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BTest and Adjustment ––––B1Engine Test, AdjustmentEngines 104, 119, 120 CFI . . . . . . . . . . . . . . . . . . . . . . . . .Engines 104, 119, 120 LH-SFI . . . . . . . . . . . . . . . . . . . . . . .Engines 104, 111 HFM-SFI . . . . . . . . . . . . . . . . . . . . . . . . .Engines 111, 119, 120 ME-SFI . . . . . . . . . . . . . . . . . . . . . .b Diagnostic Manual Engines 08/00Page11/121/122/123/1B1C/1

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentListing of Test Steps1Test equipment2CFI control module on-off ratio test (Ignition: ON)3CFI control module on-off ratio test (Engine: closed throttle)4Diagnsotic trouble code read-out of CFI control module (Ignition: ON)5Engine systems (MAS) control module (N16) diagnostic trouble code readout (Ignition: ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Ignition control module diagnostic trouble code read-out (at engine rpm)7Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 Linkage rods.perform.8.1 Closed throttle (idle) contactconnect/disconnect.perform (wait until readout display oscillates).perform.perform.perform.remove and install.check throttle valve for free movement and condition. Lubricate bearings,slotted lever and ball sockets.check, adjust.8.2 Wide open throttle contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check using accelerator pedal, adjust.9check, adjust.Control pressure cable.10Cruise control (without ASR).11Engine coolant level12Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check, observe condition of oil.13Voltage at ignition coilscheck (see Test and Adjustment Data, Section A).14Ignition timing and vacuum advance . . . . . . . . . . . . . . . . . . . . . . . . . . .check, adjust.check, correct.check (see Test and Adjustment Data, Section bDiagnostic Manual Engines 08/00B 1 CFI11/1

BTest and Adjustment JobsEngines 104, 119, 120 –15Oscilloscope patterns.16Engine oil temperature17Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check for leakage.18Closed throttle (idle) speedcheck.19Lambda control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .test.20Closed throttle under loadcheck.evaluate (see section C).approximately 80 Diagnostic Manual Engines 08/00B 1 CFI11/2

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentConnection Diagram – Test EquipmentEngine 104 CFIaSet engine tester to 6 cylinder positionFigure 1R4T1X11X11/47003012013014018022030033Spark plugs (cylinder 1)Ignition coilDiagnostic connector (9-pole)Diagnostic connector (16-pole)Throttle linkageMultimeterOn-off ratio testerImpulse counter scan toolExhaust vent hoseOil thermometerHex. socket wrench 1)Engine analyzer with oscilloscopeTest cable1) Requiredonly for mixture adjustment when replacing fuelmixture adjustment tower.Note: Depending on test equipment available, it may benecessary to alternately connect the engine analyzer and on-offratio tester to diagnostic ��–––––––bDiagnostic Manual Engines 08/00B 1 CFI11/3

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentConnection Diagram – Test EquipmentEngine 119,120 CFIaSet engine tester to 4 cylinder position. Only one ignition circuitcan be checked at a time.Figure 2R4T1/1X11X11/47003012013014018022030033Spark plugs (cylinder 1)Ignition coil 1Diagnostic connector (9-pole)Diagnostic connector (16-pole)Throttle linkageMultimeterOn-off ratio testerImpulse counter scan toolExhaust vent hoseOil thermometerHex. socket wrench 1)Engine analyzer with oscilloscopeTest cableU07 0037 571) Requiredonly for mixture adjustment when replacing injectionsystem components.Note: Depending on test equipment available, it may benecessary to alternately connect the engine analyzer and on-offratio tester to diagnostic connector ��––––bDiagnostic Manual Engines 08/00B 1 CFI11/4

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentConnection Diagram – Impulse Counter Scan Tool and On/off RatioTesterEngine 104, 119,120 CFINote:Connect red wire to X4/10.Connect black wire to socket 1.Connect yellow wire of impulse counter scan tool to:Socket 3for CFI control moduleSocket 8for Ignition control moduleSocket 14for Engine systems control module (MAS)U91 0043 37AThe red wire of the impulse counter scan tool may be optionally connected tosocket 16 (circuit 15) of diagnostic onnector (X11/4) instead of terminalblock.Figure 3012013X4/10X11X11/4On/off ratio testerImpulse counter scan toolTerminal block, terminal 30/30Ü/61e87LDiagnostic connectorDiagnsotic connector ��–––––bDiagnostic Manual Engines 08/00B 1 CFI11/5

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentConnection chart for test equipment without diagnostic adapter for two circuit ignition systemsTest equipmentversionCylinder no. Type of measurementsetting ontestequipmentRPM/dwell angleof Ignition circuit ÆSUNMEA1500-MBTEngine119: 4Engine120: 6Circuit on Diagnostic connectorX11Engine 119X11/2Engine 120 L.T1/1RPM/dwell angleof Ignition circuit ÆkV-Clamp on ignitioncableignition circuitCylinder 1Engine 119: T1/1Engine 120: T1/1Engine 119: cyl. 2 1)Engine 120: cyl. 12Engine 119: T1/2Engine 120: T1/2Engine 119: cyl. 1Firing order 1–4–6–7Engine 120: cyl. 1Firing order1–5–3–6–2–4Engine 119: T1/1Firing order 1–4–6–7Engine 120: T1/1Firing order1–5–3–6–2–4Engine 119: cyl. 5Firing order 5–8–3–2Engine 120: cyl. 12Firing order12–8–10–7–11–9Engine 119: T1/2Firing order 5–8–3–2Engine 120: T1/2Firing order12–8–10–7–11–9T1/1T1/2Timingof Ignition circuit ÆT1/1Timingof Ignition circuit ÆT1/2T1/1T1/2Oscilloscopeprimary/secondary ÆT1/1and voltage atterminal 15/1 of IgnitioncoilOscilloscopeprimary/secondary Æand voltage atterminal 15/1 of Ignitioncoil1)X11/3Engine 120 R.Trigger clamp onignition cableT1/1T1/2On engine 119 subtract 90 crankshaft from measured value.Example: measured: 107 crankshaft, 107 –90 17 crankshaft –bDiagnostic Manual Engines 08/00B 1 CFI11/6

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentNotes regarding on/off ratio check using on/off ratio testerThe operation of the Lambda control can be tested by checking the on/offratio. In addition, any malfunctions that exist momentarily can berecognized. The tests distinguish between malfunctions that occur with theignition ON or with the engine at idle.The on/off ratio can be checked using the on/off ratio tester or engineanalyzer. An on/off ratio of 50% indicates that all input signals are OK, butLambda control is not functioning. A varying on/off ratio indicates that theLambda control is functioning correctly. On/off ratios from 10% to 95% areeach assigned a specific malfunction (see DTC memory, DM Engines,Volume 2, Section 2). After testing the on/off ratio, a diagnostic troublecode (DTC) readout using the impulse counter scan tool must always beperformed.Notes regarding diagnostic trouble code (DTC) readout using theImpulse counter scan toolaWhen diagnosing engine running complaints, or when the CHECK-ENGINElamp is illuminated, the DTC memory should be read out and the DTC’snoted before any repairs are attempted. This will ensure that the techniciancan differentiate between actual malfunctions and “simulated malfunctions,”since testing done on a running engine will cause malfunctions to be storedthat were caused by a simulation or a disconnected circuit.When testing is completed, the DTC memory of the CFI and Ignitioncontrol modules and the Engine systems control module (MAS) mustbe ��–bDiagnostic Manual Engines 08/00B 1 CFI11/7

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentNotes regarding DTC readout using Impulse counter scan tool1.Connect impulse counter scan tool according to diagram.The LED “U-Batt” should come on. If not, check the following:a) Voltage supply.b) Impulse counter scan tool fuse.3. Clearing DTC memoryNote: The clearing process must occur within 20 seconds after the DTCreadout.a) Push start button 2-4 seconds (Impulse display appears).b) After a waiting period of 3 seconds, push the start button for 6-8seconds which will erase the previously displayed DTC.c) Erase each DTC separately.2. DTC memory readouta) Ignition: ON.b) Push start button for 2-4 seconds.c) Read and record DTC readout.d) Push start button again.e) Read and record DTC readout.Repeats steps d) and e) until the first DTC readout �––bDiagnostic Manual Engines 08/00B 1 CFI11/8

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentSpecial Tools102 589 04 63 00129 589 00 21 00201 589 00 99 00103 589 00 91 00Test cable126-pin socket boxElectrical connecting setMeasuring connection909 589 09 21 00000 589 14 11 00123 589 05 33 00123 589 00 15 00On-off ratio tester3 mm screwdriver, 3 mmPullerDrift ��bDiagnostic Manual Engines 08/00B 1 CFI11/9

BTest and Adjustment JobsEngines 104, 119, 120 –124 589 07 21 00201 589 13 21 00104 589 00 63 00Remote thermometerTesterTest ��bDiagnostic Manual Engines 08/00B 1 CFI11/10

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentEquipmentEngine analyzer 1)Bear DACE (Model 40-960) with dual ignition adapterSun EMT-1019/Master 3 2)Sun MCM-2110 2)Sun MEA-1500MB 2)Multimeter 1)Fluke Model 23, 83, 85, 87Sun DMM-51)2)Available through the MBUSA Standard Equipment Program.On engines with dual ignition system, only one cylinder bank can be measured at a time, using the present �––bDiagnostic Manual Engines 08/00B 1 CFI11/11

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentNote:The Lambda control system test should not be performed on a veryhot engine, for example, after a fast drive or after an output test on adynamometer.Test step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O1Connect test equipmentaccording to diagramIgnition: OFF––O2Ignition: ONCoolant temperatue 80 C50%See DTC memory diagnosis(DM Engines Vol. 2, Section 2)O3CFI control moduleon/off ratio readoutEngine: closed throttle (idle)Coolant temperatue 80 CReadout oscillatesSee DTC memory diagnosis(DM Engines Vol. 2, Section 2)Adjust Lambda control O 19O4Connect impulse counter scan tool:yellow wire to socket 3 of diagnosticconnector X11/4Ignition: ONDTC readout 1See DTC memory diagnosis(DM Engines Vol. 2, Section 2)CFI control moduleon/off ratio readoutCFI control moduleDTC readout1)Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/12

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O5DTC readout 1Engine systems control moduleDTC readoutConnect impulse counterscan tool:yellow wire to socket 14 of diagnosticconnector X11/4Ignition: ONSee DTC memory diagnosis(DM Engines Vol. 2, Section 2)O6Ignition control moduleDTC readoutConnect impulse counter scan tool:yellow wire to socket 8 of diagnosticconnector X11/4Engine: StartDTC readout 1See DTC memory diagnosis(DM Engines Vol. 2, Section 2)Vacuum hose to ignition control moduleconnected. Hold engine at 3100-3600rpm for 8 seconds.Disconnect vacuum hose at idle, setparking brake, move selector lever fromtransmission range “P” to “D” and backto “P”.Hold engine at more than 5000 rpm forat least 2 seconds.Reconnect vacuum hose at idle.Raise engine to approx 2300 rpm,followed by brief opening to wide openthrottle position (wide open throttlecontacts must close).Engine: closed throttle (idle)Readout stored DTC’s from memory.1)Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/13

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O7Ignition: OFF––Operate throttle linkagewithout ASR: Ignition: OFFwith ASR: Ignition: ONSmooth operation, no binding shouldbe evident.Lubricate all bearings and ball socketsIgnition: OFFCheck closed throttle (idle) speed Accelerator pedal at closed throttlepositionpositionThrottle valve lever must rest againstclosed throttle stop.without ASR: Roller must contactslotted lever at closedthrottle stop free oftension.with ASR:Lever (53) mustcontact closed throttlestop.Adjust throttle linkage(SMS, Job No. 30-300)O 8.2Check wide open (full) throttlepositionwithout ASR:Remove air cleanerO 8.0Check condition of linkage andthrottle valveO 8.1Ignition: ON, Engine OFFAccelerator pedal at wide open throttleposition(not kickdown)with ASR:1)Adjust throttle linkageThrottle lever muststop approx. 0.5-1 mm (SMS, Job No. 30-300)away from the wideopen throttle stop.Throttle lever mustcontact wide openthrottle stop.Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/14

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O9Ignition: OFFAccelerator pedal at closed throttlepositionArrows must align (Fig. 4-7)Adjust control pressure cable(SMS, Job No. 30-300)Check cruise control(without ASR)Ignition: OFFAccelerator pedal at closed throttlepositionPush actuator lever (Fig. 4-7) to closed Adjust throttle linkagethrottle position, then pull approx. 1(SMS, Job No. 30-300)mm away from closed throttle contactand adjust linkage rod (21) so that itcan be attached free of tension.O 11Ignition: OFFMarking: min - maxCorrect engine coolant levelIgnition: OFFMarking: min - maxCorrect oil levelCheck automatic transmissioncontrol pressure cableO 10Engine coolant levelO 12Engine oil level1)Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/15

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionO 13Check voltage at ignition coilIgnition: ONNominal valuePossible cause/Remedy 1)See checking ignition system, (DMEngines Vol. 2, Section 5)Engine 104: Ignition coil T1X11f2wL 5 11–14 VX114wfEngine 119: Ignition coil T1/1X112wfL5 0VL 5 11–14 VX114wfL5 0VIgnition coil T1/2X114wf4wfL 5 11–14 VX111)L5 0VObserve Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/16

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O 14Engine: StartCheck ignition timing at closed throttle.Check ignition timing with and withoutvacuum at specified engine rpm.See Test and adjustment data(section A)See checking ignition system, (DMEngines Vol. 2, Section 5)Engine: closed throttle (idle)Evaluate with engine analyzer(section C)Briefly accelerate to 3000 rpmVoltage difference between cylindersshould be no more than 3kV.Voltage increase with engineaccelerated should be no more than 6kV over idle value.O 16Warm engine oil to operatingtemperatureEngine rpm: approx. 3000 rpmEngine oil temperature approx. 80 C–O 17Check intake system for leakageEngine: closed throttle (idle)Spray connections with carburetorcleaner.–Repair leaksCheck ignition timing andvacuum advanceO 15Evaluate oscilloscope patternsaDo not use conventional fuel for leak test(dangerous fumes). Note fire risk and donot spray on red hot parts or on ignitionsystem.1)Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/17

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O 18Engine: closed throttle (idle)Transmission range “P”, climate controlsystem OFF, engine oil temperatureapprox. 80 CSee Test and adjustment data(section A)Check closed throttle speed control(DM Engines Vol. 2, Section 2)Transmission range “P”, climate controlsystem OFF. Disconnect purge line tothrottle valve housing at purge valve andplug. Reconnect line after measurment.Engine oil temperature approx. 80 C.Engine: closed throttle (idle)See Test and adjustment data(section A)If the specified value cannot beobtained, check electrical componentswith socket box tester(DM Engines Vol. 2, Section 2)Check closed throttle (idle) rpmO 19Adjust Lambda control system 2)1)2)Observe Preparation for Test, see 22.The fuel mixture adjustment screw is secured against unauthorized adjustment by means of a steel ball in the adjustment tower. After fuel mixture adjustment at the factory, the ball is installed in theadjustment tower using a special tool and must not be removed.The fuel mixture may only be corrected when replacing a fuel injection system component or when performing an engine repair. To do so, the fuel mixture adjustment tower must be ––bDiagnostic Manual Engines 08/00B 1 CFI11/18

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O 20Check closed throttle under loadEngine: closed throttle (idle)Transmission range “D”Switch on all electrical consumers,Turn steering wheel to full lock.Engine must continue to idle withinspecified range.Check closed throttle speed control(DM Engines Vol 2, Section 2)1)Observe Preparation for Test, see bDiagnostic Manual Engines 08/00B 1 CFI11/19

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentAccelerator Control 104 CFI(without ASR)Figure 428910111213212629303243S30/2Linkage rodLinkage rodControl leverSet screwControl pressure cable for automatic transmissionRelease springSlotted leverCruise control linkage rodSpringAdjustment nutBowden cableAdjustment nutAdjustment nutKickdown –––––bDiagnostic Manual Engines 08/00B 1 CFI11/20

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentAccelerator Control 104 CFI(with ASR)Figure 538112021262930324350515253747576R25S30/2Throttle valve leverControl leverControl pressure cable for automatic transmissionTelescoping rod (backup rod)Connecting rodSpringAdjustment nutBowden cableAdjustment nutAdjustment nutConnecting rodConnecting rodLeverLeverClosed throttle stop of lever (53)Closed throttle stop of lever (52)Wide open throttle stopAccelerator pedal position sensorKickdown ��––––bDiagnostic Manual Engines 08/00B 1 CFI11/21

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentAccelerator Control 119 CFI(without ASR)Figure 6P30 0041 57211151621242627293032404142525374M16S30/2Linkage rodControl pressure cable for automatic transmissionAdjustment nutSpacer sleeveCruise control linkage rodActuator leverSpringLongitudinal control shaftAdjustment nutBowden cableAdjustment nutLinkage rodLinkage rodLinkage rodLeverLeverIdle stopCruise control actuatorKickdown ��––––bDiagnostic Manual Engines 08/00B 1 CFI11/22

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentAccelerator Control 119 CFI(with ASR)Figure nkage rodLever on longitudinal control shaftControl leverControl pressure cable for automatic transmissionAdjustment nutSpacer sleeveTelescoping rod (backup rod)Linkage rodActuator leverSpringLongitudinal control shaftAdjustment nutBowden cableAdjustment nutLinkage rodLinkage rodLeverLeverClosed throttle stopWide open throttle stopElectronic accelerator actuatorKickdown switchP30 0042 �–––bDiagnostic Manual Engines 08/00B 1 CFI11/23

BTest and Adjustment JobsEngines 104, 119, 120 –B1Engine Test, AdjustmentComponent Location: Mixture Adjustment, Purge Valve, Purge Switchover ValveP47-2040-13Figure 953Y58/1Figure 1053P47-2011-13Purge valveP07-0064-15Figure 80222361Purge valvePurge switchover valveHex. socket wrenchFuel mixture adjustment towerHex. headFuel mixture adjustment ��bDiagnostic Manual Engines 08/00B 1 CFI11/24

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, AdjustmentaWith starting or warm up complaints do not condition engine to operatingconditions but proceed according to complaint.Listing of Test Steps1Test equipment.2Base module DTC readout O Ignition: ON3LH-SFI control module DTC readout O Ignition: ON4DI control module DTC readout O Ignition: ON.perform.perform.5.1 CC/ISC control module DTC readout O Ignition: ON.perform.perform.Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.0 Throttle control linkage7.1 WOT contactperform.5.0 EA/CC/ISC control module DTC readout O Ignition: ON6connect/disconnect according to Connection Diagram.remove and install.check throttle valve for free movement and condition. Lubricate allbearings, gate levers and ball sockets.check, adjust.7.2 CTP contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check using accelerator pedal, adjust.8Control pressure cable of ATcheck, adjust.9Fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check. (Engine must be at closed throttle to test)Engine coolant levelcheck, correct.10.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/1

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, Adjustment11Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .check, observe condition of oil.12Ignition system, primary, secondary O Engine: at Idle.check (see Test and Adjustment Data, Section A).13Ignition timing and vacuum advance O Engine: at Idle.check (see Test and Adjustment Data, Section A).14Oscilloscope pattern brief acceleration to 3000 rpm O Engine: at Idle15Engine oil temperature16CTP RPM17On-off ratio control system18Not applicable for U.S. version vehicles19CTP speed under load.

of Ignition circuit Æ RPM/ dwell angle of Ignition circuit Æ Timing of Ignition circuit Æ Timing of Ignition circuit Æ Oscilloscope primary/secondary Æ and voltage at terminal 15/1 of Ignition coil Oscilloscope primary/secondary Æ and voltage at terminal 15/1 of Ignition coil T1/1 T1

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