B Test And Adjustment Jobs Engine 104, 119, 120 LH-SFI

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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.b Diagnostic Manual Engines 08/00.evaluate (see Test and Adjustment Data section C).approximately 80 C.check.check(readout oscillates).–check in TR “D” (service and parking brake applied) and with allaccessories turned on.B 1 LH-SFI21/2

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram – Test EquipmentEngine 104 LH-SFIaSet engine analyzer to 6 cylinder positionFigure tle linkageSpark plug (cylinder 1)High-voltage distributorIgnition coilDiagnostic socket (9-pole)Data link connector, (DTC readout, 38-pole)On-off ratio testerImpulse counter scan toolExhaust vent hoseOil thermometerEngine analyzer with oscilloscopePressure gaugeTrigger clamp (on cylinder 1)Kilovolt clamp (on ignition coil)Impulse counter scan tool adapterU07-5133-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/3

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram – Test EquipmentEngine 119 LH-SFI with DiagnosticSocket (X11)aSet engine analyzer to 4 cylinder position.Without the diagnostic adaptor tool only oneignition circuit can be checked at a time.Figure 62075Throttle linkageSpark plug (cylinder 1)Left high-voltage distributorRight high-voltage distributorIgnition coil 1 (right cylinder bank)Ignition coil 2 (left cylinder bank)Diagnostic socket (9-pole)Data link connector, (DTC readout, 38-pole)On-off ratio testerImpulse counter scan toolExhaust vent hoseOil thermometerEngine analyzer with oscilloscopePressure gaugeTrigger clamp (on cylinder 1)Kilovolt clamp (on ignition coil, T1/1 or T1/2)Impulse counter scan tool adapterU07-5134-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/4

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram – Test EquipmentEngine 119 LH-SFI without DiagnosticSocket (X11)aSet engine analyzer to 4 cylinder position. Withoutthe diagnostic adaptor tool only one ignition circuitcan be checked at a time.Figure 1062075077/1DI control moduleSpark plugLeft high-voltage distributorRight high-voltage distributorIgnition coil 1 (right cylinder bank)Ignition coil 2 (left cylinder bank)Data link connector (DTC readout)On-off ratio testerImpulse counter scan toolOil thermometerEngine analyzer with oscilloscopePressure gaugeOn-off ratio signal adaptor (900 589 01 15 00)Trigger clamp (on cylinder 1)Kilovolt clamp (on ignition coil)Impulse counter scan tool adaptorTN signal, on-off ratio signal connector (seeconnector A, B in wiring diagram)U07-6577-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/5

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram –Test EquipmentEngine 120 LH-SFI with Diagnostic Socket (X11)Connection diagram without diagnostic socket (X11)see engine 119.aSet engine analyzer to 6 cylinder position. Withoutthe diagnostic adaptor tool only one ignition circuitcan be checked at a time.Figure 042061062075Throttle linkageSpark plug (cylinder 1)Left high-voltage distributorRight high-voltage distributorIgnition coil 1 (right cylinder bank)Ignition coil 2 (left cylinder bank)Left diagnostic socket (9-pole)Right diagnostic socket (9-pole)Data link connector, (DTC readout, 38-pole)On-off ratio testerImpulse counter scan toolExhaust vent hoseOil thermometerEngine analyzer with oscilloscopePressure gaugeTrigger clamp (on cylinder 1)Kilovolt clamp (on ignition coil, T1/1 or T1/2)Impulse counter scan tool adapterU07-5135-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/6

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram – Impulse Counter ScanTool and On/off Ratio Tester with Diagnosticsocket (X11)Yellow wire from Impulse counter scan tool toLH-SFI control moduleEngine 104, 119Socket 4Engine 120Socket 4, cylinder 1 – 6Socket 5, cylinder 7 – 12Yellow wire from Impulse counter scan tool toDI control moduleEngine 104, 119Socket 17Engine 120Socket 17, cylinder 1 – 6Socket 18, cylinder 7 – 12Yellow wire from Impulse counter scan tool toBase moduleEngine 104, 119, 120 Socket 8Impulse Counter Scan Tool voltage supplyEngine 104, 119, 120 Socket 1, circuit 31 ground(brown wire)Socket 3, circuit 30 plus (redwire)Figure 5012013075X11X11/4P07-5004-57On-off ratio testerImpulse counter scan toolImpulse counter scan tool adapterDiagnostic socket (9-pole)Data link connector(DTC readout, 38-pole)b Diagnostic Manual Engines 08/00B 1 LH-SFI21/7

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection Diagram – Impulse Counter Scan Tooland On/off Ratio Tester without Diagnostic socket(X11)a) Impulse Counter Scan ToolYellow wire from Impulse counter scan tool to LHSFI control moduleEngine 104, 119Socket 4Engine 120Socket 4, cylinder 1 – 6Socket 5, cylinder 7 – 12Yellow wire from Impulse counter scan tool toDI control moduleEngine 104, 119Socket 17Engine 120Socket 17, cylinder 1 – 6Socket 18, cylinder 7 – 12Yellow wire from Impulse counter scan tool toBase moduleEngine 104, 119, 120 Socket 8Impulse Counter Scan Tool voltage supplyEngine 104, 119, 120 Socket 1, circuit 31 ground(brown wire)Socket 3, circuit 30 plus (redwire)b) On-off Ratio TesterBlack wire from 055/1 to X11/4Engine 119Socket 14Engine 120Socket 14, cylinder 1 – 6Socket 15, cylinder 7 – 12Figure 6012013075X11/4055/1077/1P07-6578-57On-off ratio testerImpulse counter scan toolImpulse counter scan tool adaptorData link connector (DTC readout)On-off ratio signal adaptor (900 589 01 15 00)TN signal, on-off ratio signal connector (seeconnector A, B in wiring diagram)b Diagnostic Manual Engines 08/00B 1 LH-SFI21/8

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentConnection chart for test equipment without diagnostic adapter for two circuit ignition systemsTest equipmentversionCylinder no. Type of measurementsetting ontestequipmentRPM/dwell angleof Ignition circuit ÆBear DACE(Model 40-960)Sun MEA1500MBEngine119: 4Engine120: 6Circuit on Diagnostic socketX11Engine 119T1/1RPM/dwell angleof Ignition circuit ÆTimingof Ignition circuit ÆTimingof Ignition circuit ÆX11/2Engine 120 L.1)kV-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 1/2Oscilloscopeprimary/secondary ÆT1/1and voltage atterminal 15/1 of IgnitioncoilOscilloscopeprimary/secondary Æand voltage atterminal 15/1 of IgnitioncoilX11/3Engine 120 R.Trigger clamp onignition cableT1/1T1/2On engine 119 subtract 90 CKA from measured value. Example: measured: 107 CKA, 107–90 17 ignition timingb Diagnostic Manual Engines 08/00B 1 LH-SFI21/9

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, AdjustmentNotes regarding on/off ratio check using on/off ratio testerThe operation of the on-off ratio control can be tested by checking theon-off ratio. 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, buton-off ratio control is not functioning. A varying on-off ratio indicates thatthe on-off ratio control is functioning correctly. On-off ratios from 10% to95% are each assigned a specific malfunction (see DTC memory, DMEngines, Volume 2, Section 2). After testing the on-off ratio, a diagnostictrouble code (DTC) readout using the impulse counter scan tool mustalways be performed.b Diagnostic Manual Engines 08/00Notes 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 LH-SFI controlmodule, base module, DI control module and the EA/CC/ISC controlmodule or CC/ISC control module must be cleared.B 1 LH-SFI21/10

BTest and Adjustment JobsB1Engine Test, AdjustmentNotes regarding DTC readout using Impulse counter scan tool1.Engine 104, 119, 120 LH-SFIConnect 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.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 reappears.b Diagnostic Manual Engines 08/003. Clearing DTC memoryNote: The clearing process must occur within 20 seconds after the DTCreadout.a) Ignition: ONb) Push start button 2-4 seconds (Impulse display appears).c) After a waiting period of 3 seconds, push the start button for 6-8seconds which will erase the previously displayed DTC.d) Erase each DTC separately.e) Turn off ignition for at least 30 seconds.B 1 LH-SFI21/11

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, AdjustmentSpecial Tools104 589 00 63 00201 589 00 99 00201 589 13 21 00124 589 07 21 00Test cableElectrical connecting setTesterRemote thermometer140 589 14 63 00103 589 00 91 00119 589 04 63 00124 589 19 21 00AdapterMeasuring connectionPressure hosePulse counterb Diagnostic Manual Engines 08/00B 1 LH-SFI21/12

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, Adjustment909 589 09 21 00900 589 01 15 00On-off ratio testerOn-off ratio signal adapterEquipmentEngine analyzer 1)Bear DACE (Model 40-960)Sun MEA-1500MBDigital multimeter 1)Fluke models 23, 83, 85, 871)Available through the MBUSA Standard Equipment Program.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/13

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentNote:The on-off ratio control system test should not be performed on avery hot engine, for example, after a fast drive or after an output teston a dynamometer.Test step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O1Connect test equipmentaccording to diagramIgnition: OFF––O2Connect impulse counter scan tool:Yellow wire to socket 8 of data linkconnector (X11/4)Ignition: ONDTC readout "I"See DM Engines, Vol. 2 – 3.1 or 3.2Connect impulse counter scan tool:Yellow wire to data link connector(X11/4).Engine 104, 119Socket 4Engine 120Socket 5, left LH-SFI control module(cyl. 7 – 12)Socket 4, right LH-SFI control module(cyl. 1 – 6)Ignition: ONDTC readout "I"See DM Engines, Vol. 2 – 3.1 or 3.2Base moduleDTC readoutO3LH-SFI control moduleDTC readout1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/14

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O4Connect impulse counter scan tool:yellow wire to data link connector(X11/4)Engine 104, 119Socket 17Engine 120Socket 18, left DI control module(cyl. 7 – 12)Socket 17, right DI control module(cyl. 1 – 6)Ignition: ONDTC readout "I"See DM Engines, Vol. 2 – 5.2 or 5.3O 5.0EA/CC/ISC control module (N4/1)DTC readoutConnect impulse counter scan tool:yellow wire to socket 7 of data linkconnector X11/4Ignition: ONDTC readout "I"See DM Engines, Vol. 2 – 6.2 or 6.3O 5.1Connect impulse counter scan tool:yellow wire to socket 7 of data linkconnector X11/4Ignition: ONDTC readout "I"See DM Engines, Vol. 2 – 7.1–––DI control moduleDTC readoutCC/ISC control module (N4/3)DTC readoutO 5.2Not applicable for U.S. versionvehicles1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/15

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O6Ignition: OFF––O7Check condition and freemovement of throttle linkage andthrottle valveIgnition: OFFActuate throttle linkageSmooth operation, no binding shouldbe evident.Lubricate all bearings and ball sockets.O 7.1Check WOT positionIgnition: OFFAccelerator pedal at WOT position (donot actuate kickdown switch).Throttle valve lever must rest againstwide open throttle stop (audiblecontact).Adjust WOT stop(SMS, Job No. 30 – 1010).O 7.2Ignition: OFFAccelerator pedal at CTP.Throttle valve lever must rest againstclosed throttle stop (audible contact).Adjust CTP stop on engine(SMS, Job No. 30 – 1010).Ignition: OFFAccelerator pedal at CTP.Arrows must align.Adjust control pressure cable(SMS, Job No. 30 – 1010).Remove and install air cleanerCheck CTPO8Check automatic transmissioncontrol pressure cable1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/16

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O9Connect/disconnect pressure gaugeEngine: at Idle3.2 to 3.6 barCheck fuel pumps and FP relaymodule (DM Engines, Vol. 2 – 3.1 or3.2).O 10Engine coolant levelIgnition: OFFMarking: min - maxCorrect engine coolant levelO 11Engine oil levelIgnition: OFFMarking: min - maxCorrect engine oil levelO 12Check primary and secondaryignition circuitsIgnition: at IdleSee Test and Adjustment Data(Section A)Check ignition system(DM Engines, Vol. 2 – 5.2 or 5.3)O 13Check ignition timing with andwithout vacuumEngine: at IdleTransmission range “P”Climate control system: OFFSee Test and Adjustment Data(Section A)Check ignition system(DM Engines, Vol. 2 – 5.2 or 5.3)Check fuel pressure1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/17

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O 14Engine: at IdleVoltage difference betweencylinders 3kV.Voltage increase with engineaccelerated should be no more than 6kV over idle value.Check ignition system(DM Engines, Vol. 2 – 5.2 or 5.3)Evaluate oscilloscope patternsBriefly accelerate to 3000 rpmO 15Warm engine oil to operatingtemperatureEngine rpm: Maintain at approx.3000 rpmEngine oil temperature approx. 80 C–O 16Engine: at IdleSelector lever in “P”,climate control system “OFF”.See Test and adjustment data(section A)Test program:Check EA/CC/ISC system(DM Engines, Vol. 3 – 6.2 or 6.3),Check CC/ISC system(DM Engines, Vol. 3 – 7.1)Selector lever in “P”,See Test and adjustment dataClimate control system OFF. Disconnect (section A)and plug purge line (A or B) atswitchover valve (Figure 1, 3 and 4).Reconnect line after measurment.Engine: at IdleCheck electonic components withsocket box tester(DM Engines, Vol. 2 – 3.1 or 3.2)Check closed throttle (idle) rpmO 17Check on-off ratio control system1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/18

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentTest step/Test sequenceTest conditionNominal valuePossible cause/Remedy 1)O 18Not applicable for U.S. versionvehicles–––O 19Check CTP speed under loadEngine: at IdleTR “D” (service and parking brakeapplied),Switch on all electrical consumers,Turn steering wheel to full lock.Engine must continue to idle withinspecified range.Test program:Check EA/CC/ISC system(DM Engines, Vol. 3 – 6.2 or 6.3),Check CC/ISC system(DM Engines, Vol. 3 – 7.1)1)Observe Preparation for Test, see 22.b Diagnostic Manual Engines 08/00B 1 LH-SFI21/19

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentAccelerator ControlEngine 119 LH-SFI (without ASR)Figure 712112629304041Bell crankConnecting linkControl pressure cable for automatic transmissionSpringAdjustment screwBowden cableIdle travel rodConnecting linkP30-0147-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/20

BTest and Adjustment JobsB1Engine 104, 119, 120 LH-SFIEngine Test, AdjustmentAccelerator ControlEngine 119 LH-SFI (with ASR)Figure 812112629304041Bell crankConnecting linkControl pressure cable for automatic transmissionSpringAdjustment screwBowden cableIdle travel rodConnecting linkP30-0146-57b Diagnostic Manual Engines 08/00B 1 LH-SFI21/21

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, AdjustmentComponent LocationsP47-5047-13P07-5240-13AP47-5056-13Figure 9Model Model 140, Engine 104, 119Figure 10Model Model 140, Engine 120Figure 11Model Model 140, Engine 120Y58/1ABY58/2Y58/3Purge control valvePurge line to enginePurge line to charcoal canisterb Diagnostic Manual Engines 08/00ABLeft purge control valve (located on right side ofengine)Purge line to enginePurge line to charcoal canisterABRight purge control valve (located on left side ofengine)Purge line to enginePurge line to charcoal canisterB 1 LH-SFI21/22

BB1Test and Adjustment JobsEngine 104, 119, 120 LH-SFIEngine Test, AdjustmentComponent LocationsP47-5057-13Figure 12Model Model 124, Engine 119Y58/1ABPurge control valvePurge line to enginePurge line to charcoal canisterb Diagnostic Manual Engines 08/00B 1 LH-SFI21/23

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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