions and AS00.00-Z-
Wear closed and snug-
burns from working on the vehicle as it is being started or 0005-01A
fitting work clothes.
when the engine is running
Do not touch hot or
rotating parts.
8 Conduct engine test run and check the engine for leaks
OIL COOLING
BA18.30-P-1001-01G Bolt, oil-water heat exchanger to oil filter housing Nm 12 12
REMOVE/INSTALL OIL DIPSTICK GUIDE TUBE - AR18.40-P-3510GZ
Fig. 103: Identifying Oil Dipstick Guide Tube Remove/Install Components

Remove/install
Risk of injury to skin and eyes caused by Wear safety gloves, protective clothing AS00.00-Z-
installing or aligning hoods, doors, trunk lids, moving parts. 0011-01A
tailgates or sliding roof
1
position 1000GZ
manufacturer.
AR00.60-P-
1000GZ
AR01.10-P-
3 Remove engine cover (5) at front
2405GZ
Pull oil dipstick out of oil dipstick guide tube
4
(1)
5 Remove bolts (4) and take out shield (3)
*BA01.20-
6 Remove bolt (2)
P-1001-01E
7 Detach lower engine compartment paneling compartment paneling only after engine 1105GZ
test run.
Installation: Introduce oil
dipstick guide tube (1) into oil pan from
below.
8 Remove oil dipstick guide tube (1) up and out Installation: Replace sealing
ring (6) of oil dipstick guide tube (1).
When fitting the oil dipstick guide tube
(1), ensure the sealing ring (6) is not
pressed into the oil pan.
AS00.00-Z-
0005-01A
Check engine oil level approx. 5
Carry out an engine test run and check engine minutes after switching off warm
10
for leaks engine, adjust to correct level if
required.
CRANKCASE VENTILATION, CYLINDER HEAD COVER

BA01.20-P-1001-01E Cylinder head cover bolt Nm 9
REMOVE/INSTALL OIL DIPSTICK GUIDE TUBE - AR18.40-P-3510GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 104: Identifying Oil Dipstick Guide Tube Remove/Install Components

MODIFICATION NOTES
19.1.06 Engine oil Engine 272.967/981 *BF18.00-P-1001-01M
Remove/install
by itself when engine is running. Risk of injury starting off by itself.
AS00.00-Z-
caused by contusions and burns from working on Wear closed and snug-fitting work
0005-01A
the vehicle as it is being started or when the clothes.
engine is running Do not touch hot or rotating parts.
AH00.00-N-
0001-01A
Risk of explosion caused by oxyhydrogen gas. smoking. AS54.10-Z-
Risk of poisoning and caustic burns caused by Wear acid-resistant gloves, clothing 0001-01A
swallowing battery acid. Risk of injury caused and glasses. Only pour battery acid
by burns to skin and eyes from battery acid or into suitable and appropriately marked
when handling damaged lead-acid batteries containers.

AR54.10-P-
1 Disconnect ground line of battery Model 164
0003GZ
Model 251
Insulate ground line clamp as a
protection against unintentional
contact of ground line with ground
point of battery.
Vehicles with Keyless Go, AR54.10-P-
code 889: Press Keyless Go start/stop 0003RT
switched off.
Remove the Keyless Go transmitter
AH54.10-P-
Notes on battery
0001-01A
Remove front engine cover (2) and right engine
2
air intake duct (1)
AR09.10-P-
3 Remove air filter housing Only for model 251 without 4MATIC
1150GZA
Remove coolant expansion reservoir and place AR20.30-P-
4 Only for model 251 without 4MATIC
to one side with lines still attached 4950RT
*BA01.45-
5 Remove bolt (4)
P-1006-01M
6 Drain engine oil, collect if necessary
ring.
*BA01.45-
P-1001-01M
*BF18.00-
Engine oil P-1001-01M
Only for model 164 with engine 272
7 Remove alternator and for model 251 with engine 272
and 4MATIC
AR15.40-P-
Model 164
5032GZA
AR15.40-P-
Model 251
5032RTA
8 Remove oil dipstick
Remove oil cooling lines from bracket on engine
9 Only for model 251 without 4MATIC
oil pan
*BA27.55-
P-1005-01D
Remove electrical wiring harness retaining
10 clamp (3) from oil dipstick guide tube (5) Only for vehicles with 4MATIC
*BA01.45-
11 Remove retaining plate (8) bolt
P-1006-01M
ring (7) on oil dipstick guide tube (5).
12 Remove oil dipstick guide tube (5) to the top When installing oil dipstick guide tube
(5), make sure sealing ring (7) is not
pressed into the oil pan.
Check engine oil level approx. 5 minutes after The vehicle must be on a level
14 switching off engine (after reaching operating surface, otherwise false measurements
temperature), if required adjust to correct level will occur.
15
engine for leaks
Faults which may have been
caused by disconnecting wires or by a
16 Read out fault memory and erase if necessary simulation must be erased in the fault
OIL PAN
BA01.45-P-1001-01M Oil drain screw to oil pan Nm 30 30
BA01.45-P-1006-01M Mounting bolt, oil dipstick guide tube Nm 9 9

BA27.55-P-1005-01D Bolt, oil cooling line double clamp to bracket Nm 8
ENGINE LUBRICATION
272 273.922/923/924/960/961/962/963/965/967/968
Filling capacity
Liters - -
without oil filter
Filling capacity
Liters 8,0 8.5
with oil filter
BF18.00- BB00.40-
Engine Sheet P-0229- BB00.40-P-0229-01A
P-1001-
oil 01A
01M Specifications
for Operating BB00.40-
Fluids Sheet P-0229- BB00.40-P-0229-03A
03A
BB00.40-
P-0229-
Sheet BB00.40-P-0229-05A
05A
REMOVE/INSTALL OIL DIPSTICK GUIDE TUBE - AR18.40-P-3510GZS
Fig. 105: Identifying Oil Dipstick Guide Tube, Dipstick And Sealing Ring
Remove/install

necessary.
manufacturer.
smoking.
Wear acid-resistant gloves, clothing AS54.10-Z-
and glasses. Only pour battery acid 0001-01A
into suitable and appropriately
marked containers.
Insulate ground line clamp as a

contact of dismounted ground line

with ground point of battery.
code 889: Switch off engine, remove
Keyless Go cards out of vehicle and
store outside of the transmitter range.
AR54.10-P-
Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
0001-01A
Keep body parts and limbs well clear AS00.00-Z-
of moving parts. 0011-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR62.30-P-
3 Remove partition wall between wheelhouses Model 251 only
2400RT
AR09.10-P-
1150GZS
AR62.30-P-
2300GZ
AR62.30-P-
Model 251
2300RT
Pull oil dipstick (2) out of oil dipstick guide tube
6
(1)
Remove engine intake air
7 Mount engine hoist
duct
AR33.10-P-
Model 164
0100-01GZ
AR33.10-P-
Model 251
0100-01RT
Engine supporting frame basic *WE58.40-
frame side piece (M/S-class) Z-1027-11A
Model 251: ?
Engine lifting device side adapter *WH58.30-
for model 251 Z-1019-07A
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
Installation: Only install

9 Detach lower engine compartment paneling engine compartment paneling after
engine test run.
AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
AR22.10-P-
10 Loosen both engine mounts from below
1260GZS
Pay attention when lifting
out engine that no cables and lines
11 Raise engine with engine lifting device
are damaged and that engine does
not lean against the partition wall.
12 Remove screw (3)
sealing ring (4) for dipstick guide
13 Remove oil dipstick guide tube (1) up and out tube (1). When fitting oil dipstick
guide tube (1), ensure sealing ring
(4) is not pressed into oil pan.
AR00.19-P-
0200GZ
AR00.19-P-
Model 251
0200RT
16 horizontally on the wheels, otherwise
necessary
AS00.00-Z-
0005-01A
Check engine oil level
Perform engine test run and check leaktightness approx. 5 minutes after switching off
17
of oil dipstick guide tube warm engine, adjust to correct level
if required

Number Designation
07A unlingen
WORKSHOP EQUIPMENT
REMOVE/INSTALL SENSOR FOR ENGINE OIL TEMPERATURE - AR18.40-P-4123AMG
ENGINE 156
Fig. 106: Identifying Sensor For Engine Oil Temperature Remove/Install Components
Remove/install
Risk of injury to skin or Depressurize the AS00.00-Z-0013-01A
eyes caused by hydraulic hydraulic system
fluid spraying out under completely before
high pressure. Risk of starting any work on the
poisoning caused by system. Wear protective
swallowing hydraulic clothing and safety
fluid. glasses.
1 Open engine hood and Model 216, 221
raise to vertical position
Model 164 AR88.40-P-1000GZ

Model 209 AR88.40-P-1000Q
Model 211 AR88.40-P-1000T
Model 219 AR88.40-P-1000TX
Model 251 AR88.40-P-1000RT
2 Remove right and left
intake air duct
3 Remove front engine Do not tilt front
cover engine cover, but lift
upwards vertically
otherwise the retaining
lugs can break off.
4 Remove poly-V belt Model 164, 251 AR13.22-P-1202GZS
Models 209, 211, 219 AR13.22-P-1202TMG
Model 216, 221 AR13.22-P-1202SMG
5 Raise vehicle with lifting Model 164 AR00.60-P-1000GZ
platform
Model 209 AR00.60-P-1000P
Model 211 AR00.60-P-1000T
Model 219 AR00.60-P-1000TX
Model 216, 221 AR00.60-P-1000SX
Model 251 AR00.60-P-1000RT
6 Remove lower engine Installation:
compartment paneling Install engine
only after engine test run.
Model 164 AR61.20-P-1105GZ
Model 209 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 219 AR61.20-P-1105TX
Model 216, 221 AR61.20-P-1105SX
Model 251 AR61.20-P-1105RT
7 Remove bolt (1) and take Except for model 216,
off double clamp (2) on 221
engine oil lines
8 Detach refrigerant Place refrigerant
compressor (A9) compressor (A9) with
connected lines to the
side.
Model 164 AR83.55-P-5300GZ
Models 209, 211, 219 AR83.55-P-5300TMG
Model 216, 221 AR83.55-P-5300SMG
Model 251 AR83.55-P-5300RT
9 Disconnect electrical
connector (3) from oil
temperature sensor (B1)
10 Remove oil temperature Installation:
sensor (B1) Replace sealing ring.
*BA15.60-P-1001-01C
Checking
procedure or when
as it is running
12 Check for leaks with
engine running
TEMPERATURE SENSOR
BA15.60-P-1001-01C Oil temperature Nm 21
crankcase
REMOVE/INSTALL OIL SENSOR - AR18.40-P-5112GZ

Fig. 107: Identifying Oil Sensor And Electrical Connector

Remove/Install
AR88.40-P-
1 Open engine hood
1000GZ
Risk of death cased by vehicle slipping or AS00.00-Z-
manufacturer.
AR00.60-P-
2 Raise vehicle.
1000GZ
3 compartment paneling only after the 1105GZ
paneling
engine test run.
4 Drain engine oil
ring of oil drain plug, see: ?
AP18.00-P-
0101GZ
*BA01.45-
P-1003-01B
*BF18.00-P-
1001-01H
Detach electrical connector (1) from oil

5 sensor (oil level, temperature and quality)
(B40)
Unscrew bolts (2) and take oil sensor (oil Installation: Replace sealing
6 level, temperature and quality) (B40) out of ring of oil sensor (oil level,
oil pan temperature and quality) (B40).
*BA18.40-
P-1005-01B
off by itself when engine is running. Risk moving.
AS00.00-Z-
0005-01A
8
engine for leaks
OIL PAN
BA01.45-P-1003-01B Oil drain screw to oil pan M14 Nm 30

BA18.40-P-1005-01B Oil level sensor tot oil pan bottom section Nm 10
ENGINE LUBRICATION
Filling capacity with oil filter Liters 8.5
Filling capacity without oil filter Liters -
BF18.00-P-1001-01H Engine oil Sheet BB00.40-P-0229-01A
Specifications for Operating Fluids Sheet BB00.40-P-0229-03A
Sheet BB00.40-P-0229-05A
REMOVE/INSTALL OIL LEVEL CHECK SWITCH - AR18.40-P-5113GZS

Fig. 108: Identifying Oil Level Check Switch And Electrical Connector
Remove/install

manufacturer.
or crushed when removing, installing or Keep body parts and limbs well clear AS00.00-Z-
aligning hoods, doors, trunk lids, tailgates or of moving parts. 0011-01A
sliding roof.
AH00.00-N-
0001-01A
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR00.60-P-
1000GZ
AR00.60-P-
Model 251
1000RT
3 Remove bottom engine compartment paneling Installation: Only install

lower engine compartment paneling

AR61.20-P-
Model 164
1105GZ
AR61.20-P-
Model 251
1105RT
*BF18.00-P-
4 Drain engine oil and collect it for recycling Engine oil 1001-01V
Remove the electrical connector (2) at the oil
5
level check switch (S43)
AR01.45-P-
7555GZS
*BA01.45-
7 Remove bolts (3)
P-1004-01R
Remove oil level check switch (S43) from oil Installation: Install new O-
8
pan ring.
Checking
AS00.00-Z-
0005-01A
OIL PAN
BA01.45-P-1004-01R Oil level / oil level switch M6 Nm 8.4
ENGINE LUBRICATION SYSTEM

model 164 model 251
BF18.00-P- Engine oil Filling capacity Liters 9.7 9.6
1001-01V (oil and filter
change)
Specifications Sheet BB00.40-P- BB00.40-P-
for Operating 0229-05A 0229-05A
Fluids
REMOVE/INSTALL THE OIL LEVEL CHECK SWITCH - AR18.40-P-5113SX
ENGINE 272
ENGINE 273
Fig. 109: Identifying Oil Level Check Switch Remove/Install Components

Remove/install
1 Remove oil pan bottom section (2a)
Remove the electrical connector (1) at the oil
2
level check switch (S43)
*BA18.40-P-1001-
3 Remove bolts (3)
02B
Remove oil level check switch (S43) from oil Installation: Install
4
pan new O-ring.
system 1048-13A
Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-
fault memory 04A
OIL SENSOR
BA18.40-P-1001-02B Bolt, oil level check switch to oil pan Nm 14 14

Number Designation

OIL PRESSURE - BE18.00-P-1000-01B
Engine 112, 113, 137, 155, 156, 272, 273

Number Designation Engine 112, Engine
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969
BE18.00- Oil bar > or = 0,7
P-1001- pressure at
01B operating at rpm 700
temperature bar > or = 3,0
at rpm 3000

155 156 272 273
BE18.00-P- Oil pressure at bar > or = 0,7 > or = 0,8 > or = 0,7 > or = 0,7
1001-01B operating at rpm 600 560 700 700
temperature bar > or = 3,5 > or = 4,4 > or = 3,0 > or = 3,0
at rpm 3000 3000 3000 3000
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ENGINE LUBRICATION, ENGINE OIL
COOLING - BE18.00-Z-9999AZ
MODEL all
Oil pressure ENGINE 604, 605, 606, 612.981, 628, BE18.00-P-1000-

629, 646, 647 / 981, 648 01A
Oil pressure ENGINE 112, 113, 137, 155, 156, 272, BE18.00-P-1000-
273... 01B
Oil pressure ENGINES BE18.00-P-1000-
166.940/960/961 /990/991 /995 01C
Oil pressure ENGINES 668.914/940/941/942 BE18.00-P-1000-
01D
Oil pressure ENGINE 275, 285 BE18.00-P-1000-
01G
Oil pressure ENGINE 266.920/940/960/980 BE18.00-P-1000-
01H
Oil pressure ENGINE 640 BE18.00-P-1000-
01I
Oil pressure ENGINE 271 BE18.00-P-1000-
01J
Engine lubrication - ENGINE 103, 104, 111, 119, 120, 166 BE18.00-P-1000-
general 02A
Engine lubrication, ENGINE 601, 602, 603, 604, 605, 606, BE18.00-P-1000-
general 611, 612, 613, 628, 642... 02B
Engine lubrication, ENGINE 112, 113, 155... BE18.00-P-1000-
general 02C
Engine lubrication - ENGINE 668 BE18.00-P-1000-
general 02D
Specified engine oilENGINE 102, 103, 104, 110, 111, 112, BE18.00-P-1000-
quality levels 113, 115, 117, 119, 120, 137, 155, 166, 03A
601, 602, 603, 604, 605, 606, 616, 617...
Oil pressure sensor ENGINE 605, 606 in MODEL 124 BE18.40-P-1000-
01A
Test values for ENGINE 111 BE18.40-P-1000-
dipstick, dipstick 02A
guide tube
Test values for ENGINE 605.96 BE18.40-P-1000-
dipstick, dipstick 02B
guide tube
MAINTENANCE
SUCTION OFF ENGINE OIL - AP18.00-P-0101-02Z
1. Extract engine oil through oil dipstick guide tube.
Extract engine oil only when engine at normal operating temperature.
Fig. 110: Identifying Suction Off Engine Oil - Shown On Engine 104
REPLACE OIL FILTER ELEMENT, DRAIN OIL FILTER - AP18.00-P-0101-06GZ
OIL FILTER

1. Unscrew screw cover (2) using socket and remove with oil filter element (4).
2. Loosen oil filter element (4) by briefly knocking on the center rod of the screw cover (2).
Use a suitable receptacle.
3. Replace compression ring (3).

4. Slide new oil filter element (4) onto center rod of screw cover (2).
5. Tighten screw cover (2) using socket .
Fig. 112: Identifying Oil Filter Element, Compression Ring And Screw Cover
REPLACE OIL FILTER ELEMENT, DRAIN OIL FILTER - AP18.00-P-0101-06GZC
OIL FILTER
BA18.20-P-1001-01O Screw cap to oil filter housing Nm 25

1. Remove front engine cover.

2. Unscrew screw cap (1) using socket and remove.
To catch the dripping oil, use an oil receptacle.
3. Detach oil filter element (2) from screw cap (1)

4. Replace seals (3).
5. Push new oil filter element (2) onto screw cap (1).
6. Screw in screw cap (1) and tighten .
Fig. 114: Identifying Oil Filter Element, Screw Cap And Seals
REPLACE OIL FILTER ELEMENT, DRAIN OIL FILTER - AP18.00-P-0101-06SX
OIL FILTER
BA18.20-P-1001-01O Screw cap to oil filter Nm 25
housing

1. Remove front engine cover (1).

2. Unscrew screw cap (2) using socket and remove.
To catch the dripping oil, use an oil receptacle.
3. Remove oil filter element (3) from screw cap (2).
Fig. 116: Identifying Oil Filter Element, Screw Cap, Front Engine Cover And Sealing Ring
4. Replace seals (4).

5. Push new oil filter element (3) onto screw cap (2).
6. Screw screw cap (2) into oil filter housing and tighten .
7. Mount front engine cover (1) after engine test run and leak tightness test.
ENGINE OIL AND FILTER CHANGE - AP18.00-P-0101GZ
ENGINE 113, 273, 156 in MODEL 164
Shown on ENGINE 156
Fig. 117: Identifying Sealing Ring, Drain Plug, Engine Oil Cooler And Pan
MODIFICATION NOTES
damage through
contamination and
Do not extract engine oil Step 4.1
from engine 156 but only
drain, added
Drain engine oil from Step 6
engine 156 at engine oil
cooler, added
Removal

toppling off of the liftingand position four support
procedure or when
as it is running
Risk of injury to skin Wear safety gloves, AS00.00-Z-0002-01A
and eyes caused by protective clothing and
handling hot or glowing safety glasses, if
objects. necessary.
damage through
contamination and
foreign objects
Only replace engine oil
when the engine is at
operating temperature
1 Start engine Allow engine to
warm up until coolant
and engine oil have
reached operating
temperature.
2 Turn off engine The vehicle must be
horizontal, otherwise the
complete quantity of
engine oil cannot be
sucked out or drained
which may lead to an
incorrect engine oil fill
with consequential
damage.
3 Empty oil filter housing Engine 113 AP18.00-P-0101-06GZ
and replace oil filter
element
Engine 156 AP18.00-P-0101-06TMG
Engine 273 AP18.00-P-0101-06SX
Engine 113 *BA18.20-P-1001-01D
Engine 156 *BA18.20-P-1001-01V

Engine 273 *BA18.20-P-1001-01O
Engine 113, 273:
4.1 Suction off engine oil Engines 113, 273 AP18.00-P-0101-02Z
Engine 156: Do not
extract engine oil, but
only drain by unscrewing
the drain screws (1a, 2a)
otherwise a larger
quantity of engine oil
remains in the engine
which may lead to
consequential damage.
Maintain a waiting
time of at least 5 minutes
after switching off the
engine until the engine oil
has flowed back into the
engine oil pan, otherwise
the complete quantity of
engine oil is not drawn
off. Any quantity of oil
remaining in the engine
will result in an excess
amount of oil being
recorded after filling with
the specified oil change
quantity, which in turn
may result in damage to
the engine and the
catalytic converter.
4.2 Remove bottom engine when draining
compartment paneling the engine oil by
unscrewing the drain
screws (1a, 2a).
Remove/install bottom Model 164 AR61.20-P-1105GZ
engine compartment
paneling
Model 209 AR61.20-P-1105P
Model 251 AR61.20-P-1105RT
5 Unscrew drain screw (2a) when draining
from engine oil pan (2) the engine oil by
and drain engine oil unscrewing the drain
screw (2a).
Only use
pin box wrench for model
164.175 with engine
113.964.
Allow engine oil
to drain for at least 10
minutes.
Oil level check *BF18.00-P-1001-03U
Box wrench Fig. 118
6 Unscrew drain screw (1a) Engine 156
from engine oil cooler (1) Allow engine oil
and drain engine oil to drain for at least 10
minutes.
Install
7 Screw drain screw (2a) Replace seal ring
into engine oil pan (2) (2d).
and tighten
Engine 113 *BA01.45-P-1003-01B
Engine 156 *BA01.45-P-1001-01R
Engine 273 *BA01.45-P-1001-01M
8 Screw drain screw (1a) Engine 156
into engine oil cooler (1)
and tighten
*BA18.30-P-1017-01B
9 Pour in engine oil Use only
approved engine oils.
Specified and approved AH18.00-P-1000-01BA
quality grades and
viscosity classes
conforming to SAE at
enduring low outside
temperatures
Notes concerning AH18.00-P-0102-01A
extension of the oil
change interval
Engine 113 *BF18.00-P-1001-01H
Engine 156 *BF18.00-P-1001-01V
Engine 273 *BF18.00-P-1001-01M
Service Information: * Not for USA, Japan SI18.00-P-0011A
Engine oil change
Specified engine oils BB00.40-P-0223-02A

(service) - survey
Approved engine oils BB00.40-P-0226A
(service)
10 Conduct engine test run In order to avoid
and check the engine for engine damage, only raise
leaks the engine speed for 10
seconds after starting the
engine (maximum 3000
rpm)
11 Switch off engine and after draining the
install lower engine engine oil by unscrewing
compartment paneling drain screw (2a).
Remove/install bottom Model 164 AR61.20-P-1105GZ
engine compartment
paneling
Model 209 AR61.20-P-1105P
Model 251 AR61.20-P-1105RT
12.1 Check the engine oil level The vehicle must be
with the engine oil on a level surface,
dipstick approx. 5 otherwise false
minutes after switching measurements will occur.
off the engine which is at Insert engine oil
operating temperature, dipstick up to the stop
correct if necessary and keep a residence time
for at least 3 seconds.
Model 164 with AR18.00-P-3035-01GZ
engine 113
Use oil dipstick.
Dipstick marking *BE18.00-P-1001-02C
Oil dipstick Fig. 19
12.2 Check engine oil level via Model 164 with engine
the control system 113
approx. 5 minutes after The vehicle must be
switching off the engine positioned horizontally
which is at operating on the wheels, otherwise
temperature, correct if false measurements
necessary occur:?
See: Perform adjustments AR54.30-P-1000-
on control system. 02GZC
13 Reset service indicator Model 209 AP00.20-P-0042PIT
Model 164 AP00.20-P-0042GZ
Model 251 AP00.20-P-0042RT
Notes concerning AH18.00-P-0102-01A
extension of the oil

change interval
Service Information: * Not for USA, Japan SI18.00-P-0011A
Engine oil change
TEST VALUES FOR ENGINE LUBRICATION - GENERAL

Engine 113.944/964/980/
Number Designation 981/984/986/ 991
BE18.00-P-1001-02C Oil dipstick marking Number on grip 11304
OIL COOLING SYSTEM

BA18.30-P-1017-01B Drain plug to oil cooler Nm 30
OIL PAN
BA01.45-P-1003- Oil drain screw to M14 Nm 30
01B oil pan
OIL PAN
BA01.45-P-1001-01R Oil drain screw to oil pan Nm 30
OIL PAN
BA01.45-P-1001-01M Oil drain screw to oil pan Nm 30
OIL FILTER
Number Designation Engine 113.964/ 971
OIL FILTER
BA18.20-P-1001-01V Threaded cap to oil filter Nm 25
housing
OIL FILTER
BA18.20-P-1001-01O Threaded cap to oil filter Nm 25
housing
OIL LEVEL CHECK


BF18.00-P-1001- Oil level Maximum mm 127
03U Minimum mm 101
BF18.00-P-1002- Dipstick indication 88 mm Replenish oil +2,9
03U 88 mm to 124 mm quantity in liters
(oil level too low) 90 mm Replenish oil +2.8
quantity in liters
92 mm Replenish oil +2,6
quantity in liters
94 mm Replenish oil +2.5
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
quantity in liters
BF18.00-P-1003- Oil dipstick 126 mm Oil quantity in liters 0.0
03U indication 126 mm 127 mm Oil quantity in liters 0.0
to 128 mm (oil level
correct) 128 mm Oil quantity in liters 0.0

BF18.00-P-1004- Oil dipstick 130 mm Extract oil quantity -0,3
03U indication 130 mm in liters
to 138 mm (oil level 132 mm Extract oil quantity -0.5
too high) in liters
134 mm Extract oil quantity -0.7
in liters
136 mm Extract oil quantity -0.9
in liters
138 mm Extract oil quantity -1,1
in liters
ENGINE LUBRICATION
Engine
Number Designation 113.964/971
BF18.00-P-1001- Engine oil Filling capacity with Liters 8.5
01H oil filter
Filling capacity Liters -
without oil filter
Specifications for Sheet BB00.40-P-0229-
Sheet BB00.40-P-0229-
03A
Sheet BB00.40-P-0229-
05A

Engine 156
Engine 156 in model 209, Engine 156
Number Designation in model 164 211, 219 in model 251
BF18.00-P- Engine oil Filling capacity (oil Liters 9,7 8,8 9,6
1001-01V and filter change)
ENGINE LUBRICATION
Engine 273.922/923/92
4/960/961/962/
Number Designation 963/965/967/ 968
BF18.00-P-1001- Engine oil Filling capacity Liters -
01M without oil filter
Filling capacity with Liters 8.5
oil filter
Specifications for Sheet BB00.40-P-0229-01A

service products Sheet BB00.40-P-0229-03A
Sheet BB00.40-P-0229-05A
Fig. 118: Identifying Box Wrench (117 589 02 07 00)



ENGINE OIL AND FILTER CHANGE - AP18.00-P-0101GZC
MODIFICATION NOTES
19.1.06 Engine oil Engine 272.967/981 *BF18.00-P-1001-01M
Removal
Risk of death caused by vehicle slipping Align vehicle between the columns of AS00.00-Z-
or toppling off of the lifting platform. the lifting platform and position the 0010-01A

necessary.
AS00.00-Z-
0005-01A
Only replace engine oil when the engine is
at operating temperature
Open engine hood and raise to vertical
1
position
AP18.00-P-
2 Drain oil filter, replace oil filter element 0101-
06GZC
*BA18.20-
P-1001-01O
Socket Fig. 21
Only required, if the engine
3.1 Suction off engine oil oil is not drained by unscrewing the AP18.00-P-
oil drain screw. 0101-02Z
Engine oil extractor
Only necessary if engine oil is
3.2 Raise vehicle with lifting platform
drained by unscrewing oil drain screw.
AR00.60-P-
1000GZ
Remove rear part of the lower engine Only necessary if engine oil is
4.1
compartment paneling drained by unscrewing oil drain screw.
Detach/attach lower engine compartment AR61.20-P-
paneling 1105GZ
Unscrew oil drain screw and drain engine Only necessary if engine oil is
5.1
oil drained by unscrewing oil drain screw.
Install
Only necessary after draining
engine oil by unscrewing oil drain
6.1 Screw in oil drain screw screw.
ring.
*BA01.45-
P-1001-01M
7 Lower vehicle
8 Pour in engine oil Use only approved engine
oils
Specified and approved quality grades and
AH18.00-P-
viscosity classes conforming to SAE at All engines
1000-01BA
enduring low outside temperatures
Notes concerning extension of the oil AH18.00-P-
change interval 0102-01A
*BF18.00-P-
1001-01M
SI18.00-P-
Service Information: Engine oil change * Not for USA, Japan
0011A
BB00.40-P-
Specified engine oils (service) - survey
0223-02A
BB00.40-P-
Approved engine oils (service) Passenger cars engines
0226A
10 Turn off engine
Only necessary if the engine
Attach rear part of the lower engine
11.1 oil has been drained by unscrewing
the oil drain screw.
Detach/attach lower engine compartment AR61.20-P-
paneling 1105GZ
Using the dipstick, check engine oil level horizontally on the wheels, otherwise
approx. 5 minutes after switching off the false measurements occur.
12
warm engine, if required adjust to correct Insert dipstick fully in the
level dipstick guide tube and leave for at
least 3 seconds.
Measuring rod Fig. 19
AP00.20-P-
13 Reset service indicator
0042GZ
Notes concerning extension of the oil AH18.00-P-
change interval 0102-01A
SI18.00-P-
Service Information: Engine oil change * Not for USA, Japan
0011A
OIL FILTER
BA18.20-P-1001-01O Screw cap to oil filter housing Nm 25
OIL PAN
ENGINE LUBRICATION
Filling capacity without oil filter Liters -
Filling capacity with oil filter Liters 8.0
BF18.00-P-1001-01M Engine oil Sheet BB00.40-P-0229-01A
Specifications for Operating Fluids Sheet BB00.40-P-0229-03A
Sheet BB00.40-P-0229-05A


REMOVAL & INSTALLATION

DETERMINE OIL CONSUMPTION - SM18.00-P-0002-01A
Test sheet for excessive OF18.00-P-3000-03A

oil consumption, form
OIL PAN

Weigh engine oil (after consumption measuring drive):
The customer visits the workshop due to an oil level warning message.
1. Weigh empty oil container ("TARE").

2. Put vehicle on lifting platform when oil temperature is 90°C.
The waiting time of 15 min begins when the engine is switched off.
3. Open oil filler cap and pull oil filter.

4. Remove under-ride guard and open oil drain screw.
5. Drain engine oil into oil container and tighten oil drain screw again.
Observe the waiting time of 15 min (see operation step 2).
6. Place filled oil container on scales and weigh.

7. Determine oil consumption in the way described on test sheet.
PREPARE OIL CONSUMPTION MEASURING DRIVE - SM18.00-P-0002A
ENGINE 272.### ## up to 053879 in MODEL 164
1 Provide scales (with Fig. 17

accuracy of 5 g), oil
container (10 l), stop
watch and remote
thermometer
Checking

procedure or when
as it is running
Risk of injury to skin Wear safety gloves, AS00.00-Z-0002-01A
and eyes caused by protective clothing and
handling hot or glowing safety glasses, if
objects. necessary.
2 Weigh empty oil
container ("TARE")
3 After conditioning, place The waiting time
vehicle on lifting of 15 min (see operation
platform when oil step 6) begins after the
temperature is 90°C engine is switched off.
4 Open oil filler cap and
pull oil filter
5 Remove under-ride guard
and open oil drain screw
6 Drain engine oil into oil Observe the
container and tighten oil waiting time of 15 min
drain screw again. (see operation step 3).
*BA01.45-P-1001-01M
7 Place filled oil container
on scales and weigh
8 Top up oil container with
oil to 6.8 kg and pour into
engine.
9 Install oil filter and fit oil
filler cap
10 Document weight of oil Have the OF18.00-P-3000-03A
poured into engine and customer perform the oil
mileage of vehicle consumption measuring
drive.
OIL PAN

CAPACITIES & SPECIFICATIONS

FILLING CAPACITIES, ENGINE LUBRICATION SYSTEM - BF18.00-P-1000-01H
Engines 112, 113
MODIFICATION NOTES
20.12.04 Engine oil filling capacity Engine 113.967
with oil filter modified.
ENGINE LUBRICATION
Number Designation Engine 112 except Engine Engine
112.916/953/975 112.916/953 112.975
BF18.00-P- Engine oil Filling capacity Liters 8.0 7.5 8.0
1001-01H with oil filter
Filling capacity Liters 7.5 7.0 7.5
without oil filter
Specifications for Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
Operating Fluids 01A 0229-01A 0229-01A
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
03A 0229-03A 0229-03A
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
05A 0229-05A 0229-05A
ENGINE LUBRICATION
113.948/966 113.940/941/942/943/960/961/962/969/982 113.944/980/981
BF18.00- Engine Filling Liters 8.0 8.0 7.5
P-1001- oil capacity with
01H oil filter
Filling Liters 7.5 - -
capacity
without oil
filter
Specifications Sheet BB00.40-P- BB00.40-P-0229-01A -
Fluids Sheet BB00.40-P- BB00.40-P-0229-03A -
0229-03A
Sheet BB00.40-P- BB00.40-P-0229-05A BB00.40-P-0229
0229-05A
ENGINE LUBRICATION
113.963/963/965 113.964/971 113.967
BF18.00-P- Engine oil Filling capacity Liters 7.5 8.5 7.5
Filling capacity Liters 7.0 - -
without oil filter
Specifications for Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
Operating Fluids 01A 0229-01A 0229-01A
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
03A 0229-03A 0229-03A
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
05A 0229-05A 0229-05A
ENGINE LUBRICATION
Number Designation Engines Engine
113.987/988/990/992/993/995 113.989
BF18.00-P- Engine oil Filling capacity Liters 8.5 8.0
Filling capacity Liters 8.0 7.5
without oil filter
Specifications Sheet - -
for Operating Sheet - -
Fluids Sheet BB00.40-P-0229-05A BB00.40-P-
0229-05A
FILLING CAPACITIES, ENGINE LUBRICATION SYSTEM - BF18.00-P-1000-01M
Engine 272, 273
MODIFICATION NOTES
1.2.06 Engine oil Engine 272.941/970
ENGINE LUBRICATION
Number Designation Engine 272 Engine

273.922/923/92
4/960/961/962/
963/965/967/ 968
BF18.00-P- Engine oil Filling capacity Liters - -
1001-01M without oil filter
Filling capacity Liters 8.0 8.5
with oil filter
Specifications for Sheet BB00.40-P- BB00.40-P-0229-01A
Operating Fluids 0229-01A
Sheet BB00.40-P- BB00.40-P-0229-03A
0229-03A
Sheet BB00.40-P- BB00.40-P-0229-05A
0229-05A
CAPACITIES: PASSENGER CARS: ENGINE LUBRICATION, ENGINE OIL COOLING - BF18.00-Z-

9999AZ
MODEL all
Filling ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 642, 646, 647, 648... BF18.0
capacities, P-1000-
engine 01A
lubrication
system
Filling ENGINE 103, 104, 119, 120 BF18.0
capacities, P-1000-
engine 01B
lubrication
system
Filling ENGINE 112, 113... BF18.0
capacities, P-1000-
engine 01H
lubrication
system
Filling ENGINE 166 BF18.0
capacities, P-1000-
engine 01I
lubrication
system
capacities, P-1000-
engine 01J
lubrication
system
Filling ENGINE 137.970, 275.950/951 /953/954/980 /981 /982, 285.950/980 BF18.0

capacities, P-1000-
engine 01K
lubrication
system
Filling ENGINE 111, 271 BF18.0
capacities, P-1000-
engine 01L
lubrication
system
Filling ENGINE 272, 273 BF18.0
capacities, P-1000-
engine 01M
lubrication
system
Filling ENGINE 155.980 BF18.0
capacities, P-1000-
engine 01O
lubrication
system
capacities, P-1000-
engine 01Q
lubrication
system
Filling ENGINE 640 without particle filter BF18.0
capacities, P-1000-
engine 01R
lubrication
system
Filling ENGINE 640, 642, 646, 647, 648... BF18.0
capacities, P-1000-
engine 01S
lubrication
system
Filling ENGINE 629 in MODEL 164 ENGINE 629 in MODEL 211, 221 BF18.0
capacities, P-1000-
engine 01U
lubrication
system
Filling ENGINE 156 in MODEL 164, 209, 211, 216, 219, 221, 251 BF18.0
capacities, P-1000-
engine 01V
lubrication
system
Filling ENGINE 628.960/961/962/963 BF18.0
capacities, P-1000-
engine 01W
lubrication
system
Oil ENGINE BF18.0
consumption 111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977 P-1000-
measurement 02A
Oil ENGINE 112 BF18.0
consumption P-1000-
measurement 02B
Oil ENGINE 604.910/912/915/917 BF18.0
consumption P-1000-
measurement 02C
Oil ENGINE 605.910/911/912/960/962 BF18.0
consumption P-1000-
measurement 02D
Oil ENGINE 606.961 /962/964 BF18.0
consumption P-1000-
measurement 02E
Oil ENGINE 602.982/983 BF18.0
consumption P-1000-
measurement 02F
Oil ENGINE 120 BF18.0
consumption P-1000-
measurement 02G
Oil ENGINE 611.960 BF18.0
consumption P-1000-
measurement 02I
Oil level ENGINE 137.970 BF18.0
inspection P-1000-
03A
Oil level ENGINE 612.961 in MODEL 210 BF18.0
check P-1000-
03AA
check P-1000-
03AB
Oil level ENGINE 112... BF18.0
check P-1000-
03B
check P-1000-
03BA
Oil level ENGINE 112.917/954 in MODEL 211 4-Matic BF18.0
check ENGINE 112.975 in MODEL 220 4-Matic P-1000-
03BM
check P-1000-
03C
Oil level ENGINE 113.991 in MODEL 215, 220 BF18.0
check P-1000-
03DA
Oil level ENGINE 113.941 /960 in MODEL 220 ENGINE 113.960 in MODEL 215 BF18.0
check P-1000-
03DB
check P-1000-
03DC
check P-1000-
03DD
check P-1000-
03G
Oil level ENGINE 112.921/941 in MODEL 210 4-MATIC BF18.0
check P-1000-
03GM
Oil level ENGINE 113.940 in MODEL 210.08/28 4-MATIC BF18.0
check P-1000-
03GN
Oil level ENGINE 113.990 in MODEL 211,219 ENGINE 113.992/995 in MODEL 230 BF18.0
check P-1000-
03I
Oil level ENGINE 113.987 in MODEL 209 ENGINE 113.988 in MODEL 203 BF18.0
check P-1000-
03IA
check P-1000-
03IB
check P-1000-
03IC
Oil level ENGINE 113.986 in MODEL 215, 220 BF18.0
check P-1000-
03IE
Oil level ENGINE 113.969 in MODEL 211 4-MATIC BF18.0
check ENGINE 113.948 /966 in MODEL 220 4-MATIC P-1000-
03J
Oil level ENGINE 112.916 /953 in MODEL 203 4-MATIC BF18.0
check P-1000-
03K
Oil level ENGINE 646.951 /962 BF18.0
check P-1000-
03L
check P-1000-
03LA
check P-1000-
03LB
Oil level ENGINE 271 in MODEL 171, 203, 209, 211 BF18.0
check P-1000-
03M
check P-1000-
03O
Oil level ENGINE 646.961 /963/966 BF18.0
check P-1000-
03OA
check P-1000-
03P
check P-1000-
03PA
check P-1000-
03PB
check P-1000-
03PC
Oil level ENGINE 612.962 ## as of 134164 up to 150687 in MODEL 203.016/216 BF18.0
check P-1000-
03PD
Oil level ENGINE 648 in MODEL 220 BF18.0
check P-1000-
03Q
check P-1000-
03R
check P-1000-
03S
check P-1000-
03T
check P-1000-
03TA
check P-1000-
03TB
check P-1000-
03TC
Oil level ENGINE 113.964 in MODEL 164 ENGINE 113.971 in MODEL 251 BF18.0
check P-1000-
03U
ENGINE LUBRICATION, ENGINE OIL COOLING, GENERAL - BA18.00-P-1000-01D
Engine 112, 113, 155, 271, 272, 273

Number Designation Engine 112 except
112.951/976,113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967
BA18.00- Bolt, oil- Nm 15
P-1001- spray
01D nozzle at
crankcase

Number Designation Engines 113.987/988/990/991/993 Engine 113.989
BA18.00-P- Bolt, oil-spray Nm 13 13
1001-01D nozzle at
crankcase

BA18.00-P- Bolt, oil-spray Nm - 8 8
1001-01D nozzle at
crankcase

BA18.00-P-1001-01D Bolt, oil-spray nozzle at Nm 20
crankcase
ENGINE LUBRICATION, ENGINE OIL COOLING, GENERAL - BA18.00-P-1000-01G
Engine 156

BA18.00-P-1001-01G Oil spray nozzle fitted Nm 13
bolt on crankcase
TIGHTENING TORQUES: PASSENGER CARS: ENGINE LUBRICATION, ENGINE OIL COOLING

- BA18.00-Z-9999AZ
MODEL all
Engine lubrication, ENGINE 604, 605, 606/ BA18.00-P-1000-

engine oil cooling - 01A
general
Engine lubrication, ENGINE 601, 602/, 603/ BA18.00-P-1000-
engine oil cooling - 01B
general
Engine lubrication, ENGINE 104/ BA18.00-P-1000-
engine oil cooling - 01C
general
Engine lubrication, ENGINE 112, 113, 155, 271, 272, 273... BA18.00-P-1000-
engine oil cooling, 01D
general
Engine lubrication, ENGINE 668.914/940/941/942 BA18.00-P-1000-
engine oil cooling 01E
general
Engine lubrication, ENGINE 266.920/940/960/980 BA18.00-P-1000-
engine oil cooling, 01F
general
Engine lubrication, ENGINE 156 BA18.00-P-1000-
engine oil cooling, 01G
general
Engine lubrication, ENGINE 646.8 in MODEL BA18.00-P-1000-
engine oil cooling, 211.007 /008 /208 /608 01H
general
Oil pump ENGINE 111, 601 /943, BA18.10-N-1000-
602.980 /982 /983 /984 /985 01A
Oil pump ENGINE 103, 104, 111, 119, 120, 601, BA18.10-P-1000-
602, 603, 604, 605, 606, 628... 01A
Oil pump ENGINE 112, 113, 137, 155, 272, 273, BA18.10-P-1000-
275, 285... 01B
Oil pump ENGINE 166.940 /960 /961 /990 /991 /995 BA18.10-P-1000-
01C
Oil pump ENGINE 668.914/940/941/942 BA18.10-P-1000-
01D
Oil pump ENGINE 611, 612, 613, 646, 647, 648... BA18.10-P-1000-
01E
Oil pump ENGINE 271 BA18.10-P-1000-
01F
Oil pump ENGINE 266.920/940/960/980 BA18.10-P-1000-
01I
01J
Oil pump ENGINE 642/ BA18.10-P-1000-
01K
Transmission oil ENGINE 629 BA18.10-P-1000-
pump 01M
01N
Oil filter ENGINE 601, 602.982 /, BA18.20-N-1000-
611.980/981/983/987, 612.981, 647.981 01A
Oil filter ENGINE 601, 602, 603, 604, 605, 606 BA18.20-P-1000-
(except, 602.982) 01A
Oil filter ENGINE 102, 103, 104, 111, 119, 120 BA18.20-P-1000-
01B
Oil filter ENGINE 112, 113, 137, 155... BA18.20-P-1000-
01D
Oil filter ENGINE 166.940 /960 /961 /990 /991 /995 BA18.20-P-1000-
01E
Oil filter ENGINE 668.914/940/941/942 BA18.20-P-1000-
01F
Oil filter ENGINE 611, 612, 613, 616, 617, 628, BA18.20-P-1000-
629, 646, 647, 648... 01G
Oil filter ENGINE 271 BA18.20-P-1000-
01I
Oil filter ENGINE 275, 285 BA18.20-P-1000-
01L
Oil filter ENGINE 628.961,629 BA18.20-P-1000-
01M
Oil filter ENGINE 272, 273 BA18.20-P-1000-
01O
01P
Oil filter ENGINE 266.920/940/960/980 BA18.20-P-1000-
01R
Oil filter ENGINE 642/ BA18.20-P-1000-
01T
Oil filter ENGINE 113.971 in MODEL 251 BA18.20-P-1000-
01U
01V
Oil cooling ENGINE 103/, 104/, 119, 120, 601, 602/, BA18.30-P-1000-
603/, 604, 605, 606 / (except, 602.98) 01A
Oil cooling ENGINE 112, 113, 137, 155, 156, 275, BA18.30-P-1000-
285... 01B
Oil cooling ENGINE 611, 612, 613, 647... BA18.30-P-1000-
01C
Oil cooling ENGINE 628.960 /961 /962 /963, 629, BA18.30-P-1000-
646.951/8 /961 /962 /963, 647.961, 01D
648.960 /961
Oil cooling ENGINE 271 BA18.30-P-1000-
01F
Oil cooling ENGINE 272, 273 BA18.30-P-1000-
01G
Oil cooling ENGINE 640 BA18.30-P-1000-
01I
Oil cooling ENGINE 642/ BA18.30-P-1000-
01J
Oil-water heat ENGINE 271.940/942/943/946/948 BA18.30-P-1000-
exchanger 02A
Oil level/pressure ENGINE 601 /943, 602.980/982 BA18.40-N-1000-
sensor 01B
Oil level/pressure ENGINE 103/, 104/, 111, 119, 120 BA18.40-P-1000-
sensor 01A
Oil level/oil ENGINE 112, 113, 137, 275... BA18.40-P-1000-
pressure sensor 01B
Oil level/oil ENGINE 166.940/960/961 /990/991 /995 BA18.40-P-1000-
pressure sensor 01C
Oil level/oil ENGINE 611, 612, 613, 628, 629, 646, BA18.40-P-1000-
pressure sensor 647, 648 01D
Oil level/oil ENGINE 668.914/940/941/942 BA18.40-P-1000-
pressure sensor 01E
Oil level/pressure ENGINE 601, 602 /, 603, 604, 605, 606 BA18.40-P-1000-
sensor (except, 602.98/98) 01F
Oil level/oil ENGINE 271 BA18.40-P-1000-
pressure sensor 01I
Oil level/oil ENGINE 285.950 BA18.40-P-1000-
pressure sensor 01J
Oil level/oil ENGINE 266.920/940/960/980 BA18.40-P-1000-
pressure sensor 01L
Oil level/oil ENGINE 642/ BA18.40-P-1000-

pressure sensor 01M
Oil level/oil ENGINE 155.980 BA18.40-P-1000-
pressure sensor 01N
Oil sensor ENGINE 271 BA18.40-P-1000-
02A
Oil sensor ENGINE 272, 273 BA18.40-P-1000-
02B
OIL PUMP - BA18.10-P-1000-01B
Engine 112, 113, 137, 155, 272, 273, 275, 285
OIL PUMP
112.910/911/914/915/916/920/921/922/923/940/941/942/943/944/945/947/953/
BA18.10- Bolt, oil M8x30 Nm 20
P-1001- pump to screw
01B crankcase M7x40 Nm -
M6x16 Nm -
BA18.10- Bolt, oil pump Nm -
P-1002- oil pipe to
01B crankshaft
bearing cap
P-1003- cap with oil pipe
01B to oil pump
BA18.10- Bolt, oil M6x16 Nm -
P-1004- suction
01B pipe to
oil pump.
BA18.10- Oil suction pipe Nm -
P-1005- to crankcase
01B
BA18.10- Bolt, oil baffle to Nm -
P-1006- crankcase
01B
P-1007- chain tensioning
01B device to oil
pump
BA18.10- Bolt, oil Stage Nm -
P-1008- pump to 1
01B crankcase Stage Nm -
2
BA18.10- Bolt, bottom part Nm -
P-1009- of intake
01B manifold to oil
pan
OIL PUMP
112.948 112.951/976 112.961
AMG
BA18.10-P- Bolt, oil pump M8x30 Nm 20 20 20
1001-01B to crankcase screw
M7x40 Nm - - -
M6x16 Nm - - -
BA18.10-P- Bolt, oil pump oil pipe to Nm 4 - 4
1002-01B crankshaft bearing cap
BA18.10-P- Bolt, oil pump cap with oil Nm 10 10 10
1003-01B pipe to oil pump
BA18.10-P- Bolt, oil M6x16 Nm - - -
1004-01B suction pipe to
oil pump.
BA18.10-P- Oil suction pipe to Nm - - -
1005-01B crankcase
BA18.10-P- Bolt, oil baffle to crankcase Nm - - -
1006-01B
BA18.10-P- Bolt, oil pump chain Nm - - -
1007-01B tensioning device to oil
pump
BA18.10-P- Bolt, oil pump Stage 1 Nm - - -
1008-01B to crankcase Stage 2 Nm - - -
BA18.10-P- Bolt, bottom part of intake Nm - - -
1009-01B manifold to oil pan
OIL PUMP
113.962/940/941/942/943/944/948/960/961/965/966/980/981/982/984/986/992/
BA18.10- Bolt, oil M8x30 Nm 20
P-1001- pump to screw
01B crankcase M7x40 Nm -
M6x16 Nm -
P-1002- oil pipe to
01B crankshaft
bearing cap

P-1003- cap with oil pipe
01B to oil pump
BA18.10- Bolt, oil M6x16 Nm -
P-1004- suction
01B pipe to
oil pump.
BA18.10- Oil suction pipe Nm -
P-1005- to crankcase
01B
BA18.10- Bolt, oil baffle to Nm -
P-1006- crankcase
01B
P-1007- chain tensioning
01B device to oil
pump
BA18.10- Bolt, oil Stage Nm -
P-1008- pump to 1
01B crankcase Stage Nm -
2
BA18.10- Bolt, bottom part Nm -
P-1009- of intake
01B manifold to oil
pan
OIL PUMP
Number Designation Engine Engine Engine 137 Engine
113.989 113.968 155
BA18.10-P- Bolt, oil pump M8x30 Nm 20 20 20 -
M7x40 Nm - - - 15
M6x16 Nm - - - 10
BA18.10-P- Bolt, oil pump oil pipe to Nm 4 4 - -
BA18.10-P- Bolt, oil pump cap with oil Nm 10 10 - -
BA18.10-P- Bolt, oil M6x16 Nm - - - -
oil pump.
BA18.10-P- Oil suction pipe to Nm - - - -
1005-01B crankcase
BA18.10-P- Bolt, oil baffle to Nm - - - -
1006-01B crankcase
BA18.10-P- Bolt, oil pump chain Nm - - - -

pump
BA18.10-P- Bolt, oil pump Stage 1 Nm - - - -
1008-01B to crankcase Stage 2 Nm - - - -
BA18.10-P- Bolt, bottom part of intake Nm - - - -
OIL PUMP
Number Designation Engine 272 Engine Engine 275 Engine
273 285.950
BA18.10-P- Bolt, oil pump M8x30 Nm - - 20 20
M7x40 Nm - - - -
M6x16 Nm - - - -
BA18.10-P- Bolt, oil pump oil pipe to Nm - - - -
BA18.10-P- Bolt, oil pump cap with oil Nm - - - -
BA18.10-P- Bolt, oil M6x16 Nm 9 9 8 8
oil pump.
BA18.10-P- Oil suction pipe to Nm 9 9 9 9
1005-01B crankcase
BA18.10-P- Bolt, oil baffle to Nm 9 9 - -
1006-01B crankcase
BA18.10-P- Bolt, oil pump chain Nm 10 10 - -
pump
BA18.10-P- Bolt, oil pump Stage 1 Nm 5 5 - -
1008-01B to crankcase Stage 2 Nm 20 20 - -
BA18.10-P- Bolt, bottom part of intake Nm - 9 - -
OIL PUMP - BA18.10-P-1000-01N
Engine 156
OIL PUMP
BA18.10-P-1001- Oil pump fitted bolt Nm 20
01N on crankcase
BA18.10-P-1002- Oil line on oil pump M6 x 16 Nm 8.5
01N
BA18.10-P-1003- Oil suction pipe axle Nm 10
01N journal on oil pump
BA18.10-P-1004- Bolt for oil suction M6 x 16 Nm 8.5
01N pipe on oil pump.
BA18.10-P-1005- Oil suction pipe on M6 x 16 Nm 8.5
01N crankcase bottom
section
BA18.10-P-1006- Oil line on M6 x 16 Nm 8.5
01N crankcase bottom
section
OIL FILTER - BA18.20-P-1000-01D
Engines 112, 113, 137, 155
OIL FILTER
112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/942/943/944/945/946
BA18.20- Screw Nm 25
P-1001- cap at oil
01D filter
BA18.20- Bolt, oil Nm 70
P-1002- filter
01D housing
to timing
case
BA18.20- Bolt, oil Nm -
P-1003- line to oil
01D filter
housing
BA18.20- Bolt for Nm -
P-1004- oil line
01D bracket
BA18.20- Oil filter Nm -
P-1005- housing
01D on
crankcase
OIL FILTER
Number Designation Engine Engine Engine Engine Engine
113.987/988 113.989 113.990/991/993 113.992/995 137
BA18.20- Screw cap Nm 25 25 25 25 25
P-1001- on oil filter
01D
BA18.20- Bolt, oil Nm 70 70 70 70 70

P-1002- filter
01D housing to
timing case
BA18.20- Bolt, oil Nm 9 9 9 10 -
P-1003- line to oil
01D filter
housing
BA18.20- Bolt for oil Nm - - 10 10 -
P-1004- line bracket
01D
BA18.20- Oil filter Nm - - - - -
P-1005- housing on
01D crankcase
OIL FILTER
BA18.20-P-1001-01D Screw cap on oil filter Nm -
BA18.20-P-1002-01D Bolt, oil filter housing to Nm -
timing case
BA18.20-P-1003-01D Bolt, oil line to oil filter Nm -
housing
BA18.20-P-1004-01D Bolt for oil line bracket Nm -
BA18.20-P-1005-01D Oil filter housing on Nm 10
crankcase
OIL FILTER - BA18.20-P-1000-01O
Engine 272, 273
OIL FILTER
272 273
BA18.20-P-1001-
Screw cap to oil filter housing Nm 25 25
01O
BA18.20-P-1002- Self-tapping screw connecting oil filter housing to timing
Nm 20 20
01O case cover
BA18.20-P-1003-
Bolt connecting to oil filter housing to crankcase Nm 20 20
01O
OIL FILTER - BA18.20-P-1000-01V
Engine 156
OIL FILTER
BA18.20-P-1001- Screw cap on oil Nm 25
01V filter housing
BA18.20-P-1002- Bolt for oil filter M8 x 35 Nm 20
01V housing on timing M8 x 80 Nm 20
case cover M8 x 100 Nm 20
BA18.20-P-1003- Oil filter bracket, M12 Nm 20
01V fixture for hose
package
OIL COOLING - BA18.30-P-1000-01B
Engine 112, 113, 137, 155, 156, 275, 285
MODIFICATION NOTES
3.3.06 Oil line to oil cooler Engine 156.980/983
3.3.06 Bolt connecting bracket Engine 156.980/983
to retaining frame
3.3.06 Oil line fitting to oil Engine 156.980/983
cooler
3.3.06 Bolt connecting oil line to Engine 156.980/983
oil cooler flange
OIL COOLING SYSTEM

112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/942/943/944/945/9
BA18.30- Oil-water Nm 11
P-1001- heat
01B exchanger
to oil filter
housing
BA18.30- Oil cooler Nm -
P-1002- heat
01B exchanger
to
crankcase
BA18.30- Oil line to Nm -
P-1003- oil cooler
01B
P-1004- crankcase
01B
BA18.30- Bolt Nm -
P-1005- connecting
01B fan to
engine oil
cooler
BA18.30- Bolt Nm -
P-1006- connecting
01B bracket to
retaining
frame
BA18.30- Nut Nm -
P-1007- connecting
01B bracket to
retaining
frame
BA18.30- Bolt Nm -
P-1008- connecting
01B retaining
bracket of
engine
cooler to
front end
assembly
BA18.30- Nut Nm -
P-1009- connecting
01B retaining
bracket of
engine
cooler to
front end
assembly
BA18.30- Bolt, oil Nm -
P-1010- line to
01B bracket
P-1011- additional
01B oil cooler
BA18.30- Nut Nm -
P-1012- connecting
01B bracket to
low
temperature
radiator
BA18.30- Oil line Nm -
P-1013- fitting to
01B oil cooler

BA18.30- Crankcase Nm -
P-1014- engine oil
01B line
retaining
clamp on
engine oil
cooler
BA18.30- Bolt Nm -
P-1015- connecting
01B retaining
bracket of
engine
radiator to
radiator
support
BA18.30- Bolt Nm -
P-1016- connecting
01B oil line to
oil cooler
flange
BA18.30- Drain plug Nm -
P-1017- to oil
01B cooler
OIL COOLING SYSTEM

Number Designation Engine 113.989 Engine 113.990 Engine 113.992
with code 030
BA18.30-P- Oil-water heat Nm 9 9 9
1001-01B exchanger to oil
filter housing
BA18.30-P- Oil cooler heat Nm - - -
1002-01B exchanger to
crankcase
BA18.30-P- Oil line to oil Nm 30 30 30
1003-01B cooler
BA18.30-P- Oil line to Nm - - -
1004-01B crankcase
BA18.30-P- Bolt connecting Nm - 4 4
1005-01B fan to engine oil
cooler
BA18.30-P- Bolt connecting Nm 9 9 -
1006-01B bracket to
retaining frame
BA18.30-P- Nut connecting Nm 9 9 10
1007-01B bracket to
retaining frame
BA18.30-P- Bolt connecting Nm - - 10
1008-01B retaining bracket
of engine cooler to
front end assembly
BA18.30-P- Nut connecting Nm - - -
of engine cooler to
front end assembly
BA18.30-P- Bolt, oil line to Nm - - -
1010-01B bracket
BA18.30-P- Oil line to Nm - 8 -
1011-01B additional oil
cooler
BA18.30-P- Nut connecting Nm - 6 -
1012-01B bracket to low
temperature
radiator
BA18.30-P- Oil line fitting to Nm - - -
1013-01B oil cooler
BA18.30-P- Crankcase engine Nm - - -
1014-01B oil line retaining
clamp on engine
oil cooler
BA18.30-P- Bolt connecting Nm - - -
of engine radiator
to radiator support
BA18.30-P- Bolt connecting oil Nm - - -
1016-01B line to oil cooler
flange
BA18.30-P- Drain plug to oil Nm - - -
1017-01B cooler
OIL COOLING SYSTEM

BA18.30-P-1001- Oil-water heat Nm - -
01B exchanger to oil
filter housing
BA18.30-P-1002- Oil cooler heat Nm - -
01B exchanger to
crankcase
BA18.30-P-1003- Oil line to oil cooler Nm 58 9
01B
BA18.30-P-1004- Oil line to crankcase Nm - -

01B
BA18.30-P-1005- Bolt connecting fan Nm - -
01B to engine oil cooler
BA18.30-P-1006- Bolt connecting Nm - 9
01B bracket to retaining
frame
BA18.30-P-1007- Nut connecting Nm - 9
01B bracket to retaining
frame
BA18.30-P-1008- Bolt connecting Nm - -
01B retaining bracket of
engine cooler to
front end assembly
BA18.30-P-1009- Nut connecting Nm - -
engine cooler to
front end assembly
BA18.30-P-1010- Bolt, oil line to Nm - -
01B bracket
BA18.30-P-1011- Oil line to Nm - -
01B additional oil cooler
BA18.30-P-1012- Nut connecting Nm - -
01B bracket to low
temperature radiator
BA18.30-P-1013- Oil line fitting to oil Nm 60 9
01B cooler
BA18.30-P-1014- Crankcase engine Nm - -
01B oil line retaining
clamp on engine oil
cooler
BA18.30-P-1015- Bolt connecting Nm - -
engine radiator to
radiator support
BA18.30-P-1016- Bolt connecting oil Nm - 9
01B line to oil cooler
flange
BA18.30-P-1017- Drain plug to oil Nm - 30
01B cooler
OIL COOLING SYSTEM

275.950/951/953/954,285 275.980/981/982
BA18.30-P- Oil-water heat Nm - -
1001-01B exchanger to oil

filter housing
BA18.30-P- Oil cooler heat Nm - -
1002-01B exchanger to
crankcase
BA18.30-P- Oil line to oil Nm 30 30
1003-01B cooler
BA18.30-P- Oil line to Nm 8 8
1004-01B crankcase
BA18.30-P- Bolt connecting Nm - 4
1005-01B fan to engine
oil cooler
BA18.30-P- Bolt connecting Nm - 10
1006-01B bracket to
retaining frame
BA18.30-P- Nut connecting Nm - -
1007-01B bracket to
retaining frame
BA18.30-P- Bolt connecting Nm 8 27
1008-01B retaining
bracket of
engine cooler to
front end
assembly
BA18.30-P- Nut connecting Nm - 10
1009-01B retaining
bracket of
engine cooler to
front end
assembly
BA18.30-P- Bolt, oil line to Nm 8 -
1010-01B bracket
BA18.30-P- Oil line to Nm - -
1011-01B additional oil
cooler
BA18.30-P- Nut connecting Nm - -
1012-01B bracket to low
temperature
radiator
BA18.30-P- Oil line fitting Nm - -
1013-01B to oil cooler
BA18.30-P- Crankcase Nm 8 8
1014-01B engine oil line
retaining clamp
on engine oil
cooler
BA18.30-P- Bolt connecting Nm 8 8
1015-01B retaining
bracket of
engine radiator
to radiator
support
BA18.30-P- Bolt connecting Nm - -
1016-01B oil line to oil
cooler flange
BA18.30-P- Drain plug to Nm - -
1017-01B oil cooler
OIL COOLING - BA18.30-P-1000-01G
Engine 272, 273
OIL COOLING SYSTEM

BA18.30-P-1001-01G Bolt of oil-water heat exchanger to oil filter housing Nm 12 12
OIL LEVEL/OIL PRESSURE SENSOR - BA18.40-P-1000-01B
Engines 112, 113, 137, 275
MODIFICATION NOTES
16.9.04 Value changed Value changed in series 1003 on models
from 14 Nm to 113.940/941/942/943/944/945/946/960/961/962/963/
15 Nm 965/967/968/969/980/981/982/984/986/ 992

Number Designation Engine 112 except Engine
112.916/951/953/975 112.916/953/975,
113.948/966
BA18.40-P- Screw plug to crankcase Nm 20 -
1001-01B
BA18.40-P- Oil level sensor on oil pan Nm 10 -
1002-01B top part
BA18.40-P- Self-tapping Thread pre- Nm 10 -
1003-01B bolt, oil level tapped
sensor to oil
pan top Thread not Nm 14 -
section pre-tapped
BA18.40-P- Oil level sensor on oil pan Nm - 8
1004-01B top section

BA18.40-P- Oil level sensor on oil pan Nm - -
1005-01B bottom section
BA18.40-P- Bolt, oil level sensor to oil Nm - -
1006-01B pan

112.951/976
BA18.40-P-1001- Screw plug to crankcase Nm -
01B
BA18.40-P-1002- Oil level sensor on oil pan top part Nm -
01B
BA18.40-P-1003- Self-tapping bolt, Thread pre-tapped Nm -
01B oil level sensor to Thread not pre- Nm -
oil pan top section tapped
BA18.40-P-1004- Oil level sensor on oil pan top section Nm -
01B
BA18.40-P-1005- Oil level sensor on oil pan bottom Nm 11
01B section
BA18.40-P-1006- Bolt, oil level sensor to oil pan Nm -
01B

113.940/941/942/943/944/945/946/960/961/962/963/965/967/968/969/980/981/98
BA18.40- Screw plug to Nm 20
P-1001- crankcase
01B
BA18.40- Oil level Nm 10
P-1002- sensor on oil
01B pan top part
BA18.40- Self- Thread Nm 10
P-1003- tapping pre-
01B bolt, tapped
oil
level Thread Nm 15
sensor not
to oil pre-
pan top tapped
section
BA18.40- Oil level Nm -
P-1004- sensor on oil
01B pan top part
BA18.40- Oil level Nm 10

P-1005- sensor at oil
01B pan bottom
section
BA18.40- Bolt, oil level Nm -
P-1006- sensor to oil
01B pan

113.971 113.987/988/990 113.991/993
BA18.40-P- Screw plug to crankcase Nm 20 20 20
1001-01B
BA18.40-P- Oil level sensor on oil Nm - 10 9
1002-01B pan top part
BA18.40-P- Self- Thread pre- Nm - 9 9
1003-01B tapping tapped
bolt, oil
level sensor Thread not Nm - 14 14
to oil pan pre-tapped
top section
BA18.40-P- Oil level sensor on oil Nm - - -
1004-01B pan top part
BA18.40-P- Oil level sensor at oil Nm 10 10 -
1005-01B pan bottom section
BA18.40-P- Bolt, oil level sensor to Nm - - -
1006-01B oil pan

Number Designation Engine 113.989 Engines 137,
275
BA18.40-P- Screw plug to crankcase Nm 20 20
1001-01B
BA18.40-P- Oil level sensor on oil pan top part Nm 10 8
1002-01B
BA18.40-P- Self-tapping Thread pre- Nm 9 -
1003-01B bolt, oil level tapped
sensor to oil pan Thread not pre- Nm 14 -
top section tapped
BA18.40-P- Oil level sensor on oil pan top part Nm - -
1004-01B
BA18.40-P- Oil level sensor at oil pan bottom Nm - -
1005-01B section
BA18.40-P- Bolt, oil level sensor to oil pan Nm - -
1006-01B
OIL SENSOR - BA18.40-P-1000-02B
Engine 272, 273
OIL SENSOR
BA18.40-P-1001-02B Bolt of oil level check switch to oil pan Nm 14 14
FORMS
TEST SHEET FOR EXCESSIVE OIL CONSUMPTION, FORM - OF18.00-P-3000-03A

Fig. 124: Test Sheet For Excessive Oil Consumption, Form

2006-2008 ENGINE Complete engine - Testing & Repair - 164 Chassis
2006-2008 ENGINE
Complete engine - Testing & Repair - 164 Chassis
TESTING & REPAIR

INSPECTING CYLINDERS WITH LIGHT PROBE - AR01.00-P-0200GZ
Fig. 1: Inspecting Cylinders With Light Probe (Engine 113.964)

Remove/install

implants (e.g. heart pacemakers) must
not carry work out on the ignition
system
Risk of injury to skin and eyes from Wear safety gloves, protective clothing AS00.00-Z-
the hydraulic hoist and position the four
Risk of death cased by vehicle slipping AS00.00-Z-
manufacturer.
Risk of injury caused by fingers being When moving components, ensure that
jammed or pinched when removing, no body parts or limbs are within the
AS00.00-Z-
installing or aligning hoods, doors, operating range of moving parts.
0011-01A
trunk lid/rear-end door or sliding roof.
AR88.40-P-
1 Open engine hood
1000GZ
Remove a spark plug from each
2
cylinder
AP15.10-P-
Replace spark plugs
1580GZ
To do this, crank the engine at the
Position piston of cylinder to be
3 central bolt of the crankshaft in the
inspected to BDC
direction of rotation of the engine:?
AR01.00-P-
Firing order
1300-03HA
Connect cylinder inspection lamp (05)
and insert the flexible endoscope for the *WH58.30-
4 Cylinder inspection light
inspection lamp via the spark plug bore Z-1014-05A
into the respective cylinder
*WH58.30-
Flexible inspection light Z-1006-05A
*WH58.30-
Flexible inspection light Z-1007-05A
Check
Normal condition:
Mat-grey surface, no honing pattern.
5 Inspect cylinder walls
If the condition of the cylinder wall is
not clearly recognizable:?
AR01.30-P-
Remove cylinder head
5800GZ
General information on inspecting AH01.00-P-
cylinder walls 0300-01A
Inspect the other cylinders in the same
6
way

Number Designation
Flexible endoscope, package contents 1 (complete unit),
WH58.30-Z-
Firma Richard Wolf GmbH D-75438 Knittlingen
1006-05A
Firma Karl Storz GmbH D-78532 Tuttlingen
Flexible endoscope package contents 2 (for workshops which already have an
WH58.30-Z- approved endoscope from the Wolf or Storz company),
1007-05A Firma Richard Wolf GmbH D-75438 Knittlingen
Firma Karl Storz GmbH D-78532 Tuttlingen
WH58.30-Z-
Cylinder inspection equipment
1014-05A
INSPECT CYLINDERS USING A LIGHT PROBE - AR01.00-P-0200GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 2: Inspecting Cylinders Using Light Probe (Engine 272, 273)

Remove/install

Risk of death caused by contact voltages. Persons who wear electronic AS15.10-Z-
with parts conducting high voltages. implants (e.g. heart pacemakers) should never 0001-01A
perform any work on the ignition system
objects.
platform.
manufacturer.

Turn key in ignition lock to position Press Keyless Go start/stop button repeatedly
1
"0" until ignition is switched off. Remove the
Keyless Go transmitter card or transmitter
key from vehicle and store beyond reach of
the transmitter (at least 2 m).

AR09.10-P-
1150GZA
AR15.12-P-
2003GZA
*BA15.10-
4 Remove spark plugs
P-1001-01C
Rotate engine at crankshaft center
bolt in the engine's direction of
5 Fig. 3
rotation until piston of cylinder to be
inspected is at bottom dead center
Connect cylinder inspection lamp
(1) and insert flexible endoscope
(test probe) (2) of cylinder
6
inspection lamp into cylinder to be
inspected through tapped bore of the
spark plug
Checking
If there is "scoring" (wear to the
Check cylinder wall, piston crown cylinder), the cylinder wall has become rough
7
and valves and the honing marks are no longer visible.
In case of doubt, remove cylinder head:?
AR01.30-P-
Remove right cylinder head
5780GZA
AR01.30-P-
Remove left cylinder head
5770GZA
General information on inspecting AH01.00-P-
cylinder walls 0300-01VA
Inspect other cylinders in the same
8
way
SPARK PLUGS

INSPECTING CYLINDERS WITH A LIGHT PROBE - AR01.00-P-0200GZS
Fig. 4: Inspecting Cylinders With Light Probe (Engine 156)

Remove/install

Risk of death caused by contact AS15.10-Z-
with parts conducting high voltages. 0001-01A
system
objects.
platform and position four support plates at AS00.00-Z-
lifting platform support points specified by 0010-01A
platform.
On vehicles with code 889, Keyless
Turn key in ignition switch to Go: Press keyless go start/stop button
1 repeatedly until ignition is switched off
position "0".
Remove keyless go transmitter card or

2 Model 164
AR88.40-P-
Model 251
1000RT
3 Model 251
wheelhouses 2400RT
AR09.10-P-
1150GZS
AR15.12-P-
2003GZS
AR15.12-P-
1010GZS
Rotate engine at crankshaft center
bolt in engine's direction of rotation
7 Socket Fig. 3
until piston of cylinder to be
inspected is at bottom dead center
Connect cylinder inspection lamp
(1) and insert flexible endoscope
(test probe) (2) on cylinder *WH58.30-
8 Cylinder inspection light
inspection lamp into cylinder to be Z-1014-05A
inspected through tapped bore of
spark plug
*WH58.30-
Flexible endoscope Z-1006-05A
*WH58.30-
Flexible endoscope Z-1007-05A
Checking
If there is "scoring" (wear to the
cylinder), the cylinder wall has become
Check cylinder wall, piston crown AR01.30-P-
9 rough and the honing marks are no longer
and valves 5800GZS
visible.
In case of doubt, remove cylinder head:
AH01.00-P-
General information on inspecting
0300-
cylinder walls
01AMG
Inspect the other cylinders in the
10
same way


Number Designation
Flexible endoscope, package contents 1 (complete unit),
WH58.30-Z-
Company Richard Wolf GmbH D-75438 Knittlingen
1006-05A
Company Karl Storz GmbH D-78532 Tuttlingen
Flexible endoscope package contents 2 (for workshops which already have an
WH58.30-Z- approved endoscope from the Wolf or Storz company),
1007-05A Company Richard Wolf GmbH D-75438 Knittlingen
Company Karl Storz GmbH D-78532 Tuttlingen
WH58.30-Z-
Cylinder inspection equipment
1014-05A
TESTING COMPRESSION PRESSURE - AR01.00-P-1200GZ
Fig. 6: Testing Compression Pressure (Engine 113.964)

Remove/install

moving.
off by itself when engine is running. Risk of AS00.00-Z-
injury caused by contusions and burns when 0005-01A
clothes.
working in engine during starting procedure
Test compression pressure
Bring the engine up to operating temperature
1 only when engine is at normal
(approx. 80°C)
operating temperature.
installing or aligning hoods, doors, trunk within the operating range of moving 0011-01A
lid/rear-end door or sliding roof. parts.
AR88.40-P-
2 Open engine hood
1000GZ
AR09.10-P-
1150GZ
4 Remove a spark plug from each cylinder
AP15.10-P-
Replace spark plugs
1580GZ
Switch ignition off, remove ignition key Go, code 889: Press keyless go
5
(transmitter key). start/stop button repeatedly until
Crank engine by pressing
contact switch at compression tester
(01).
AR01.10-P-
6 Crank engine with starter In order to remove the 0110GZ
combustion residue from the
cylinders, crank the engine for about
5 seconds with the starter.
Check
Insert compression tester (01) into spark
7 Compression recorder Fig. 7
plug bore
Crank engine by pressing AR01.10-P-
8 Crank engine with starter. contact switch at compression tester 0110GZ
(01).
Perform inspection of the other cylinders at
9
the same time as the first cylinder
Compare measurements obtained with the Compression pressure, tolerance *BE01.00-
10
specified pressures when installed or new value P-1001-01D
Compression pressure wear limit or *BE01.00-

limit value P-1002-01D
Compression pressure, permissible
difference between individual
cylinders
If the pressure is below the *BE01.00-
minimum compression pressure or if P-1003-01D
the permissible difference between
the individual cylinders is
exceeded:?
AR01.00-P-
Inspect cylinders for leaks
1300GZ
COMPRESSION PRESSURE
113.964
BE01.00-P-1001-
Compression pressure, tolerance when installed or new value bar 9...12
01D
BE01.00-P-1002-
Compression pressure wear limit or limit value bar 9.0
01D
BE01.00-P-1003- Compression pressure, permissible difference between individual
bar 1.5
01D cylinders
Fig. 7: Identifying Compression Recorder (001 589 76 21 00)

TEST COMPRESSION PRESSURE - AR01.00-P-1200GZA
ENGINE 272, 273 in MODEL 164, 251

Fig. 8: Testing Compression Pressure (Engine 272, 273)

Remove/install

Only test compression pressure
Bring engine to operating temperature
1 when engine is at normal operating
(approx. 80°C)
temperature.
Vehicles with Keyless Go, code
2 Remove key from the ignition lock Remove the Keyless Go transmitter card or
beyond reach of the transmitter (at least 2
m).
AR09.10-P-
1150GZA
AR15.12-P-
2003GZA
*BA15.10-
P-1001-01C
Do not crank engine by turning

the key in the ignition switch, but use

contact switch of compression recorder
Connect electrical feed lines of
instead. AR01.10-P-
6 compression recorder (01) and crank
Crank engine for about 5 seconds 0010-01GZ
engine with starter
to remove combustion residue from
cylinders.
Fig. 7
Fig. 10
Checking
Press compression recorder (01) on The sealing cone of compression
7 tapped bore of spark plug of first recorder (01) must tightly seal tapped bore
cylinder of spark plug.
Crank engine with contact switch of
compression recorder (01) until
8
increase in pressure is no longer
indicated on compression recorder
Carry out testing procedure in cylinder
9 order on the remaining cylinders in the
same way
Compare measurements obtained with Compression installation tolerance or new *BE01.00-
10
the specified pressures value P-1001-01B
Compression pressure permissible *BE01.00-
difference between individual cylinders P-1002-01B
Compression pressure wear limit or limit
value
If pressure is below the minimum *BE01.00-
compression pressure or if permissible P-1003-01B
difference between individual cylinders is
exceeded:?
AR01.00-P-
Check cylinder leakage.
1300GZA
272 273
BE01.00-P-1001-
Compression installation tolerance or new value bar 12 to 15 12 to 16
01B
BE01.00-P-1002- Compression pressure permissible difference between
bar < or =1.5 < or =1.5
01B individual cylinders
BE01.00-P-1003-
Compression pressure wear limit or limit value bar 10 10
01B
SPARK PLUGS

Fig. 9: Identifying Compression Tester (001 589 76 21 00)


TESTING COMPRESSION PRESSURE - AR01.00-P-1200GZS

Fig. 11: Testing Compression Pressure (Engine 156)

Remove/install

by itself.
clothes.
Test compression pressure only
(approx. 80°C)
temperature.
Keyless Go: Press keyless go start/stop
Turn key in ignition switch to position button repeatedly until ignition is switched
2
"0". off Remove keyless go transmitter card or
3 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT

4 Model 251
wheelhouses 2400RT
AR09.10-P-
1150GZS
AR15.12-P-
2003GZS
AR15.12-P-
1010GZS
The engine is not cranked by
turning the key in ignition switch but by
actuating compression recorder contact
Connect electrical supply lines for AR01.10-P-
8 switch.
compression recorder (01) 0010-01GZ
Crank engine for about 5 seconds
to remove combustion residue from
cylinders.
Compression recorder Fig. 7
Checking
Press compression recorder (01) on The sealing cone of compression
9 tapped bore of spark plug of first recorder (01) must tightly seal tapped bore
cylinder of spark plug.
Crank engine with contact switch of
compression recorder (01) until
10
increase in pressure is no longer
indicated on compression recorder
Carry out the testing procedure in the
11 cylinder order on the remaining
cylinders in the same way
Compare measurements obtained with Compression installation tolerance or new *BE01.00-
12
specified pressures value P-1001-01B
Compression pressure permissible *BE01.00-
difference between individual cylinders P-1002-01B
Compression pressure wear limit or limit
value
If pressure indicated is less than the *BE01.00-
minimum compression pressure or if P-1003-01B
permissible difference between individual
cylinders is exceeded:?
AR01.00-P-
Inspect cylinders for leaks
1300GZS
156
BE01.00-P-1001-
Compression installation tolerance or new value bar 12 - 16
01B
BE01.00-P-1002- Compression pressure permissible difference between individual
bar < or =2.0
01B cylinders
BE01.00-P-1003-
Compression pressure wear limit or limit value bar 10
01B


CONNECT CYLINDER LEAKAGE TESTING UNIT - AR01.00-P-1300-01VA
Fig. 14: Identifying Threaded Adapter (272 589 00 91 00)

1. Calibrate cylinder leakage tester (04).

Cylinder leakage tester, see GOTIS:http://gotis.aftersales.daimlerchrysler.com
2. Screw threaded adapter (06) to high-pressure testing hose (05).
Fig. 15: Identifying Cylinder Leakage Tester, Threaded Adapter & High-Pressure Testing Hose
3. Turn threaded adapter (06) with high-pressure testing hose (05) in tapped bore for spark plug.
4. Mount high-pressure testing hose (05) on cylinder leakage tester (04).
Fig. 16: Identifying High-Pressure Testing Hose & Cylinder Leakage Tester - Shown On Engine 272.963
FIRING ORDER - AR01.00-P-1300-03HA
Fig. 17: Identifying Firing Order (Engines 111, 601, 604, 611, 271)
Fig. 18: Identifying Firing Order (Engines 602, 605)

Fig. 19: Identifying Firing Order (Engines 603, 606)

Fig. 20: Identifying Firing Order (Engine 112)




ENGINES 137,275,285
Fig. 24: Identifying Firing Order (Engines 137,275,285)

FIRING ORDER - AR01.00-P-1300-03SLR
Firing order
Fig. 25: Identifying Firing Order

INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300GZ

Fig. 26: Inspecting Cylinders For Leaks (Engine 113.964)

Remove/Install

off by itself when engine is running. Riskmoving.
AS00.00-Z-
0005-01A
Check the cylinder for leaks
Bring the engine up to operating
1 only when the engine is at normal
temperature (approx. 80°C)
operating temperature.
2 Remove key from the ignition lock Go, code 889: Press keyless go
AR88.40-P-
3 Open engine hood
1000GZ
Risk of injury to skin and eyes suffering
spray. Risk of poisoning from swallowing 0001-01A
beverage bottles.
coolant.
clothing and eye protection.
4 Undo cap of coolant expansion reservoir

5 Remove oil filler cap
6 Remove a spark plug from each cylinder
AP15.10-P-
Replace spark plugs
1580GZ
Position the piston of the cylinder to be Crank the engine at the
7 checked at the top dead center with the top center bolt of the crankshaft in the
dead center selector direction of rotation of the engine.
*WH58.30-
Cylinder leakage tester Z-1015-05A
Calibrate cylinder leakage
8 Connect cylinder leak tester (04) tester (04) and screw the connection
hose into the spark plug bore
*WH58.30-
Cylinder leakage tester Z-1015-05A
Check
Pressurize the cylinder with compressed air
Cylinder leakage permissible total *BE01.00-P-
9 and read off the pressure loss on the
loss indication 1001-02Z
cylinder leak tester (04)
Cylinder leaktightness permissible
*BE01.00-P-
losses at valves and cylinder head
1002-02Z
gasket
Cylinder leakage permissible loss at
*BE01.00-P-
pistons and piston rings
1003-02Z
If the crankshaft rotates:?
AR03.30-P-
Install retaining lock for crankshaft
5000GZ
Check the other cylinders in the firing order AR01.00-P-
10 Firing order
of the engine 1300-03HA
CYLINDER LEAKAGE
Number Designation All
engines
BE01.00-P-1001-
Cylinder leakage permissible total loss indication % < or =25
02Z
BE01.00-P-1002- Cylinder leaktightness permissible losses at valves and cylinder head
% < or =10
02Z gasket
BE01.00-P-1003-
Cylinder leakage permissible loss at pistons and piston rings % < or =20
02Z
Fig. 27: Identifying Socket (001 589 65 09 00)


Number Designation
WH58.30-Z-1015-05A Cylinder leakage testing unit
INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 28: Inspecting Cylinders For Leaks (Engine 272, 273)

Remove/install

when engine is running. Risk Secure vehicle to prevent it from moving by itself.
AS00.00-Z-
of injury caused by contusions Wear closed and snug-fitting work clothes.
0005-01A
and burns during starting Do not touch hot or rotating parts.
procedure or when working
near the engine as it is running
Bring engine to operating Only check cylinder for leaks when the
1
temperature (approx. 80°C) engine is at normal operating temperature.
Press Keyless Go start/stop button repeatedly until
Remove key from the ignition ignition is switched off.
2
lock Remove the Keyless Go transmitter card or
transmitter key from vehicle and store beyond
reach of the transmitter (at least 2 m).
temperature is below 90°C. Open cap slowly and
caused by scalding from
release the pressure. Do not pour coolant into AS20.00-Z-
contact with hot coolant spray.
beverage containers. 0001-01A
Wear protective gloves, protective clothing and
swallowing coolant.
safety glasses.
Unscrew cap (1) from coolant
3
expansion reservoir (2)
4 Remove the oil filler cap (3)
AR09.10-
1150GZA
AR15.12-
6 Remove ignition coils P-
2003GZA
*BA15.10-
7 Remove spark plugs P-1001-
01C
Position piston of cylinder to
be checked at top dead center Crank engine at crankshaft center bolt in
8
with the top dead center direction of rotation of engine.
selector
Cylinder leakage tester, see GOTIS Fig. 3

AR01.00-
Connect cylinder leakage
9 P-1300-
testing unit (04)
01VA
Checking
Pressurize cylinder with
*BE01.00-
compressed air and read off Cylinder leaktightness: permissible loss total
10 P-1001-
pressure loss on cylinder indication
02Z
leakage testing unit (04)
*BE01.00-
Cylinder leaktightness: permissible losses at valves
P-1002-
and cylinder head gasket
02Z
Cylinder leaktightness: permissible losses at pistons *BE01.00-
and piston rings P-1003-

If the crankshaft rotates:? 02Z
AR03.30-
Install retaining lock for crankshaft. P-
5000GZA
AR01.00-
Check other cylinders in firing
11 Firing order P-1300-
order of the engine
03HA
CYLINDER LEAKAGE
engines
BE01.00-P-1001-
Cylinder leaktightness: permissible loss total indication % < or =25
02Z
BE01.00-P-1002- Cylinder leaktightness: permissible losses at valves and cylinder head
% < or =10
02Z gasket
BE01.00-P-1003-
Cylinder leaktightness: permissible losses at pistons and piston rings % < or =20
02Z
SPARK PLUGS

INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300GZS

Fig. 30: Inspecting Cylinders For Leaks (Engine 156)

Remove/install

moving by itself.
clothes.
swallowing coolant.
Only check cylinder for leaks
(approx. 80°C)
temperature.
Keyless Go:
Press keyless go start/stop button
2 Remove key from the ignition lock
off Remove keyless go transmitter
and store outside of transmission
range (min. 2 m)
3 Model 164
position 1000GZ
AR88.40-P-
Model 251
1000RT
Unscrew cap (1) for coolant expansion
4
reservoir (2)
5 Remove the oil filler cap (3)
6 Model 251
wheelhouses 2400RT
AR09.10-P-
1150GZS
AR15.12-P-
2003GZS
AR15.12-P-
1010GZS
Position piston of cylinder to be checked Crank engine at crankshaft
10 at top dead center using top dead center center bolt in direction of rotation of
selector engine.
Socket Fig. 3
*WH58.30-
Cylinder leakage testing unit Z-1015-05A
AR01.00-P-
11 Connect cylinder leakage testing unit (04)
1300-01VA
*WH58.30-
Cylinder leakage testing unit Z-1015-05A
Checking
Pressurize cylinder with compressed air
Cylinder leaktightness permissible *BE01.00-P-
12 and read off the pressure loss on cylinder
loss total indication 1001-02Z
leakage testing unit (04)
*BE01.00-P-
losses at valves and cylinder head
1002-02Z
gasket
losses at pistons and piston rings *BE01.00-P-
1003-02Z
If the crankshaft rotates:?
AR03.30-P-
Install retaining lock for crankshaft
5000GZS
Check the other cylinders in the firing AR01.00-P-
13
order of the engine 1300-03SLR
CYLINDER LEAKAGE
engines
BE01.00-P-1001-
Cylinder leaktightness permissible loss total indication % < or =25
02Z
BE01.00-P-1002- Cylinder leaktightness permissible losses at valves and cylinder head

% < or =10
02Z gasket
BE01.00-P-1003-
Cylinder leaktightness permissible losses at pistons and piston rings % < or =20
02Z


Number Designation
WH58.30-Z-1015-05A Cylinder leakage testing unit
DISCONNECTING / CONNECTING THE ENGINE WIRING HARNESS - AR01.00-P-2410GZ

Fig. 32: Identifying Engine Wiring Harness Components - Model 164 (1 Of 2)

Fig. 33: Identifying Engine Wiring Harness Components - Model 164 (2 Of 2)

Removing/installing

of the hydraulic hoist and position
the four support plates below the
hoist support points specified by the
injury caused by burns to skin and eyes from and safety glasses. Only pour 0001-01A
battery acid or when handling damaged lead- battery acid into suitable and
acid batteries appropriately marked containers.
Insulate ground line as a
contact of detached ground line
AR54.10-P-
1 Disconnect ground cable of battery Vehicles with Keyless Go, 0003GZ
code 889:
Switch off engine, remove Keyless
Go cards from the vehicle and keep
outside the range of the transmitter.
AH54.10-P-
Notes on battery All models 0001-01A

AR88.40-P-
2 Open engine hood
1000GZ
AR01.10-P-
3 Remove engine trim panel (3)
2405GZ
Remove cover (2) on engine compartment Removal: Do this by
4
fuse and relay box (F58) unscrewing bolts (1).
Remove cover (2) on engine compartment Installation: Check rubber
5
fuse and relay box (F58) seal in cover, replace if required.
Remove electrical connector (4) and
6
electrical connector (5)
7 Detach rubber seal (7) on the right
Do not unscrew bolt (8)
8 Loosen bolt (8) on bulkhead cover (9) fully. Fold bulkhead cover (9)
upwards.
Disconnect connector (6) on wiring harness
9
(12)
Remove engine wiring harness (10) from Place wiring harness down
10
retaining clamp (11) on engine.
AR00.60-P-
1000GZ
12 Detach connections on alternator See ?
AR15.40-P-
Remove alternator
5032GZ
13 Disconnect ground (engine support) (W11/4)
Unclip and separate the connector of the left
O2 sensor upstream of the catalytic converter
14 Release electric feed lines
(G3/3x1) and/or connector of the right O2
from the retaining clamps.
sensor upstream of the catalytic converter
(G3/4x1) from the retaining clamps.
Unclip and separate the connector of the left
O2 sensor downstream of the catalytic
converter (G3/5x1) and/or connector of the Release electric feed lines
15
right O2 sensor upstream of the catalytic from the retaining clamps.
converter (G3/6x1) from the retaining
clamps.
Disconnect connector for transmission
16 Removal: See: ?
control (13)
Removing/installing shield at AR27.40-P-
transmission 0700-01GZ
*BA27.40-
P-1014-01A
Disconnect automatic transmission/intelligent
17
servo module connector (X22/6)

caused by disconnecting cables or
19 Read out fault memory and erase if necessary by simulation during test
operations, must be erased in the
fault memory after completing the
work.
system Z-1048-13A
AR00.19-P-
0200GZ
HOUSING
BA27.40-P-1014-01A Bolt for heat shield on transmission housing Nm 9

Number Designation
DISCONNECT, CONNECT ENGINE WIRING HARNESS - AR01.00-P-2410GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 34: Identifying Engine Wiring Harness Components - Engine 272, 273 (1 Of 3)
Fig. 37: Identifying Transmission Control Plug

Remove/install

platform.
AH54.00-P-
0001-01A
AR54.10-P-
1 Disconnect battery ground line Model 164
0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-P-
Notes on battery
0001-01A
AR09.10-P-
1150GZA
3 Pull off rubber seal (3)
Remove nut (13), detach positive
4
lead (1).
5 Unscrew bolt (4)
Unclip cover (2) and disconnect
6
cable tie
7 Unclip positive lead (1) from clip (6)
Detach engine control unit ME
8
connector (9)
9 Detach ignition coil connector (11)
Detach injection valve connector
10
(10)
Remove bottom engine compartment
11
paneling
Undo ground (engine support)

12
(W11/4) on engine
AR27.40-P-
13 Remove shield at transmission
0700-01GZ
*BA27.40-P-
1014-01A
Detach transmission control plug
14
(14)
Unlatch connectors for O2 sensors
(G3/3x1, G3/4x1, G3/5x1, G3/6x1) Unclip electric leads from
15
from retaining clamps and retaining clips.
disconnect
Remove heat shield (16) and
16
17
at SPS [PML] solenoid valve
necessary
HOUSING
DISCONNECT, CONNECT ENGINE WIRING HARNESS - AR01.00-P-2410GZS

Fig. 38: Identifying Engine Wiring Harness Components - Engine 156

Remove/install

manufacturer.
caused by burns to skin and eyes from battery clothing and safety glasses. Only 0001-01A
sliding roof.
AR88.40-P-
1000GZ
AR54.10-P-
0003GZ
AH54.10-P-
0001-01A
Only in area of cable

3 Pull off rubber seal (3)
passage.
4 Unscrew bolt (4)
5 Unclip cover (2)
6 Remove nut (8), detach positive lead (1).
Removal: Remove cable
tie (5) and lay positive line (1) on
7 Remove positive line (1) from cable passage engine.
Installation: Replace tie
straps (5).
Unscrew ground line (7) between alternator Unscrew ground line (7)
8
and body at body.
9 Disconnect connector (11, 12)
10 Disconnect connector at engine control unit See: ?
Remove/install injection system AR07.08-P-
control unit 7008GZS
Removal: Detach fuse
Remove nuts (9), push engine wiring harness box to weave out engine wiring
11 (6) with bracket (10) through wheelhouse in harness (6). Unclip retaining
direction of engine compartment clamps (13) and lay engine wiring
harness (6) on engine.
Unscrew ground line (7) on the right at body
12
frame
The connectors are
13 Disconnect plug connections of O2 sensors located below the transmission
bell.
AR27.40-P-
14 Remove shield at transmission
0700-01GZ
*BA27.40-
P-1014-01A
15 Detach connector for transmission control
AR00.19-P-
0200GZ
HOUSING
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9113AB
ENGINE 113
Inspecting cylinders with light ENGINE 112, 113, 137, AR01.00-P-0200AU

probe 275, 285...
Inspecting cylinders with light ENGINE 113.964 in AR01.00-P-0200GZ
probe MODEL 164.175
Inspecting cylinders with light ENGINE 113.971 in AR01.00-P-0200RT
probe MODEL 251.075 /175
Inspecting cylinders with light Engine 113.967 in model AR01.00-P-0200TY
probe 219.375 Engine 113.990
in model 219.376
Inspecting cylinders with light ENGINE 113.989 in AR01.00-P-0200VT
probe MODEL 171.473
Testing compression pressure ENGINE 112, 113... AR01.00-P-1200B
Testing compression pressure ENGINE 113.964 in AR01.00-P-1200GZ
MODEL 164.175
Testing compression pressure ENGINE 113.971 in AR01.00-P-1200RT
MODEL 251.075 /175
Testing compression pressure ENGINE 113.995 in AR01.00-P-
MODEL 230.472 1200RVK
Testing compression pressure Engine 113.967 in model AR01.00-P-1200TY
219.375 Engine 113.990
in model 219.376
Testing compression pressure ENGINE 112, 113... AR01.00-P-1200V
Testing compression pressure ENGINE 113.989 in AR01.00-P-1200VT
MODEL 171.473
Inspect cylinders for leaks ENGINE 113.964 in AR01.00-P-1300GZ
MODEL 164.175
Inspect cylinders for leaks ENGINE 112, 113, 137, AR01.00-P-1300HV
285...
Inspect cylinders for leaks ENGINE 113.971 in AR01.00-P-1300RT
MODEL 251.075 /175
Inspecting cylinders for leaks ENGINE 113.995 in AR01.00-P-
MODEL 230.472 1300RVK
Inspect cylinders for leaks Engine 113.967 in model AR01.00-P-1300TY
219.375 Engine 113.990
in model 219.376
Inspect cylinders for leaks ENGINE 113.989 in AR01.00-P-1300VT
MODEL 171.473
Disconnecting and connecting ENGINES 112, 113 in AR01.00-P-2410AV
engine wiring harness MODEL 129
Disconnecting / connecting the ENGINE 113.964 in AR01.00-P-2410GZ
engine wiring harness MODEL 164.175
Disconnecting, connecting engine ENGINE 112 in AR01.00-P-2410K
wiring harness MODEL 210, 208, 202
ENGINE 113 in
MODEL 210, 208, 202

Disconnecting, connecting engine ENGINE 112, 113 in AR01.00-P-2410M
wiring harness MODEL 220
Disconnecting/connecting the ENGINE 112, 113... AR01.00-P-2410PV
engine wiring harness
Disconnect, connect engine wiring ENGINE 112, 113, 275... AR01.00-P-2410R
harness
Disconnect, connect engine wiring ENGINE 113.971 in AR01.00-P-2410RT
harness MODEL 251.075 /175
Disconnect, connect engine wiring ENGINE 112, 113... AR01.00-P-2410TC
harness
Disconnect/connect engine wiring Engine 113.967 in model AR01.00-P-2410TY
harness 219.375 Engine 113.990
in model 219.376
Disconnecting and connecting ENGINE 112, 113... AR01.00-P-2410V
Disconnecting, connecting engine ENGINE 113.989 in AR01.00-P-2410VT
wiring harness MODEL 171.473
Cranking engine with the starter. ENGINES 113, 272, 273 AR01.10-P-0110GZ
in MODEL 164
Crank engine with starter. ENGINE 111, 112, 113, AR01.10-P-0110PV
156, 271...
Crank engine with starter. ENGINE 113.971 in AR01.10-P-0110RT
MODEL 251.075 /175
Crank engine with starter Engine 113.967 in model AR01.10-P-0110TY
219.375 Engine 113.990
in model 219.376
Cranking engine with starter. ENGINE 112, 113, 137, AR01.10-P-0110V
275, 285...
Remove/install engine ENGINE 112, 113 / AR01.10-P-2400AB
(except 112.975,
113.948 /966) in
MODEL 220
Removing and installing engine ENGINE 113.988 in AR01.10-P-2400AC
MODEL 203.076 /276
with TRANSMISSION
722.6
Remove/install engine ENGINE 112, 113... AR01.10-P-2400CA
Removing and installing engine ENGINE 112, 113... AR01.10-P-2400CB
Remove/install engine ENGINE 113.964 in AR01.10-P-2400GZ
MODEL 164.175
Remove/install engine ENGINE 112, 113... AR01.10-P-2400IW
Remove, install engine ENGINE 113... AR01.10-P-2400Q
Removing and installing engine ENGINE 113.963 in AR01.10-P-2400R
MODEL 230.475
Remove/install engine ENGINE 113... AR01.10-P-
2400RVK
Remove/install engine ENGINE 112, 113... AR01.10-P-2400TC
Remove/install engine ENGINE 113.967 in AR01.10-P-2400TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Removing and installing engine ENGINE 113.989 in AR01.10-P-2400VT
MODEL 171.473 with
TRANSMISSION
722.907
Removing/installing the engine ENGINE 113.964 in AR01.10-P-2405GZ
cover MODEL 164.175
Remove/install engine cover ENGINE 113.971 in AR01.10-P-2405RT
MODEL 251.075 /175
Remove/install engine with front ENGINE 113.964 in AR01.10-P-2500GZ
axle carrier MODEL 164.175
Remove/install engine with front ENGINE 113.971 in AR01.10-P-2500RT
axle carrier MODEL 251.075 /175
Detaching and attaching engine on ENGINE 113.964 in AR01.10-P-2510GZ
front axle carrier MODEL 164.175
Detaching and attaching engine on ENGINE 113.971 in AR01.10-P-2510RT
front axle carrier MODEL 251.075 /175
Remove/install cylinder head cover ENGINE 112, 113... AR01.20-P-5014B
Remove/install cylinder head cover ENGINE 112, 113... AR01.20-P-5014BV
Remove/install cylinder head cover ENGINE 113.964 in AR01.20-P-5014GZ
MODEL 164.175
Remove/install cylinder head cover ENGINE 113.971 in AR01.20-P-5014RT
MODELS 251.075 /175
Remove/install cylinder head cover ENGINE 113.995 in AR01.20-P-
MODEL 230.472 5014RVK
Remove/install cylinder head cover Engine 113.967 in model AR01.20-P-5014TZ
219.375 Engine 113.990
in model 219.376
Remove/install cylinder head cover ENGINE 113.989 in AR01.20-P-5014VT
MODEL 171.473
Repairing spark plug thread ENGINE 112, 113... AR01.30-P-5440BV
Repairing spark plug thread ENGINE 113.964 in AR01.30-P-5440GZ
MODEL 164.175
Repairing the spark plug thread ENGINE 113.971 in AR01.30-P-5440RT
MODELS 251.075 /175
Repairing spark plug thread ENGINE 113.995 in AR01.30-P-
MODEL 230.472 5440RVK
Repairing spark plug thread Engine 113.967 in model AR01.30-P-5440TY

219.375 Engine 113.990
in model 219.376
Repairing spark plug thread ENGINE 113.989 in AR01.30-P-5440VT
MODEL 171.473
Remove/install cylinder head ENGINE 112 in AR01.30-P-5800B
MODEL 129 ENGINE
113 in MODELS 129,
202, 208, 210
Remove/install cylinder head ENGINE 112, 113... AR01.30-P-5800BA
Remove/install cylinder head ENGINE 113.964 in AR01.30-P-5800GZ
MODEL 164.175
Remove/install cylinder head ENGINE 112, 113... AR01.30-P-5800MV
Remove/install cylinder head ENGINE 112, 113... AR01.30-P-5800PV
Remove/install cylinder head ENGINE 113.971 in AR01.30-P-5800RT
MODELS 251.075 /175
Remove/install cylinder head ENGINE 113.995 in AR01.30-P-
MODEL 230.472 5800RVK
Remove/install cylinder head Engine 113.967 in model AR01.30-P-5800TZ
219.375 Engine 113.990
in model 219.376
Remove/install cylinder head ENGINE 113.989 in AR01.30-P-5800VT
MODEL 171.473
Remove/install timing case cover ENGINE 112, 113... AR01.40-P-8000B
Remove/install timing case cover ENGINE 113.964 in AR01.40-P-8000GZ
MODEL 164.175
Remove/install timing case cover ENGINE 112, 113... AR01.40-P-8000PV
Remove/install timing case cover ENGINE 113.995 in AR01.40-P-
MODEL 230.472 8000RKV
Remove/install timing case cover ENGINE 113.971 in AR01.40-P-8000RT
MODELS 251.075 /175
Remove/install timing case cover ENGINE 113.990 in AR01.40-P-
MODELS 211.076 /276 8000RVK
ENGINE 113.991 in
MODELS 215.374,
220.074 /174
Remove/install timing case cover ENGINE 113.967 in AR01.40-P-8000TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install timing case cover ENGINE 113.989 in AR01.40-P-8000VT
MODEL 171.473
Remove/install end cover ENGINE 113.988 in AR01.40-P-8913AC
MODEL 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install the end cover ENGINE 112, 113... AR01.40-P-8913B
Removing/installing the end cover ENGINE 113.964 in AR01.40-P-8913GZ
MODEL 164.175
Removing/installing the end cover ENGINE 113.971 in AR01.40-P-8913RT
MODELS 251.075 /175
Remove/install end cover ENGINE 113.995 in AR01.40-P-
MODEL 230.472 8913RVK
Removing/installing the end cover ENGINE 113.967 in AR01.40-P-8913TY
MODEL 219.375
ENGINE 113.990 in
MODEL219.376
Measuring, boring and honing ENGINE 112, 113... AR01.40-P-9201AA
cylinder bores
Measure cylinder bores ENGINE 112, 113... AR01.40-P-9202AV
Measuring cylinder bores ENGINE 113.964 in AR01.40-P-9202GZ
MODEL 164.175
Measuring cylinder bores ENGINE 113.971 in AR01.40-P-9202RT
MODELS 251.075 /175
Measuring cylinder bores ENGINE 113.967 in AR01.40-P-9202TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oil pan ENGINE 112 in AR01.45-P-7500F
MODELS 210.06 /26 /66
ENGINE 113 in
MODEL 210 ENGINE
113.980 in MODELS
210.074 /274
Remove/install oil pan ENGINE 112, 113... AR01.45-P-7500FB
Remove/install oil pan ENGINE 112 in AR01.45-P-7500FC
MODELS 208, 202
ENGINE 113 in
MODEL 208 ENGINE
113.944 in MODELS
202.033 /093
Remove/install oil pan ENGINE 112, 113 in AR01.45-P-7500FD
MODEL 129
Remove/install oil pan ENGINE 113.964 in AR01.45-P-7500GZ
MODEL 164.175
Remove/install oil pan ENGINE 112, 113 / AR01.45-P-7500I
(except 112.975,
113.948 /966) in
MODEL 220
Remove/install oil pan ENGINE 112, 113... AR01.45-P-7500IW

Remove/install oil pan ENGINE 112, 113... AR01.45-P-7500PV
Remove/install oil pan ENGINE 113... AR01.45-P-7500R
Remove/install oil pan ENGINE 113.971 in AR01.45-P-7500RT
MODEL 251.075 /175
Remove/install oil pan ENGINE 112, 113... AR01.45-P-7500TV
Remove, install oil pan ENGINE 113.967 in AR01.45-P-7500TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oil pan ENGINE 113.989 in AR01.45-P-7500VT
MODEL 171.473
Remove/install bottom part of oil ENGINE 113.988 in AR01.45-P-7555AC
pan MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install bottom part of oil ENGINE 113.964 in AR01.45-P-7555GZ
pan MODEL 164.175
Remove/install bottom part of oil ENGINE 112, 113... AR01.45-P-7555IW
pan
Remove/install bottom part of oil ENGINE 112, 113... AR01.45-P-7555PV
pan
Remove/install oil pan bottom ENGINE 113... AR01.45-P-7555R
section
Remove/install bottom part of oil ENGINE 113.971 in AR01.45-P-7555RT
pan MODEL 251.075 /175
Remove/install oil pan bottom ENGINE 113.967 in AR01.45-P-7555TY
section MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install bottom part of oil ENGINE 112.942 in AR01.45-P-7555V
pan MODEL 163.154
ENGINE 112.970 in
MODEL 163.157
ENGINE 113.942 in
MODEL 163.172
Remove/install bottom part of oil ENGINE 112, 113... AR01.45-P-7555VA
pan
Remove/install bottom part of oil ENGINE 113.965 in AR01.45-P-7555VE
pan MODEL 163.175
ENGINE 113.981 in
MODEL 163.174

ENGINE 156
Inspecting cylinders ENGINE 156 in MODEL 164, AR01.00-P-0200GZS

with a light probe 251
Inspect cylinders with ENGINE 156 in MODEL 216, AR01.00-P-0200SMG
a light probe 221
Inspecting cylinders ENGINE 156.983 in MODELS AR01.00-P-0200TMG
with light probe 211.077 /277, 219.377 ENGINE
156.982 in MODELS
209.377 /477
Testing compression ENGINE 156 in MODEL 164, AR01.00-P-1200GZS
pressure 251
Test compression ENGINE 156 in MODEL 216, AR01.00-P-1200SMG
pressure 221
Test compression ENGINE 156.983 in MODEL AR01.00-P-1200TMG
pressure 211.077 /277, 219.377 ENGINE
156.982 in MODEL 209.377 /477
Inspect cylinders for ENGINE 156 in MODEL 164, AR01.00-P-1300GZS
leaks 251
Inspect cylinders for ENGINE 156 in MODEL 216, AR01.00-P-1300SMG
leaks 221
Inspect cylinders for ENGINE 156.983 in MODELS AR01.00-P-1300TMG
leaks 211.077 /277, 219.377 ENGINE
156.982 in MODELS
209.377 /477
Disconnect, connect ENGINE 156 in MODEL 164 AR01.00-P-2410GZS
Disconnect, connect ENGINE 156.982 in MODEL AR01.00-P-2410QMG
engine wiring harness 209.377 /477
Disconnect, connect ENGINE 156 in MODEL 251 AR01.00-P-2410RTS
Disconnect, connect ENGINE 156 in MODEL 216, AR01.00-P-2410SMG
engine wiring harness 221
Disconnect, connect ENGINE 156.983 in MODEL AR01.00-P-2410TMG
engine wiring harness 211.077 /277, 219.377
Crank engine with ENGINE 156 in MODEL 164, AR01.10-P-0110GZS
starter. 251
Crank engine with ENGINE 111, 112, 113, 156, AR01.10-P-0110PV
starter. 271 ...
Crank engine with ENGINE 156, 272, 273, 275, 642 AR01.10-P-0110SX
starter. in MODEL 221 ENGINE 156,
273, 275 in MODEL 216
Crank engine with ENGINE 156.983 in MODELS AR01.10-P-0110TMG
starter. 211.077 /277, 219.377
Remove/install engine ENGINE 156.982 in MODEL AR01.10-P-2400QMG

209.377 /477
Remove/install engine ENGINE 156 in MODEL 221, AR01.10-P-2400SMG
216
Remove/install engine ENGINE 156.983 in MODEL AR01.10-P-2400TMG
211.077 /277, 219.377
Remove/install engine ENGINE 156 in MODEL 164, AR01.10-P-2500GZS
with front axle carrier 251
Detach/attach engine ENGINE 156 in MODEL 164, AR01.10-P-2510GZS
on front axle carrier 251
Remove/install the ENGINE 156.980 /982 /983 /984 AR01.20-P-
centrifuge 2100AMG
Remove, install ENGINE 156 in MODEL 164, AR01.20-P-5014GZS
cylinder head cover 251
Remove, install ENGINE 156 in MODEL 216, AR01.20-P-5014SMG
cylinder head cover 221
Remove, install ENGINE 156.983 in MODELS AR01.20-P-5014TMG
cylinder head cover 211.077 /277, 219.377 ENGINE
156.982 in MODELS
209.377 /477
Remove/install ENGINE 156 in MODEL 164, AR01.30-P-5800GZS
cylinder head 251
Remove/install ENGINE 156 in MODEL 216, AR01.30-P-5800SMG
cylinder head 221
Remove/install ENGINE 156.983 in MODEL AR01.30-P-5800TMG
cylinder head 211.077 /277, 219.377 ENGINE
156.982 in MODEL 209.377 /477
Remove/install timing ENGINE 156 AR01.40-P-
case cover 8000AMG
Measure cylinder ENGINE 156 AR01.40-P-
bores 9202AMG
Remove/install oil pan ENGINE 156 in MODEL 164, AR01.45-P-7500GZS
251
Remove/install oil pan ENGINE 156.982 in MODEL AR01.45-P-7500QMG
209.377 /477
Removing and ENGINE 156 in MODEL 216, AR01.45-P-7500SMG
installing oil pan 221
Remove/install oil pan ENGINE 156.983 in MODEL AR01.45-P-7500TMG
211.077/277, 219.377
Remove/install bottom ENGINE 156 in MODEL 164, AR01.45-P-7555GZS
part of oil pan 251
Removing, installing ENGINE 156 in MODEL 216, AR01.45-P-7555SMG
bottom part of oil pan 221
Remove/install bottom ENGINE 156.982 in MODEL AR01.45-P-7555TMG
part of oil pan 209.377 /477

ENGINE 156.983 in MODEL
211.077 /277, 219.377

ENGINE 272
Crank engine ENGINE 272, 273 ... AR01.00-P-0100T

Inspect cylinders using a light ENGINE 272, 273 in AR01.00-P-0200GZA
probe MODEL 164, 251
Inspecting cylinders with a ENGINE 272, 273 ... AR01.00-P-0200QB
light probe
Inspect cylinders with light ENGINE 272, 273 in AR01.00-P-0200RX
probe MODEL 230
Inspecting cylinders with a ENGINE 273, 275 in AR01.00-P-0200SX
light probe MODEL 216 ENGINE
272, 273, 275 in MODEL
221
Inspecting cylinders with light ENGINE 272, 273 in AR01.00-P-0200TS
probe MODELS 211, 219
Inspecting cylinders with a ENGINE 272.942 in AR01.00-P-0200V
light probe MODEL 171.454 ENGINE
272.963 in MODEL
171.456
Test compression pressure ENGINE 272, 273 in AR01.00-P-1200GZA
MODEL 164, 251
Testing compression pressure ENGINE 272, 273 ... AR01.00-P-1200QB
Test compression pressure ENGINE 272, 273 in AR01.00-P-1200RX
MODEL 230
Testing compression pressure ENGINE 273 in MODEL AR01.00-P-1200SX
216 ENGINE 272, 273 in
MODEL 221
Test compression pressure ENGINE 272, 273 in AR01.00-P-1200TS
MODELS 211, 219
Testing the compression ENGINE 272.942 in AR01.00-P-1200VA
pressure MODEL 171.454 ENGINE
272.963 in MODEL
171.456
Inspect cylinders for leaks ENGINE 272, 273 in AR01.00-P-1300GZA
MODEL 164, 251
Inspect cylinders for leaks ENGINE 272, 273 ... AR01.00-P-1300QB
Inspect cylinders for leaks ENGINE 272, 273 in AR01.00-P-1300RX
MODEL 230
Inspect cylinders for leaks ENGINE 273 in MODEL AR01.00-P-1300SX
216 ENGINE 272, 273 in
MODEL 221
Inspect cylinders for leaks ENGINE 272, 273 in AR01.00-P-1300TS
MODELS 211, 219
Inspect cylinders for leaks ENGINE 272.942 in AR01.00-P-1300VA
272.963 in MODEL
171.456
Disconnect, connect engine ENGINE 272, 273 in AR01.00-P-2410GZA
wiring harness MODEL 164, 251
Disconnect, connect engine ENGINE 272, 273 in AR01.00-P-2410RX
wiring harness MODEL 230
Disconnect, connect engine ENGINE 272, 273 ... AR01.00-P-2410SX
wiring harness
Crank engine with starter. ENGINE 271, 272, 642, AR01.10-P-0110CW
646 in MODEL 204
Crank engine with starter. ENGINE 113, 272, 273 in AR01.10-P-0110GZ
MODEL 164, 251
Cranking engine using the ENGINE 272, 273 ... AR01.10-P-0110QB
starter.
Crank engine with starter. ENGINE 272, 273 in AR01.10-P-0110RX
MODEL 230
Crank engine with starter. ENGINE 156, 272, 273, AR01.10-P-0110SX
275, 642 in MODEL 221
ENGINE 156, 273, 275 in
MODEL 216
Crank engine with starter. ENGINE 271, 272, 273 in AR01.10-P-0110TS
MODEL 211 ENGINE
272, 273 in MODEL 219
Remove/install engine ENGINE 272 in MODEL AR01.10-P-2400GZA
164
Remove/install engine ENGINE 272 ... AR01.10-P-2400VA
Remove/install engine ENGINE 272 ... AR01.10-P-2400VB
Remove/install engine with ENGINE 272 in MODEL AR01.10-P-2401CV
transmission 204.05 /25
Remove/install engine with ENGINE 272, 273 ... AR01.10-P-2401QB
transmission
Remove/install engine with ENGINE 272 ... AR01.10-P-2401QD
transmission
Remove/install engine with ENGINE 272, 273 ... AR01.10-P-2401TS
transmission
Remove/install engine with ENGINE 272 in MODEL AR01.10-P-2500CWX
front axle carrier 204.08

Remove/install engine with ENGINE 272, 273 in AR01.10-P-2500GZA
front axle carrier MODEL 164, 251
Remove/install engine with ENGINE 272, 273 in AR01.10-P-2500RX
front axle carrier MODEL 230
Remove/install engine with ENGINE 273.924 /968, AR01.10-P-2500SW
front axle carrier 272.975 in MODEL
221.08 /18
Remove/install engine with ENGINE 272.946 /965 in AR01.10-P-2500SX
front axle carrier MODEL 221 ENGINE
273.922 /961 in MODEL
221 ENGINE 273.961 in
MODEL 216
Detach/attach engine on front ENGINE 272 in MODEL AR01.10-P-2510CWX
axle carrier 204.08
Detach/attach engine on front ENGINE 272, 273 in AR01.10-P-2510GZA
axle carrier MODEL 164, 251 with
TRANSMISSION 722.9
Remove, install engine ENGINE 272, 273, 275 in AR01.10-P-2510RX
from/onto front axle carrier MODEL 230
Detach/attach engine on front ENGINE 272, 273, 275 ... AR01.10-P-2510SX
axle carrier
Detach/attach engine on front ENGINE 273.962 in AR01.10-P-2510TW
axle carrier MODEL 211.090 /290
ENGINE 273.924 /968,
272.975 in MODEL
221.08 /18
Remove/install centrifuge ENGINE 272 in MODEL AR01.20-P-2100CV
204
Remove/install centrifuge ENGINE 272, 273 in AR01.20-P-2100GZA
MODEL 164, 251
Remove/install the centrifuge ENGINE 272, 273 ... AR01.20-P-2100QB
Remove/install the centrifuge ENGINE 272, 273 in AR01.20-P-2100RX
MODEL 230
Remove/install the centrifuge ENGINE 273 in MODEL AR01.20-P-2100SX
216 ENGINE 272, 273 in
MODEL 221
Remove/install the centrifuge ENGINE 272, 273 in AR01.20-P-2100TS
MODELS 211, 219
Remove/install the centrifuge ENGINE 272.942 /963 in AR01.20-P-2100VA
MODEL 171
Remove/install centrifuge ENGINE 272, 273 ... AR01.20-P-2120QB
cover
Remove/install centrifuge ENGINES 272.942 /963 in AR01.20-P-2120V
cover MODEL 171

Remove/install right cylinder ENGINE 272 in MODEL AR01.20-P-5012CV
head cover 204
Remove/install right cylinder ENGINE 272, 273 in AR01.20-P-5012GZA
head cover MODEL 164, 251
Remove/install left cylinder ENGINE 272 in MODEL AR01.20-P-5013CV
head cover 204
Remove/install left cylinder ENGINE 272, 273 in AR01.20-P-5013GZA
head cover MODEL 164, 251
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014QB
cover
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014QC
cover
Remove/install cylinder head ENGINE 272, 273 in AR01.20-P-5014RX
cover MODEL 230 Left cylinder
head cover
Remove/install cylinder head ENGINE 272, 273 in AR01.20-P-5014RY
cover MODEL 230 Right
cylinder head cover
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014SX
cover
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014SY
cover
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014TS
cover
Remove, install cylinder head ENGINE 272, 273 ... AR01.20-P-5014TT
cover
Remove, install cylinder head ENGINE 272.985 in AR01.20-P-5014TX
cover MODEL 219.357 Left
cylinder head cover
Remove, install cylinder head ENGINE 272.985 in AR01.20-P-5014TY
cover MODEL 219.357 Right
cylinder head cover
Removing/installing the ENGINES 272.942 /963 in AR01.20-P-5014VA
cylinder head cover MODEL 171 Left cylinder
head cover
Removing/installing the ENGINE 272.942 /963 in AR01.20-P-5014VB
cylinder head cover MODEL 171 Right
cylinder head cover
Remove/install oil separator ENGINE 272 in MODEL AR01.20-P-9750CV
204
Remove/install oil separator ENGINE 272, 273 in AR01.20-P-9750GZA
MODEL 164, 251
Remove/install oil separator ENGINE 272, 273 ... AR01.20-P-9750QB
Remove/install oil separator ENGINE 272, 273 in AR01.20-P-9750RX

MODEL 230
Remove/install oil separator ENGINE 273 in MODEL AR01.20-P-9750SX
216 ENGINE 272, 273 in
MODEL 221
Remove/install oil separator ENGINE 272, 273 in AR01.20-P-9750TS
MODELS 211, 219
Remove/install oil separator ENGINES 272.942 /963 in AR01.20-P-9750VA
MODEL 171
Remove/install front cover on ENGINE 272 in MODEL AR01.30-P-5700CVL
cylinder head 204 On left cylinder head
Remove/install front cover on ENGINE 272 in MODEL AR01.30-P-5700CVR
cylinder head 204 On right cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700GZA
cylinder head MODEL 164, 251 Left
cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700GZC
cylinder head MODEL 164, 251 Right
cylinder head
Remove/install front cover on ENGINE 272, 273 ... AR01.30-P-5700QB
cylinder head
Remove/install front cover on ENGINE 272, 273 ... AR01.30-P-5700QC
cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700RX
cylinder head MODEL 230 Front cover
at left cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700RY
cylinder head MODEL 230 Front cover
at right cylinder head
Remove/install front cover on ENGINE 272, 273 ... AR01.30-P-5700SX
cylinder head
Remove/install front cover on ENGINE 272, 273 ... AR01.30-P-5700SY
cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700TS
cylinder head MODEL 211, 219 Front
cover at left cylinder head
Remove/install front cover on ENGINE 272, 273 in AR01.30-P-5700TT
cylinder head MODEL 211, 219 Front
cover at right cylinder head
Removing/installing front ENGINES 272.942 /963 in AR01.30-P-5700VA
cover on the cylinder head MODEL 171 Right
cylinder head
Removing/installing front ENGINE 272.942 /963 in AR01.30-P-5700VB
cover on cylinder head MODEL 171 Left cylinder
head
Removing / installing the ENGINE 272 in MODEL AR01.30-P-5770CV

cylinder head 204
Remove/install he cylinder ENGINE 272, 273 in AR01.30-P-5770GZA
head MODEL 164, 251
Removing / installing right ENGINE 272 in MODEL AR01.30-P-5780CV
cylinder head 204
Remove/install right cylinder ENGINE 272, 273 in AR01.30-P-5780GZA
head MODEL 164, 251
Remove/install cylinder head ENGINE 272, 273 ... AR01.30-P-5800QB
Remove/install cylinder head ENGINE 272, 273 ... AR01.30-P-5800QC
Remove/install cylinder head ENGINE 272, 273 in AR01.30-P-5800RX
MODEL 230 Left cylinder
head
Remove/install cylinder head ENGINE 272, 273 in AR01.30-P-5800RY
MODEL 230 Right
cylinder head
Remove/install cylinder head ENGINE 272, 273 ... AR01.30-P-5800SX
Remove/install cylinder head ENGINE 272, 273 ... AR01.30-P-5800SY
Remove/install cylinder head ENGINE 272, 273 in AR01.30-P-5800TS
MODEL 211, 219 Left
cylinder head
Remove/install cylinder head ENGINE 272, 273 in AR01.30-P-5800TT
MODEL 211, 219 Right
cylinder head
Remove/install cylinder head ENGINE 272 ... AR01.30-P-5800VA
Remove/install cylinder head ENGINE 272 ... AR01.30-P-5800VB
Remove/install timing case ENGINE 272 in MODEL AR01.40-P-8000CV
cover 204
Remove/install timing case ENGINE 272, 273 in AR01.40-P-8000GZA
cover MODEL 164, 251
Remove/install timing case ENGINE 272, 273 ... AR01.40-P-8000QB
cover
Remove/install timing case ENGINE 272, 273 in AR01.40-P-8000RX
cover MODEL 230
Remove/install timing case ENGINE 272, 273 ... AR01.40-P-8000SX
cover
Remove/install timing case ENGINE 272, 273 in AR01.40-P-8000TS
cover MODEL 211, 219
Remove/install timing case ENGINE 272.942 in AR01.40-P-8000VA
cover MODEL 171.454 ENGINE
272.963 in MODEL
171.456
Measure cylinder bores ENGINE 272 in MODEL AR01.40-P-9202CV
204
Measure cylinder bores ENGINE 113, 272, 273 in AR01.40-P-9202GZ

MODEL 164, 251
Measure cylinder bores ENGINE 272, 273 ... AR01.40-P-9202QB
Measure cylinder bores ENGINE 272, 273 in AR01.40-P-9202TS
MODELS 211, 219
Remove/install oil pan ENGINE 272 in MODEL AR01.45-P-7500CV
204.0 /2 Vehicles with rear
sump
Remove/install oil pan ENGINE 272 in MODEL AR01.45-P-7500CWX
204.0 Vehicles with middle
sump
Remove/install oil pan ENGINE 272, 273 in AR01.45-P-7500GZA
MODEL 164, 251
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7500QB
Remove/install oil pan ENGINE 272.970 in AR01.45-P-7500QD
MODEL 203.087 /287
ENGINE 272.941 in
MODEL 203.092 /292
Remove/install oil pan ENGINE 272, 273 in AR01.45-P-7500RX
MODEL 230
Remove/install oil pan ENGINE 273, 272 in AR01.45-P-7500SW
MODEL 221 Vehicles
with middle sump
Remove/install oil pan ENGINE 272 in MODEL AR01.45-P-7500SY
221 Vehicles with front
sump
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7500TS
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7500TW
Remove/install oil pan ENGINE 272.942 in AR01.45-P-7500VA
272.963 in MODEL
171.456
Remove/install bottom part of ENGINE 272 in MODEL AR01.45-P-7555CV
oil pan 204.0 /2 Vehicles with rear
sump
Remove/install bottom part of ENGINE 272 in MODEL AR01.45-P-7555CWX
oil pan 204.0 Vehicles with middle
sump
Remove/install bottom part of ENGINE 272, 273 in AR01.45-P-7555GZA
oil pan MODEL 164, 251
Remove/install oil pan bottom ENGINE 272, 273 ... AR01.45-P-7555QB
section
Remove/install oil pan bottom ENGINE 272.970 in AR01.45-P-7555QD
section MODEL 203.087 /287
ENGINE 272.941 in
MODEL 203.092 /292
Remove/install bottom part of ENGINE 272, 273 in AR01.45-P-7555RX
oil pan MODEL 230
Remove/install bottom part of ENGINE 273, 272 in AR01.45-P-7555SW
oil pan MODEL 221 Vehicles
with middle sump
Remove/install oil pan bottom ENGINE 272, 273 ... AR01.45-P-7555SX
section
Remove/install bottom part of ENGINE 272, 273 in AR01.45-P-7555TS
oil pan MODEL 211, 219 Vehicles
with rear sump
Remove/install oil pan bottom ENGINE 272, 273 in AR01.45-P-7555TW
section MODEL 211 Vehicles
with front sump
Remove/install oil pan bottom ENGINE 272.942 in AR01.45-P-7555VB
section MODEL 171.454 ENGINE
272.963 in MODEL
171.456

ENGINE 273
Crank engine ENGINE 272, 273 ... AR01.00-P-0100T

Inspect cylinders using a ENGINE 272, 273 in AR01.00-P-0200GZA
light probe MODEL 164, 251
Inspecting cylinders ENGINE 272, 273 ... AR01.00-P-0200QB
with a light probe
Inspect cylinders with ENGINE 272, 273 in AR01.00-P-0200RX
light probe MODEL 230
Inspecting cylinders ENGINE 273, 275 in AR01.00-P-0200SX
with a light probe MODEL 216 ENGINE 272,
273, 275 in MODEL 221
Inspecting cylinders ENGINE 272, 273 in AR01.00-P-0200TS
with light probe MODELS 211, 219
Test compression ENGINE 272, 273 in AR01.00-P-1200GZA
pressure MODEL 164, 251
Testing compression ENGINE 272, 273 ... AR01.00-P-1200QB
pressure
Test compression ENGINE 272, 273 in AR01.00-P-1200RX
pressure MODEL 230
Testing compression ENGINE 273 in MODEL AR01.00-P-1200SX
pressure 216 ENGINE 272, 273 in

MODEL 221
Test compression ENGINE 272, 273 in AR01.00-P-1200TS
pressure MODELS 211, 219
Inspect cylinders for ENGINE 272, 273 in AR01.00-P-1300GZA
Inspect cylinders for ENGINE 272, 273 ... AR01.00-P-1300QB
leaks
Inspect cylinders for ENGINE 272, 273 in AR01.00-P-1300RX
leaks MODEL 230
Inspect cylinders for ENGINE 273 in MODEL AR01.00-P-1300SX
leaks 216 ENGINE 272, 273 in
MODEL 221
Inspect cylinders for ENGINE 272, 273 in AR01.00-P-1300TS
leaks MODELS 211, 219
Disconnect, connect ENGINE 272, 273 in AR01.00-P-2410GZA
engine wiring harness MODEL 164, 251
Disconnect, connect ENGINE 272, 273 in AR01.00-P-2410RX
engine wiring harness MODEL 230
Disconnect, connect ENGINE 272, 273 ... AR01.00-P-2410SX
Crank engine with ENGINE 113, 272, 273 in AR01.10-P-0110GZ
starter. MODEL 164, 251
Cranking engine using ENGINE 272, 273 ... AR01.10-P-0110QB
the starter.
Crank engine with ENGINE 272, 273 in AR01.10-P-0110RX
starter. MODEL 230
Crank engine with ENGINE 156, 272, 273, 275, AR01.10-P-0110SX
starter. 642 in MODEL 221
ENGINE 156, 273, 275 in
MODEL 216
Crank engine with ENGINE 271, 272, 273 in AR01.10-P-0110TS
starter. MODEL 211 ENGINE 272,
273 in MODEL 219
Remove/install engine ENGINE 272, 273 ... AR01.10-P-2401QB
with transmission
Remove/install engine ENGINE 272, 273 ... AR01.10-P-2401TS
with transmission
Remove/install engine ENGINE 272, 273 in AR01.10-P-2500GZA
with front axle carrier MODEL 164, 251
Remove/install engine ENGINE 272, 273 in AR01.10-P-2500RX
with front axle carrier MODEL 230
Remove/install engine ENGINE 273.924 /968, AR01.10-P-2500SW
with front axle carrier 272.975 in MODEL
221.08 /18
Remove/install engine ENGINE 272.946 /965 in AR01.10-P-2500SX
with front axle carrier MODEL 221
ENGINE 273.922 /961 in
MODEL 221
ENGINE 273.961 in
MODEL 216
Remove/install engine ENGINE 273.962 in AR01.10-P-2500TW
with front axle carrier MODEL 211.090 /290
Detach/attach engine on ENGINE 272, 273 in AR01.10-P-2510GZA
front axle carrier MODEL 164, 251 with
TRANSMISSION 722.9
Remove, install engine ENGINE 272, 273, 275 in AR01.10-P-2510RX
from/onto front axle MODEL 230
carrier
Detach/attach engine on ENGINE 272, 273, 275 ... AR01.10-P-2510SX
front axle carrier
Detach/attach engine on ENGINE 273.962 in AR01.10-P-2510TW
front axle carrier MODEL 211.090 /290
ENGINE 273.924 /968,
272.975 in MODEL
221.08 /18
centrifuge MODEL 164, 251
Remove/install the ENGINE 272, 273 ... AR01.20-P-2100QB
centrifuge
Remove/install the ENGINE 272, 273 in AR01.20-P-2100RX
centrifuge MODEL 230
Remove/install the ENGINE 273 in MODEL AR01.20-P-2100SX
centrifuge 216 ENGINE 272, 273 in
MODEL 221
Remove/install the ENGINE 272, 273 in AR01.20-P-2100TS
centrifuge MODELS 211, 219
centrifuge cover
Remove/install right ENGINE 272, 273 in AR01.20-P-5012GZA
cylinder head cover MODEL 164, 251
Remove/install left ENGINE 272, 273 in AR01.20-P-5013GZA
cylinder head cover MODEL 164, 251
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014QB
head cover
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014QC
head cover
Remove/install cylinder ENGINE 272, 273 in AR01.20-P-5014RX
head cover MODEL 230 Left cylinder
head cover
Remove/install cylinder ENGINE 272, 273 in AR01.20-P-5014RY
head cover MODEL 230 Right cylinder
head cover
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014SX
head cover
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014SY
head cover
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014TS
head cover
Remove, install cylinder ENGINE 272, 273 ... AR01.20-P-5014TT
head cover
Remove/install oil ENGINE 272, 273 in AR01.20-P-9750GZA
separator MODEL 164, 251
Remove/install oil ENGINE 272, 273 ... AR01.20-P-9750QB
separator
Remove/install oil ENGINE 272, 273 in AR01.20-P-9750RX
separator MODEL 230
Remove/install oil ENGINE 273 in MODEL AR01.20-P-9750SX
separator 216 ENGINE 272, 273 in
MODEL 221
Remove/install oil ENGINE 272, 273 in AR01.20-P-9750TS
separator MODELS 211, 219
Remove/install front ENGINE 272, 273 in AR01.30-P-5700GZA
cover on cylinder head MODEL 164, 251 Left
cylinder head
Remove/install front ENGINE 272, 273 in AR01.30-P-5700GZC
cover on cylinder head MODEL 164, 251 Right
cylinder head
Remove/install front ENGINE 272, 273 ... AR01.30-P-5700QB
cover on cylinder head
Remove/install front ENGINE 272, 273 ... AR01.30-P-5700QC
Remove/install front ENGINE 272, 273 in AR01.30-P-5700RX
cover on cylinder head MODEL 230 Front cover at
left cylinder head
Remove/install front ENGINE 272, 273 in AR01.30-P-5700RY
cover on cylinder head MODEL 230 Front cover at
right cylinder head
Remove/install front ENGINE 272, 273 ... AR01.30-P-5700SX
Remove/install front ENGINE 272, 273 ... AR01.30-P-5700SY
Remove/install front ENGINE 272, 273 in AR01.30-P-5700TS
cover on cylinder head MODEL 211, 219 Front

cover at left cylinder head
Remove/install front ENGINE 272, 273 in AR01.30-P-5700TT
cover on cylinder head MODEL 211, 219 Front
cover at right cylinder head
Remove/install he ENGINE 272, 273 in AR01.30-P-5770GZA
cylinder head MODEL 164, 251
Remove/install right ENGINE 272, 273 in AR01.30-P-5780GZA
cylinder head MODEL 164, 251
Remove/install cylinder ENGINE 272, 273 ... AR01.30-P-5800QB
head
Remove/install cylinder ENGINE 272, 273 ... AR01.30-P-5800QC
head
Remove/install cylinder ENGINE 272, 273 in AR01.30-P-5800RX
head MODEL 230 Left cylinder
head
Remove/install cylinder ENGINE 272, 273 in AR01.30-P-5800RY
head MODEL 230 Right cylinder
head
Remove/install cylinder ENGINE 272, 273 ... AR01.30-P-5800SX
head
Remove/install cylinder ENGINE 272, 273 ... AR01.30-P-5800SY
head
Remove/install cylinder ENGINE 272, 273 in AR01.30-P-5800TS
head MODEL 211, 219 Left
cylinder head
Remove/install cylinder ENGINE 272, 273 in AR01.30-P-5800TT
head MODEL 211, 219 Right
cylinder head
Remove/install timing ENGINE 272, 273 in AR01.40-P-8000GZA
case cover MODEL 164, 251
Remove/install timing ENGINE 272, 273 ... AR01.40-P-8000QB
case cover
Remove/install timing ENGINE 272, 273 in AR01.40-P-8000RX
case cover MODEL 230
Remove/install timing ENGINE 272, 273 ... AR01.40-P-8000SX
case cover
Remove/install timing ENGINE 272, 273 in AR01.40-P-8000TS
case cover MODEL 211, 219
Measure cylinder bores ENGINE 113, 272, 273 in AR01.40-P-9202GZ
MODEL 164, 251
Measure cylinder bores ENGINE 272, 273 ... AR01.40-P-9202QB
Measure cylinder bores ENGINE 272, 273 in AR01.40-P-9202TS
MODELS 211, 219
Remove/install oil pan ENGINE 272, 273 in AR01.45-P-7500GZA

MODEL 164, 251
Remove/install oil pan ENGINE 272, 273 in AR01.45-P-7500RX
MODEL 230
Remove/install oil pan ENGINE 273, 272 in AR01.45-P-7500SW
MODEL 221 Vehicles with
middle sump
Remove/install oil pan ENGINE 273 in MODEL AR01.45-P-7500SX
216, 221 Vehicles with front
sump
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7500TS
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7500TW
Remove/install bottom ENGINE 272, 273 in AR01.45-P-7555GZA
part of oil pan MODEL 164, 251
bottom section
Remove/install bottom ENGINE 272, 273 in AR01.45-P-7555RX
part of oil pan MODEL 230
Remove/install bottom ENGINE 273, 272 in AR01.45-P-7555SW
part of oil pan MODEL 221 Vehicles with
middle sump
Remove/install oil pan ENGINE 272, 273 ... AR01.45-P-7555SX
bottom section
Remove/install bottom ENGINE 272, 273 in AR01.45-P-7555TS
part of oil pan MODEL 211, 219 Vehicles
with rear sump
Remove/install oil pan ENGINE 272, 273 in AR01.45-P-7555TW
bottom section MODEL 211 Vehicles with
front sump
CONNECT COMPRESSION TESTER - AR01.10-P-0010-01GZ


1. Remove cover (1) of left fuse and relay box in the engine compartment.
Installation: Check rubber seal in cover (1) and replace if necessary. The cover (1) must be
seated in the groove.
Fig. 41: Identifying Rubber Seal In Cover

2. Detach starter relay (2) from socket.

Fig. 42: Identifying Starter Relay

3. Plug corresponding adapter line from electrical connection kit into socket of relay base (see arrow).
4. Connect adapter line to compression tester line.
5. Clip terminal clamp (4) of compression tester onto connection (5).
Fig. 43: Identifying Terminal Clamp And Compression Tester

ENGINE 113, 272, 273 in MODEL 164, 251
Fig. 44: Identifying Engine With Starter Components (Shown On Model 164.1)
Remove/install

AS00.00-Z-
0005-01A

Switch ignition off, remove ignition key button repeatedly until ignition is
1
(transmitter key) switched off.
Remove the Keyless Go transmitter

AR01.10-
2 Connect up compression recorder (01) P-0010-
01GZ
Fig. 10
Fig. 7
3 Crank engine with starter contact switch (01a) at compression
recorder (01).
If ignition was switched on
during the process.
Read out fault memory and erase if caused by disconnecting cables or by
5
necessary simulation during test operations,

Fig. 46: Identifying Compression Tester (001 589 76 21 00)

CRANK ENGINE WITH STARTER. - AR01.10-P-0110GZS

Shown on model 164
Fig. 47: Identifying Engine With Starter Components (Shown On Model 164)
Remove/install

moving by itself.
clothes.
Keyless Go:
Press keyless go start/stop button
Switch ignition off, remove ignition key repeatedly until ignition is switched
1
(transmitter key). off Remove keyless go transmitter
and store outside of transmission
range (min. 2 m)
AR88.40-P-
1000GZ
AR88.40-P-
Model 251
1000RT
AR01.10-P-
3 Connect up compression recorder (01) 0010-01GZ

Compression recorder Fig. 7
4 Crank engine with starter contact switch (01a) at compression
recorder (01).
If ignition was switched on
during the process.
Read out fault memory and erase if Stored faults which may be
6 caused by disconnecting cables or by
required
simulation during test operations,
*WH58.30-
Z-1048-13A



Number Designation
REMOVE/INSTALL ENGINE - AR01.10-P-2400GZ
Fig. 50: Identifying Engine Remove/Install Components - Engines 113.964


Fig. 51: Identifying Engine Remove/Install Components (Shown On Vehicle With Offroad Package, Code
430)
Fig. 52: Identifying Engine Remove/Install Components - Engines 113.964 (1 Of 2)

Fig. 53: Identifying Engine Remove/Install Components - Engines 113.964 (2 Of 2)

MODIFICATION NOTES
25.6.07 Steps adapted to changed repair method
Observe tightening procedure when assembling propeller shaft, added Operation step 24, 36
Remove/install
Risk of death caused by Align vehicle between columns of vehicle lift and AS00.00-
vehicle slipping or toppling off position four support plates at vehicle lift support Z-0010-
of the lifting platform. points specified by vehicle manufacturer. 01A
fingers being pinched or
AS00.00-
crushed when removing, Keep body parts and limbs well clear of moving
Z-0011-
installing or aligning hoods, parts.
01A
doors, trunk lids, liftgates or
sliding roof
AH00.00-
Notes on self-locking nuts and
N-0001-
bolts
01A

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

1
Insulate ground line as a protection against
unintentional contact of detached ground line with
Disconnect battery ground Vehicles with Keyless Go, code 889: Press AR54.10-
3 Keyless Go start/stop button repeatedly until
cable P-0003GZ
Remove the Keyless Go transmitter card or
transmitter key from vehicle and store beyond reach
of the transmitter (at least 2 m).
AH54.10-
01A
AR01.10-
P-2405GZ
fuel igniting, risk of poisoning No fire, sparks, open flames or smoking.
AS47.00-
caused by inhaling and Pour fuels only into suitable and appropriately
Z-0001-
swallowing fuel and risk of marked containers.
01A
injury to eyes and skin caused Wear protective clothing when handling fuel.
by contact with fuel
AR07.03-
Remove fuel hose (1) from fuel Release fuel pressure with pressure hose
5 P-1460-
distributor via service valve 01GZ
*BA07.52-
P-1001-
01A
Fig. 55
Suction off hydraulic fluid
6 from the expansion reservoir of Fig. 56
power steering (7)
AR20.00-
P-1142GZ
AH20.00-
01A
Detach coolant hose at
Check condition of coolant hose and hose
8 thermostat housing connection
clamps, replace if required.
fitting (2)
9 Remove coolant hoses at top

coolant pump connection Check condition of coolant hoses and hose
fitting (3) and bottom coolant clamps, replace if required.

pump connection fitting (4)
AR20.40-
10 Remove fan shroud with fan
P-5000GZ
Attach guard plate for
11
radiator/condenser
WF58.50-
Guard plate for
P-0110-
radiator/condenser
01A
AR13.22-
P-1202GZ
Remove banjo bolt (5) power
AR46.25-
13 steering line at power steering Seal the connections.
P-3015RT
pump
Fig. 54
Detach vacuum line for brake
In doing so, push outer face to the rear and
14 booster (6) at hot film mass air
pull out vacuum line.
flow sensor
Remove coolant hose (8) of
Check condition of coolant hose (8) and hose
15 heat exchanger from
connection to firewall (9) clamp; replace if necessary.
Disconnect electrical plug
16 connector (10) at purge
switchover valve (Y58/1)
Remove purge line (12) from
17
purge control valve (Y58/1)
Remove purge switchover
Put down purge control valve (Y58/1) with
18 valve (Y58/1) from rubber
remaining connected line on the engine.
support
Disconnect engine wiring AR01.00-
19
harness P-2410GZ
Secure vehicle on the lifting AR00.60-
20
platform P-0100GZ
Remove bottom engine AR61.20-
21
Attach refrigerant compressor to bottom of AR83.55-
22 Remove refrigerant compressor
engine compartment with lines connected. P-5300GZ
On vehicles with engine damage it is necessary
to inspect the exhaust system for swarf before
Remove complete exhaust AR49.10-
23 installing it and to remove any swarf present,
system P-7000GZ
otherwise damage to the catalytic converter system
may occur.
Detach rear axle transmission Mark rear propeller shaft (14) relative to
24
propeller shaft (14) from propeller shaft flange.
transfer case (15)

AR41.10-
Installation: Observe tightening procedure
P-0050-
for rear propeller shaft (14) to transfer case (15). 17GZ
Fig. 58
*BA41.10-
P-1001-
01F
25 Remove heat protection Only on vehicles with offroad package code 430.
Disconnect electrical Only on vehicles with offroad package code 430.
26 connectors (16a) at transfer
Three connectors.
case (15)
Disconnect ISM connector
(16b) at intelligent servo
27
module for DIRECT SELECT
(A80)
Remove bolts (17) and remove Only necessary on the right side of the
28
exhaust bracket (18) transmission (25).
*BA49.10-
P-1001-
01S
Remove shield (19) and detach
AR27.40-
transmission control electrical
29 P-0700-
connector (20) from electric
01GZ
controller unit
*BA27.40-
P-1003-
01E
Remove cover (21) and detach Do not use an impact wrench or compressed-air AR27.20-
30 torque converter (35) from tool, otherwise the threads in the torque converter P-0100-
drive plate (36) (35) will be damaged. 01GZ
*BA27.20-
P-1002-
01C
*BA27.55-
Remove bolt (22) at oil pan oil
31 P-1003-
cooler line bracket (23)
01D
Remove bolt (26) for double *BA27.55-
32 hose clamp at alternator bracket P-1004-
(27) 01D
Detach oil cooler lines (24) Do not bend or kink oil cooler lines (24).
from transmission (25) and Seal connections on transmission (25) and
33
engine oil pan and place to one oil cooler lines (24) immediately using stop plugs.
side Installation: Replace O-rings.
*BA27.55-
P-1002-
01D
Fig. 54
Lower the transmission (25) slightly and
secure it on the transmission plate (01) with a
Support transmission (25) tensioning strap to prevent it from falling down.
34 using transmission jack and Transmission platform, see GOTIS
transmission platform (01) http://gotis.aftersales.daimlerchrysler.com
Transmission jack, see GOTIS
Installation: The bolts (29) must be
Remove bolts (28) and bolt AR22.10-
replaced.
35 (29), remove engine P-
crossmember (30) Check rear engine mount for wear and replace if 1170GZA
necessary.
AH00.00-
Notes on bolted connections
P-0007-
with self tapping screws
01SF
Mark front propeller shaft (34) to the
propeller shaft flanges.
Remove front propeller shaft
36 Installation: Observe tightening procedure
(34)
for front propeller shaft (34). AR41.10-P-0070-
03GZ
Fig. 58
*BA41.10-
P-1003-
01F
*BA41.10-
P-1004-
01F
First unscrew the bolt on the vent line
cylinder crankcase and oil pan
37 bracket (32) and remove the vent line (33).
by removing the bolts (31) of
the transmission bell housing Secure starter to prevent it from falling out.
*BA27.40-
P-1001-
01E
*BA27.40-
P-1002-
01E
*BA15.30-
P-1003-
01A
Remove transmission (25) from Secure torque converter (35) to prevent it

38 from falling out.
below
Installation: Align tapped holes of torque
converter (35) to bore holes for drive plate (36).

*BA22.10-
Remove front bolts of engine
39 P-1002-
mount to engine support (37)
03G
Attach engine hoist with
Engine hoist (self-locking) see GOTIS
40 adapter for engine hoist in
engine lifting eyes
Fig. 57
Set engine in an horizontal position in
41 Lift out engine stages with engine hoist and run out to the front
with engine hoist.
Fill power steering pump and AR46.30-
43
bleed P-0010GZ
AR20.00-
44 Fill cooling system
P-1142GZ
If cylinder head gaskets are new, warm up
Inspecting cooling system for engine first of all to operating temperature AR20.00-
45
leaks otherwise complete filling of the engine with P-1010GZ
coolant is not assured.
AR18.00-
46 Check engine oil level P-3035-
01GZ
Fig. 59
*BF18.00-
P-1001-
03U
*BF18.00-
P-1002-
03U
*BF18.00-
P-1003-
03U
*BF18.00-
P-1004-
03U
Check oil level in transmission AR27.00-
47
(25) and correct if necessary P-0100W
when engine is running. Risk Secure vehicle to prevent it from moving by itself. AS00.00-
of injury caused by contusions Wear closed and snug-fitting work clothes. Z-0005-
and burns during starting Do not touch hot or rotating parts. 01A
Carry out engine test run and

48 check engine for proper
operation and leaktightness
FUEL DISTRIBUTOR
Number Designation Engine 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/
963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/988
BA07.52-P- Fuel feed line to
Nm 38
1001-01A fuel distributor
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2
Stage
Nm 40
01F axle) Stage
Angle° 90
2
Stage
Nm 40
BA41.10-P-1004- 1
Self-locking bolt, propeller shaft to front axle gear
01F Stage
Angle° 90
2
TORQUE CONVERTER
722.9
Straight threaded
Nm 42
connection
01C plate
Stage 3 Angle° 90
EXHAUST SYSTEM
Number Designation Engine 113.964 in model
164.1
BA49.10-P-1001- Bolt, catalytic converter bracket to catalytic
Nm 20
01S convertor

722.9
Stage
Nm 5
Banjo 1
2
BA27.55-P-1003-
01D
BA27.55-P-1004-
01D
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

BA22.10-P-1002-03G Bolt connecting front engine mount to engine support Nm 53
STARTER
BA15.30-P-1003-01A Bolt connecting starter to crankcase Nm 40
HOUSING
164
BA27.40-P-1001-
01E
Nm 39
01E pan
BA27.40-P-1003-
01E
OIL LEVEL CHECK

113.964/971
Oil level
Replenish oil
88 mm +2.9
quantity in liters
Replenish oil
90 mm +2.8
quantity in liters
Replenish oil
92 mm +2.6
quantity in liters
Replenish oil
94 mm +2.5
quantity in liters
Replenish oil
96 mm quantity in liters +2.4

Replenish oil
98 mm +2.3
quantity in liters
Replenish oil
100 mm +2.2
quantity in liters
Replenish oil
102 mm +2.1
quantity in liters
Replenish oil
104 mm +1.9
quantity in liters
Replenish oil
106 mm +1.8
quantity in liters
Replenish oil
108 mm +1.7
quantity in liters
Replenish oil
BF18.00-P- Dipstick indication 88 mm to 124 mm 110 mm +1.5
quantity in liters
1002-03U (oil level too low)
Replenish oil
112 mm +1.4
quantity in liters
Replenish oil
114 mm +1.2
quantity in liters
Replenish oil
116 mm +1.0
quantity in liters
Replenish oil
118 mm +0.9
quantity in liters
Replenish oil
120 mm +0.7
quantity in liters
Replenish oil
122 mm +0.5
quantity in liters
Replenish oil
124 mm +0.3
quantity in liters
130 mm -0.3
in liters
132 mm -0.5
in liters
BF18.00-P- Oil dipstick indication 130 mm to 138 Extract oil quantity
134 mm -0.7
1004-03U mm (oil level too high) in liters
136 mm -0.9
in liters
138 mm -1,1
in liters



Fig. 57: Identifying Adapter For Engine Hoist (164 589 00 62 00)


REMOVE/INSTALL ENGINE - AR01.10-P-2400GZA

Fig. 60: Identifying Engine Remove/Install Components - Engine 272 (1 Of 5)





MODIFICATION NOTES
11.5.07 Bolt connecting exhaust rubber mount bracket (inner) to body
11.5.07 Bolt connecting exhaust rubber mount bracket (outer) to bumper bracket
Remove/install

AS00.00-
Z-0011-
01A
doors, trunk lids, tailgates or
sliding roof.
oxyhydrogen gas. Risk of
poisoning and caustic burns No fire, sparks, open flames or smoking.
AS54.10-
caused by swallowing battery Wear acid-resistant gloves, clothing and glasses.
Z-0001-
acid. Risk of injury caused by Only pour battery acid into suitable and
01A
burns to skin and eyes from appropriately marked containers.
Disconnect ground line from AR54.10-
1
battery P-0003GZ
Notes on battery AH54.10-

P-0001-
01A
AR09.10-
Remove air filter housing (3)
3 P-
with engine intake air ducts (1)
1150GZA
AR07.07-
Remove hot film mass air flow
4 P-
sensor (B2/5)
1453GZA
AR09.20-
5 Remove air guide housing (4) P-
0080GZA
Detach purge line (5) from
purge control valve (Y58/1) on
6
vacuum line for crankcase
ventilation system (6)
Disconnect brake booster
7 vacuum line (7) on intake
manifold
AR01.00-
Disconnect engine wiring
8 P-
harness
2410GZA
fuel igniting, risk of poisoning No fire, sparks, open flames or smoking.
AS47.00-
caused by inhaling and Only pour fuels into suitable and appropriately
Z-0001-
swallowing fuel and risk of marked containers.
01A
injury to eyes and skin caused Wear protective clothing when handling fuel.
by contact with fuel
AR07.03-
Reduce fuel pressure via the
9 P-1460-
service valve (8)
01GZ
Fig. 55
Unscrew fuel feed line (9) on Collect feathering-out fuel and seal
10
fuel distributor (10) connections.
*BA07.03-
P-1001-
01B
Fig. 54
Suction off steering gear oil
11 from expansion reservoir (11) Fig. 56
of power steering pump (12)
Unscrew banjo bolt (13) and
12 remove high pressure line (14) Installation: Replace sealing rings (2 x).
on power steering pump (12)
*BA46.30-
P-1008-
01H
Disconnect low-pressure line
13 Installation: Replace hose clamp.
(15) at top of radiator
Disconnect low-pressure line
14 Installation: Replace hose clamp.
(16) at bottom of radiator
temperature is below 90°C. Open cap slowly and
caused by scalding from AS20.00-
release the pressure. Do not pour coolant into
contact with hot coolant spray. Z-0001-
Risk of poisoning caused by 01A
Wear protective gloves, protective clothing and
swallowing coolant.
safety glasses.
AR20.00-
15 Drain coolant at radiator P-
1142GZC
AH20.00-
01A
Disconnect coolant line (17) on
16
heat exchanger connection (18)
Detach coolant line (19) from
17
thermostat housing
Detach coolant lines (20) from
18
coolant pump
AR20.40-
19 Remove electric fan P-
5000GZA
Withdraw oil dipstick from oil
20
dipstick guide tube
21
condenser
WF58.50-
Guard plate for radiator /
P-0110-
condenser
01A
AR13.20-
22 Remove poly-V belt (21) P-
0001GZA
Risk of death caused by Align vehicle between columns of vehicle lift and AS00.00-
vehicle slipping or toppling off position four support plates at vehicle lift support Z-0010-
the lifting platform. points specified by vehicle manufacturer. 01A
23
platform P-0100GZ
24
25 *BA46.30-
Disconnect bracket (22) of high P-1002-
pressure line (14) on oil pan 01H

Unclip left O2 sensor
connector, upstream of TWC
(G3/3x1), right O2 sensor
(G3/4x1), left O2 sensor
connector, downstream of
26
TWC (G3/5x1), right O2
sensor connector, downstream
of TWC (G3/6x1) and
electrical lines of O2 sensors
from bracket (24) and brackets
at side of transmission
Detach left O2 sensor
(G3/3x1), right O2 sensor
27 (G3/4x1), left O2 sensor
TWC (G3/5x1) and right O2
TWC (G3/6x1)
Remove bracket (24) for O2
28
sensors
AR07.52-
Remove left O2 sensor,
29 Required for removal of exhaust system. P-
downstream of TWC (G3/5)
5303GZP
AR49.10-
Remove complete exhaust
30 P-
system
7100GZA
Remove coolant compressor Remove refrigerant compressor connector
(A9) from timing case cover (A9x1) on refrigerant compressor (A9). Attach AR83.55-
31
and engine support by refrigerant compressor (A9) with connected pipe P-5300GZ
unscrewing bolts (23) system laterally at bottom of engine compartment.
Detach transmission oil line *BA27.55-
32 (25) and transmission oil line P-1002-
(26) on transmission 01D
Fig. 54
Only loosen bolt and turn double hose
Detach double hose clamps
33 clamp by 90°, place transmission oil lines (25, 26)
(27) at right side of oil pan
on front axle carrier.
*BA27.55-
P-1004-
01D
AR27.10-
P-
34 Remove transmission Support engine at front. 0500GZA
*BA22.10-
Unscrew engine mount (29)
35 P-1001-
bolts (28) at front axle carrier
03G
Observe manufacturer's assembly
Attach engine hoist to engine specifications and safety information.
36
lifting eyes Engine hoist, see GOTIS
Model 164 only Fig. 57
When lifting the engine out make sure that
37 Lift out engine engine does not come into contact with partition
wall and that steering coupling or lines cannot be
damaged.
Check engine oil level and
39 Check leakage when engine is running.
correct if necessary
40
and correct if necessary P-0100W
Fill and bleed power steering AR46.30-
41
pump (12) P-0010GZ
AR20.00-
42 Pour in coolant P-
1142GZC
AR20.00-
Inspect cooling system for
43 P-
leaks
1010GZC
when engine is running. Risk Secure vehicle to prevent it from moving by itself. AS00.00-
of injury caused by contusions Wear closed and snug-fitting work clothes. Z-0005-
and burns during starting Do not touch hot or rotating parts. 01A
Check bolted connection for fuel feed line,
connections for transmission oil lines on
transmission, pressure and low-pressure lines for
power steering, connections for coolant lines,
exhaust system and oil drain screw for signs of
leaks.
disconnecting cables or by simulation during test
45 operations, must be erased in the fault memory after
erase if necessary

Number Designation Engine 272 without Engine 272 with
code 917 code 917
BA07.03-P-1001- Union nut, fuel feed line to fuel
Nm 20 20
01B distributor

BA22.10-P-1001-03G Bolt, front engine mount to front axle carrier Nm 53
POWER STEERING PUMP

251
BA46.30-P-1002- Bolt, power steering pressure line bracket to engine
Nm 10
01H oil pan
BA46.30-P-1008- Banjo bolt, power steering pressure line to power
Nm 45
01H steering pump

722.9
Stage
Nm 5
Banjo 1
2
BA27.55-P-1004-
01D


Fig. 67: Identifying Adapter For Engine Hoist (164 589 00 62 00)

REMOVING/INSTALLING THE ENGINE COVER - AR01.10-P-2405GZ

Fig. 69: Identifying Engine Cover Remove/Install Components

Removing/installing

AR88.40-P-
1 Open engine hood
1000GZ
When unclipping the engine
Unclip mounting clamps (1, 2) by raising the cover just raise the it slightly in the
2
engine cover somewhat (arrows A) area of the mounting clamps
otherwise the cover could break.
Unclip fixing clips (1, 2) by pulling out the
3 front engine cover slightly to the front (arrow
B)
4 Remove engine cover
POSITION PORTABLE LIFTING PLATFORM - AR01.10-P-2500-01A
WORKSHOP EQUIPMENT
WE58.40-Z-1006-05A Lashing strap
WE58.40-Z-1009-05A Major assembly lifting platform
WE58.40-Z-1010-05A Universal major assemblies support (in combination
with major assemblies lifting table)
The lifting platform (01) is variably adjustable in the vehicle longitudinal direction at the adjusting
screw (03). The mounting plates (2) guided in rails are also variably adjustable in the vehicle longitudinal
direction and transverse direction at the adjusting screw (04) to the transmission and front axle carrier. The
respectively individual mounting plates (2) can be adjusted for height by means of an adjusting rod (05) to the
required tilt of the transmission and front axle carrier.
Fig. 70: Identifying Position Portable Lifting Platform

Ensure that no cables of lines get caught when lowering.
1. Position lifting platform (01) with aggregate mount (02) under the front axle carrier (1).
Take note in doing so of even alignment of the mounting plates (2) on the engine / transmission
unit.
2. Fix the whole engine / transmission unit by means of tensioning straps (3) to the mounting plates (2).
Fig. 72: Identifying Transmission Unit

REMOVE/INSTALL ENGINE WITH FRONT AXLE CARRIER - AR01.10-P-2500GZ

Fig. 73: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 113.964

Fig. 74: Identifying Engine With Front Axle Carrier Remove/Install Components (Shown On Vehicle
With Offroad Package, Code 430)
Fig. 75: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 113.964 (1 Of
2)
Fig. 76: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 113.964 (2 Of
2)
MODIFICATION NOTES
Observe tightening procedure when assembling the propeller shaft, added Step 26
Remove/install
Risk of death caused by vehicle Align vehicle between columns of vehicle lift AS00.00-
slipping or toppling off of the and position four support plates at vehicle lift Z-0010-
lifting platform. support points specified by vehicle manufacturer. 01A
vehicle starting off by itself when
engine is running. Risk of injury AS00.00-
itself.
caused by contusions and burns Z-0005-
during starting procedure or when 01A
working near the engine as it is
running
being pinched or crushed when AS00.00-
Keep body parts and limbs well clear of moving
removing, installing or aligning Z-0011-
parts.
hoods, doors, trunk lids, tailgates 01A
or sliding roof.
AH00.00-
N-0001-
bolts
01A
On vehicles with memory
package (driver seat, steering
column, mirrors) code 275 the
easy entry/exit must be disabled
otherwise damage can occur when
reconnecting the battery, as the
driver seat and steering wheel can
move into another position, when
for example the driver door is
opened or closed. Disabling takes
place via the buttons on the
steering wheel in the "comfort"
menu of the multifunction display
poisoning and caustic burns No fire, sparks, open flames or smoking. Wear
AS54.10-
caused by swallowing battery acid-resistant gloves, clothing and glasses. Only
Z-0001-
acid. Risk of injury caused by pour battery acid into suitable and appropriately
01A
burns to skin and eyes from marked containers.
1
Insulate ground line as a protection against AR54.10-
3 Disconnect battery ground cable unintentional contact of detached ground line
P-0003GZ
AH54.10-
01A
Vehicles with Keyless Go code 889:
Press the Keyless Go start and stop button
repeatedly until the ignition is switched off.
4
platform P-0100GZ
AR01.10-
P-2405GZ
Risk of explosion caused by fuel
igniting, risk of poisoning caused No fire, sparks, open flames or smoking. AS47.00-
by inhaling and swallowing fuel Pour fuels only into suitable and appropriately Z-0001-
and risk of injury to eyes and marked containers. 01A

skin caused by contact with fuel Wear protective clothing when handling fuel.
AR07.03-
Detach fuel line (1) from fuel Release fuel pressure with pressure hose P-1460-
6
distributor via service valve 01GZ
*BA07.52-
P-1002-
01A
Fig. 55
Vehicles with automatic air conditioning AR83.30-
7 Discharge air conditioning system code 580 or comfort automatic air conditioning
P-1760GZ
code 581.
Suction off hydraulic fluid from
8 the expansion reservoir of power Fig. 56
steering (7)
AR20.00-
P-1142GZ
AH20.00-
01A
Detach coolant hose at thermostat Check condition of coolant hose and hose
10
housing connection fitting (2) clamps, replace if required.
Remove coolant hoses on upper
coolant pump connection fitting Check condition of coolant hoses and hose
11
(3) and lower coolant pump clamps, replace if required.
connection fitting (4)
Detach power steering lines at
12 Seal all connections immediately.
radiator connections (8)
Fig. 54
Detach oil cooler lines at radiator
connections (9)
Fig. 54
Detach vacuum line for brake
In doing so, push outer face to the rear
14 booster (6) at hot film mass air
flow sensor and pull out vacuum line.
Dismount coolant hose (10) for
Check condition of coolant hose (10) and
15 heat exchanger from connection
hose clamp; replace if necessary.
to the firewall (11)
Remove refrigerant lines (5) on AR83.55-
16 Installation: Replace the gaskets.
refrigerant compressor P-5300GZ
Installation: On vehicles with memory
Fix steering wheel in center package (driver seat, steering column, mirrors)
17
position code 275 the holding device must be removed
before connecting the battery
Fig. 80
Disconnect steering shaft (16) on The bolt (18) must be completely
18
universal joint (17) unscrewed since it is fed into a groove.
*BA46.10-
P-1001-
01J
Disconnect electrical plug
19 connector (19) on purge
switchover valve (Y58/1)
Disconnect purge line (19a) on
20
purge control valve (Y58/1)
Remove purge switchover valve Put down purge control valve (Y58/1)
21
(Y58/1) from rubber support with remaining connected line on the engine.
AR01.00-
22 Disconnect engine wiring harness
P-2410GZ
23 Remove wheels on the front axle
AP40.10-
Remove/install wheels
P-4050Z
24
On vehicles with engine damage it is
necessary to inspect the exhaust system for swarf AR49.10-
25 Remove exhaust system before installing it and to remove any swarf P-7000GZ
present, otherwise damage to the catalytic
converter system may occur.
Detach rear propeller shaft (14) Mark rear propeller shaft (14) relative to
26
from transfer case (13) the propeller shaft flange (14a).
procedure for rear propeller shaft (14) to transfer P-0050-
case (13). 17GZ
Fig. 58
*BA41.10-
P-1001-
01F
27 Remove heat shield (15) Only on vehicles with offroad package code 430.
Disconnect electrical connectors Only on vehicles with offroad package code 430.
28
(15a) at transfer case (13) Three connectors.
Disconnect connectors of right
front brake pad contact sensor and
29
left front brake pad contact sensor
at brake calipers (26)
Fasten brake calipers with lines
Unscrew guide pins (20), remove
30 connected to upper transverse control arms (25).
brake calipers (26)
Installation: Replace guide bolts (20).
*BA42.10-
P-1002-
10L
31 Remove bracket (21) Installation: Install new tie straps.
Unscrew left front rpm sensor
Fasten all lines using a cable tie to
32 (L6/1) and right front rpm sensor
(L6/2) from wheel carriers suspension strut on corresponding side.
*BA42.30-
P-1001-
01G
*BA32.20-
Unscrew nuts (23) on link rods of
33 P-1004-
stabilizer bar (22)
02L
*BA33.20-
Unscrew nuts (24) on transverse
34 P-1001-
control arms (25)
01J
Fig. 81
Fig. 82
*BA32.25-
Detach shock-absorber struts on
35 P-1002-
lower transverse control arms
01G
Remove left and right underfloor AR61.30-
36
paneling P-1001GZ
AR88.10-
37 Remove front wheelhouse lining Remove both sides. P-1300GZ
Support front axle and transmission.
When doing so ensure that mounting plates are
correctly aligned.
Position portable lifting platform Before removal the complete unit must
with universal major assembly be secured with the aid of a tensioning strap!
38
support at front axle carrier (33) Lifting platform (Master Gear) refer to GOTIS
and transmission oil pan http://gotis.aftersales.daimlerchrysler.com
Universal major assembly support
refer to GOTIS
AR22.10-
Remove bolts (27) on engine
39 P-
crossmember (28)
1170GZA
AH00.00-
Notes on bolted connections with
P-0007-
self tapping screws
01SF
Remove bolts (29) on front axle
40 Installation: Replace bolts (29).
carrier (33) at front
*BA33.10-
P-1001-01I
Unscrew bolts M10 (30) and bolts Installation: Replace bolts M10 (30)
41
M8 (31) on stiffening plates (32) and bolts M8 (31).
*BA33.10-
P-1002-01I
*BA33.10-
P-1003-01I
Remove bolts (34) on front axle
42 Installation: Replace bolts (34).
carrier (33) at front
*BA33.10-
P-1001-01I
Lower engine using front axle
43
carrier (33)
45
bleed P-0010GZ
AR20.00-
46 Fill cooling system
P-1142GZ
If cylinder head gaskets are new, warm up
Inspecting cooling system for engine first of all to operating temperature AR20.00-
47
leaks otherwise complete filling of the engine with P-1010GZ
coolant is not assured.
AR18.00-
48 Check engine oil level P-3035-
01GZ
Fig. 59
*BF18.00-
P-1001-
03U
*BF18.00-
P-1002-
03U
*BF18.00-
P-1003-
03U
*BF18.00-
P-1004-
03U
49
50 check engine for proper operation
and leaktightness
AR40.20-
51 Perform a wheel alignment check
P-0200GZ
FUEL DISTRIBUTOR
960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/
981/982/984/ 986/988
BA07.52-P- Bolt, fuel distributor
Nm 10
1002-01A to intake manifold
STEERING SHAFT
BA46.10-P-1001-01J Bolt, steering coupling to steering shaft Nm 33
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2

Number Designation Model 164 except 164.177
BA42.10-P-1002-10L Guide pin on caliper support Nm 55

FRONT AXLE STABILIZER BAR

Stage 1 Nm 100
2nd stage loosen Angle° 180
BA32.20-P-1004-02L Nut, link rod to stabilizer bar
Stage 3 Nm 45
Stage 4 Angle° 60
WHEEL LOCATION, HUB

164.1/8
Stage
Nm 20
BA33.20-P-1001- Self-locking nut, upper wishbone follower joint to 1
01J steering knuckle Stage
Angle° 90
2
FRONT AXLE SHOCK ABSORBER

BA32.25-P-1002-01G Self-locking nut, shock absorber to wishbone Nm 265
FRONT AXLE CARRIER

Number Designation Model 164.1/8 except
164.177
Stage
Nm 100
1
Stage
Angle° 120
2
BA33.10-P-1001- Bolt, front axle carrier to M14 X Stage
Angle° -180
01I longitudinal member 1.5 3
Stage
Nm 100
4
Stage
Angle° 90
5
BA33.10-P-1002- Bolt, stiffening plate to longitudinal
M10 Nm 61
01I member
BA33.10-P-1003-
Bolt, stiffening plate to body M8 Nm 31
01I
OIL LEVEL CHECK

113.964/971
Oil level
Replenish oil
88 mm +2,9
quantity in liters
Replenish oil
90 mm +2.8
quantity in liters
Replenish oil
92 mm +2,6
quantity in liters
Replenish oil
94 mm +2.5
quantity in liters
Replenish oil
96 mm +2.4
quantity in liters
Replenish oil
98 mm +2,3
quantity in liters
Replenish oil
100 mm +2.2
quantity in liters
Replenish oil
102 mm +2.1
quantity in liters
Replenish oil
104 mm +1,9
quantity in liters
Replenish oil
106 mm +1.8
quantity in liters
Replenish oil
108 mm +1,7
quantity in liters
Replenish oil
110 mm +1.5
quantity in liters
Replenish oil
112 mm +1,4
quantity in liters
BF18.00-P- Dipstick indication 88 mm to 124 mm Replenish oil
114 mm +1,2
1002-03U (oil level too low) quantity in liters
Replenish oil
116 mm +1,0
quantity in liters
Replenish oil
118 mm +0.9
quantity in liters
Replenish oil
120 mm +0.7
quantity in liters
Replenish oil
122 mm +0,5
quantity in liters
Replenish oil
124 mm +0,3
quantity in liters
130 mm -0,3
in liters
132 mm -0.5
in liters
BF18.00-P- Oil dipstick indication 130 mm to 138 Extract oil quantity
134 mm -0.7
1004-03U mm (oil level too high) in liters
136 mm -0.9
in liters
138 mm -1,1
in liters



Fig. 80: Identifying Holding Device (129 589 01 21 00)


Fig. 82: Identifying Thrust Piece (140 589 00 63 00)



REMOVE/INSTALL ENGINE WITH FRONT AXLE CARRIER - AR01.10-P-2500GZA
ENGINE 272, 273 in MODEL 164, 251
Fig. 85: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (1 Of
6)
6)
6)
6)
6)
6)
MODIFICATION NOTES
25.6.07 Observe tightening procedure when assembling propeller shaft, added Step 28
Remove/install
AS00.00-
Z-0011-
01A
sliding roof.
AH00.00-
N-0001-
bolts
01A
For vehicles with code 275,
Memory package (driver seat,
steering column, mirrors), the
easy entry/exit function must
be disabled otherwise damage
can occur on reconnection of
battery, since the driver seat
and steering wheel will be
moved to another position if,
for example, the driver door is
opened or closed. The system
is deactivated in the "Comfort"
menu of multifunction display
using buttons on steering wheel
Only tighten nuts and bolts of
chassis components when
Installation vehicle is in a ready-to-drive
condition.
Set DIRECT SELECT gear
1 selector switch to position "N"
and release parking brake
Bring front wheel into straight- The steering wheel must not be turned when
2 ahead position and fix steering the steering coupling is detached, otherwise the
wheel in center position clock spring contact will be destroyed.
Fig. 80
3 Model 164
platform P-0100GZ
AR00.60-
Model 251
P-0100RT
4 Disconnect battery ground Model 164 AR54.10-
cable P-0003GZ
Model 251
Insulate ground line as a protection against AR54.10-
unintentional contact of detached ground line P-0003RT
AH54.10-
01A
until ignition is switched off.
AR09.10-
Remove air filter housing (3)
5 P-
with engine intake air ducts (1)
1150GZA
Suction refrigerant out of air
6 Engine 273
conditioning
AR01.00-
7 P-
harness
2410GZA
Engine 272 AR07.52-
Remove left O2 sensor
8 Required for removal of exhaust P-
downstream of TWC
system. 5303GZP
AR49.10-
Remove complete exhaust
9 P-
system
7100GZA
Detach purge line (4) from
purge switchover valve and on
10
vacuum line for crankcase
ventilation system (5)
Disconnect brake booster
11 vacuum line (6) on intake
manifold
Extract leak oil from power
12 steering expansion reservoir Fig. 56
(10)
Remove power steering (14)
13 return line at power steering Installation: Replace hose clamp.
(10) expansion reservoir
Remove power steering (15)
14 return line at engine radiator Installation: Replace hose clamp.
(19)
Remove transmission oil lines
15 (17, 18) at radiator (19) Fig. 54

AR13.20-
16 Remove poly-V belt (20) Only for engine 272 P-
0001GZA
Remove coolant compressor
(A9) from timing case cover
17 Only for engine 272
and engine support, to do this
unscrew the bolts (21)
AR83.55-
Model 164
P-5300GZ
Model 251
Remove refrigerant compressor
connector (A9x1) on refrigerant compressor AR83.55-
(A9). Attach refrigerant compressor (A9) with P-5300RT
connected pipe system laterally at bottom of
engine compartment.
Installation: Move refrigerant
compressor (A9) into installation position and
mount timing case cover and engine support,
before the motor is moved completely into the
engine compartment.
Remove bolt (24) and take off *BA46.10-
18 steering coupling from bottom Model 164 P-1001-
steering shaft (22) 01J
*BA46.10-
Model 251 P-1001-
01K
Remove refrigerant line (33) at
refrigerant compressor (A9)
19 Only for engine 273
and refrigerant line (34) at
separation point
AR83.55-
Model 164
P-5300GZ
AR83.55-
Model 251
P-5300RT
AR07.03-
Release fuel pressure over
20 Collect escaping fuel. P-1460-
service valve (7)
01GZ
Fig. 55
Remove fuel feed line (8) on Collect feathering-out fuel and seal
21
fuel distributor (9) connections.
*BA07.03-
P-1001-
01B
Fig. 54
AR20.00-
22 Drain coolant at radiator (19) P-
1142GZC
AH20.00-
01A
Disconnect coolant line (25)
23 from heater heat exchanger
connection (26)
AR09.41-
Dismount coolant line (27) at
24 See "Disconnect Henn coupling". P-1311-
thermostat housing (28)
01AL
AR09.41-
Remove coolant line (29) on
25 See "Disconnect Henn coupling". P-1311-
coolant pump (30)
01AL
Unscrew bolts from the
26 stiffening bridge under the Only for model 251
propeller shaft
*BA61.10-
P-1005-
01F
Mark propeller shaft to
27 propeller shaft flange on
transfer case/ adapter housing
Remove rear propeller shaft at
28 procedure for rear propeller shaft to transfer P-0050-
transfer case/ adapter housing
case/ adapter housing. 17GZ
Fig. 58
*BA41.10-
Model 164 P-1001-
01F
*BA41.10-
Model 251 P-1001-
01G
Remove wheels on the front
29
axle
AP40.10-
Remove/install wheels Model 164
P-4050Z
AP40.10-
Model 251
P-4050RT
Remove front section for right
30
and left wheelhouse covering
Remove left and right
31
underfloor paneling
Remove bracket (36) from
32 steering knuckles (37) Installation: replace cable tie (38).

Remove left front rpm sensor Unclip electrical lines of rpm sensors
and right front rpm sensor from brackets.
33
(L6/1, L6/2) from steering Fasten all lines using a cable tie to
knuckle (37) suspension strut on corresponding side.
*BA42.30-
Model 164 P-1001-
01G
*BA42.30-
Model 251 P-1001-01I
Remove guide pins (39) and
Fix brake caliper with attached lines to
34 brake calipers (40) from brake
upper transverse control arms using cable ties.
caliper supports
AR42.10-
Model 164
P-0070GZ
AR42.10-
Model 251
P-0070RT
*BA32.20-
Detach link rods (41) from
35 Model 164 P-1003-
shock absorbers (42)
02L
*BA32.20-
Model 251 P-1003-
02N
Detach shock absorber (42) *BA32.25-
36 from lower transverse control Model 164 P-1002-
arm (44) 01G
*BA32.25-
Model 251 P-1002-
01H
Detach upper transverse control
37 arm (45) from steering Fig. 81
knuckles (37)
Fig. 82
*BA33.20-
Model 164 P-1001-
01J
*BA33.20-
Model 251 P-1001-
01L
38 correctly aligned.
Before removal the complete unit must
be secured against falling down with the aid of AR01.10-
Prop front axle carrier (46) a tensioning strap! P-2500-
using lifting platform Lifting platform (Master Gear) refer to GOTIS 01A
Universal major assembly support refer to
GOTIS
Remove rear engine AR22.10-
39 crossmember (47) from frame Installation: Install new bolts. P-
floor assembly 1180GZD
Remove bolts (48) on
stiffening plates (49) and bolts AR33.10-
40 Model 164
(50) on longitudinal members P-0100GZ
(51)
Model 251 AR33.10-
Installation: Install new bolts. P-0100RT
For engine 272 ensure that refrigerant
Lower engine transmission unit
41 compressor (A9) does not get caught on power
with front axle carrier (46)
steering (10) expansion reservoir.
Check engine oil level and
43
correct if necessary
Fill and bleed power steering AR46.30-
44 Model 164
pump (11) P-0010GZ
AR46.30-
Model 251
P-0010RT
45
AR40.20-
46 Perform chassis alignment Model 164
P-0200GZ
AR40.20-
Model 251
P-0200RT
erase if necessary
when engine is running. Risk AS00.00-
itself.
of injury caused by contusions Z-0005-
and burns during starting 01A

Number Designation Engine 272 without Engine 272 with Engine
code 917 code 917 273

BA07.03-P- Union nut, fuel feed line to
Nm 20 20 20
1001-01B fuel distributor

Stage 1 Nm 100
BA32.20-P-1003-02L Nut, link rod to front shock Stage 2 loosen Angle° 180
Stage 3 Nm 200

BA61.10-P-1005-01F Bolt, stiffening bridge to frame floor assembly Nm 20

BA32.25-P-1002-01G Self-locking nut, shock absorber to wishbone Nm 265

BA32.25-P-1002-01H Self-locking nut, shock absorber to wishbone Nm 265
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2
PROPELLER SHAFT
251
Stage
Nm 40
01G axle) Stage
Angle° 90
2

BA42.30-P-1001-01I Self-locking bolt, front axle rpm sensor to steering knuckle Nm 8

BA32.20-P-1003-02N Nut, link rod to front shock Nm 200
WHEEL LOCATION, HUB

164.1/8
Stage
Nm 20
Angle° 90
2
WHEEL LOCATION, HUB

251
Stage
Nm 20
BA33.20-P-1001- Self-locking nut, upper wishbone follower joint to steering 1
01L knuckle Stage
Angle° 90
2

STEERING SHAFT
STEERING SHAFT
BA46.10-P-1001-01K Bolt, steering coupling to steering shaft Nm 33







REMOVE/INSTALL ENGINE WITH FRONT AXLE CARRIER - AR01.10-P-2500GZS

Fig. 98: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 156 (1 Of 4)
MODIFICATION NOTES
Observe tightening procedure when assembling the propeller shaft, added Step 35
Remove/install
AS00.00-Z-
0010-01A
off of the lifting platform. points specified by vehicle manufacturer.
crushed when removing, Keep body parts and limbs well clear of moving AS00.00-Z-
installing or aligning hoods, parts. 0011-01A
sliding roof.
poisoning and caustic burns No fire, sparks, open flames or smoking.
caused by swallowing battery Wear acid-resistant gloves, clothing and glasses. AS54.10-Z-
acid. Risk of injury caused by Only pour battery acid into suitable and 0001-01A
burns to skin and eyes from appropriately marked containers.
when engine is running. Risk
Secure vehicle to prevent it from moving by itself.
of injury caused by AS00.00-Z-
contusions and burns during 0005-01A
starting procedure or when
working near the engine as it
is running
AH00.00-
N-0001-
bolts
01A
1
Vehicles with memory package (driver seat, steering
column, mirrors), code 275.
Otherwise the driver seat and steering wheel
move into a different position if the driver door is
Deactivate easy entry/exit
3 opened or closed for example. The upper frame may
function
be damaged when the holding device is installed.
Deactivation ensues via buttons on the
steering wheel in the "Comfort" menu of the
multifunction display.
Vehicles with Keyless Go code 889:

4
Press the Keyless Go start and stop button
Turn key in ignition lock to repeatedly until the ignition is switched off.
position "0" Remove the Keyless Go transmitter card or

transmitter key from vehicle and store beyond reach
of the transmitter (at least 2 m).
Disconnect battery ground Insulate ground line as a protection against
5 unintentional contact of detached ground line with
cable
AR54.10-
Model 164
P-0003GZ
AR54.10-P-
Model 251
0003RT
AH54.10-
01A
Fix steering wheel in center
6 Fig. 80
position
7 Model 164
platform P-0100GZ
AR00.60-P-
Model 251
0100RT
Remove wheels on the front
8
axle
AP40.10-P-
4050RT
AP40.10-P-
4050Z
Completely remove front
9 Model 164
wheelhouse panels
AR88.10-
Rear section
P-1300GZ
Front section AR88.10-
Model 251 P-1310GZ
AR88.10-P-
Rear section
1300RT
AR88.10-P-
Front section
1310RT
Remove left and right AR61.30-
10 Model 164
underfloor paneling P-1001GZ
AR61.30-P-
Model 251
1001RT
AR09.10-
1150GZS
fuel igniting, risk of No fire, sparks, open flames or smoking.
poisoning caused by inhaling Pour fuels only into suitable and appropriately AS47.00-Z-
and swallowing fuel and risk marked containers. 0001-01A

of injury to eyes and skin Wear protective clothing when handling fuel.
caused by contact with fuel
AR07.03-P-
Dismount fuel line (1) from Release fuel pressure with pressure hose via 1460-
12
fuel distributor service valve 01TMG
*BA07.03-
P-1001-
01C
Fig. 55
Vehicles with automatic air conditioning,
Discharge air conditioning code 580 and comfort automatic air conditioning,
13
system code 581
Installation: Replace desiccant cartridge.
AR83.30-
Model 164
P-1760GZ
AR83.30-P-
Model 251
1760RT
Suction off hydraulic fluid
14 from the expansion reservoir Fig. 56
of power steering (2)
15 Model 164
AR61.20-P-
Model 251
1105RT
16 Drain engine oil
AR20.00-
17 Drain coolant at radiator P-
1142GZS
AH20.00-
01A
Model 251 only
Disconnect lines on oil/water Unclip coolant hoses (6a). Unscrew bolts
18 heat exchanger (1a) in right (2a) and nut (3a) on brackets (4a, 5a).
front wheel well Remove bracket (5a) and remove oil/water heat
exchanger (1a) completely with bracket (4a).
Disconnect coolant hose (3) at Check condition of coolant hose (3) and hose
19
engine radiator (4) at top clamp; replace if necessary.
Disconnect vent line (5) at Check condition of vent line (5) and replace if
20
distributor (6) necessary.
Remove air line (7) for
21 additional air pump
completely
Release hydraulic lines (8, 9)

at top of power steering
Fig. 54
Remove refrigerant lines at
23 connectors (10, 11) on Installation: Replace the gaskets.
refrigerant compressor (A9)
AR83.55-
Model 164
P-5300GZ
AR83.55-P-
Model 251
5300RT
Disconnect hose (12) at purge
24 line (13) on engine at the left
front
Remove brake booster
Remove clip and lay brake booster (14)
25 vacuum line (14) at intake
manifold vacuum line to one side.
Disconnect steering shaft (15) The bolt (17) must be completely
26
on universal joint (16) unscrewed since it is fed into a groove.
*BA46.10-
Model 164 P-1001-01J
*BA46.10-
Model 251 P-1001-
01K
Dismount coolant hose (18)
27 for heat exchanger at firewall Check condition of coolant hose (18) and hose
clamp; replace if necessary.
(19) connection
Unclip upper transmission oil
AR27.10-
cooler line at engine radiator
28 Seal off connection immediately. P-0501-
(4) above from bracket and
03RT
disconnect
Fig. 54
AR01.00-
29 Model 164 P-
harness
2410GZS
AR01.00-P-
Model 251
2410RTS
Disconnect ground line at
30 Model 164 only
alternator
Disconnect engine oil lines
31 Installation: Replace sealing rings.
(20) at flange connections (21)
Remove coolant hose at
Check condition of coolant hose and hose clamp,
32 connection fitting (23) of
replace if required.
coolant pump (24)
Disconnect transmission oil AR27.10-
33
cooler line (22) at engine P-0501-
radiator (4) Seal off connection immediately. 03RT

Fig. 54
AR49.10-
34.1 Remove exhaust system Model 164 P-
7000GZS
Remove exhaust system up to AR49.10-P-
34.2 Model 251
rear flange connection 7000RT
In addition on model 251: Remove the cross
strut below the rear propeller.
Detach rear propeller shaft Mark the rear propeller shaft relative to the
35
from transfer case (25) propeller shaft flange. Unscrew bolts from vibration
damper on transfer case (25), then push the vibration
damper over the rear propeller shaft.
Installation: Observe tightening procedure AR41.10-P-
for rear propeller shaft to transfer case (25). 0050-17GZ
Fig. 58
*BA41.10-
Model 164 P-1001-
01F
*BA41.10-
Model 251 P-1001-
01G
Unscrew left front rpm sensor
Fasten all electrical lines with a cable tie to
36 (L6/1) and or right front rpm
suspension strut on corresponding side.
sensor (L6/2) on wheel carrier
AR42.30-
Model 164
P-0712GZ
AR42.30-P-
Model 251
0712RT
Unplug connector for speed-
37
sensitive power steering
Remove control rod for Xenon
38 or level control at lower ball
head
Disconnect right front brake
39
pad contact sensor connector
40 Remove bracket (26) Installation: Install new tie straps.
On both sides.
Unclip outer tension spring,
Fasten brake caliper with line connected to
41 remove guide pins (27) and
remove brake caliper (28) upper transverse control arm (29).
Installation: Replace guide bolts (27).
*BA42.10-
P-1002-
10L
Unscrew nut (30) on link rod

42 On both sides.
of stabilizer bar (31)
AR32.20-
Model 164
P-0300GZ
AR32.20-P-
Model 251
0300RT
Unscrew nut (32) on upper
43 On both sides.
transverse control arm (29)
*BA33.20-
Model 164 P-1001-01J
*BA33.20-
Model 251 P-1001-
01L
Fig. 81
Fig. 82
Remove shock-absorber struts
44 (33) at lower transverse On both sides.
control arm
AR32.25-
Model 164
P-1017GZ
AR32.25-P-
Model 251
1017RT
Position portable lifting correctly aligned.
platform with universal major Before removal the complete unit must be
45 assembly support at front axle secured with the aid of a tensioning strap!
carrier (40) and transmission Lifting platform (Master Gear) see GOTIS
oil pan http://gotis.aftersales.daimlerchrysler.com
Universal main assembly mount see GOTIS
*BA22.10-
Remove bolts (34) on engine
46 Model 164 P-1005-
crossmember (35)
03G
*BA22.10-
Model 251 P-1005-
03F
AH00.00-
Notes on bolted connections
P-0007-
with self tapping screws
01SF
Remove bolts (36, 37, 38) at
Installation: Replace bolts (36, 37, 38).
47 front axle carrier (40) and at
stiffening plate (39) Model 164
*BA33.10-
P-1001-01I
*BA33.10-
P-1002-01I
*BA33.10-
Model 251 P-1003-01I
*BA33.10-
P-1001-
01L
*BA33.10-
P-1002-
01L
*BA33.10-
P-1003-
01L
Lower engine using front axle
48
carrier (40)
AR20.00-
50 Fill cooling system P-
1142GZS
AR20.00-
Inspecting cooling system for
51 P-
leaks
1010GZS
52 Model 164
bleed P-0010GZ
AR46.30-P-
Model 251
0010RT
*BF18.00-
53 Check engine oil level Engine oil P-1001-
01V
Check oil level in
AR27.00-
54 transmission and correct if
P-0100W
necessary
Read out fault memory and disconnecting cables or by simulation during test
55
erase if necessary operations, must be erased in the fault memory after
Perform a wheel alignment AR40.20-
56 Model 164
check P-0200GZ
AR40.20-P-
Model 251
0200RT


BA07.03-P-1001-01C Union nut, fuel feed line to fuel distributor Nm 20
STEERING SHAFT
STEERING SHAFT
BA46.10-P-1001-01K Bolt, steering coupling to steering shaft Nm 33
PROPELLER SHAFT
164.1/8
Stage
Nm 40
Angle° 90
2
PROPELLER SHAFT
251
Stage
Nm 40
01G axle) Stage
Angle° 90
2

Number Designation Model 164.177 Model 251.077 / 177
BA42.10-P-1002-10L Guide pin on caliper support Nm 30 30
WHEEL LOCATION, HUB

164.1/8
Stage
Nm 20
Angle° 90
2
WHEEL LOCATION, HUB

251
Stage
Nm 20
BA33.20-P-1001- Self-locking nut, upper wishbone follower joint to steering 1
01L knuckle Stage
Angle° 90
2

BA22.10-P-1005-03G Bolt, rear engine crossmember to body Nm 55

BA22.10-P-1005-03F Bolt, rear engine crossmember to body Nm 55
FRONT AXLE CARRIER

Number Designation Model 164.1/8 except
164.177
Stage
Nm 100
1
Stage
Angle° 120
2
BA33.10-P-1001- Bolt, front axle carrier to M14 X Stage
Angle° -180
01I longitudinal member 1.5 3
Stage
Nm 100
4
Stage
Angle° 90
5
BA33.10-P-1002- Bolt, stiffening plate to longitudinal
M10 Nm 61
01I member
BA33.10-P-1003-
Bolt, stiffening plate to body M8 Nm 31
01I
FRONT AXLE CARRIER

251
Stage
Nm 130
1
Stage
Angle° -180
BA33.10-P-1001- Self-locking bolt, front axle carrier (front) to 2
M14X1.5
01L longitudinal member Stage
Nm 100
3
Stage
Angle° 45
4
Stage
1 Nm 130
Stage
Angle° -180
2
BA33.10-P-1002- Self-locking bolt, front axle carrier at rear to M14 X
01L longitudinal member 1.5 Stage
Nm 100
3
Stage
Angle° 90
4
BA33.10-P-1003-
Bolt, stiffening plate to longitudinal member M10 Nm 61
01L

model 164 model 251
Filling capacity (oil and filter
Liters 9,7 9,6
change)
BF18.00-P-1001- Engine
01V oil Specifications for Operating
Sheet BB00.40-P-0229-05 BB00.40-P-0229-0
Fluids
A 5A







DETACH/ATTACH ENGINE ON FRONT AXLE CARRIER - AR01.10-P-2510GZ
Fig. 109: Identifying Engine On Front Axle Carrier Components (Engine 113.964)
MODIFICATION NOTES
25.6.07 Observe tightening procedure for assembly of the propeller shaft - added Step 7
Remove/install
AS00.00-Z-
0010-01A
off the lifting platform. points specified by vehicle manufacturer.
crushed when removing,

installing or aligning hoods, Keep body parts and limbs well clear of moving AS00.00-Z-
doors, trunk lids, tailgates or parts. 0011-01A
sliding roof.
AH00.00-
Notes on self-locking nuts
N-0001-
and bolts
01A
Remove engine with the front AR01.10-P-
1
axle carrier (8) 2500GZ
Secure front axle carrier (8) on portable
Hook engine and mechanism lifting platform with tensioning strap.
2 with engine hoist into the Engine hoist (self-locking),
lifting eye on the engine refer to GOTIS
Only raise far enough for chain on engine
3 Raise engine
hoist to be lightly tensioned.
*BA22.10-
Remove bolts (1) from the
4 P-1002-
engine mounts
03G
*BA46.30-
Remove bracket (2) at oil pan
5 P-1002-
(3)
01H
Unscrew banjo bolt (4) on
6 Installation: Replace the gaskets.
power steering pump (5)
*BA46.30-
P-1001-
01H
Remove front propeller shaft propeller shaft flange (6a).
7
(6) on transfer case (7) Detach vent line for front axle gear on vent
valve.
Installation: Observe tightening procedure AR41.10-P-
for front propeller shaft (6). 0070-03GZ
Fig. 58
*BA41.10-
P-1003-01F
Lift engine and transmission
8 out of the front axle carrier
(8)

BA22.10-P-1002-03G Bolt, front engine mount to engine support Nm 53
POWER STEERING PUMP

251
BA46.30-P-1001- High-pressure expansion hose to power steering
Nm 40
01H pump
BA46.30-P-1002- Bolt, power steering pressure line bracket to engine
Nm 10
01H oil pan
PROPELLER SHAFT
164.1/8
Stage
Nm 40
BA41.10-P-1003- Self-locking bolt, propeller shaft to transfer case (to 1
01F front axle) Stage
Angle° 90
2
Fig. 110: Ident

ML 2006 2011

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MERCEDES ML-CLASS 2006-2011 2007 Mercedes-Benz ML350

2006-2008 HVAC Air Compressor, Belt Drives - 164 Chassis

REPAIR 2006-2008 HVAC MANUAL

Remove, install poly-V- ENGINE 113... AR13.21-P-1202RVK

Remove/install poly V- ENGINE 113.967 in AR13.25-P-3200TY

Remove/install poly V- ENGINE 156 in MODEL AR13.22-P-1202GZS

Remove/install ENGINE 272 in MODEL AR13.20-P-0001CV

components of belt drive MODEL 221 ENGINE

Remove/install ENGINE 272, 273 in AR13.20-P-0001GZA

Remove/install poly V- ENGINE 272, 273 ... AR13.22-P-1202QB

REMOVE, INSTALL POLY V-BELT - AR13.22-P-1202

Remove, install poly V-belt - AR13.22-P-1202GZ

ENGINE 113.964 in MODEL 164.175

Fig. 1: Identifying Poly V-Belt Components

COOLANT PUMP, COOLANT THERMOSTAT

Remove/install poly V-belt - AR13.22-P-1202GZS

ENGINE 156 in MODEL 164, 251

Fig. 2: Identifying Poly V-Belt Components

BELT TENSIONING DEVICE

ROUTING DIAGRAM OF POLY V-BELT - AR13.22-P-3902

Routing diagram of poly V-belt - AR13.22-P-3902-02AMG

Fig. 3: Identifying Poly V-Belt Components Location

Running diagram of poly V-belt - AR13.22-P-3902-02GZ

6-groove single-belt drive, with AC compressor

Fig. 4: Poly V-Belt Running Diagram

Routing diagram of poly V-belt - AR13.22-P-3902-02VA

Shown on engine 272.963

Fig. 5: Routing Diagram Of Poly V-Belt (Shown On Engine 272.963)

REMOVE/INSTALL POLY-V-BELT TENSIONING DEVICE - AR13.25-P-3200

Remove/install poly-V-belt tensioning device - AR13.25-P-3200GZ

ENGINE 113.964 in MODEL 164.175

Fig. 6: Identifying Poly-V-Belt Tensioning Device Components

When moving components,

BELT TENSIONING DEVICE

Remove/install poly-V belt tensioning device - AR13.25-P-3200GZS

ENGINE 156 in MODEL 164, 251

Fig. 7: Identifying Poly-V-Belt Tensioning Device Components

Risk of injury caused by fingers being jammed

the fan downwards.

BELT TENSIONING DEVICE

Check visible area of poly-V belt for wear - AP13.22-P-1352GZ

ENGINE 113.9, 156.9 in MODEL 164.1

ENGINE 156.9 in MODEL 209

Fig. 8: Identifying Poly V-Belt

Fig. 9: Identifying V-Belts Damage Patterns

Model 164 with engine AR13.22-P-1202GZ

Check visible area of poly-V belt for wear - AP13.22-P-1352GZC

ENGINE 272, 273 in MODEL 164.1

ENGINE 273 in MODEL 164.8

Fig. 10: Checking Poly-V Belt

Fig. 11: Identifying Poly-V Belt Damage Pattern

1 Open engine hood

Multi-belt drive ENGINE BA13.21-P-

BELT TENSIONING DEVICE - BA13.25-P-1000

Belt tensioning device - BA13.25-P-1000-01D

Engines 113, 137, 275, 285

BELT TENSIONING DEVICE

BELT TENSIONING DEVICE

1003-01D device to belt tensioning device

Belt tensioning device - BA13.25-P-1000-01P

Engine 272, 273

BELT TENSIONING DEVICE

Belt tensioning device - BA13.25-P-1000-01U