Mercedes S-Class W220 Workshop Manual 1998-2006

ACCESSORIES/SAFETY EQUIPMENT
Mercedes-Benz - Air Bag Restraint Systems
DESCRIPTION & OPERATION
WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components.
All models are equipped with Supplemental Restraint System (SRS). The main components of SRS are driver-
side air bag module, passenger-side air bag module, side impact air bag modules (located in doors), SRS control
module, side air bag sensors, SRS warning light, driver-side knee bolster, passenger-side knee bolster and seat
belt pretensioners or Emergency Tensioning Retractor (ETR) seat belt assembly. Additionally, some vehicles
may be equipped with head impact (curtain type) air bags.
Both SRS and ETR are electronically activated by a single control module. There are 2 thresholds which must
be exceeded to trigger an ETR action, air bag deployment, or both. If a moderately severe frontal collision
occurs exceeding first triggering threshold where protection from seat belt is sufficient, only Emergency
Tensioning Retractor (ETR) is activated if seat belt is buckled. If a moderately severe frontal collision occurs
exceeding first triggering threshold where protection from seat belt is sufficient, but seat belt is not buckled, air
bag is deployed and ETR is not activated.
If a severe frontal collision occurs exceeding second triggering threshold where protection from seat belt is
insufficient, air bag is deployed. ETR is activated if seat belt is buckled. If seat belt is not buckled, ETR is not
activated when second triggering threshold is reached. Passenger air bag will deploy even if passenger seat is
not occupied when a triggering threshold is exceeded. During certain types of collisions, the air bags will be
deploy, but ETRs will not be activated.
The side air bag on the driver-side deploys whenever the driver-side air bag module is deployed and when there
is a substantial side impact crash. The air bag on the passenger-side will activate only when a sensor (Occupied
Seat Recognition Sensor) in the passenger seat sends a signal to the SRS control module that the passenger-side
seat is occupied. Side air bags mounted in rear doors will deploy when side impacts occur that exceed preset
parameters.
Head impact air bag modules will deploy when certain side impacts occur that exceed preset parameters. Head
impact air bag will deploy independently of other air bags on side of impact.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
Component Location
AIR BAG warning light Instrument Panel Cluster
Clockspring Under steering wheel
Driver-side air bag module On steering wheel
Emergency Tensioning Retractor (ETR) Driver-side & passenger-side lower B- & C-pillars(1)
Front Passenger Seat Occupied Recognition With Under passenger front seat cushion
Automatic Child Seat Recognition (ACSR) sensor
Head impact air bag modules Driver-side & passenger-side roof rails over front &
rear doors
Knee bolsters Driver-side and passenger-side lower instrument
panel
Passenger-side air bag module Passenger-side instrument panel
Side impact air bag modules In front & rear doors
Side impact sensors On floor inboard of door openings
(1) On C Class, rear seat ETRs are part of seat belt buckle assemblies.
SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS
components must be thoroughly inspected, including wiring harness. Before component replacement, check for
SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK . SRS service
life is 10 years from manufactured date or 10 years from SRS replacement date after accident related repairs are
completed.
SYSTEM OPERATION CHECK

SRS warning light indicates SRS and Emergency Tensioning Retractor (ETR) system readiness. Turn ignition
on. SRS warning light will illuminate, then turn off after approximately 4-6 seconds indicating SRS system is
functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously
illuminated, there is a system fault. Repair malfunctioning system.
AIR BAG SAFETY PRECAUTIONS

Observe these precautions when servicing the air bag system:
 When working around SRS components and before any repairs are performed, disable air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM .
 Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
 Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits which are irritating to the skin.
 Always use control module and impact sensors made by same manufacturer. Using components produced
by different manufacturers could cause accidental air bag or ETR deployment.
 DO NOT repair any portion of SRS wiring harness.
 If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.
 If SRS components show signs of damage, they must be replaced.
 Always handle air bag module with trim cover facing away from your body.
 Always place air bag module on workbench with trim cover up, away from loose objects.
 DO NOT expose any SRS component to temperatures in excess of 212°F (100°C).
 DO NOT expose any SRS component to grease, oil or cleaning agents.
DISABLING & ACTIVATING AIR BAG SYSTEM

DISABLING SYSTEM
Turn ignition off and remove key. Disconnect negative battery cable and shield cable end. Disconnect SRS
control module electrical connector.
ACTIVATING SYSTEM
Connect SRS control module electrical connector. Ensure no one is in vehicle. Turn ignition on. Connect
negative battery cable. Go to SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES
Several situations may arise requiring some form of disposal action, including:
 Scrapping a vehicle containing deployed air bag modules and ETRs.

 Scrapping a vehicle with live air bag modules and ETRs.
 Disposal of a live but electrically faulty air bag module and/or ETR.
 Disposal of a deployed air bag module and/or ETR.
DEPLOYED AIR BAG OR ETR
Deployed air bag modules and ETRs can be disposed of like any other part.
SCRAPPED VEHICLE
Undeployed air bag modules and ETRs CANNOT be disposed of without first being deployed. Contact
manufacturer for additional information.
UNDEPLOYED AIR BAG OR ETR
Undeployed air bag modules and Emergency Tensioning Retractor (ETR) seat belts CANNOT be disposed of
without first being deployed. Contact manufacturer for additional information.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION
Removal and installation information is not available.
DIAGNOSTICS
Air bag system diagnostic information is not available. All air bag system diagnosis must be carried out using
manufacturers proprietary test equipment.
WIRE REPAIR
If any part of SRS wiring harness is damaged, DO NOT repair wiring harness, replace complete wiring harness.
WIRING DIAGRAMS
Wiring diagrams are not available.
ACCESSORIES/SAFETY EQUIPMENT
Mercedes-Benz - Air Bag Restraint Systems
NOTE: The following 2000 information represents the latest information available at
time of publication and may be useful in diagnosing 2001 vehicles. 2001 wiring
diagrams have been included at the end of this article.
All models are equipped with Supplemental Restraint System (SRS). The main components of SRS are driver-
side air bag module, passenger-side air bag module, side air bag modules (located in doors), SRS control
module, side air bag sensors, SRS warning light, driver knee bolster, passenger knee bolster, and Emergency
Tensioning Retractor (ETR) seat belt assembly. Additionally, some vehicles may be equipped with head impact
(curtain type) air bags (located around door windows behind door frame trims).
Both SRS and ETR are electronically activated by a single control module. There are 2 thresholds which must
be exceeded to trigger an ETR action, air bag deployment, or both. If a moderately severe frontal collision
occurs exceeding first triggering threshold where protection from safety belt is sufficient, only Emergency
Tensioning Retractor (ETR) is activated if safety belt is buckled. If a moderately severe frontal collision occurs
exceeding first triggering threshold where protection from safety belt is sufficient, but safety belt is not buckled,
air bag is deployed and ETR is not activated.
If a severe frontal collision occurs exceeding second triggering threshold where protection from safety belt is
insufficient, air bag is deployed. ETR is activated if safety belt is buckled. If safety belt is not buckled, ETR is
not activated when second triggering threshold is reached. Passenger air bag will deploy even if passenger seat
is not occupied when a triggering threshold is exceeded. If during a severe frontal collision the power supply is
interrupted, the driver and passenger air bag can still be deployed, but ETR cannot be activated.
The side air bag on the driver-side deploys whenever the driver-side air bag module is deployed and when there
is a substantial side impact crash. The air bag on the passenger-side will activate only when a sensor (Occupied
Seat Recognition Sensor) in the passenger seat sends a signal to the SRS control module that the passenger-side
seat is occupied. During a collision, the side air bag will then deploy.
COMPONENT LOCATIONS
Fig. 1: Locating Restraint System Components (2000 E Class Shown; Others Are Similar)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for driver and passenger air
bag units. All SRS components must be thoroughly inspected, including wiring harness. Before component
replacement, check for SRS fault codes by performing system operation check. See SYSTEM OPERATION
CHECK . SRS service life is 10 years from manufactured date, or 10 years from SRS replacement date after
accident related repairs are completed.
SYSTEM OPERATION CHECK

SRS warning light indicates air bag and Emergency Tensioning Retractor (ETR) system readiness. Turn
ignition on. SRS warning light will illuminate, then turn off after approximately 4-20 seconds indicating system
is functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously
illuminated, there is a system fault. Repair malfunctioning system. See DIAGNOSTICS .
AIR BAG SAFETY PRECAUTIONS

Observe following precautions when working with air bag systems:
 When working around steering column components and before any repairs are performed, disable air bag
 Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
 Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits which are irritating to the skin.
 DO NOT repair any portion of SRS wiring harness.
 Always handle air bag module with trim cover away from your body. Always place air bag module on
workbench with trim cover up, away from loose objects.
 DO NOT expose any SRS component to temperatures in excess of 212 F (100 C).
 DO NOT expose any SRS component to cleaning agents such as solvents, gasoline, lye, etc.
 DO NOT connect Hand-Held Tester (6511 0001 99) to Data Link Connector (DLC) with ignition on.
Damage to HHT may result.
 DO NOT connect HHT (6511 0001 99) to vehicle if a battery charger is connected to vehicle battery.
Damage to HHT may result.
ADJUSTMENTS
If fixing screws were not used during clockspring removal or clockspring was rotated during removal, turn
clockspring clockwise until resistance is detectable. Turn clockspring counterclockwise 2-2.5 turns until fixing
screws can be unscrewed holding clockspring in this position.
DISABLING & ACTIVATING AIR BAG SYSTEM

DISABLING SYSTEM
CAUTION: On CL500, open doors before disconnecting battery. Opening doors

allows windows to automatically lower thus preventing roof seal damage.
Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Record radio presets and obtain anti-theft
code. Turn ignition switch to OFF position and remove ignition key. If welding on vehicle, disconnect negative
battery cable and disconnect air bag control module.
ACTIVATING SYSTEM
Ensure ignition is off. Reconnect air bag system components (if disconnected). Reconnect negative battery
cable. Perform See SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES
WARNING: An undeployed air bag module or ETR should never be disposed of

without first being deployed. See SCRAPPED VEHICLE . If deployment is
not possible, contact vehicle manufacturer for further instructions.
Several situations may arise requiring some form of disposal action, including:
 Scrapping a vehicle containing a deployed air bag module and-or ETR.

 Scrapping a vehicle with a live air bag module and-or ETR.
 Disposal of a live but electrically faulty air bag module and-or ETR.
 Disposal of a deployed air bag module and-or ETR.
DEPLOYED AIR BAG OR ETR
Deployed air bag module and-or ETR unit can be thrown away. None of its components are reusable. Deployed
air bag module is NOT classified as hazardous material.
SCRAPPED VEHICLE
WARNING: An undeployed air bag module and-or ETR seat belt CANNOT be disposed
of without first being deployed. If this is not possible through procedures
outlined below, contact vehicle manufacturer for further instructions.
Perform remote deployment outdoors. Keep personnel at least 20 feet
away.
1. Before proceeding, follow service precautions. See AIR BAG SAFETY PRECAUTIONS . Move
vehicle outdoors to a remote area, away from workshop and other personnel. Disconnect and shield
negative battery cable. Open all vehicle windows and doors.
2. Ensure air bag module is secured to steering wheel, and passenger air bag is secured to dash. Ensure ETR
seat belt assemblies are secured to "B" pillars and all seat belt buckles are latched. Remove loose objects
from front seat. DO NOT allow anyone inside vehicle.
3. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect Trigger
Device (126-589-00-90-00) and Adapter Cable (126 589 21 63 00) to SRS system connector (X29-9)
located at passenger footwell area. Move away from vehicle as far as trigger device wiring will allow.
4. To deploy driver air bag and ETR, turn rotary knob on trigger device to position No. 1. Push battery
check push button and ignition push button simultaneously. Trigger light should illuminate indicating
driver air bag and ETR deployed. If trigger light is illuminated and driver air bag and-or ETR did not
deploy, driver air bag module and-or ETR is faulty. See UNDEPLOYED AIR BAG-ETR .
5. To deploy passenger air bag detonator No. 1, turn rotary knob on trigger device to position No. 2. Push
battery check push button and ignition push button simultaneously. Trigger light should illuminate
indicating passenger air bag detonator No. 1 deployed. If trigger light is illuminated and passenger air bag
detonator No. 1 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR BAG-
ETR .
6. To deploy passenger air bag detonator No. 2, turn rotary knob on trigger device to position No. 3. Push
battery check push button and ignition push button simultaneously. Trigger light should illuminate
indicating passenger air bag detonator No. 2 deployed. If trigger light is illuminated and passenger air bag
detonator No. 2 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR BAG-
ETR .
UNDEPLOYED AIR BAG-ETR
After deploying procedures and-or diagnostic testing have confirmed air bag module and-or ETR is
undeployable, contact vehicle manufacturer for proper disposal instructions.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
CLOCKSPRING ASSEMBLY
Removal & Installation
1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
2. Remove driver air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel bolt.
Using a puller, remove steering wheel. Disconnect lower clockspring connector. Turn 2 fixing screws
(locating on clockspring) counterclockwise until clockspring cannot be rotated. Remove clockspring
mounting screws as necessary. Disconnect all necessary electrical connectors. Remove clockspring
assembly. To install, reverse removal procedure. Activate air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Perform system operation check to ensure system is functioning
properly. See SYSTEM OPERATION CHECK .
CONTROL MODULE
Removal & Installation (C Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove shift lever cover
bezel. Lift shift lever cover enough to disconnect electrical connector. Remove shift lever cover.
2. Remove storage compartment mounting screws from center console. Remove storage compartment.
Remove ashtray. Disconnect electrical connectors as necessary. Disconnect SRS control module electrical
connector. Remove SRS control module mounting bolts. Remove SRS control module.
3. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set
parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate
air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM
OPERATION CHECK .
Removal & Installation (E Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove gear shift cover
panel. Remove ashtray and ashtray housing at front of console. Remove radio (if necessary).
2. Remove center console right side cover screws and right side cover. Disconnect electrical connector for
control module. Remove 2 control module mounting screws. Remove control module.
OPERATION CHECK .
Removal & Installation (S Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove radio. Remove
ashtray. Remove wooden surround for ashtray. Remove shift lever cover mounting screws. Push shift
lever cover toward rear of vehicle and remove in an upward direction.
2. Remove center console cover screws. Remove center console cover by pulling from bottom in an upward
direction. When removing covers, disconnect electrical connectors as necessary. Disconnect SRS control
module electrical connector. Remove SRS control module.
OPERATION CHECK .
Removal & Installation (SL Class)

DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove radio. Push up
and pull out heater control panel. Unplug 2 connectors. Remove screw in middle of storage tray.
2. Bend up at top corners and lift out storage tray. Remove screws below storage tray. Lift wood trim panel
at rear, pull down and out of catches. Unplug switch connectors and remove wood trim panel. Unplug
connectors at control module and remove Torx mounting screws. Remove control module.
OPERATION CHECK .
Removal & Installation (CLK & SLK)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove cover on center
console. Remove cover on shift lever. Remove ash tray housing with storage compartment at front of
center console. Unplug connectors at control module and remove Torx mounting screws. Remove control
module.
OPERATION CHECK .
DRIVER-SIDE AIR BAG MODULE
NOTE: Air bag module and steering wheel must be replaced following a collision in
which air bag was deployed.
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove 2 Torx screws
from rear of steering wheel. Lift off air bag module enough to unplug connector from rear of module.
Place module away from work area, with pad facing upward.
2. To install, reverse removal procedure. Tighten Torx screws to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. Perform system operation check to ensure system is
functioning properly. See SYSTEM OPERATION CHECK .
SIDE AIR BAG UNIT (DRIVER-SIDE & PASSENGER-SIDE)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Drill out rivets at
retaining plate of side air bag unit. Pull air bag unit out of door. Disconnect connector at driver-side air
bag squib. Remove unit from vehicle. See Fig. 2 .
2. To install, connect connector so that connector audibly clicks when connector engages. Install unit in
door trim panel and rivet using only special rivets (Part No. 003 990 0097). Perform system operation
check to ensure system is functioning properly. See SYSTEM OPERATION CHECK .
Fig. 2: Removing Side Air Bag Unit (2000 Models)

SIDE AIR BAG SENSOR (DRIVER-SIDE & PASSENGER-SIDE)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. On SLK 230, remove
door sill moulding. On all models, remove front seat. Fold floor covering in area toward rear. Unclip
connector on side bag sensor. Remove 2 mounting screws. Remove sensor from vehicle.
2. To install, reverse removal procedure. Ensure that arrow on sensor points toward outside. Perform system
operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK .
Fig. 3: Removing Side Air Bag Sensor (2000 E Class Shown; Others Are Similar)
OCCUPIED SEAT RECOGNITION SENSOR
2. Remove cover on front seat cushion. Remove ignition key. Unclip connection for occupied seat
recognition sensor on seat connector block. Remove electrical connection lead from seat and pull upward
out of rubberized fiber matting. See Fig. 4 .
3. To install, lay out occupied seat recognition sensor uniformly on rubberized fiber matting. Fabric side
should point upward. Do not kink occupied seat sensor. Reverse removal procedure. Perform system
operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK .
Fig. 4: Removing Occupied Seat Recognition Sensor (2000 Models)
PASSENGER-SIDE AIR BAG MODULE
Removal & Installation (C Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove instrument panel.
Disconnect passenger-side air bag module squib connector. Remove 4 passenger-side air bag module
mounting nuts.
2. To install, reverse removal procedure. Ensure passenger-side air bag module squib connector audibly
clicks when connecting connector. Activate air bag system. Perform system operation check to ensure
system is functioning properly. See SYSTEM OPERATION CHECK .
Removal & Installation (E Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove 2 central
mounting bolts for passenger-side air bag module. Lift air bag module enough to unplug connector from
rear of module. Place module away from work area, with pad facing upward.
2. If necessary to replace passenger air bag installation frame, remove 4 frame mounting bolts. Remove
installation frame from vehicle.
3. To install air bag module or installation frame, reverse removal procedure. Activate air bag system.
Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION
CHECK .
Removal & Installation (S Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Open glove box door.
Remove 4 clips securing glove box. Remove glove box compartment. When removing compartment,
disconnect glove box light. Remove glove box door lock striker.
2. Disconnect passenger-side air bag module squib connector. Remove 4 passenger-side air bag module
mounting nuts. Remove passenger-side air bag module through glove box opening. Place module away
from work area with pad facing up.
3. To install, reverse removal procedure. Ensure module squib connector audibly clicks when connecting
connector. Activate air bag system. Perform system operation check to ensure system is functioning
properly. See SYSTEM OPERATION CHECK .
Removal & Installation (SL Class)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove cover below
instrument panel. Remove one bolt in installation slot of center air outlet, and one bolt below right air
outlet.
2. Remove air bag panel (3 Phillips screws and 2 hex bolts). Unplug connector at squib of passenger-side air
bag unit. Remove mounting bolts. Pull off and take air bag out of panel opening.
3. To install air bag module, reverse removal procedure. Activate air bag system. Perform system operation
Removal & Installation (CLK 320)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove instrument panel.
Disconnect passenger-side air bag module connector. Remove 4 screws and passenger-side air bag
module.
Removal & Installation (SLK 320)
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove top section of
instrument panel. Fold vapor barrier toward front to reveal 2 screws. Disconnect passenger-side air bag
module connector. Remove 4 screws and passenger-side air bag module.
DIAGNOSTICS
NOTE: After component replacement, perform a system operation check to ensure

proper system operation. See SYSTEM OPERATION CHECK .
Before proceeding, see AIR BAG SAFETY PRECAUTIONS . The SRS control module is capable of
diagnosing air bag system components and ETR components. If a fault is detected by the SRS control module
or system is malfunctioning, SRS warning light will do one or more of the following:
 SRS warning light goes out after 2 minutes. System fault is noted, however occupant protection is not
affected. See RETRIEVING FAULT CODES .
 SRS warning light illuminates continuously. System is faulty which may result in a non deployment or
false deployment. See RETRIEVING FAULT CODES .
 SRS warning light blinks continuously. Control module has been replaced without setting control module
parameters.
RETRIEVING FAULT CODES
NOTE: Fault codes may only be retrieved using Hand-Held Tester (965 589 00 01) and
Adapter (965 589 00 40 or 965 589 00 50).
1. Check vehicle fuses. Replace any blown fuses as necessary. Ensure vehicle battery voltage is 11 volts or
more. Ensure SRS warning light functions. Turn ignition off. Connect Hand-Held Tester (HHT) (965 589
00 01) to Data Link Connector (DLC).
2. DLC is located in right rear corner of engine compartment. It may be necessary to use Adapter (965 589
00 40 or 965 589 00 50) to connect HHT to DLC. After HHT displays module number and version, press
return key to start diagnosis. Using HHT, follow HHT prompts to retrieve SRS fault codes. For SRS
control modules beginning with number 000, fault code 1 is valid. For SRS control modules beginning
with number 001, fault code 2 is valid. See Fig. 6 .
3. HHT will display a 3 digit fault code, and may display additional graphic information. This additional
graphic information will help in diagnosis of fault code. See Fig. 5 . During diagnosis HHT will display 4
different graphic displays informing technician if a test passes or fails, or if seat belt buckle is latched or
not latched. See Fig. 5 .
4. These graphic displays are displayed as applicable by HHT during testing. See FAULT CODES table.
During diagnosis, system values are continuously updated, so by moving components and connections
intermittent failures can be diagnosed. HHT will also display fault frequency and time span.
5. After retrieving fault codes using HHT, carefully observe testing instructions in this article. Some testing
is executed with HHT connected to DLC and some tests are executed with HHT removed from DLC.
Turn ignition off when removing or connecting HHT to DLC.
6. Contact Box (124 589 00 21) with Test Cable (124 589 35 63) is necessary to complete some test steps.
Resistance Substitution Unit (124 589 09 63) is necessary to substitute resistance values for testing
purposes.
Fig. 5: Hand Held Tester Graphic Information (2000 Models)
FAULT CODES
Fig. 6: Diagnostic Trouble Code (DTC) Memory (2000 Models-1 Of 4)



CLEARING FAULT CODES
Connect Hand-Held Tester (965 589 00 01) to Data Link Connector (DLC). DLC is located in right rear corner
of engine compartment. It may be necessary to use Adapter (965 589 00 40 or 965 589 00 50) to connect HHT
to DLC. After HHT displays module number and version, press return key to start sequence. Using HHT,
follow HHT prompts to clear SRS fault codes. SRS codes are clear when ignition is turned on and SRS warning
light functions normally. See SYSTEM OPERATION CHECK .
UNDERSTANDING DIAGNOSTIC CHART INFORMATION
NOTE: Refer to table to properly identify components or connectors being tested. See
COMPONENT IDENTIFICATION table.
SRS & ETR Diagnosis Chart Column Identification
First column of chart identifies TEST STEP (1.0 for example). See Fig. 10 . Second column of chart identifies
HHT fault code (017, 003 for example). First code in column is for vehicles without side air bags. Second code
in column (when listed) is for vehicles with side air bags only. Other 5 columns are self-explanatory.
Using SRS & ETR Diagnosis Chart

For reading and understanding fault code diagnosis chart, use the following example: Read test step 3.0 (first
column), HHT fault Code 002, 004 (second column). See Fig. 10 . Read TEST SCOPE-HHT ACTUAL
VALUE NO.-TEXT column (third column). Driver-side air bag squib connector R12-3 is being tested. HHT
will identify if problem is with too much resistance or not enough resistance in driver-side air bag squib circuit.
Read TEST CONDITION column (fifth column). Test circuit with HHT connected to DLC, with ignition in
position "2". Read NOMINAL VALUE-HHT DISPLAY column (sixth column). HHT will display a check or
an "F". If HHT displays a check, circuit is okay. If HHT displays an "F", go to step 3.1.
Read TEST CONNECTION (NOT FOR HHT) column (forth column). Driver-Side air bag squib connector
R12-3, terminals No. 1 and 2 are identified. Read TEST CONDITION column. Test circuit with HHT
connected to DLC and ignition key removed. Remove driver-side air bag module. Disconnect driver-side air
bag module squib connector R12-3. Connect Resistance Substitution Unit (124 589 09 63) to driver-side air bag
module squib connector (harness side). Set resistance substitution unit to 2 ohms. Turn ignition key to position
"2". Read NOMINAL VALUE-HHT DISPLAY column. If HHT displays a check, replace driver-side air bag
module. If HHT displays an "F", go to step 3.2.
Read TEST CONNECTION (NOT FOR HHT) column. Horn-air bag clockspring connector A45x1, terminals
No. 1 and 2 are identified. Read TEST CONDITION column. Test circuit with HHT connected to DLC.
Remove ignition key. Connect Resistance Substitution Unit (124 589 09 63 00) to horn-air bag clockspring
connector A45x1. Set resistance substitution unit to 2 ohms. Read NOMINAL VALUE-HHT DISPLAY
column. If HHT displays a check, check horn-air bag clockspring for continuity. Replace horn-air bag
clockspring as necessary. If HHT displays an "F", go to step 3.4.
NOTE: Some testing is identified by model number. Refer to table to identify models by
model number. See MODEL IDENTIFICATION table.
MODEL IDENTIFICATION
Model Number Model
129 SL Class
140 S Class
163 M Class
170 SLK Class
202 C Class
203 C 240 & C 320
208 CLK Class
210 E Class
215 CL 500
220 S 430 & S 500
COMPONENT IDENTIFICATION
Component Manufacturer's Designation
A1e15 SRS warning light
A45 Horn-air bag clockspring
A53 Driver-side air bag sensor
A54 Passenger-side air bag sensor
B41-1 Passenger-side seat occupied recognition sensor
N2-2 SRS control module
N2-7 SRS control module
N72e1 Automatic child seat recognition light
R12-1 Driver-side ETR squib connector
R12-2 Passenger-side ETR squib connector
R12-3 Driver-side air bag squib connector
R12-8 Passenger-side air bag squib connector
R12-9 Side air bag (driver-side) squib connector
R12-10 Side air bag (passenger-side) squib connector
R12-20 Passenger-side air bag squib
R12-21 Driver-side air bag squib
R12-22 Left window air bag squib
R12-23 Right window air bag squib
S68-3 Driver-side belt buckle switch
S68-4 Passenger-side belt buckle switch
W26 Control module ground
X11-4 Data link connector
X11-13 10-pin SRS test connection
CONTROL MODULE PROGRAMMING
After control module replacement, SRS warning light will blink or illuminate continuously. This indicates need
to program and set parameters of SRS control module. This process requires use of Hand-Held Tester (965 589
00 01). During programming, the following conditions need to be met:
Vehicles Without Side Air Bag
Version with passenger-side air bag module, when replacing SRS control module is to be set to YES when
programming control module. Version with seat belt buckle switch is to be programmed NO.
Vehicles With Side Air Bag
Version is set to YES when replacing SRS control module. Version with seat belt buckle switch is set to YES.
Seat occupation recognition is set to YES.
Parameters
After programming, SRS warning light will continue to blink, indicating need to set parameters. Currently,
parameters set is identical for all models.
DIAGNOSTIC TESTS
Fig. 10: SRS & ETR Diagnosis (2000 Models, Except E Class-1 Of 17)
Fig. 27: SRS & ETR Diagnosis (2000 E Class-1 Of 23)














Fig. 50: Connecting Socket Box (2000 Models)
Fig. 53: Connecting Resistance Substitution Unit (2000 Models)
Fig. 56: Testing Side Air Bag Sensor (2000 Models)
Fig. 57: Testing Seat Occupation Recognition Sensor (2000 Models)
Fig. 58: Testing Seat Occupation Recognition Sensor (2000 Models)
WIRE REPAIR
If any part of SRS wiring harness is damaged, DO NOT repair wiring harness, replace complete wiring harness.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS(1)
Application Ft. Lbs (N.m)
Steering wheel hub bolt 52-66 (70-90)
INCH Lbs. (N.m)
Driver air bag module bolts (torx) 44-62 (5-7)
(1) Torque specifications are not available for clockspring assembly, control module or passenger-side
air bag module.
WIRING DIAGRAMS
Fig. 59: Air Bag System Wiring Diagram (2000 C230 & C280)
Fig. 60: Air Bag System Wiring Diagram (2000 CLK320 & CLK430)
Fig. 61: Air Bag System Wiring Diagram (2000 E320 & E430-1of 2)
Fig. 62: Air Bag System Wiring Diagram (2000 E320 & E430-2of 2)
Fig. 63: Air Bag System Wiring Diagram (2000 SLK230)
Fig. 64: Air Bag System Wiring Diagram (2000 S430 & S500-1 Of 2)
Fig. 66: Air Bag System Wiring Diagram (2001 E320 & E430-1 Of 2)
Fig. 67: Air Bag System Wiring Diagram (2001 E320 & E430-2 Of 2)
Fig. 68: Air Bag System Wiring Diagram (2001 ML320 & ML430 With Memory Seats-1 Of 2)
Fig. 69: Air Bag System Wiring Diagram (2001 ML320 & ML430 With Memory Seats-2 Of 2)
Fig. 70: Air Bag System Wiring Diagram (2001 ML320 & ML430 Without Memory Seats-1 Of 2)
Fig. 71: Air Bag System Wiring Diagram (2001 ML320 & ML430 Without Memory Seats-2 Of 2)
Fig. 72: Air Bag System Wiring Diagram (2001 SLK230 & SLK 320)
Engine
Air Intake, Turbo Charging - 215 & 220 Chassis
BASIC KNOWLEDGE
TURBOCHARGING, FUNCTION - GF09.00-P-2000
Turbocharging, Function - Gf09.00-P-2000Am
Engine 113.990 In Models 211, 219
Engine 113.992 In Model 230
Recirculated Air Flap Closed, Compressor Actuated
Fig. 1: Identifying Turbocharging System Components With Compressor Actuated
Recirculated Air Flap Open, Compressor Not Actuated

Fig. 2: Identifying Turbocharging System Components With Compressor Not Actuated
Charging Increases The Performance Of The Engine In The Upper Partial Loading And Full Loading Ranges.
The Compressor (50) Compresses The Intake Air And Therefore Increases The Degree Of Filling Of The
Cylinder.
The Metered Fuel Quantity Is Increased As A Result Of The Rise In The Air Quantity. This Increases The
Torque Produced And The Engine Performance.
The Charge Air Cooler (110/2) Lowers The Charge Air Temperature And Thus Improves The Degree Of Filling
Of The Cylinder. This Increases Engine Output, Reduces Fuel Consumption And Lowers The Exhaust Gas
Temperature. A Low Exhaust Gas Temperature Means Low No Issues.
Function
The Drive Power Needed To Drive The Compressor Is Taken From The Crankshaft Over A Separate Belt
Drive.
The Magnetic Coupling Of The Mechanical Supercharger (Y2/1) Is Responsible For Switching The
Compressor On And Off.
The Magnetic Clutch Is Actuated Map-Controlled By The Me-Sfi [Me] Control Unit (N3/10) If A High Engine
Torque Is Requested.
The Compressor Is Always Actuated For Technical Reasons From An Engine Speed Of About 3500 Rpm.
The Charge Air Pressure Is Regulated By The Recirculated Air Flap Actuator (M16/7) Which Is Directly
Controlled By The Me Control Unit In Accordance With The Performance Map. In The Case Of A Switched
Off Supercharger The Intake Air Can Circumvent The Compressor Via The Air Recirculation Flap. The Air
Can Be Suctioned In Directly In Such A Way That The Supercharger Does Not Have To Turn. This Means That
The Fuel Consumption Is Reduced During Idling And In The Partial Loading Range.
The Opening Angle Of The Recirculated Air Flap Changes In The Opposite Direction To The Opening Angle
Of The Throttle Valve. This Means: If The Throttle Valve Open By 20° For Example Then The Air
Recirculation Flap Closes By 20°. The Recirculated Air Flap Is Completely Closed At Full Load (Maximum
Charge Pressure) While The Throttle Valve Is Wide Open (Maximum Intake Air).
The Charge Air Temperature And The Charge Air Pressure Are Measured In The Charge Air Distributor Pipe
And Sent To The Me Control Unit In Order To Allow Adjustment Of The Correct Fuel Quantity For The
Degree Of Filling Of The Cylinder.
The Compressor Is Switched On Shortly When Starting At External Temperatures Below 0°C In Order
To Free Up The Compressor From Any Icing Which May Have Occurred (Through The Presence Of
Condensate In The Compressor).
Pressure sensor, GF07.04-P-5014AM

location/task/design/function
Charge air temperature sensor, GF07.04-P-5039AM
location/task/ design/function
Charge air cooler GF09.41-P-3100AM
Location/task/design/function
Air recirculation flap actuator except model 230 to GF09.50-P-3101AM
Location/task/design/function 06/2002
Compressor GF09.50-P-3102AM
Supercharger magnetic clutch, GF09.50-P-3103AM
Throttle valve actuator, GF30.22-P-4101AM
location/task/design/ function
Turbocharging, Function - Gf09.00-P-2000M
Engine 275.950 In Model 215, 220

Fig. 3: Identifying Turbocharging Function
For Exhaust-Gas Turbocharging The Flow Kinetic Energy Of The Exhaust Gases Coming Out Of Each
Cylinder Bank Is Used To Drive The Turbocharger (110A, 110B). The Turbochargers Take In Clean Air
Downstream Of The Air Filters. The Compressed Air (E) Is Cooled In The Charge Air Cooler (5/1, 5/2).
Downstream Of The Charge Air Coolers, The Combined Charge Air (E) From The Right And Left
Turbochargers Flows To The Intake Manifold (12) Via The Throttle Valve Actuator (M16/6).
There Is A Coolant Cooled Turbocharger (Biturbo) Installed In Every Cylinder Bank. An Optimal Response
Characteristic And A Resulting High Boost Pressure Are Achieved Even At Low Rpm Speeds By Installing
The Turbochargers Immediately On The Exhaust Manifolds. Short Exhaust Gas Paths Guarantee Fast Warm Up
And Thus A High Efficiency Of The Three Way Catalytic Converters.
The Turbochargers Start To Produce Boost Pressure At Approx. 1500 Rpm. The Maximum Boost Pressure Is
Reached At Approx. 2000 Rpm. Injection Quantity And Ignition Timing Are Controlled By The Me-Sfi [Me]
Control Unit (N3/10) As Needed For The Present Load Condition.
The Boost Pressure Is Measured Through The Signal Of The Pressure Sensor Upstream Of The Throttle Valve
Actuator (B28/6), The Load Is Measured Through The Signal Of The Pressure Sensor Downstream Of The
Throttle Valve Actuator (B28/7).
Boost Pressure Control Of Both Turbochargers Is Performed By Means Of The Boost Pressure Control Pressure
Transducer (Y31/5) And The Pressure Regulator Valves (Wastgate Valves) Operated By The Vacuum Cells In
The Turbine Housings.
Additionally, Fast Control Operations And Load Adjustments Below The Basic Charge Pressure Are Performed
Via The Throttle Valve Actuator.
The Maximum Boost Pressure At Sea Level Is:
 For Engine 275.950/951/953/954 Approx. 0.9 Bar

 For Engine 285.950 About 1.3 Bar
 For Engine 275.980/981/982, 285.980 (Amg) About 1.5 Bar.
The Cooled Air Downstream Of The Charge Air Coolers Has A Higher Density. Through This, The Cylinder
Charge And Hence The Engine Output Are Increased. Furthermore The Tendency To Knock Is Reduced. The
Maximum Boost Pressure Is Released Only When The Charge Air Temperature Is Less Than 70°C. The Charge
Air Temperature Sensor (B17/8) Is Mounted At The Intake Manifold.
If The Charge Air Temperature Becomes Too High, The Reason For This Could Be Air Bubbles In
The Low Temperature Cooling Circuit.
During A Load Change, E.G. When Changing Into Deceleration Mode, A Deceleration Air Valve Opens At
Each Compressor Housing. Through This The Boost Pressure Is Quickly Reduced And Charger Noises Are
Prevented.
A Pressure Sensor Downstream Of Air Filter For The Left Or Right Cylinder Bank (B28/4, B28/5) Is Located
In The Air Filter Housing After Every Air Filter In Order To Recognize The Pressure Drop Over The Air Filter.
In Order To Limit The Maximum Charger Rpm The Pressure Conditions Downstream And Upstream Of The
Turbocharger Is Calculated (Based On Pressure Values For The Pressure Sensor Downstream Of Air Filter And
Pressure Sensor Upstream Of Throttle Valve Actuator (B28/6)) And Regulated Dependent On The Performance
Map By The Boost Pressure Control.
In Higher Altitudes The Maximum Boost Pressure Is Limited.
Boost pressure control, GF09.40-P-3000M

function
Divert air actuation, GF09.40-P-3002M
function
Charge air cooling system, GF09.41-P-3104M
function
ME-SFI pneumatic PP07.61-P-5000M
diagrams
AIR INTAKE, FUNCTION - GF09.00-P-3000A
Engine 112 (Except 112.960 /961) Without Supercharger

Fig. 4: Identifying Air Intake Components - Without Supercharger
Purpose Reducing intake noises

Design/function A Helmholtz resonator
(branching filter) with a
volume of about 0.6 liters,
is installed to reduce the
intake noises. This is active
in the engine speed range
from approx. 3500 - 4500
rpm. As a side effect the air
flow in this engine speed
range is improved at the hot
film mass air flow sensor
and the measurement of the
air mass is thus more
accurate.
INTAKE MANIFOLD, LOCATION/TASK/DESIGN/FUNCTION - GF09.20-P-3102A
Engine
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
Engine 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /967 /966 /968 /969
Fig. 5: Identifying Intake Manifold Design/Function
Intake manifold, location GF09.20-P-3102-01A

Intake manifold, task Optimizing engine torque
curve by means of two
different intake manifold
lengths
Intake manifold, design GF09.20-P-3102-03A
Intake manifold, function GF09.20-P-3102-02A
Intake Manifold, Location - Gf09.20-P-3102-01A
Shown On Engine 113
Fig. 6: Identifying Variable Intake Manifold - Shown On Engine 113

Intake Manifold, Function - Gf09.20-P-3102-02A
Engine 112, 113
Section Through Variable Intake Manifold In Cylinder Plane
Fig. 7: Identifying Intake Manifold Function - Section Through Variable Intake Manifold In Cylinder
Plane
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
Intake 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, Design - Gf09.20-P-3102-03A
Shown On Engine 112

Fig. 8: Identifying Intake Manifold Components - Shown On Engine 112
The Intake Manifold Is Assembled Out Of Several 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 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
Interconnected Flap Shafts Are Closed By Means Of Vacuum By The Intake Manifold Switchover Diaphragm
Unit.
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 Variable Flaps Open By Means Of Spring Force.
VARIABLE INTAKE MANIFOLD SWITCHOVER VALVE, COMPONENT DESCRIPTION -

GF09.20-P-6001SM
Engine 113.986
Engine 113.987
Engine 113.988
Engine 113.989
Fig. 9: Locating Variable Intake Manifold Switchover Valve
The Variable Intake Manifold Switchover Valve Is Located At The Front To The Left Of The Variable Intake
Manifold.
Task
The Variable Intake Manifold Switchover Valve Discharges The Variable Intake Manifold Vacuum Capsule
For The Purpose Of Intake Manifold Switchover With Vacuum Pressure And Then Ventilates The Variable
Intake Manifold Vacuum Capsule.
Design
The Variable Intake Manifold Switchover Valve Is An Electromagnetic Switchover Valve In Plastic Housing
With A Coil Resistance Of Around 25ohms.
A Valve Plated Operated By A Coil Armature Switches Between Ambient Pressure And The Vacuum Memory.
Function
Fig. 10: Identifying Variable Intake Manifold Function
N3/10 The Variable Intake Manifold Switchover Valve Is Actuated On The Earth Side By The Me Control Unit
Through Its Own Output Stage. Supply Voltage Is Provided By "Circuit 87 M2E".
VARIABLE INTAKE MANIFOLD COMPONENT DESCRIPTION - GF09.20-P-6002SM
Engine 113.986
Engine 113.987
Engine 113.988
Engine 113.989
Fig. 11: Identifying Variable Intake Manifold - Engine 113.988
The Variable Intake Manifold Is Located Centrally Between The Cylinder Banks.
Task
The Variable Intake Manifold Optimizes The Engine Torque In The Partial Load Range By Modifying The
Intake Routes (Intake Lengths).
Design
Fig. 12: Identifying Variable Intake Manifold Design - Engine 113.988
Cross-Section View From Rear (At Cylinder Level)
Fig. 13: Identifying Variable Intake Manifold Cross-Section View From Rear (At Cylinder Level) -
Engine 113.988
Design
The Variable 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 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. The
Opening Can Be Opened Or Closed By The Variable Valve, Which Rotates By Around 60°.
The Variable Intake Manifold Can Not Be Disassembled.
Function
The Variable Valves (22/2) Are Attached To Steel Shafts. One Steel Shaft Is Installed For Each Bank Of
Cylinders. The Interconnected Shafts Are Closed By Vacuum Pressure By The Variable Intake Manifold
Vacuum Capsule (22/6) By Vacuum Pressure.
(Y22/6) When The Variable Intake Manifold Switchover Valve Is Open, The Vacuum Is Supplied From A
Vacuum Reservoir With Check Valve From The Variable Intake Manifold. The Reservoir Volume Is Designed
For About 5 Operations Without Renewed Evacuation.
The Variable Valves Are Opened From Closed Position By Spring Force.
BOOST PRESSURE CONTROL, FUNCTION - GF09.40-P-3000M

Fig. 14: Identifying Boost Pressure Control Components Function
The Me-Sfi [Me] Control Unit Actuates The Boost Pressure Control Pressure Transducer For The Boost
Pressure Control By Means Of Pulse Width Modulation With A Duty Cycle Of 5 To 95% And With A
Frequency Of 30 Hz. According To The Duty Cycle, The Boost Pressure Operates Fully Or Partially In The
Vacuum Cells Of The Turbocharger.
The Boost Pressure Control Valves (Wastegate Valves) Are Actuated Via Vacuum Cells And Control Rods. For
Limitation Of The Boost Pressure, The Boost Pressure Control Valves Open And Part Of The Exhaust Is
Guided Past The Turbine Wheel.
The Boost Pressure Is Calculated Based On The Pressure Conditions Downstream And Upstream Of The
Turbochargers (Based On The Pressure Values Of The Pressure Sensor Downstream Of Air Filter And Pressure
Sensor Upstream Of Throttle Valve Actuator).
The Boost Pressure Control Is Performed In Line With The Performance Map.
Identification Of The Load (Dependent On Throttle Valve Angle) Is Performed Through The Signal Of The
Pressure Sensor Downstream Of Throttle Valve Actuator.
Boost Pressure Control Shown On A Turbocharger Duty Cycle (T I ) On Boost Pressure Control
Pressure Transducer <5 %
Fig. 15: Identifying Turbocharger Duty Cycle For Boost Pressure Control
Without Actuation, The Entire Boost Pressure In The Vacuum Cell Is Used. The Boost Pressure Control Valve
Opens At Approx.
300 Mbar Boost Pressure (Mechanical Basic Boost Pressure). The Boost Pressure Does Not Increase Further
And Power Shortage Is The Consequence.
Boost Pressure Control Shown On A Turbocharger Duty Cycle (T I ) On Boost Pressure Control
Pressure Transducer >5%
Fig. 16: Identifying Turbocharger Duty Cycle For Boost Pressure Control
The Vacuum Cell Is Vented To The Atmosphere So That No Boost Pressure Can Act Anymore In The Vacuum
Cell. In Unpressurized Condition, A Spring Holds The Boost Pressure Control Valve Closed In The Vacuum
Cell. The Whole Exhaust Gas Drives The Turbine Wheel And The Maximum Boost Pressure Is Generated.
The Input Parameters For The Boost Pressure Control Are:
 Pressure Values Of Pressure Sensor Downstream Of Air Filter

 Pressure Values From Pressure Sensor Upstream Of Throttle Valve Actuator
 Charge Air Temperature, Signal From Charge Air Temperature Sensor
 Load Recognition From Pressure Sensor Downstream Of Throttle Valve Actuator
 Ambient Pressure (Altitude Correction), Signal From Pressure Sensor In Me-Sfi [Me] Control Unit
 Engine Speed
 Coolant Temperature
 Engaged Drive Mode
 Engine Oil Temperature
 Pressure Drop In Air Filter, Detection By Pressure Sensor Downstream Of Air Filter
 Exhaust Gas Temperature (From Model Calculation/Performance Map)
 Knock Control Active (Maximum Boost Pressure Only Possible With Ron 98)
 Catalytic Converter Damaging Misfire Recognized/Not Recognized
If The Hose Lines Between The Vacuum Cells, Pressure Transducer And Charge Air Cooler On The
Right Cylinder Bank Are Leaky The Fault "Boost Pressure Too High" Is Stored In The Me-Sfi [Me] Control
Unit.
The Maximum Boost Pressure Is Only Released Via The Signal From The Charge Air Temperature Sensor, If
The Charge Air Temperature Is Less Than < 70°C.
If The Charge Air Temperature Becomes Too High, The Reason For This Could Be Air Bubbles In
The Low Temperature Cooling Circuit.
In Order To Protect The Exhaust Gas Turbochargers From Overspeed When In Altitude Mode And In Case Of
Soiled Air Filters, The Maximum Boost Pressure Is Limited Pressure Conditions Upstream/Downstream Of The
Turbochargers.
Further To The Boost Pressure Control It Is Possible Under Certain Conditions (E.G. For An Excessively High
Boost Pressure Due To Leaky Lines To The Vacuum Cell) For Load Limiting To Take Place Through Closing
Of The Throttle Valve.
The Function Of The Boost Pressure Control Can Only Be Evaluated If The Message "Boost Pressure
Control Adapted" Is Read Out Using The Das. After Replacing The Me-Sfi [Me] Control Unit Or A
Turbocharger Is A Long Drive Under Certain Operating Conditions Is Required To Perform The Adaptation.
ME-SFI control unit, GF07.61-P-5000M

Boost pressure control pressure GF07.17-P-3160M
transducer,
Pressure sensor upstream of GF07.04-P-5048M
throttle valve actuator,
location/task/function
Pressure sensor downstream of GF07.04-P-5049M
Charge air temperature sensor, GF07.04-P-5038M
location/task/ function
Turbocharger, GF09.40-P-3100M
air filter, location/task/function
ME-SFI pneumatic diagrams PP07.61-P-5000M
ACTUATION DIVERT AIR, FUNCTION - GF09.40-P-3002M

Fig. 17: Identifying Actuation Divert Air Components Function
Fig. 18: Identifying Vacuum Reservoir
Function
If The Engine Control Unit Identifies The Transition From Load To Deceleration Operation, The Switchover
Valve Deceleration Switchover (Y101) Is Actuated. Through This Both Deceleration Air Valves At The
Turbochargers Are Discharged With Vacuum From The Vacuum Tank (22). The Deceleration Air Valves Open
A Bypass Around The Individual Compressor Turbine Wheel, Through Which The Boost Pressure Is
Immediately Removed. Charger Noises (Brief Howling) During Transition Into The Deceleration Mode Cannot
Result From Pressure Points In The Charger.
The Turbochargers Rotate A Little, By Means Of The Inertia Of Masses Of Shaft, The Compressor And The
Turbine Wheel After Start Of Deceleration And Create Against The Closed Throttle Valve Briefly Further
Boost Pressure. This Pressure Is Quickly Released Through The Deceleration Air Valves.
Fig. 19: Identifying Charge Air Cooler And Test Connection For Divert Air
Without Actuation At The Switchover Valve Deceleration Switchover The Diaphragm Chambers Of The
Deceleration Air Valves Are Connected With The Intake Manifold. The Deceleration Air Valves Close In Load
Operation Through The Boost Pressure And The Spring Load. If A Deceleration Air Valve Does Not Close,
Less Boost Pressure Is Released.
In The Vacuum Tank Vacuum Is Gathered In The Suction Operation Of The Engine And In The Deceleration.
The Check Valve Opens Only At Vacuum.

Accelerator pedal sensor, GF30.20-P-4010M
Divert air switchover valve GF07.05-P-3104M
location/task/
structure/function
Turbocharger, GF09.40-P-3100M
ME-SFI pneumatic diagrams PP07.61-P-5000M
TURBOCHARGER, LOCATION/TASK/FUNCTION - GF09.40-P-3100M

Fig. 20: Identifying Turbocharger Components Location Function
Turbocharger, location In each cylinder bank a

turbocharger out of steel
casting (Biturbo) is built-
in. The turbine housing is
integrated in the exhaust
manifold.
Turbocharger task Building up the boost
pressure for each engine
operating state.
Turbocharger, function GF09.40-P-3100-01M
Turbocharger, Function - Gf09.40-P-3100-01M
Cut-Away Model Left Turbocharger

Fig. 21: Identifying Turbocharger Components Function
Fig. 22: Identifying Turbocharger Components
Function
The Exhaust Gases Of Each Cylinder Bank Are Directed Through The Exhaust Manifold Into The Turbine
Housing Onto The Turbine Wheel (110C). The Flow Energy Of The Exhaust Gases (B) Set The Turbine Wheel
In Rotation.
As A Result, The Compressor Turbine Wheel (110D), Which Is Connected To The Turbine Wheel By The
Shaft (110E), Is Also Driven At The Same Speed. The Clean Air Suctioned By The Compressor Turbine Wheel
(D) Is Compressed (E) And Allocated To The Engine.
The Boost Pressure Control Is Performed By Opening And Closing The Boost Pressure Control Valve
(110/3A), Which Releases A Bypass Around The Turbine Wheel. The Boost Pressure Control Valve (110/3A)
Is Operated Via The Vacuum Cell (110/3) With The Control Rod (110/3B). The Controlled Range On The
Control Rod Is Approx. 8 Up To 13 Mm. The Vacuum Cells (110/3) Of Both Turbochargers Are Discharged
Together With The Pressure Of The Boost Pressure Control Pressure Transducer (Y31/5).
Each Turbocharger Has A Deceleration Air Valve, Which On Transition From Load To Deceleration Operation
Releases A Bypass Around The Compressor Turbine Wheel. Through The Quick Boost Pressure Removal
Charger Noises Are Prevented.
The Shaft Housing Of Both Turbochargers Are Cooled With Coolant And Connected To The Engine
Lubrication.
The Compressor Turbine Wheel At The Left Turbocharger Can Be Slightly Smeared With Oil Due To
The Vapors Of The Crankcase Ventilation.
Observe Installation Notes For Exhaust Manifold/Turbocharger With Assembly Tool!
For Troubleshooting When Boost Pressure Is Missing, Continue As Follows:
1. Check Leaktightness Of Boost Pressure Pipes (Check Gaskets And Hose Clamps Between Compressor
Housing And Intake Manifold)
2. Check Function Of Boost Pressure Control With Boost Pressure Control Pressure Transducer (Y31/5).
3. Check Leaktightness And Actuation Of Deceleration Air Valves.
4. Check Rotation Of Both Turbochargers (Exhaust System Removed).
Fig. 23: Identifying Left Turbocharger
CHARGE PRESSURE COOLER - LOCATION/TASK/DESIGN/FUNCTION - GF09.41-P-3100
Charge Pressure Cooler - Location/Task/Design/Function - Gf09.41-P-3100Am
Engine 113.990 /991 /992 /993 /995

Fig. 24: Identifying Charge Air Cooler
Charge air cooler position GF09.41-P-3100-02AM

Charge air cooler task The charge air cooler cools
charge air which has been
warmed by compressing it.
Charge air cooler design The charge air cooler is an
air/liquid heat exchanger.
Charge air cooler GF09.41-P-3100-01AM
function
Charge Air Cooler Function - Gf09.41-P-3100-01Am
Shown On Charge Air Cooling Models 220, 463
Fig. 25: Identifying Charge Air Cooler Function - Shown On Charge Air Cooling Models 220, 463
The Charge Air Cooler Is Connected To A Separate Coolant Circuit With A Low Temperature Radiator And
Electrical Charge Air Cooler Circulation Pump.
The Air Heated During The Charge Operation Dissipates Its Heat To The Coolant Which Flows Through The
Charge Air Cooler.
The Coolant Is Subsequently Cooled In The Low Temperature Cooler And Then Pumped Back To The Charge
Air Cooler Over The Circulation Pump For Charge Air Cooler.
Due To Charge Air Cooling, The Volumetric Efficiency Of The Cylinder Is Improved And The Level Of No X
Emissions Reduced.
There Is A Second Auxiliary Low Temperature Cooler Installed On The Models 220, 463 In Addition
To The Normal Low Temperature Cooler.
The Water Cooling Makes It Possible To Achieve A Higher Efficiency Compared To Air-Cooled
Charge Air Coolers.
Charge Air Cooler Position - Gf09.41-P-3100-02Am
Fig. 26: Identifying Charge Air Cooler Position
The Charge Air Cooler Is Located In The V Angle Of The Engine Below The Compressor.
Charge Pressure Cooler, Location/Task/Design/Function - Gf09.41-P-3100M

Fig. 27: Identifying Charge Pressure Cooler Components Location
Charge air cooler position For each cylinder bank, a

charge air cooler is
mounted behind the air
filter.
Charge air cooler task Cool off charge air which is
compressed and heated by
the turbochargers.
Charge air cooler design The compact charge air
coolers out of aluminum
are designed as a water/air
cooler. Its own low
temperature cooling circuit
dissipates the heat.
Charge air cooler GF09.41-P-3100-01M
function
Charge Air Cooler, Function - Gf09.41-P-3100-01M
Low Temperature Circuit Shown: Model 240

Fig. 28: Identifying Charge Air Cooler, Function - Shown On Model 240
The Charge Air Coolers Are Connected To A Separate Coolant Circuit With A Low Temperature Cooler
(110/11) And An Electrical Charge Air Cooler Circulation Pump (M44). The Air That Is Heated During The
Charging Process Dissipates The Heat To The Coolant Flowing Through The Charge Air Cooler.
The Coolant Is Subsequently Cooled In The Low Temperature Cooler And Then Pumped Back To The Charge
Air Coolers From The Charge Air Cooler Circulation Pump.
The Function Of The Charge Air Cooler Is Dependent Crucially From The Air Bubble Free Filling Of
The Low Temperature Cooling Circuit. A Special Tool (Vacuum Pump) Is Required For Filling And Work
Instructions Must Be Followed Carefully.
Open The Cap At The Low Temperature Coolant Circuit Only When The Charge Air Temperature Is Increased
(Power Shortage) And When The Engine Is Cold. The Coolant Must Reach Up To The Cap.
CHARGE AIR COOLING CIRCULATION PUMP - LOCATION/TASK/FUNCTION - GF09.41-P-3102
Charge Air Cooling Circulation Pump - Location/Task/Function - Gf09.41-P-3102Am
Engine 113.990 /991 /992 /993 /995

Fig. 29: Identifying Charge Air Cooling Circulation Pump
Charge air cooler Model 211, 219 GF09.41-P-3102-01T

circulation pump -
position
Model 215, 220 GF09.41-P-3102-01R
Model 230 GF09.41-P-3102-01HA
Model 463 GF09.41-P-3102-01GA
Charge air cooler The charge air cooler
circulation pump - task circulation pump ensures
the circulation of the
coolant in the cooling
circuit between charge air
cooler and low
temperature cooler.
Charge air cooler GF09.41-P-3102-02AM
circulation pump -
function
Charge Air Cooling Circulation Pump Position - Gf09.41-P-3102-01R
Models 215, 220

Fig. 30: Identifying Charge Air Cooler Circulation Pump
The Charge Air Cooler Circulation Pump Is Located At The Front, Behind The Front Right Wheelhouse.
Charge Air Cooling Circulation Pump Function - Gf09.41-P-3102-02Am
Fig. 31: Identifying Charge Air Cooling Circulation Pump Components Location Function
The Charge Air Cooler Recirculation Pump Is Actuated By The Me-Sfi [Me] Control Unit (N3/10) Over The
Corresponding Relay.
Charge Air Cooling Circulation Pump, Location/Task/Function - Gf09.41-P-3102M

Fig. 32: Identifying Charge Air Cooling Circulation Pump Components Location Function
Charge air cooling Model 215, 220 GF09.41-P-3102-01K

circulation pump,
arrangement
Model 216, 221 GF09.41-P-3102-01MS
Model 230 GF09.41-P-3102-01RA
Model 240 GF09.41-P-3102-01M
Charge air cooling Keep the charge air
circulation pump task temperature below 70°C
by means of coolant
circulation.
Charge air cooling The circulation pump is
circulation pump function actuated via a relay by the
engine control unit.
Switching on:
Charge air temperature
above approx. 47°C
Switching off:
Charge air temperature
below approx. 35°C
Charge Air Cooling Circulation Pump, Location - Gf09.41-P-3102-01K

Fig. 33: Identifying Charge Air Cooler Circulation Pump
Mounted Underneath The Right Lamp Unit In The Feed Line To The Low Temperature Cooler.
LOW TEMPERATURE COOLER, LOCATION/TASK/DESIGN/FUNCTION - GF09.41-P-3103
Low Temperature Cooler, Location/Task/Design/Function - Gf09.41-P-3103Am
Engines 113.990 /991 /992 /993 /995
Fig. 34: Identifying Low Temperature Cooler (Except Models 211, 219)
Fig. 35: Identifying Low Temperature Cooler (Models 211, 219)
Position of the low Models 211, 219 GF09.41-P-3103-01T

temperature cooler
Model 220 GF09.41-P-3103-01AM
Models 215, 230 GF09.41-P-3103-01RA
Model 463 GF09.41-P-3103-01GA
Task of the low The low temperature
temperature cooler cooler cools the coolant
heated in the charge air
cooler in the low-
temperature cooling
circuit.
Design of the low The low temperature
temperature cooler cooler is an air/fluid heat
exchanger.
Function of the low The airstream flows
temperature cooler through the cooling fins
and thus cools the coolant
flowing through the low
temperature cooler.
The water cooling
makes it possible to
achieve a higher efficiency
of the charge air cooling.
Position Of The Low Temperature Cooler - Gf09.41-P-3103-01Am
Model 220
Fig. 36: Identifying Low Temperature Coolers Location
The Low Temperature Cooler Is At The Front Positioned Crosswise, Installed In Front Of The Radiator.
The Auxiliary Low Temperature Cooler Is Installed At The Front Positioned Crosswise, Behind The Fender.
Position Of The Low Temperature Cooler - Gf09.41-P-3103-01Ra
Model 215, 230
Shown On Model 230
Fig. 37: Identifying Position Of Low Temperature Cooler - Shown On Model 230
The Low Temperature Cooler Is Positioned Behind The Front Fender In Front Of The Radiator.
Low Temperature Cooler, Location/Task/Design/Function - Gf09.41-P-3103M

Shown Is Model 240
Fig. 38: Identifying Low Temperature Cooler Components Location - Shown On Model 240
Position of the low Located in the cooler

temperature cooler module at vehicle front
behind the cooler of the
engine cooling system.
Engine 275.98285.98: In
front of the cooler of the
engine cooling system.
Task of the low The coolant which is heated
temperature cooler in the charge air cooler is
cooled off in the low
temperature coolant circuit.
Design of the low The low temperature cooler
temperature cooler is designed as an air/fluid
heat exchanger.
Engine 275.98285.98:
Increased cooling due to
larger low temperature
coolers.
Function of the low The airstream flows through
temperature cooler the numerous radiator fins
and thus cools the coolant
flowing through the low
temperature cooler.
CHARGE AIR COOLING SYSTEM, FUNCTION - GF09.41-P-3104
Charge Air Cooling System, Function - Gf09.41-P-3104Am
Charge Air Cooling System Models 211, 219
Fig. 39: Identifying Charge Air Cooling System Function For Models 211 And 219
Fig. 40: Identifying Charge Air Cooler Function - Shown On Charge Air Cooling Models 220, 463

Fig. 41: Identifying Charge Air Cooling System Function For Models 215 And 230
Due To The Charge Air Cooling, The Volumetric Efficiency Of The Cylinder Is Improved And Reduces The
Level Of No X Emissions.
The Charge Air Cooling Has A Separate Coolant Circuit (Low-Temperature Cooling Circuit) Which Consists
Of The Following Components:
 Charge Air Cooler

 Low-Pressure Cooler
 Additional Low Temperature Cooler (Only For Models 220, 463)
 Charge Air Cooler Circulation Pump
The Charge Air Cooler Circulation Pump Is Actuated By The Me-Sfi [Me] Control Unit (N3/10) Via The
Following Relay:
Models 211, 219 Charge Air Cooler Circulation Pump Relay (N10/2Ka)
Model 215, 220 Charge Air Relay (K40/8Kw)
Model 230 Charge Air Cooler Circulation Pump Relay (K40/5Kr)
Model 463 Charge Air Cooler Circulation Pump Relay (K61)
Function
The Suctioned Air Warms Up Due To The Charging Process. The Charge Air Gives Up Its Heat To Coolant In
The Charge Air Cooler Which Is Located Directly After The Compressor.
The Coolant Is Subsequently Cooled In The Low Temperature Cooler And The Coolant Is Pumped Back By
Charge Air Cooler Circulation Pump To The Charge Air Cooler Where The Coolant Circulation Starts Again.
The Charge Air Temperature And Charge Air Pressure Are Measured After The Charge Air Cooler And The
Measurements Are Sent To The Me Control Unit.

ME-SFI control unit, GF07.61-P-5000AM
Charge air cooler GF09.41-P-3100AM
Charge air cooling circulation GF09.41-P-3102AM
pump Location/task/function
Low-pressure cooler GF09.41-P-3103AM
Location/task/function
Charge air cooling circulating GF09.41-P-3106AM
pump relay
Charge Air Cooling System, Function - Gf09.41-P-3104M
Shown Is Model 240

Fig. 42: Identifying Charge Air Cooling System Components Function
The Cooled Air Downstream Of The Charge Air Coolers Has A Higher Density. This Increases The Cylinder
Charge And Thus The Engine Output. In Addition, The Tendency To Knock And No X Formation Is Reduced
By The Low Exhaust Gas Temperatures
The Maximum Boost Pressure Becomes Available Only When The Charge Air Temperature Is Lower Than 70°
C. The Charge Air Temperature Sensor Detects The Temperature (B17/8) At The Intake Manifold.
A Water/Charge Air Cooler Is Built Into Each Cylinder Bank. Both Water/ Charge Air Coolers Are Connected
To The Low Temperature Cooling Circuit With Low Temperature Cooler And Electric Circulation Pump
(M44). The Circulation Pump (M44) Is Actuated Via The Charge Air Cooler Circulation Pump Relay By The
Engine Control Unit In The Following Manner:
 Switching On At A Charge Air Temperature Above Approx. 47°C

 Switching Off At A Charge Air Temperature Below Approx. 35°C
The Function Of The Charge Air Cooler Is Fully Dependent On The Air Bubble Free Filling Of The
Low Temperature Cooling Circuit. A Special Tool (Vacuum Pump) Is Required For Filling And The Work
Instructions Must Be Followed Carefully.
Open The Cap At The Low Temperature Coolant Circuit Only When The Charge Air Temperature Is Increased
(Power Shortage) And The Engine Is Cold. The Coolant Must Reach Up To The Cap.

Charge pressure cooler, GF09.41-P-3100M
Charge air cooling circulation GF09.41-P-3102M
pump, location/ task/function
Low temperature cooler, GF09.41-P-3103M
Charge air cooler circulation GF09.41-P-3106M
pump relay,
CHARGE AIR COOLER CIRCULATION PUMP RELAY - LOCATION/TASK/DESIGN/FUNCTION -

GF09.41-P-3106
Charge Air Cooler Circulation Pump Relay - Location/Task/Design/Function - Gf09.41-P-3106Am
Engine 113.990 /991 /992 /993 /995

Fig. 43: Identifying Charge Air Cooler Circulation Pump Relays
Relay for the charge air Models 211, 219 GF09.41-P-3106-01TA

cooler recirculation pump -
location
Models 215, 220 GF09.41-P-3106-01M
Model 230 GF09.41-P-3106-01R
Model 463 GF09.41-P-3106-01GA
Relay for the charge air The circulating pump relay
cooler recirculation pump - actuates the charge air
task cooler circulation pump
(M44).
Relay for the charge air The relay for the charge air
cooler recirculation pump - cooler recirculation pump
design is a 4-pin plug-in relay.
Relay for the charge air On actuation through the
cooler recirculation pump - ME-SFI [ME] control unit
function (N3/10) by a ground
signal, the power supply
contact closes and thus
supplies the charge air
cooler recirculation pump
with a voltage from circuit
87.
Location Of The Relay For The Charge Air Cooler Recirculation Pump - Gf09.41-P-3106-01M
Models 215, 220
The Fuse And Relay Box For The Engine Is Located In The Engine Compartment At The Rear On The Right.
Fig. 44: Identifying Charge Air Cooler Recirculation Pump Relays Location
Charge Air Cooler Circulation Pump Relay, Location/Task/Design/Function - Gf09.41-P-3106M
Shown On Engine 275.950/951/980, 285
Fig. 45: Identifying Charge Air Cooler Circulation Pump Relays
Relay for charge air cooler Model 215, 220 GF09.41-P-3106-01MA

recirculation pump
location
Model 216, 221 with GF09.41-P-3106-01MS
engine 275.953/982
Model 230 with engine GF09.41-P-3106-01RA
275.951/954
Model 230 with engine GF09.41-P-3106-01RB
275.981
Model 240 GF09.41-P-3106-01MM
Relay for charge air cooler Actuates the charge air
recirculation pump - task cooler recirculation pump.
Relay for charge air cooler Relay for charge air cooler
recirculation pump - recirculation pump is a 4-
design pin plug-in relay.
Relay for charge air cooler On actuation of the ME
recirculation pump, control unit by a ground
function signal, the power supply
contact closes and thus
supplies the charge air
cooler recirculation pump
(M44) fused with a voltage
(circuit 87).
Relay For The Charge Air Cooler Recirculation Pump - Location - Gf09.41-P-3106-01Ma
Fig. 46: Identifying Charge Air Cooler Recirculation Pump
SUPERCHARGER CONTROL FUNCTION - GF09.50-P-3001AM

Fig. 47: Identifying Supercharger Control Components Function
The Compressor Is Switched On And Off By Means Of Actuation Of The Supercharger Magnetic Clutch By
The Me Control Unit.
Actuation Of The Magnetic Clutch Is Undertaken By The Me-Sfi [Me] Control Unit In Accordance With The
Performance Map According To The Engine Speed And Engine Load.
Here The Magnetic Clutch Is Actuated By The Me-Sfi [Me] Control Unit By Means Of A Ground Signal.
The Voltage Supply To The Magnetic Clutch Is Via "Terminal 15 Secured".
The Compressor Is Actuated Between Idling Speed And An Engine Speed Of About 3500 Rpm When A High
Demand For Torque (High Engine Loading) Is Present.
The Compressor Is Always Actuated For Technical Reasons From An Engine Speed Of About 3500 Rpm.
The Compressor Remains Switched On During The Thrust Phase Of The Engine. This Avoids Any Delay In
Actuation During The Changeover From The Thrust Phase To The Pulling Phase.
The Compressor Is Not Actuated On A Stationary Vehicle, No Matter What The Engine Speed Is, To Protect It.
The Compressor Is Also Not Actuated When The Battery Voltage Falls Below 9 V Or When An Error Is
Recognized In The Charge Air Cooling System Due To An Implausible Value From The Temperature Sensor.
The Compressor Is Switched On Shortly When Starting At External Temperatures Below 0°C In Order To Free
Up The Compressor From Any Icing Which May Have Occurred (Through The Presence Of Condensate In The
Compressor).
Diagnosis Of The Magnetic Clutch On The Mechanical Supercharger Is Possible Using The Menu
"Actuations" For The Me 2.8.1 Control Unit In The Star Diagnosis Equipment.
Crankshaft position sensor, GF07.04-P-4116AM

Air recirculation flap actuator except model 230 to GF09.50-P-3101AM
Location/task/design/function 06/2002
Compressor GF09.50-P-3102AM
Supercharger magnetic clutch, GF09.50-P-3103AM
Accelerator pedal sensor, GF30.20-P-4010HA
Throttle valve actuator, GF30.22-P-4101AM
RECIRCULATED AIR FLAP ACTUATOR - LOCATION/TASK/DESIGN/FUNCTION - GF09.50-P-

3101AM
Engine 113.990 /991, 113.992 As Of 1.7.02, 113.993 /995
Fig. 48: Identifying Recirculated Air Flap Actuator
Recirculated air flap GF09.50-P-3101-01AM

actuator - location
Recirculated air flap The air recirculation flap
actuator - task actuator changes the intake
air guidance upstream of the
compressor over continuous
adjustment (0 to 90°) of the
air recirculation flap.
Recirculated air flap The recirculated air flap
actuator - design actuator consists of:
 Housing
 Electrical connection
 Actuator motor
 Actual value
potentiometer 2
 Recirculated air flap
Recirculated air flap The air recirculation flap

actuator - function actuator is actuated by the
ME-SFI [ME] control unit
(N3/10) by means of a
ground signal. The actual
value potentiometers sends
the current position of the
throttle valve to the ME-SFI
[ME] control unit. The air
recirculation flap is always
closed at full load (maximum
boost pressure) and when
starting (getting the
compressor to rotate).
Recirculated Air Flap Actuator - Position - Gf09.50-P-3101-01Am

Fig. 49: Identifying Recirculated Air Flap Actuator
The Air Recirculation Flap Actuator Is Located Between The Compressor Input And Charge Air Distribution
Pipe In The V Angle Of The Engine.
SUPERCHARGER - LOCATION/TASK/DESIGN/FUNCTION - GF09.50-P-3102AM
Engine 113.990 /991 /992 /993 /995
Fig. 50: Identifying Compressor And Mechanical Supercharger Magnetic Clutch
Supercharger location The compressor is located

between the two banks of
cylinders in the V-angle of
the engine.
Supercharger task The compressor
compresses the quantity of
air required for
combustion, thus
enhancing the cylinder
charge of the engine.
This increases engine
torque and engine output.
Supercharger design GF09.50-P-3102-01AM
Supercharger function GF09.50-P-3102-02AM
Supercharger Design - Gf09.50-P-3102-01Am
Fig. 51: Identifying Supercharger Components Design
Between The Opening On The Suction Side (A) And The Opening The Pressure Side (B) Is Located In The
Operating Space For The Compressor (50).
The Operating Space Is Made Up Of The Outer Housing And The Two Contra-Rotating Helical Spindles 1 And
2 (50/1, 50/2). A Tight Gap Is Achieved To Ensure A Seal Between The Two Helical Spindles Themselves And
The Housing.
The Synchronizer Gear (50/3) Which Ensures Contact-Free Rotation Of The Two Helical Spindles, Is Located
Outside Of The Operating Chamber.
The Compressor Is Switched On By The Supercharger Magnetic Clutch On The Pulley Wheel.
Translation Of Power Between The Compressor And The Engine Is Governed By The Difference Of Pressure
On The Two Pulley Wheels. The Compressor Speed Is Up To 02/2006 Somewhat More Than Double The
Engine Speed And From 03/2006 About 3.5 Times The Engine Speed.
No Setting Or Maintenance Operations Are Necessary At The Supercharger. Lubrication Of The Supercharger
Transmission Is "Lubrication For Life".
The Package Contents (In The Case Of A Repair) Includes The Supercharger With Supercharger
Magnetic Clutch, Belt Pulley And Guide Pulley.
Supercharger Function - Gf09.50-P-3102-02Am
Fig. 52: Identifying Supercharger Components Function
The Compressor (50) Is A Screw-Type Compressor Which Operates According To The Positive Displacement
Principle With Inner Compression.
The Air Flowing In Is Led To The Suction Side Opening (A) At The Rear Of The Operating Space Of The
Compressor.
Rotation In Connection With The Geometry Of The Two Helical Spindles 1 And 2 (50/1, 50/2) Seals Off The
Operating Chamber From The Outer Environment After Entry Of The Intake Air. The Enclosed Air Volume Is
Compressed Through A Reduction In Size Of The Operating Chamber Between The Housing And The Two
Helical Spindles.
Further Turning Of The Screw Spindles Causes Compressed Air To Be Pushed Out Of The Opening On The
Pressure Side (B) In The Direction Of The Charge Air Cooler.
The Maximum Charge Pressure Is About 0.8 Bar On Achieving The Engine Breakway Speed.
The Compressor Is Driven Directly From The Crankshaft Over The Magnetic Clutch On The Mechanical
Charger And A Separate Poly-V-Belt.
The Supercharger Is Actuated Via The Supercharger Magnetic Clutch By The Me-Sfi [Me] Control Unit
(N3/10).
SUPERCHARGER MAGNETIC CLUTCH, LOCATION/TASK/DESIGN/FUNCTION - GF09.50-P-

3103AM
Engines 113.990 /991 /992 /993 /995

Fig. 53: Identifying Compressor And Supercharger Magnetic Clutch Location
Magnetic clutch for the The magnetic clutch is

mechanical supercharger - flange-mounted at the front
location on the compressor at the
height of the belt.
Magnetic clutch for the The magnetic clutch
mechanical supercharger - quietly switches the
task compressor on and off
depending on the operating
condition of the engine.
Magnetic clutch for the GF09.50-P-3103-03AM
mechanical supercharger -
design
Magnetic clutch for the The magnetic clutch is
mechanical supercharger - actuated by the MESFI
function [ME] control unit (N3/10).
Here a magnetic field is
built up between the
anchor and rotor by the
solenoid whereby a
friction-type connection is
made between the friction
linings on the anchor and
rotor. The power
consumption is about 47
W.
Magnetic Clutch For The Mechanical Supercharger - Design - Gf09.50-P-3103-03Am

Fig. 54: Identifying Magnetic Clutch For Mechanical Supercharger Components - Design
There Is An Air Gap Between The Rotor (80/5) And The Anchor (80/7) Of Between 0.3 And 0.5 Mm Which Is
Not Under Power And Which Cannot Be Adjusted.
He Magnetic Clutch For The Mechanical Supercharger (Y2/1) Can Only Be Replaced As A Complete
Unit With The Compressor.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AR09.00-
Z-9112AB
Engine 112
Remove/install air filter ENGINE 112, 113... AR09.10-P-1150SVK

housing
Remove/install intake ENGINE 112, 113... AR09.20-P-1310A
manifold
Remove/install top charge ENGINE 112, 113... AR09.41-P-1320SVK
air distributor
Remove/install charge air ENGINE 112, 113... AR09.41-P-6817SVK
cooler
Remove, install low ENGINE 112.960 in MODEL AR09.41-P-6831SVK
temperature water cooler 170.466 ENGINE 112.961 in
MODEL 203.065 /265
cooler circulation pump
Remove compressor, ENGINE 112, 113... AR09.50-P-4705SVK
install
Remove/install ENGINES 112.960 /961, AR09.50-P-4787R
compressor belt pulley 113.990 /991 /992 /995
Z-9113AB
Engine 113
Removing/installing air ENGINE 113... AR09.10-P-1150AC

cleaner housing
Remove/install air cleaner ENGINE 113.964 in MODEL AR09.10-P-1150GZ
housing 164.175
Remove/install air filter ENGINE 113.971 in MODEL AR09.10-P-1150RT
housing 251.075 /175
Remove/install air filter ENGINE 112, 113... AR09.10-P-1150SVK
housing
Remove/install air cleaner ENGINE 113.967 in MODEL AR09.10-P-1150TY
housing 219.375
Removing/installing the air ENGINE 113.990 in MODEL AR09.10-P-1150TZ
cleaner housing 219.376
Remove/install intake ENGINE 112, 113... AR09.20-P-1310A
manifold
Remove/install intake ENGINE 113.964 in MODEL AR09.20-P-1310GZ
manifold 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 MODEL AR09.20-P-1310TY
manifold 219.375
Remove/install top charge ENGINE 112, 113... AR09.41-P-1320SVK
air distributor
Removing/installing the top ENGINE 113.990 in MODEL AR09.41-P-1320TZ
charge air distributor 219.376
Remove/install charge air ENGINE 113.990 in MODEL AR09.41-P-6817RVK
cooler 211.076 /276
ENGINE 113.991 in MODEL
215.374, 220.074
cooler
Removing/installing the ENGINE 113.990 in MODEL AR09.41-P-6817TZ
charge air cooler 219.376
Remove/install low ENGINE 113... AR09.41-P-6831RVK
temperature radiator
Removing/installing the low ENGINE 113.990 in MODEL AR09.41-P-6831TZ
temperature radiator 219.376
cooler circulation pump
Removing and installing the ENGINE 113.990 in MODEL AR09.41-P-6925TX
circulation pump for the low 219.376
temperature water circuit
Remove compressor, install ENGINE 112, 113... AR09.50-P-4705SVK
Remove/install compressor ENGINE 113.990 in MODEL AR09.50-P-4705TZ
219.376
Remove and install ENGINE AR09.50-P-4786R
electromagnetic clutch 113.990 /991 /992 /995
compressor
Remove/install compressor ENGINES 112.960 /961, AR09.50-P-4787R
belt pulley 113.990 /991 /992 /995
Remove/install recirculated ENGINE 113... AR09.50-P-8843T
air flap actuator
Z-9137AB
Engine 137
Remove air cleaner, ENGINE 137.970 in AR09.10-P-1050L

install MODELS 215.378,
220.178 /878
Remove, install intake ENGINE 137.970 in AR09.20-P-1310L
manifold MODELS 215.378,
220.178 /878
Z-9275AB
Engine 275
Remove/install air filter ENGINE 275 in MODEL AR09.10-P-1050LA

215, 220, 230
Remove/install air filter ENGINE 275 in MODEL AR09.10-P-1150LA
housing 215, 216, 220, 221, 230
Remove/install divert air ENGINE 275 in MODEL AR09.40-P-3000M
switchover valve 215, 216, 220, 221, 230
ENGINE 285 in MODEL
240
Removing/installing the ENGINE 275 in AR09.40-P-3001M
deceleration air valve MODELS 215, 220
Removing/installing the ENGINE 275 in MODEL AR09.40-P-3001R
deceleration air valve 230
Remove/install deceleration ENGINE 275 in MODEL AR09.40-P-3001SZ
air valve 216, 221
Remove/install turbocharger ENGINE 275 in MODEL AR09.40-P-6020MC
215, 216, 220, 221, 230
Remove/install charge air ENGINE 275 in MODEL AR09.41-P-1310HH
manifold 215, 216, 220, 221, 230
ENGINE 285 in MODEL
240
Remove/install charge air ENGINE 275 in MODEL AR09.41-P-6817HH
cooler 215, 216, 220, 221, 230
ENGINE 285 in MODEL
240
Remove/install circulation ENGINE 275 in MODEL AR09.41-P-6925LA
pump for low-temperature 215, 216, 220, 221
water circuit
Removing and installing the ENGINE 275 in MODEL AR09.41-P-6925R
circulation pump for the low 230
Remove/install low ENGINE 275.980 in AR09.41-P-6935IM
temperature water circuit MODELS 215.379,
radiator 220.179
Remove/install low ENGINE 275.950 in AR09.41-P-6935MC
temperature water circuit MODEL 220.176
radiator
Removing and installing ENGINE 275 in MODEL AR09.41-P-6935R
radiator for low temperature 230
water circuit
Remove/install low ENGINE 275.982 in AR09.41-P-6935SXM
temperature water circuit MODEL 216.379,
radiator 221.179
Remove/install low ENGINE 275 (except AR09.41-P-6935SZ
temperature water circuit 275.982) in MODEL 216,
radiator 221
Remove/install engine charge ENGINE 275 in MODEL AR09.41-P-8623H
air duct upstream of charge 215, 216, 220, 221, 230
air cooler ENGINE 285 in MODEL
240
Remove/install charge air ENGINE 275 in MODEL AR09.50-P-8680H
duct downstream of charge 215, 216, 220, 221, 230
air cooler ENGINE 285 in MODEL
240
REMOVE/INSTALL AIR FILTER - AR09.10-P-1050
Remove Air Cleaner, Install - Ar09.10-P-1050L
Engine 137.970 In Models 215.378, 220.178 /878
Shown On Engine 137 In Model 215

Fig. 55: Identifying Air Cleaner Remove/Install Components - Shown On Engine 137 And 215
Removing, installing
1 Remove air intake hoses
(1, 2)
2 Unscrew bolt (3) and lift
cover (4) up and off
3 Unscrew bolts (5)
4 Pull out air cleaner (6) to Ensure that the hot
the front film mass air flow sensor is
not pulled off the
electronic accelerator
actuator.
5 Install in the reverse order Installation: Air
cleaner (6) is fixed in place
on the right and left at the
intake manifold
Remove/Install Air Filter - Ar09.10-P-1050La
Engine 275 In Model 215, 220, 230
Shown On Engine 275.950 In Model 220

Fig. 56: Identifying Air Filter Components Location - Shown On Engine 275 And 220
Remove/install
1 Remove engine trim panel Engine 275.950/ 951/ 954 AR01.10-P-2405LA
Engine 275.980/ 981 AR01.10-P-2405IM
2.1 Remove the electrical To remove from
connector at the pressure the air filter housing cover
sensor downstream of the (2) on the right side.
air filter, right cylinder
bank (B28/5)
3 Unscrew bolts(1) and
remove air filter housing
cover (2).
4 Remove air filter. Installation:
Before installing the air
filter, eliminate
contamination in the air
filter housing.
5 Install in the reverse order
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150
Remove/Install Air Filter Housing - Ar09.10-P-1150La
Engine 275 In Model 215, 216, 220, 221, 230
Illustrated On Model 220.176

Fig. 57: Identifying Air Filter Housing Remove/Install Components
Remove/install
1 Remove engine trim panel. Engine 275.95 AR01.10-P-2405LA
Engine 275.98 AR01.10-P-2405IM
2 Disconnect electrical
connector at pressure
sensor downstream of air
filter, left cylinder bank
(B28/4) and at pressure
filter, right cylinder bank
(B28/5)
3 Unscrew screws (5) and *BA09.10-P-1001-01E
screws (6).
4 Lift air filter housing, right
side (3) and pull back and
out of air intake pipe, right
side (2)
5 Unclip pneumatic line (8)
at air filter housing, left
side (4)
6 Disconnect pneumatic line
(8)
7 Lift air filter housing, left Observe
side (4) and pull back and crankcase ventilation
out of air intake pipe, left system (7) hose.
side (1) Installation:
Ensure that crankcase
ventilation system (7)
hose is put on intake
manifold (4/1).
Air Filter
Number Designation Engine 275, 285.950
BA09.10-P-1001-01E Bolt, air filter housing to Nm 8
bracket
Remove/Install Air Filter Housing - Ar09.10-P-1150Svk
Engines 112.912 /946 /961 In Model 203
Engines 112.912 /955 In Model 209
Engines 112.913 /949, 113.990 In Model 211
Engines 113.992 /995 In Model 230
Shown On Engine 113.990

Fig. 58: Identifying Air Filter Housing Remove/Install Components - Shown On Engine 113.990
Remove/install
1 Remove engine trim panel Detach engine
(1) cover (1) on both sides of
the air filter housing (2)
and at the bracket towards
the top.
2 Remove engine intake air
ducts (3)
3 Remove air filter housing When removing
(2). the air filter housing (2)
make sure that the intake
lines (6) are not twisted.
If the air filter housing (2)
is removed incorrectly,
the steel ring in the intake
line (6) can become
deformed and work itself
loose when the engine is
running.
Carefully lift air
filter housing (2) and
remove crankcase bleed
hose (4) from fitting (5)
on intake line (6).
Installation: Ensure
that the catches (7) do not
break off when fitting
onto the throttle valve
actuator (M16/6.). The
catches (7) can be sucked
in by the engine and cause
engine damage.
Installation:
Moisten sealing ring,
throttle valve actuator
(M16/6) and retaining
rubbers with liquid
lubricant.
Lubricant *BR00.45-Z-1002-06A
Repair Materials
Number Designation Order number
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
REMOVE/INSTALL INTAKE MANIFOLD - AR09.20-P-1310
Remove/Install Intake Manifold - Ar09.20-P-1310A
Engine 112.910 In Model 202.026/086
Engine 112.920 In Model 202.029/089
Engine 112.921 In Model 210.063/081 /263 /281
Engine 112.922 In Model 220.063/163
Engine 112.923 In Model 129.059
Engine 112.940 In Model 208.365/465
Engine 112.941 In Model 210.065/082/265/282
Engine 112.944 In Model 220.065/165
Engine 113.940 In Model 210.070/270
Engine 113.941 In Model 220.070/170
Engine 113.960 In Model 215.375, 220.075/175
Engine 113.944 In Model 202.033/093
Engine 113.980 In Model 210.074/274
Engine 113.943 In Model 208.370/470

Engine 112.912 In Model 203.061/261, 209.361 /461
Engine 112.946 In Model 203.064/264
Engine 113.968 In Model 209.375/475
Engine 112.913 In Model 211.061/261
Engine 112.949 In Model 211.065/265
Engine 113.967 In Model 211.070/270
Engine 113.987 In Model 209.376/476
Engine 112.955 In Model 209.365/465
Engine 112.916 In Model 203.081/281
Engine 112.953 In Model 203.084/284
Engine 112.972 In Model 220.067/167
Engine 112.975 In Model 220.087/187
Engine 113.948 In Model 220.083/183
Engine 113.966 In Model 220.084/184
Engine 112.917 In Model 211.080/280
Engine 112.954 In Model 211.082/282
Engine 113.969 In Model 211.083/283
Engine 113.988 In Model 203.076/276

Shown On Engine 112
Fig. 59: Identifying Intake Manifold Remove/Install Components - Shown On Engine 112
Fig. 60: Identifying Crankcase Ventilation Hose And Line
Remove/install
Risk of No fire, sparks, open flames or smoking. AS47.00
explosion Only pour fuels into suitable and appropriately marked containers. Z-0001-
caused by fuel Wear protective clothing when handling fuel. 01A
igniting, risk
of poisoning
caused by
inhaling and
swallowing
fuel and risk of
injury to eyes
and skin caused
by contact with
fuel
1 Remove key Only on vehicles with electronic ignition switch.
from electronic Vehicles with Keyless Go code 889: Switch off engine, remove
ignition switch Keyless Go-Cards out of vehicle and store outside of the sender range.
2 Remove cover Model 129, 211, 215, 220, 230 only
on front side of
engine
3.1 Remove engine Except model 171.473, 203.076 /276, , 209.376 /476 from 24.4.04
cover with The air filter is integrated in the engine cover. Remove engine cover
integrated air or air filter by pulling it vertically up and off the cylinder head covers.
filter
3.2 Remove air Model 171.473 AR09.1
filter housing Model 203.076/ 276 P-1150A
Model 209.376/ 476 as of 24.4.04
4 Remove hot Engine 112.910/ 920/ 921/940/ 941/ 942/ 970 AR07.0
film mass air Engine 113.940 P-1454A
flow sensor
with air intake
pipe
Engine 112.922 /944 /972 /973 /975 AR07.0
Engine 113.941/ 948/ 960/ 961/ 963/ 966 P-1454A
Engine 112.912 /913 /916 /917 /946 /947 /949 /954 /953 /955 AR07.0
Engine 113.968 /967 /969 /987 /988 /989 P-1454S
Engine 112.923 /943 AR07.0
Engine 113.943 /944 /980 /984 P-1454A
Engine 113.942 /965/981 AR07.0
P-
1454MV
5 Disconnect Release fuel pressure via service valve and collect fuel.
lead line (17/2)
at the fuel
distributor
*BA07.
P-1001-
01A
Fig. 61
6 Removing fuel Engine 112.910 /920 /921 /923 /940 /941 /942 /943 /970 AR07.0
rail with Engine 113.940 /942 /943 /944 /961 /965 /980 /981 /984 P-1451A
injection valves
Engine AR07.0
112.912/913 /916 /917 /922 /944 /946 /947 /949 /953 /954 /955 /972 /973 /975 P-1451A
Engine 113.941 /948 /960 /963 /966 /967 /968 /969 /987 /988 /989
7.1 Unscrew Model 230.475 only
cylinder head
cover (2/1) bolt
*BA01.
P-1001-
01E
7.2 Remove Model 171.473 only
crankshaft Remove cylinder head cover (2/1) bolt in order to detach exhaust gas
ventilation recirculation valve (89) bracket.
hose (2) and
line (89/2) and
place to one
side
*BA01.
P-1001-
01E
8 Disconnect Installation: Observe intake manifold connection diagram. ?
vacuum lines
from intake
pipe (19)
Engine 112 except 112.913 /917 /949 /954 AR09.2
P-1310-
01A
Engine 112.913/917 /949 /954 AR09.2
P-1310-
01T
Engine 112 with USA version, code 494, except engine AR09.2
112.913 /916 /917 /949 /953 /954 /975 P-1310-
Engine 112.913/916 /917 /949 /953 /954 /975 with USA version, code 494 01AA
Engine 113 except 113.967 /969 AR09.2
P-1310-
01AU
Engine 113.967/969 AR09.2
P-1310-
01TA
Engine 113 with USA version, code 494, except engine AR09.2
113.948 /963 /966 /984 /967 /969 /989 /988 P-1310-
Engine 113.948 /963 /966 /984 /967 /969 /988 /989 with USA version, code 01AC
494
9 Disconnect
electrical
connectors
10 Unscrew acorn Counterhold connection fitting when unscrewing.
nut from pipe
(89/2) to
exhaust gas
recirculation
valve (89)
*BA14.
P-1002-
01B
11 Unscrew screw Except engine 113.987 as of 24.04.04,
(19/1) Engine 113.988/989
*BA09.
P-1001-
01D
11.2 Remove bolts Only with engine 113.987 as of 24.04.04
from right Engine 113.988/989
combination
valve (6) and
left
combination
valve (6)
*BA09.
P-1001-
01D
12.1 Remove Except engine 113.987 as of 24.04.04
combination Engine 113.988/989
valve (6) Installation: Install new gasket
12.2 Loosen right Only engine 113.987 from 24.04.04
combination Engine 113.988/989
valve (6) and Installation: Replace the gaskets.
left
combination
valve (6) and
place to one
side
13 Dismount Plug intake ducts. Use centering bolt for exact positioning of intake
intake manifold manifold and for centering the gasket (19/3).
(19)
*BA09.
P-1001-
01D
Fig. 62
14 Replace gasket
(19/3)
15 Install in the
reverse order
Crankcase Ventilation, Cylinder Head Cover

Number Designation Engine
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/
BA01.20- Cylinder 10
P-1001- head cover
01E bolt Nm
Fuel Distributor
Engine 112 except
Number Designation 112.945/951/960/961
BA07.52-P-1001-01A Fuel feed line to fuel Nm 38
distributor
Fuel Distributor
Number Designation Engine113.987 Engine113.940/941/942/943/944/945/946/948/960/961/962/9
BA07.52- Fuel feed Nm 38 38
P-1001- line to
01A fuel
distributor
Intake Manifold
Number Designation Engine112,113
BA09.20-P-1001- Bolt, intake M8 Nm 20
01D manifold to
cylinder head
Exhaust Gas Recirculation

112.910/912/916/920/921/922/923/940/941/942/943/944/945/946/947/953/9
BA14.20- Union nut, Nm 40
P-1002- exhaust gas
01B recirculation
pipe to
exhaust gas
recirculation
valve
Exhaust Gas Recirculation

Number Designation Engine113.989
BA14.20-P-1002-01B Union nut, exhaust gas Nm 40
recirculation pipe to
exhaust gas recirculation
valve
Fig. 61: Identifying Pressure Hose (119 589 04 63 00)
Fig. 62: Identifying Set Of Dowel Bolts (112 589 02 62 00)
Intake Manifold Connection Diagram - Ar09.20-P-1310-01Aa
Connection Diagram Of Intake Manifold Engine 112 With Usa Version Code 494A
Fig. 63: Intake Manifold Connection Diagram - Connection Diagram Of Intake Manifold - Engine 112
With Usa Version Code 494A
Intake Manifold Connection Diagram - Ar09.20-P-1310-01Ac
Shown On Engine 113 With Usa Version Code 494A
Fig. 64: Intake Manifold Connection Diagram - Shown On Engine 113 With Usa Version Code 494A
Intake Manifold Connection Diagram - Ar09.20-P-1310-01Au
Shown On Engine 113

Fig. 65: Intake Manifold Connection Diagram - Shown On Engine 113
Remove, Install Intake Manifold - Ar09.20-P-1310L
Engine 137.970 In Models 215.378, 220.178 /878
Fig. 66: Identifying Intake Manifold Remove/Install Components (1 Of 2)

Fig. 67: Identifying Intake Manifold Remove/Install Components (2 Of 2)
Risk of injury to skin Do not open cooling AS20.00-Z-0001-01A
and eyes from scalding system unless coolant
with hot coolant which temperature is below 90°
splashes out. C. Open cap slowly and
Risk of poisoning from release the pressure. Do
swallowing coolant. not pour coolant into
beverage bottles.
Wear protective gloves,
protective clothing and
eye protection.
Notes on coolant All engines. AH20.00-N-2080-01A
1 Remove air cleaner AR09.10-P-1050L
2 Remove ECI mains unit
(N91)
3 Detach coolant vent line Collect coolant
(7) at thermostat housing which flows out in a
and remove cover (4) suitable vessel.
4 Disconnect crankcase Removal:
ventilation hose (2) at Remove crankcase
couplings (A) and (B) ventilation hose (2).
5 Remove switchover
valves (Y32/1) and
(Y32/2)
Intake manifold M137 AR09.20-P-1310-01L
connection diagram
Intake manifold M137 AR09.20-P-1310-01LA
connection diagram
6 Release fuel pressure Collect fuel.
through service valve
(1/1)
Fig. 68
Fig. 61
7 Unscrew fuel feed line Collect fuel.
(17/2) at fuel distributor
(17)
*BA07.52-P-1001-01A
8 Unscrew fuel feed line Removal: It is not
(17/2) mounting clamp at permissible to bend fuel
left cylinder head cover feed line out of the way.
There is a risk of splits
forming at the fuel rail,
and also at the fuel feed
line.
9 Remove hot film mass air AR07.07-P-1453L
flow sensor (B2/5)
10 Remove electronic Disconnect AR30.20-P-1262L
accelerator actuator vacuum lines (5, 6).
(M16/6) together with
flap connection
11 Disconnect electrical Cylinder shutoff
connectors valve cylinders 10-12
(Y81/1), camshaft Hall
sensor (B6/2) on left and
(B6/3) on right, coolant
temperature sensor
(B11/4), intake air
temperature sensor (B17),
right variable camshaft
timing solenoid (Y49/2)
and injectors (Y62).
12 Unscrew engine wiring Unscrew bolts
harness at intake (8), (2 x). Replace
manifold mounting clip.
13 Remove engine wiring
harness from firewall and
place to the side
14 Remove rubber mount (9)
15 Unscrew bolts (19/1) (14 *BA09.20-P-1001-01G
x)
16 Remove complete intake Removal: Seal intake
manifold (19) with intake ports. Do not disassemble
fittings (1), intake air the intake manifold. Do
pipes (3) and fuel not reuse the screws
distributor (17). (19/1).
Installation: In the
event of engine damage,
be sure to check for and, if
applicable, remove any
metal chips inside the
intake manifold.
17 Replace seals (19/3) Installation: Fix
seals (19/3) in place at
cylinder head using stud
bolts.
19 Adjust coolant to correct Cooling system is
level bled automatically
Fuel Rail
Number Designation Engine 137
BA07.52-P-1001-01A Fuel feed line to fuel rail Nm 38
Intake Manifold
BA09.20-P-1001- Bolt, intake 1st stage M6 Nm 8
01G manifold on M8 Nm 20
cylinder head 2nd stage M6 Nm 8
3rd stage M6 Angle° 90
Fig. 68: Identifying Tester (51 103 589 00 21 00)
Connection Diagram Of Intake Manifold - Ar09.20-P-1310-01La
Connection Diagram Of Intake Manifold Engine 137

Fig. 70: Intake Manifold Connection Diagram
REMOVE/INSTALL DIVERT AIR SWITCHOVER VALVE - AR09.40-P-3000M

Engine 275 In Model 215, 216, 220, 221, 230
Engine 285 In Model 240
Fig. 71: Identifying Divert Air Switchover Valve Remove/Install Components
Remove/install
1 Remove right air filter Model 215, 216, 220, 221, AR09.10-P-1150LA
housing. 230
Model 240 AR09.10-P-1150H
2 Dismount right charge air Do not open low AR09.41-P-6817HH
cooler from engine and temperature circuit.
connect with connected
coolant hoses to engine
hood
3 Remove pneumatic line (1) Installation:
on divert air switchover Check pneumatic lines (1)
valve (Y101) and hose clamps for wear
and damage; replace if
required.
4 Disconnect the electrical
plug connector (2) on the
divert air switchover valve
(Y101)
5 Lift locking detent (4) and
detach divert air
switchover valve (Y101) in
direction of travel from
bracket (3)
REMOVING/INSTALLING THE DECELERATION AIR VALVE - AR09.40-P-3001M
Engine 275 In Models 215, 220

Fig. 72: Identifying Deceleration Air Valve Remove/Install Components (1 Of 2)
Fig. 73: Identifying Deceleration Air Valve Remove/Install Components (2 Of 2)
Modification Notes
23.4.03 Detach pneumatic lines Step 14
from T-piece, newly
recorded
23.4.03 Pressurize deceleration air Step 15
valve with a vacuum of 700
millibar, newly recorded
Removing/installing
Risk of death caused by Align vehicle between the AS00.00-Z-0010-01A
vehicle slipping or toppling columns of the and
off the lifting platform. position the four support
plates below the lifting
platform support points
specified by the vehicle
manufacturer.
Risk of injury caused by When moving AS00.00-Z-0011-01A
fingers being jammed or components, ensure that
pinched when removing, no body parts or limbs are
installing or aligning hoods, within the operating
doors, trunk lid/rear-end range of moving parts.
door or sliding roof.
1 Open engine hood AR88.40-P-1000M
2 Remove engine trim panel Installation: AR01.10-P-2405LA
Install only after
inspection.
Right deceleration air
valve
3 Remove right air filter AR09.10-P-1150LA
housing (1).
4 Dismount coolant expansion
reservoir (2) and place with
connected coolant hoses to
the side
5 Unscrew bolts (3) of *BA09.40-P-1014-01H
deceleration air valve
(110/4)
6 Remove pneumatic line (4a) Check pneumatic line
on the deceleration air valve (4a) and hose clamp for
(110/4) damage, replace if
necessary.
Left deceleration air valve
7 Remove lower engine AR61.20-P-1105M
compartment paneling
8 Remove left air filter AR09.10-P-1150LA
housing (1)
9 Remove bolt (5a) for *BA09.40-P-1014-01H
(110/4)
10 Remove bolt (5b) for *BA09.40-P-1014-01H
(110/4)
11 Remove bolt (5c) for *BA09.40-P-1014-01H
(110/4)
12 Remove pneumatic line (4b) Check pneumatic line
on the deceleration air valve (4b) and hose clamp for
(110/4) damage, replace if
necessary.
Check
14 Remove pneumatic lines (4a, Check pneumatic
4b) from T-piece (7) lines (4a, 4b) and hose
clamps for damage,
replace if necessary.
15 Pressurize deceleration air If the vacuum
valve (110/4) with a vacuum drops within a minute to
of 700 millibar maximum 50 millibar,
then the deceleration air
valve is OK.
Vacuum pump Fig. 74
New Turbocharger
BA09.40-P-1014-01H Bolt for deceleration air Nm 7
valve on turbocharger
Fig. 74: Identifying Vacuum Pump (450 589 18 21 00)
REMOVE/INSTALL TURBOCHARGER - AR09.40-P-6020MC
Engine 275 In Model 215, 216, 220, 221, 230
Illustrated On Right Turbocharger

Fig. 75: Identifying Turbocharger Remove/Install Components (1 Of 4)

Modification Notes
22.11.05 Remove model 230 with Step 1.2
front axle carrier, added
Remove/install
1.1 Remove engine Model 220 with special
protection version, code
979, light armoring, code
Z04 or top protection,
code Z07
Model 215, 220 without AR01.10-P-2400MC
special protection version,
light armoring or top
protection
1.2 Remove engine with front Model 216, 221 AR01.10-P-2500SZ
axle carrier
Model 230 AR01.10-P-2500RC
2 Mount engine onto Model 215, 220
assembly stand
3 Remove right air filter AR09.10-P-1150LA
housing.
4 Remove intercooler AR09.41-P-6817HH
5 Remove engine charge air AR09.41-P-8623H
channel upstream of
charge air cooler
6 Remove ignition coil AR15.12-P-1100LA
module
7 Remove support (1) from *BA09.40-P-1009-01H
turbocharger (2)
*BA09.40-P-1010-01H
8 Remove engine supports *BA22.10-P-1001-02A
(3)
9 Remove coolant feed line Installation:
(4) from crankcase to Install new sealing rings.
turbocharger (2)
*BA09.40-P-1005-01H
*BA09.40-P-1007-01H
10 Remove oil return line (5) Installation:
from turbocharger (2) Replace gasket and
sealing ring.
*BA09.40-P-1004-01H
*BA09.40-P-1006-01H
11 Dismount pneumatic lines Installation:
(6) from deceleration air Check condition of
valve (7) and from vacuum pneumatic lines (6) and
cell (8) hose clamps; replace if
necessary.
12 Unscrew bolts (9) of oil Installation:
feed line (10) and of Replace gaskets and
coolant return line (11) at sealing rings.
turbocharger (2)
*BA09.40-P-1002-01H
*BA09.40-P-1003-01H
13 Remove shields (12) at *BA09.40-P-1012-01H
turbocharger (2)
14 Unscrew bolts (13) of *BA09.40-P-1001-01H
coolant line (14) at
cylinder head (15)
15 Mount assembly tool (16) Turbocharger and
with 4 bolts (bolt M8x20) exhaust manifold are one
onto turbocharger (2) unit and must not be
disassembled, as this can
lead to leakage.
Assembly tools
(16) serve to fix the
flexible exhaust manifold
parts in place.
Fig. 82
16 Unscrew nuts (17) at Installation: AR09.40-P-6020-11MC
exhaust manifold Observe torque diagram.
Fig. 80
Fig. 81
*BA09.40-P-1011-01H
17 Remove turbocharger (2) Installation:
with exhaust manifold Replace seal.
from cylinder head (15)
Turbocharger
BA09.40-P-1001-01H Coolant line to cylinder Nm 9
head
BA09.40-P-1002-01H Bolt, oil feed line to Nm 8
turbocharger
BA09.40-P-1003-01H Bolt, coolant return flow Nm 8
line to turbocharger
BA09.40-P-1004-01H Bolt, oil return flow line to Nm 8
turbocharger
BA09.40-P-1005-01H Bolt connecting coolant Nm 8
feed line to turbocharger
BA09.40-P-1006-01H Bolt, oil return flow line to Nm 8
crankcase
BA09.40-P-1007-01H Banjo bolt, coolant feed Nm 25
line to crankcase
BA09.40-P-1009-01H Bolt, support to Nm 30
turbocharger
BA09.40-P-1010-01H Bolt, turbocharger support Nm 20
to crankcase
BA09.40-P-1011-01H Exhaust manifold to Nm 15
cylinder head
BA09.40-P-1012-01H Shield to turbocharger Nm 9
Engine Support (Engine Side)

BA22.10-P-1001- Bolt, engine support Stage 1 Nm 20°
02A to crankcase Stage 2 Angle° 90
Fig. 79: Identifying Assembly Arm (285 589 00 61 00)
Fig. 80: Identifying Box Wrench Bit (285 589 00 03 00)
Fig. 81: Identifying Torque Wrench (001 589 87 21 00)
Torque Diagram For Exhaust Manifold - Ar09.40-P-6020-11Mc

Turbocharger
BA09.40-P-1011-01H Exhaust manifold on Nm 15
cylinder head
Fig. 82: Identifying Assembly Arm (285 589 00 61 00)
Do Not Use Any Assembly Paste Or Similar Product!
1. Tighten All The Nuts (1 To 12) To The Specified Tightening Sequence With The Specified Torque.
2. Dismount Assembly Tool (01, 02).
3. Tighten All The Nuts (1 To 12) Once Again To The Specified Tightening Sequence With The Specified
Torque.
Fig. 83: Identifying Exhaust Manifold Nuts
REMOVE/INSTALL CHARGE AIR MANIFOLD - AR09.41-P-1310HH

Engine 275 In Model 215, 216, 220, 221, 230
Fig. 84: Identifying Charge Air Manifold Remove/Install Components
Remove/install
1 Remove fuel distributor AR07.03-P-1451H
rail (1)
2 Dismount hose (3) of Check hose (3) and
crankcase ventilation hose clamp for damage,
system replace if required.
3 Dismount hose (2) at Check hose (2) and
charge air manifold (4) hose clamp for damage,
replace if required.
4 Dismount rear vacuum Engine 275
supply hose of brake Check vacuum supply
system at charge air hose and hose clamp for
manifold (4) damage, replace if
required.
5 Unscrew bolts (5) of *BA09.20-P-1001-01L
charge air manifold (4)
6 Take out charge air Installation:
manifold (4) Replace seals (6)..
Intake Manifold
Number Designation Engine 275, 285
BA09.20-P-1001- Bolt, intake manifold M6 Nm 8
01L to cylinder head
REMOVE/INSTALL TOP CHARGE AIR DISTRIBUTOR - AR09.41-P-1320SVK
Engine 112.961 In Models 203.065 /265
Engine 113.990 In Models 211.076 /276
Engine 113.991 In Models 215.374, 220.074 /174
Fig. 85: Identifying Top Charge Air Distributor Remove/Install Components
Remove/install
1 Remove top engine cover Detach engine
cover above on both sides
of the air filter housing
(1) and at the bracket
towards the top.
2 Remove right and left
engine intake air duct
3 Remove air filter housing When removing AR09.10-P-1150SVK
(1). the air filter housing (1)
make sure that the intake
lines (4) are not twisted.
If the air filter housing (1)
is removed incorrectly,
the steel ring in the intake
line (4) can become
deformed and work itself
loose when the engine is
running.
Carefully lift air
filter housing (1) and
remove crankcase bleed
hose (2) from fitting (3)
on intake line (4).
that the catches (5) do not
break off when fitting
onto the throttle valve
actuator. The catches (5)
can be sucked in by the
engine and cause engine
damage.
Installation:
Moisten sealing ring,
throttle valve actuator and
rubber retainers with
liquid lubricant.
4 Loosen hose clamps (6) at
the top of charge air
distributor (110/6)
5 Remove bolt (110/8) at top Note the
of charge air distributor different lengths of bolts.
(110/6) Cover over openings with
a fluffy rag.
*BA09.41-P-1001-01C
6 Lift off top air distributor Installation: Use
(110/6) on left and right new seals (110/7).
Charge Air Pipe/Charge Air Cooling

Number Designation Engines Engine Engines
112.960/961 113.992/993/995 113.990/991
AMG
BA09.41-P- Bolt, upper part Nm 10 10 9
1001-01C of charge air
distributor to
bottom part of
charge air
distributor
Repair Materials
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
CHECK CHARGE AIR COOLER - AR09.41-P-6800
Check Charge Air Cooler - Ar09.41-P-6800-01H
Check Charge Air Cooler If Necessary

After Test: ?
Replace Charge Air Cooler. AR09.41-P-
6817HH
1. Check Left And Right Charge Air Cooler (5/1, 5/2) Through Visual Inspection In The Air Intake Support
(1) For Traces Of Fluid And Residues Of Coolant.
For This Use Inspection Mirror (01) And Hand Lamp (02) Or Cylinder Inspection Light With
Flexible Endoscope.
Shown On Right Charge Air Cooler In Model 240

Fig. 86: Inspecting Air Cooler Charge
Check Charge Air Cooler - Ar09.41-P-6800-01Hh
Check Charge Air Cooler If Necessary

After Test: ?
Replace Charge Air Cooler. AR09.41-P-
6817HH
If Necessary After Test: ? Replace Charge Air Cooler.
1. Carefully Tilt Left And Right Charge Air Cooler (5/1, 5/2) And Check, If Coolant Is Flowing Out Of Air
Intake Support (1).
Do Not Put Connection Fitting (5A) Of Coolant Lines Under Tension When Tilting Left And Right
Charge Air Cooler, Otherwise Leaks May Occur.
2. Check Left And Right Charge Air Cooler Through Visual Inspection In The Air Intake Support (1) For
Traces Of Fluid And Residues Of Coolant.
Shown On Right Charge Air Cooler In Model 240

Fig. 87: Identifying Charge Air Cooler And Air Intake Support
REMOVE/INSTALL CHARGE AIR COOLER - AR09.41-P-6817
Remove/Install Charge Air Cooler - Ar09.41-P-6817Hh
Engine 275 In Model 215, 216, 220, 221, 230
Shown On Engine 285

Fig. 88: Identifying Charge Air Cooler Remove/Install Components - Shown On Engine 285
Remove/install
Risk of injury to skin and Do not open cooling AS20.00-Z-0001-01A
eyes caused by scalding system unless coolant
from contact with hot temperature is below 90°
coolant spray. C. Open cap slowly and
Risk of poisoning caused release the pressure. Do
by swallowing coolant. not pour coolant into
beverage containers.
safety glasses.
1 Remove air filter housing Model 215, 216, 220, AR09.10-P-1150LA
221, 230
Model 240 AR09.10-P-1150H
2 Drain coolant from low Model 215, 216, 220, AR20.00-P-1142HM
temperature circuit 221, 230
Model 240 AR20.00-P-1142HN
3 Disconnect charge air hose Installation:
(1) at charge air cooler (2). check charge air hose (1)
and hose clamp for
damage bad replace if
required.
Clean and degrease inside
of charge air hose (1) as
well as its connection
fitting at charge air cooler
(2).
*BA09.41-P-1002-02B
*WH58.30-Z-1002-06A
LU cleaner *BR00.45-Z-1028-04A
4 Disconnect charge air duct Installation:
(3) at charge air cooler (2). check charge air duct (3)
and hose clamp for
damage and replace if
required.
*BA09.41-P-1003-02B
*WH58.30-Z-1002-06A
5 Remove pneumatic line Only when removing
(4a) at charge air cooler from right charge air
(2). cooler (2).
Installation:
Check pneumatic line
(4a) and hose clamp for
damage; replace if
necessary.
6 Disconnect electrical Only when removing
connector at pressure from right charge air
sensor upstream of throttle cooler (2).
valve actuator (B28/6) and
dismount pressure sensor
upstream of throttle valve
actuator (B28/6) from
bracket (5)
The pneumatic line
(4b) is bonded with the
fitting at the charge air
cooler (2). This
combination must not be
separated, otherwise
leakage may occur.
*BA09.41-P-1002-03A
7 Remove pneumatic line Only when removing
(4c) from charge air cooler from right charge air
(2). cooler (2).
Installation:
Install new cable ties.
8 Remove screws (6) *BA09.41-P-1001-03A
9 Remove coolant hoses on For better
fitting (2a) for charge air accessibility lift charge
cooler (2) air cooler (2) slightly
forward.
Installation:
Check coolant hoses at
fitting (2a) and hose
clamp for damage;
*WH58.30-Z-1019-02A
10 Take out charge air cooler Unclip plug
(2) connection for O2 sensor
from retaining spring at
rear of charge air cooler
(2).
12 Bleed low temperature AR20.00-P-1145H
circuit
13 Inspect cooling system for AR20.00-P-1010HN
leaks
Charge Air Duct

BA09.41-P-1002-02B Hose clamp of charge air Nm 3
hose at engine charge air
channel and at charge air
cooler
BA09.41-P-1003-02B Hose clamp of charge air Nm 3
channel as required charge
air cooler at charge air
cooler and at electronic
accelerator actuator
Charge Air Cooler

BA09.41-P-1001-03A Bolt, charge air cooler to Nm 8
cylinder head cover
BA09.41-P-1002-03A Bolt, pressure sensor in Nm 6
front of throttle valve
actuator to bracket
Commercially Available Tools

Number Designation
WH58.30-Z-1019-02A Hose clamp pliers (length 210 mm, clamping range
80 mm)
WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose
clamps with worm drive
Repair Materials
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
Remove/Install Charge Air Cooler - Ar09.41-P-6817Rvk
Engine 113.990 In Model 211.076 /276
Engine 113.991 In Model 215.374, 220.074
Shown On Engine 112
Fig. 89: Identifying Charge Air Cooler Remove/Install Components
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of lifting
toppling off the lifting platform and position four
platform. support plates at lifting
specified by vehicle
manufacturer.
Risk of explosion caused No fire, sparks, open AS47.00-Z-0001-01A
by fuel igniting, risk of flames or smoking. Only
poisoning caused by pour fuels into suitable
inhaling and swallowing and appropriately marked
fuel and risk of injury to containers.
eyes and skin caused by Wear protective clothing
contact with fuel. when handling fuel.
1 Remove engine trim panel Pull top engine
(1) cover (2) upwards at both
air filter housings and at
bracket.
2 Remove air filter housing AR09.10-P-1150SVK
(2).
3 Remove top charge air AR09.41-P-1320SVK
distributor (110/6)
4 Remove poly-V-belt for AR13.21-P-1202RVK
supercharger
5 Release fuel pressure Make sure to
through service valve (1/1) collect fuel.
Pressure hose Fig. 61
6 Unbolt feed line (17/2) at Make sure to
fuel distributor rail (17) collect fuel.
*BA07.52-P-1001-01A
Set of plugs Fig. 92
7 Disconnect electrical Press together
connectors at fuel injection security catches.
valves (Y62)
8 Remove bolts for fuel *BA07.52-P-1003-01A
distributor rail (17)
*BA07.52-P-1002-01A
9 Lift fuel distributor rail Installation:
(17) including fuel Check O-ring for damage.
injectors (Y62) from Oil O-rings.
bottom charge air
distributor (110/8) toward
top
10 Detach gray vacuum line Installation:
at rubber hose Coat gray vacuum line
with liquid lubricant.
Antifriction agent *BR00.45-Z-1010-06A
11 Unplug connector for
(M16/6)
pressure sensor (B28)
charge air temperature
sensor (B17/8)
14 Detach electrical connector Carefully detach
at the supercharger connector since the
magnetic clutch (6) connector housing can be
damaged.
15 Detach rear vacuum line at
intake manifold
16 Remove lower engine Model 215, 220 AR61.20-P-1105M
Model 211 AR61.20-P-1105T
Risk of poisoning caused release the pressure. Do
by swallowing coolant. not pour coolant into
beverage containers. Wear
protective gloves,
safety glasses.
17 Drain coolant from AR20.00-P-1142RVK
radiator
Notes on coolant All engines AH20.00-N-2080-01A
18 Detach coolant hoses (4) at Special pliers *WH58.30-Z-1005-02A
aluminum pipes (5)
19 Unscrew bolts for bottom *BA09.41-P-1002-01C
charge air distributor
(110/8)
20 Bolt bracket on Bracket Fig. 91
supercharger
21 Attach engine hoist to Engine hoist (self- *WE58.40-Z-1012-11A
lifting eye of bracket locking)
22 Lift out supercharger (50)
together with charge air
cooler (110/2) and bottom
charge air distributor
(110/8)
23 Unbolt charge air cooler *BA09.50-P-1001-01B
(110/2) from supercharger
(50)
25 Inspect cooling system for AR20.00-P-1010RVK
leaks
26 Read out fault memory
Connect STAR AD00.00-P-2000-04A
DIAGNOSIS and read out
fault memory
Fuel Distributor
Number Designation Engine 113.990/ 991
BA07.52-P-1001-01A Fuel feed line to fuel Nm 38
distributor
BA07.52-P-1002-01A Bolt, fuel distributor to Nm 10
intake manifold
BA07.52-P-1003-01A Bolt, fuel distributor to Nm 9
bottom part of charge air
distributor

Number Designation Engine 113.990/ 991
BA09.41-P-1002-01C Bolt, bottom part of Nm 20
charge air distributor to
cylinder head
Supercharger
Number Designation Engine 113.990 Engine 113.991
BA09.50-P-1001- Bolt, supercharger to Nm 20 20
01B charge air cooler
Fig. 91: Identifying Bracket (112 589 00 62 00)

Fig. 92: Identifying Set Of Stop Plugs (129 589 00 91 00)

Number Designation
WH58.30-Z-1005-02A Special pliers, Co. Muhr & Bender D-57439
Attendorn
Workshop Equipment
WE58.40-Z-1012-11A Load regulator (engine hoist), self-locking
Repair Materials
BR00.45-Z-1010-06A Antifriction agent A 000 989 03 67
REMOVE/INSTALL LOW TEMPERATURE RADIATOR - AR09.41-P-6831RVK
Engine 113.990 In Models 211.076 /276
Engine 113.991 In Models 215.374, 220.074
Shown On Model 230.474

Fig. 93: Identifying Low Temperature Radiator Remove/Install Components - Shown On Model 230.474
Remove/install
Risk of injury to skin andDo not open cooling AS20.00-Z-0001-01A
safety glasses.
1 Remove top engine cover Detach engine
cover at both air filter
housings and at bracket
upwards.
2 Drain coolant at radiator AR20.00-P-1142RVK
(4)
Notes on coolant AH20.00-N-2080-01A
*BF20.00-P-1001-02K
3 Remove radiator (4) Model 230 AR20.20-P-3865R
Model 215, 220 AR20.20-P-3865AB
Model 211 AR20.20-P-3865TV
4 Slacken space saving Special pliers *WH58.30-Z-1005-02A
clamps at low temperature
radiator (110/11)
5 Detach coolant hoses at Installation: Pay
low temperature radiator attention to correct
(110/11) seating at low
(110/11), in order to
avoid water loss.
6 Unscrew bolts at low
(110/11)
7 Remove low temperature
radiator (110/11)
leaks
Cooling System
Number Designation Engines Engine 113.990
113.992/995 in
model 230
BF20.00-P- Cooling system Total filling Liters approx.13.0 approx.13.2
1001-02K capacity
Capacity of Liters approx.6.5 approx.6.6
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.7.3 approx.7.3
anticorrosion/
antifreeze down to
-45°C
Specifications for Sheet BB00.40-P-0310- BB00.40-P-0310-
Operating Fluids 01A 01A
Sheet BB00.40-P-0325- BB00.40-P-0325-
00A 00A
Cooling System
Number Designation Engine 113.991 Engines
in model 215 113.986/991 in
model 220
BF20.00-P- Cooling system Total filling Liters approx.14.5 approx.13.5
1001-02K capacity
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.8 approx.7.4
anticorrosion/
antifreeze down to
-45°C
Sheet BB00.40-P-0325- BB00.40-P-0325-
00A 00A

Number Designation
WH58.30-Z-1005-02A Special pliers, Firma Muhr & Bender D-57439
Attendorn
REMOVE/INSTALL CHARGE AIR COOLER CIRCULATION PUMP - AR09.41-P-6832SVK
Engine 112.961 In Models 203.065 /265
Engine 113.990 In Models 211.076 /276
Engine 113.991 In Models 215.374, 220.074

Fig. 94: Identifying Charge Air Cooler Circulation Pump Remove/Install Components - Shown On Model
170.466
Shown On Model 203.065 /265
203.065 /265

230.474
Remove/install
coolant spray. Risk of C. Open cap slowly and
poisoning from release the pressure. Do
safety glasses.
1 Remove lower engine Model 170 AR61.20-P-1105A
Model 203 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Models 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
2 Drain coolant from Model 203 AR20.00-P-1142PV
radiator
Models 170, 211, 215, AR20.00-P-1142RVK
220, 230
3 Remove front fender liner Model 170 AR88.10-P-1300G
in right front fender
Model 203 AR88.10-P-1300P
Model 211 AR88.10-P-1300T
Models 215, 220 AR88.10-P-1300M
Model 230 AR88.10-P-1300R
4 Disconnect connector for
charge air cooler
circulation pump (4)
5 Unscrew bolt (3) at bracket
(1) for charge air cooler
circulation pump (M44)
6 Remove bracket (1) for Installation:
charge air cooler First of all plug in
circulation pump (M44) retaining ring with
retaining lug at top.
7 Detach coolant hose (2) at Collect coolant
charge air cooler from low temperature
circulation pump (M44) radiator with suitable
container.
Special pliers *WH58.30-Z-1005-02A
8 Remove circulation pump
for charge air cooler (M44)
10 Inspect cooling system for Model 170, 203 AR20.00-P-1010P
leaks
Models 211, 215, 220, AR20.00-P-1010RVK
230

Number Designation
WH58.30-Z-1005-02A Special pliers, Firma Muhr & Bender D-57439
Attendorn
REMOVE/INSTALL CIRCULATION PUMP FOR LOW-TEMPERATURE WATER CIRCUIT -

AR09.41-P-6925LA
Engine 275 In Model 215, 216, 220, 221
Shown On Model 220

220
Remove/install
coolant spray. Risk of C. Open cap slowly and
poisoning caused by release the pressure. Do
safety glasses.
1 Remove lower engine Model 215, 220 AR61.20-P-1105M
Model 216 AR61.20-P-1105SX
Model 221 without code
(Z07) Top protection
Model 221 with code AR61.20-P-1105SXS
2 Drain coolant out of low AR20.00-P-1142HM
3 Pull off pneumatic hose (1)
4 Pull off electrical plug
connector (2) on
circulation pump for the
charge air cooler (M44)
5 Unscrew bolt (3) and *BA09.41-P-1003-01G
remove clamp (4)
6 Remove hoses (5, 6) on
circulation pump for
charge air cooler (M44)
7 Remove circulation pump *BA09.41-P-1004-01G
for charge air cooler (M44)
9 Venting air from low AR20.00-P-1145H
temperature circuit
leaks

BA09.41-P-1003-01G Bolt, pump for low- Nm 5
to bracket
BA09.41-P-1004-01G Hose clamps to pump for Nm 3
low-temperature water
circuit
REMOVE/INSTALL LOW TEMPERATURE WATER CIRCUIT RADIATOR - AR09.41-P-6935
Remove/Install Low Temperature Water Circuit Radiator - Ar09.41-P-6935Im
Engine 275.980 In Models 215.379, 220.179
Shown On Model 220
Fig. 98: Identifying Low Temperature Water Circuit Radiator Remove/Install Components - Shown On
Model 220
Modification Notes
1.12.05 Cooling system Engine 275.980 in model *BF20.00-P-1001-02Q
215
Cooling system ENGINE 275.980 in *BF20.00-P-1001-02Q
MODEL 220
Remove/install
vehicle slipping or columns of the and
toppling off the lifting position the four support
platform. plates below the lifting
manufacturer.
safety glasses.
installing or aligning within the operating range
hoods, doors, trunk lid/ of moving parts.
rear-end door or sliding
roof.
1 Remove radiator unit AR20.20-P-3871IM
2 Unscrew bolts (3) from
radiator for low-
(1) and steering oil cooler
(2)
3 Remove radiator for low-
(1) and steering oil cooler
(2) from radiator (4)
4 Remove nuts (5) for
radiator for low-
(1) from steering oil cooler
(2)
5 Remove steering oil cooler
(2)
7 Pour in coolant *BF20.00-P-1001-02Q
circuit
leaks
Cooling System
Number Designation Engine Engine
275.980 in 275.980 in
model 215 model 220
BF20.00-P- Cooling Total filling Main circuit Liters approx.12.5 approx.12
1001-02Q system capacity Low Liters approx.2,1 approx.2.1
temperature
circuit
Filling capacity Main circuit Liters approx.6.25 approx.6
of anticorrosion Low Liters approx.1 approx.1
and antifreeze temperature
down to -37°C circuit
Specifications for Operating Sheet BB00.40-P- BB00.40-P-
Fluids 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P-
0325-00A 0325-00A
Remove/Install Low Temperature Water Circuit Radiator - Ar09.41-P-6935Mc

Fig. 99: Identifying Low Temperature Water Circuit Radiator Remove/Install Components (1 Of 2)
Fig. 100: Identifying Low Temperature Water Circuit Radiator Remove/Install Components (2 Of 2)
Modification Notes
1.12.05 Cooling system Engine 275.950 in model *BF20.00-P-1001-02Q
215/220
Remove/install
vehicle slipping or columns of the and
toppling off the lifting position the four support
platform. plates below the lifting
manufacturer.
safety glasses.
roof.
2 Remove central and front AR61.20-P-1105M
sections of the lower
engine compartment
paneling
3 Drain coolant from low AR20.00-P-1142HM
temperature circuit
4 Remove front bumper AR88.20-P-2000M
5 Remove retaining bracket
(1) for Active Body
Control lines from front
end assembly
6 Remove right bracket (2)
on engine oil cooler (3)
from front end assembly
7 Remove engine oil cooler
(3) with attached lines
downwards
8 Remove retaining bracket
(4)
9 Pull out expansion rivets
(5) and remove air
ductings (6)
10 Remove bolts (7)
11 Remove right radiator
console (8)
12 Take off coolant hose (9a) Hose clamp pliers *WH58.30-Z-1017-02A
from radiator (9) with Bowden cable
13 Remove engine radiator Installation:
(9) downwards Move side brackets (10)
into the cutouts on the
condenser.
14 Take off coolant hose (9b)
from radiator (9)
16 Pour in coolant *BF20.00-P-1001-02Q
circuit
leaks
Cooling System
Number Designation Engine 275.950
in model 215/220
BF20.00-P- Cooling system Total filling Main circuit Liters approx.12.2
1001-02Q capacity Low temperature Liters approx.1.55
circuit
Filling capacity of Main circuit Liters approx.6.1
anticorrosion and
Low temperature Liters approx.0.75
antifreeze down to
circuit
-37°C
Specifications for Operating Fluids Sheet BB00.40-P-0310-
01A
Sheet BB00.40-P-0325-
00A

Number Designation
WH58.30-Z-1017-02A Hose clamp pliers with Bowden cable
REMOVE/INSTALL ENGINE CHARGE AIR DUCT UPSTREAM OF CHARGE AIR COOLER -

AR09.41-P-8623H
Engine 275 In Model 215, 216, 220, 221, 230

Fig. 101: Identifying Charge Air Cooler Remove/Install Components
Remove/install
221, 230
Model 240 AR09.10-P-1150H
2 Release hose clamps (1) on Tighten hose clamps
the charge air hoses (2) (1) using the prescribed
torque so that charge air
cooler (6) can separate
from charge air ducts (7)
in the event of an
accident.
*BA09.41-P-1002-02B
3 Loosen hose clamps (3) at Tighten the hose
charge air duct (4) clamps (3) using the
downstream of charge air prescribed torque so that
cooler (6) the charge air cooler (6)
can separate from charge
air ducts (4) in the event
of an accident.
*BA09.41-P-1003-02B
4 Remove screws (5) Do not open the
low temperature water
circuit.
*BA09.41-P-1001-01G
5 Pull charge air cooler (6) Do not damage the
and charge air hoses (2) coolant hoses running to
out of charge air ducts (7) charge air coolers (6).
6 Dismount fork (8) *BA09.41-P-1001-02B
7 Remove charge air ducts
(7) upstream of charge air
coolers (6)
Charge Air Duct

BA09.41-P-1001-02B Bolt, charge air channel Nm 8
before charge air cooler to
turbocharger
BA09.41-P-1002-02B Hose clamp, charge air Nm 3
hose to engine charge air
channel and to charge air
cooler
air cooler to charge air
cooler and to electronic

BA09.41-P-1001-01G Bolt charge air cooler to Nm 8
cylinder head cover
REMOVE COMPRESSOR, INSTALL - AR09.50-P-4705SVK
Engine 112.961 In Models 203.065 /265
Engine 113.990 In Models 211.076 /276
Engine 113.991 In Models 215.374, 220.074 /174

Fig. 102: Identifying Compressor Remove/Install Components - Shown On Engine 113.990 (1 Of 4)

Modification Notes
16.5.06 "Disconnect/connect ground
line on battery" removed
Remove/install
vehicle slipping or columns of lifting platform
toppling off the lifting and position four support
platform. plates at lifting platform
support points specified by
vehicle manufacturer.
by fuel igniting, risk of flames or smoking. Only
poisoning caused by pour fuels into suitable and
inhaling and swallowing appropriately marked
fuel and risk of injury to containers.
skin and eyes caused by Wear protective clothing
contact with fuel. when handling fuel.
1.1 Activate Service mode in Model 215, 220 with code AR82.95-P-0005-03AM
Tele-Aid emergency call (347) TELE AID
system emergency call system
(D2B) or code (855) TELE
AID.
Notes regarding the Tele- AH82.95-P-0001-01AM
Aid emergency call
system
2 Remove ground line(s) at Do not connect
battery(ies) quiescent current retention
device.
Model 170 AR54.10-P-0003A
Model 215, 220 AR54.10-P-0003I
3 Remove air filter housing Installation: Do not AR09.10-P-1150SVK
(1). break off catches (5) during
bottoming on the throttle
valve actuator (M16/6).
The catches (5) can be
sucked in by the
supercharger (50) and
cause engine damage.
4 Remove top charge air AR09.41-P-1320SVK
distributor (110/6)
5 Remove the throttle valve The throttle valve AR07.61-P-1401SVK
actuator (M16/6) actuator (M16/6) plug (6)
must not be removed,
because it is bonded.
Disconnect electrical
connector (13) to remove.
6 Remove fuel distributor Installation: AR07.03-P-1451AA
Replace O-rings of
injection valves.
7 Remove bolt (7) for purge Detach purge line
line (8) at cylinder head (8) on engine side and
cover (9) place to the side.
*BA01.20-P-1001-01E
8 Detach hoses (10) for air Hoses (10)
injection at compressor remains at left aspirator
(50) shutoff valve (126/1) and at
right aspirator shutoff valve
(126/2).
9 Detach hoses (11) for air
injection at supercharger
(50)
10 Detach vacuum lines (12)
at left aspirator shutoff
valve (126/1) and at right
aspirator shutoff valve
(126/2).
11 Detach crankcase venting
hoses (15) at the left
cylinder head cover (9)
and at the right cylinder
head cover
12 Detach vacuum line (16)
at air pump switchover
valve (Y32)
connector at the charge air
temperature sensor
(B17/8)
connector at pressure
sensor (B28)
15 Disconnect electrical The electrical
connector (14) at air connector (14) on air
recirculation flap actuator recirculation flap actuator
and electrical connector
(13) for throttle valve
actuator (M16/6) are
identical and can be mixed
up with each other. The
wiring harness on the
(M16/6) is marked with
blue insulation tape. If this
not the case then mark
before disconnecting the
electrical connectors (13,
14).
Installation:
Apply contact fluid to the
pins of the electrical
connectors (13, 14).
Contact fluid *BR00.45-Z-1001-14A
16 Detach electrical Disconnect electrical
connector (23) at connector carefully so that
supercharger magnetic the connector housing of
clutch (Y2/1) the supercharger magnetic
clutch (Y2/1) is not
damaged.
17.1 Remove poly V-belt of Engine 113.990/991/992/ AR13.21-P-1202RVK
supercharger 995
18.1 Remove poly-V-belt Engines 112.960/961 AR13.22-P-1202SVK
Model 203 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
20 Drain coolant from Model 170 AR20.00-P-1142SV
radiator
Model 203 AR20.00-P-1142PV
Model 211, 215, 220, 230 AR20.00-P-1142RVK
21 Disconnect coolant hoses Close off coolant
on coolant drain line (17) hoses at coolant return line
and coolant feed line (18) (17) and coolant feed line
(18)
Fig. 108
22 Remove bolt (19) from
coolant return line (17)
bracket and coolant feed
line (18) bracket
23.1 Remove right aspirator Engine 112
shutoff valve (126/2)
*BA09.41-P-1002-01C
23.2 Remove left aspirator Engine 113
shutoff valve (126/1) and
right aspirator shutoff
valve (126/2)
*BA09.41-P-1002-01C
24 Unscrew bolts (20) and Installation: Pay
bolt (21) attention to different
lengths of bolts. The bolt
(21) has a length of 35 mm.
The bolts (20) have a
length of 30 mm.
*BA09.41-P-1002-01C
25 Screw bracket (22) onto Fig. 91
compressor (50)
26 Attach the engine hoist in Fig. 91
the lifting eye of the
bracket (22)
*WE58.40-Z-1012-11A
27 Lift out supercharger (50) Check seals
together with charge air (110/9), replace if
cooler and bottom charge necessary.
air distributor (110/10)
Installation: Use
dowel bolt (arrow) for
exact positioning of the
supercharger (50) with
charge air cooler and
bottom charge air
distributor (110/10) as well
as for centering the gasket
(110/9).
Fig. 62
28 Remove supercharger (50) *BA09.50-P-1001-01B
from charge air cooler
leaks
31 Read out fault memory STAR DIAGNOSIS *WH58.30-Z-1048-13A
and erase if necessary diagnosis system
fault memory
32 Perform basic Model 170 AR00.19-P-0200B
programming
Model 215, 220 AR00.19-P-0200M
Crankcase Ventilation, Cylinder Head Cover

112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/942/943/944/945/946/
BA01.20- Bolt for Nm 8
P-1001- cylinder
01E head
cover

Number Designation Engine Engines Engine
112.960/961 113.990/991 113.992/993/995
AMG
BA09.41-P- Bolt, bottom Nm 23 20 20
1002-01C part of charge
air distributor to
cylinder head
Supercharger
Number Designation Engine Engine Engine Engine
112.960/961 113.992/995 113.991 113.990
AMG
BA09.50-P- Bolt, Nm 20 20 20 20
1001-01B supercharger to
charge air
cooler
Fig. 107: Identifying Set Of Dowel Bolts (112 589 02 62 00)
Fig. 108: Identifying Clamping Device (000 589 40 37 00)

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
system, Compact Passenger Car
Workshop Equipment
WE58.40-Z-1012-11A Load regulator (engine hoist), self-locking
Repair Materials
BR00.45-Z-1001-14A Contact fluid A 008 989 55 71
REMOVE/INSTALL COMPRESSOR BELT PULLEY - AR09.50-P-4787R
Engines 112.960 /961, 113.990 /991 /992 /995
Fig. 109: Identifying Compressor Belt Pulley Remove/Install Components (1 Of 3)

Remove
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
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 the running
engine
vehicle slipping or columns of the lifting
toppling off the lifting platform and position the
platform. four support plates at the
lifting platform support
points specified by the
roof.
1 Open engine hood and Model 170 AR88.40-P-1000G
raise to vertical position
Model 203 AR88.40-P-1000P
Model 211 AR88.40-P-1000T
Models 215, 220 AR88.40-P-1000M
Model 219 AR88.40-P-1000TX
Model 230 AR88.40-P-1000R
2 Remove ribbed V-belt Slacken only
poly-V-belt and remove it
from the compressor belt
pulley (3).
Models 170, 203 AR13.22-P-1202SVK
Models 211, 215, 220, 230 AR13.21-P-1202RVK
Model 219 AR13.21-P-1202TZ
3 Remove bottom engine Model 211 AR61.20-P-1105T
Models 215, 220 AR61.20-P-1105M
Model 219 AR61.20-P-1105TX
Model 230 AR61.20-P-1105R
Model 170 AR61.20-P-1105A
Model 203 AR61.20-P-1105P
4 Loosen both front engine 211,215,220 *BA22.10-P-1001-01L
mounts (1)
219 *BA22.10-P-1001-01S
203 *BA22.10-P-1001-01R
170 *BA22.10-P-1001-01L
5 Mount bracket on Bracket Fig. 91
supercharger housing
6 Raise engine with engine Ensure that the
crane until the center bolt coolant hoses and
(2) is accessible with an hydraulic lines of the
impact wrench power steering pump are
not overstretched.
7 Remove center bolt (2) Loosen center
bolt using impact wrench.
*BA09.50-P-1007-01B
8 Remove supercharger belt If belt pulley is seized
pulley (3) use pulley with
corresponding
clamping pliers
To pull off, screw in
center bolt without shim
and use as a support.
Clamping pliers for Fig. 113
M112
Clamping pliers for Fig. 115
M113
Puller Fig. 114
Install
9 Attach compressor belt
pulley (3) to the magnetic
clutch (Y2/1)
10 Measure clearance at the Fit center bolt (2)
compressor belt pulley (3) of supercharger belt pulley
(3), then measure at 3
points. The clearance can
be corrected with supplied
graduated disks.
Clearance *BE09.50-P-1001-01A
11 Tighten center bolt (2) of Clean threads.
compressor belt pulley (3) Glue in center bolt (2)
with Loctite. Hold
magnetic clutch (Y2/1)
with bracket (6).
Bracket Fig. 112
Universal *WH58.30-Z-1046-06A
tensioning strap
*BA09.50-P-1007-01B
Quick glue *BR00.45-Z-1011-02A
12 Install poly-V-belt Models 170, 203 AR13.22-P-1202SVK
Models 211, 215, 220, 230 AR13.21-P-1202RVK
Model 219 AR13.21-P-1202TZ
13 Raise vehicle and tighten Models 211, 215, 220 *BA22.10-P-1001-01L
both the front engine
mounts (1)
Model 230 *BA22.10-P-1001-01X
Model 219 *BA22.10-P-1001-01S
Model 203 *BA22.10-P-1001-01R
Model 170 *BA22.10-P-1001-01L
14 Install lower engine Model 211 AR61.20-P-1105T
Models 215, 220 AR61.20-P-1105M
Model 219 AR61.20-P-1105TX
Model 230 AR61.20-P-1105R
Model 203 AR61.20-P-1105P
Model 170 AR61.20-P-1105A
15 Carry out engine test run
16 Close engine hood Model 170 AR88.40-P-1000G
Model 203 AR88.40-P-1000P
Model 211 AR88.40-P-1000T
Models 215, 220 AR88.40-P-1000M
Model 219 AR88.40-P-1000TX
Model 230 AR88.40-P-1000R
Electromagnetic Clutch
Number Designation Engines 112.960/ Engines
961 113.990 /991 /992/995
BE09.50-P-1001- Clearance mm 0.25...0.30 0.35...0.45
01A
Supercharger
Number Designation Engines Engine Engine Engines
112.960/ 961 113.990 113.991 113.992/ 995
AMG
BA09.50-P- Center bolt on Nm 20 60 60 60
1007-01B compressor belt
pulley
Engine Mounts, Engine Supports

Number Designation Engine 112.961 in model
203
BA22.10-P-1001-01R Bolt, front engine mounts Nm 35
to front axle carrier

Number Designation Engines Engine 113.990 Engine 113.991
112.947/960 in in model 211 in Model
model 170 215/220
BA22.10-P- Bolt, front Nm 35 35 35
1001-01L engine mounts
to front axle
carrier
Engine Suspension, Engine Mounts, Engine Supports

Number Designation Engine 113 in model 219
BA22.10-P-1001-01S Bolt, front engine mounts Nm 35

Number Designation Engines 112, 113 in
model 230
BA22.10-P-1001-01X Bolt, front engine mounts Nm 35
Fig. 113: Identifying Clamping Pliers (000 589 02 34 00)

Fig. 114: Identifying Puller (001 589 50 33 00)

Number Designation
WH58.30-Z-1046-06A General purpose tensioning strap
Repair Materials
BR00.45-Z-1011-02A Quick glue A 003 989 31 71
REMOVE/INSTALL CHARGE AIR DUCT DOWNSTREAM OF CHARGE AIR COOLER - AR09.50-

P-8680H
Engine 275 In Model 215, 216, 220, 221, 230

Illustrated On Model 240
Fig. 117: Identifying Charge Air Duct Downstream Remove/Install Components
Remove/install
221, 230
Model 240 AR09.10-P-1150H
charge air hoses (2) (1) using the prescribed
from charge air ducts in
the event of an accident.
*BA09.41-P-1002-02B
charge air duct (4) (3) using the prescribed
from charge air ducts (4)
in the event of an
accident.
*BA09.41-P-1003-02B
4 Remove screws (5) Do not open the
circuit.
*BA09.41-P-1001-01G
5 Lever charge air cooler (6) Do not damage
out of charge air hoses (2) coolant hoses running to
charge air coolers (6).
6 Take charge air cooler (6)
out of charge air duct (4)
7 Remove charge air duct (4)
from throttle valve actuator
(M16/6) and take it out
Charge Air Duct

hose to engine charge air
channel and to charge air
cooler
air cooler to charge air
cooler and to electronic

BA09.41-P-1001-01G Bolt, charge air cooler to Nm 8
cylinder head cover
REMOVE/INSTALL RECIRCULATED AIR FLAP ACTUATOR - AR09.50-P-8843T
Engine 113.990 In Models 211.076 /276, 219.376
Engine 113.991 In Models 215.374, 220.074
Engine 113.992 In Model 230.474 Except Code (802) Model Year 2002

Fig. 118: Identifying Recirculated Air Flap Actuator Remove/Install Components
Removing
1 Remove compressor (6) Models 211.076 /276, AR09.50-P-4705SVK
215.374, 220.474,
230.472 /474
Model 219.376 AR09.50-P-4705TZ
2 Remove coolant lines (2)
from charge air cooler (4)
3 Remove bolts (1, 3)
4 Disconnect compressor Carefully pry off
(6) from charge air cooler charge air cooler (4).
(4)
5 Remove air recirculation
flap actuator (M16/7)
Install
6 Attach air recirculation AR09.50-P-8843-01T
flap actuator (M16/7)
Torx bolt for air *BA09.50-P-1002-01B
recirculation flap actuator
7 Close off opening on
compressor (6)
8 Clean sealing surfaces No dirt particles should
(arrow) on compressor (6) be able to find their way
into the compressor (6)
while cleaning since these
could destroy the
compressor (6).
9 Close off opening on
charge air cooler (4)
10 Clean sealing surface (5) No dirt particles must
on charge air cooler (4) enter the charge air cooler
(4) while cleaning because
they can destroy the
compressor (6).
11 Apply sealant thinly No excess sealant
should be allowed to find
its way into the
compressor (6) since this
could destroy the
compressor (6).
Sealant *BR00.45-Z-1013-01A
12 Attach charge air cooler Installation:
(4) to compressor (6) Moisten sealing ring on
air recirculation flap
actuator (M16/7) with
liquid lubricant.
Bolt, compressor to *BA09.50-P-1001-01B
charge air cooler
13 Attach coolant lines (2) to
charge air cooler (4)
14 Install compressor (6) Models 211.076 /276, AR09.50-P-4705SVK
215.374, 220.474,
230.472 /474
Model 219.376 AR09.50-P-4705TZ
15 Teach in air recirculation
flap actuator using STAR
DIAGNOSIS
Connect up STAR AD00.00-P-2000-04A
fault memory
STAR DIAGNOSIS *WH58.30-Z-1048-13A
diagnosis system
Supercharger
Number Designation Engine 113.990 Engine 113.991 Engines
113.992/ 995
BA09.50-P- Bolt, supercharger Nm 20 20 20
1001-01B to charge air
cooler
BA09.50-P- Torx bolt for air Nm 7 7 7
1002-01B recirculation flap
actuator

Number Designation
Repair Materials
BR00.45-Z-1013-01A Sealant A 003 989 98 20
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
Attach Air Recirculation Flap Actuator - Ar09.50-P-8843-01T
Supercharger
Number Designation Engine 113.990 Engine 113.991 Engines
113.992/995
BA09.50-P- Torx bolt for air Nm 7 7 7
1002-01B recirculation flap
actuator
1. Clean Sealing Surfaces.

2. Insert New Seal.
3. Attach Air Recirculation Flap Actuator (M16/7) Loosely On The Charge Air Cooler. Do Not Tighten
Torx Bolts (1).
The Air Recirculation Flap Actuator (M16/7) Must Be Movable In Order To Allow Trouble-Free
Connection Of The Charge Air Cooler And Compressor.
Fig. 119: Identifying Air Recirculation Flap Actuator Torx Bolts
4. Connect Charge Air Cooler And Compressor Together And Fix Together With Bolts.
Do Not Use Sealant Since The Charge Air Cooler And Compressor Will Be Separated Again.
5. Tighten Front Torx Bolts (2) M16/7 On Air Recirculation Flap Actuator.
6. Remove Bolts And Carefully Disconnect Charge Air Cooler And Compressor.
7. Tighten All Torx Bolts On Air Recirculation Flap Actuator M16/7 .
Fig. 120: Tightening Air Recirculation Flap Actuator Torx Bolts

TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: AIR INTAKE, SUPERCHARGING -
BE09.00-Z-9999AZ
Model All
Turbocharger ENGINE 603 / BE09.40-P-1000-01A

Electromagnetic clutch ENGINE 111, 112.960 /961, BE09.50-P-1000-01A
113.990 /991 /992 /995
ELECTROMAGNETIC CLUTCH - BE09.50-P-1000-01A
Engine 111, 112, 113
Electromagnetic Clutch
Number Designation Engine Engine Engine
111.943/944/947/973/975 112.960/961 113.990/991/992/995
BE09.50-P- Clearance mm 0.25...0.40 0.25...0.30 0.35...0.45
1001-01A
MAINTENANCE
REPLACE AIR FILTER ELEMENT - AP09.10-P-0980H
Engine 275.950 In Models 215.376, 220.176
Engine 275.980 In Model 215.379, 220.179
Engine 285.950 In Model 240.078 /178
Engine 285.980 In Model 240.079 /179

Fig. 121: Identifying Air Filter Element Remove/Install Components
Remove/install
1 Remove engine trim panel
Remove/install engine Engine 275.950 in model AR01.10-P-2405LA
cover 215.376, 220.176
Engine 275.951 in model
230.476
230.477
240.078/178
240.079/179
Engine 275.980 in model AR01.10-P-2405IM
215.379, 220.179
230.479
connector at the pressure
filter, left cylinder bank
(B28/4), and at the
pressure sensor
downstream of air filter,
right cylinder bank (B28/5)
3 Remove left and right air
filter housing cover (2) and
remove left and right air
filter element (3)
Clean
4 Clean the inside of the left LU cleaner *BR00.45-Z-1028-04A
and right air filter housing
cover (2)
5 Clean the left and right air
filter housing (4) on the
inside
Repair Materials
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-1000-01A
611.960 /961 /980
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 BA09.20-P-1000-01E
166.940 /960 /961 /990 /991 /995
Intake manifold ENGINE 668.914 /940 /941 /942 BA09.20-P-1000-01F
Intake manifold ENGINE 137 BA09.20-P-1000-01G
Intake manifold ENGINE 271 BA09.20-P-1000-01I
Intake manifold ENGINE 275, 285 BA09.20-P-1000-01L
Intake manifold ENGINE 272, 273 BA09.20-P-1000-01N
Intake manifold ENGINE 266.920 /940 /960 /980 BA09.20-P-1000-01O
Intake manifold ENGINE 640 BA09.20-P-1000-01P
Intake manifold ENGINE 629, 642 / BA09.20-P-1000-01Q
Intake manifold ENGINE 156 BA09.20-P-1000-01R
Turbocharger ENGINE 602.982 /983, BA09.40-P-1000-01A
605.960 /962, 606.961 /964
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, BA09.40-P-1000-01D
629
Turbocharger ENGINE BA09.40-P-1000-01E
646.951 /961 /962 /963 /966, 647,
648
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 pipe/charge ENGINE 602, 605, 606, 611, 612, BA09.41-P-1000-01A
air cooling 613, 646, 647, 648...
Charge air pipe/charge ENGINE BA09.41-P-1000-01B
air cooler 111.943 /944 /947 /973 /975
Charge air pipe/charge ENGINE 112, BA09.41-P-1000-01C
air cooling 113.990 /991 /992 /993 /995, 155
Charge air pipe/charge ENGINE 271 BA09.41-P-1000-01D
air cooling
Charge air pipe/charge ENGINE 275, 285 BA09.41-P-1000-01G
air cooling
Charge air pipe/charge ENGINE 628.960 /961 /962 /963 BA09.41-P-1000-01H
air cooling
Charge air pipe/charge ENGINE 640 BA09.41-P-1000-01I
air cooling
Charge air pipe/charge ENGINE 642 / BA09.41-P-1000-01J
air cooling
Charge air pipe/charge ENGINE 629 BA09.41-P-1000-01M
air 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 sensor ENGINE 646.8 BA09.41-P-1000-04B
Compressor-type ENGINE 111 BA09.50-P-1000-01A
supercharger
Compressor ENGINE 112, BA09.50-P-1000-01B
113.990 /991 /992 /993 /995, 155
Compressor ENGINE 271 BA09.50-P-1000-01C
Compressor ENGINE 271.950 /952 in BA09.50-P-1000-01D
MODEL 204
INTAKE MANIFOLD - BA09.20-P-1000
Intake Manifold - Ba09.20-P-1000-01D
Engines 112, 113
Intake Manifold
Number Designation Engines 112, 113
01D to cylinder head
Intake Manifold - Ba09.20-P-1000-01G
Engine 137
Intake Manifold
BA09.20-P-1001- Bolt, intake 1st stage M6 Nm 8
01G manifold on M8 Nm 20
cylinder head 2nd stage M6 Nm 8
3rd stage M6 Angle° 90
BA09.20-P-1002- Bolt, intake pipe to intake manifold Nm 8
01G
Intake Manifold - Ba09.20-P-1000-01L
Engines 275, 285
Intake Manifold
BA09.20-P-1001- Bolt, intake manifold to cylinder M6 Nm 8
01L head
BA09.20-P-1002- Bolt of throttle Stage 1 M6 Nm 8
01L valve actuator to
intake manifold Stage 2 M6 Nm 8
Turbocharger - Ba09.40-P-1000-01H
Engine 275, 285
Turbocharger
Number Designation Engine 275 Engine 285
BA09.40-P-1001- Coolant line to Nm 9 -
01H cylinder head
BA09.40-P-1002- Bolt, oil feed line to Nm 8 8
01H turbocharger
BA09.40-P-1003- Bolt, coolant return Nm 8 8
01H flow line to
turbocharger
BA09.40-P-1004- Bolt, oil return flow Nm 8 8
01H line to turbocharger
BA09.40-P-1005- Bolt connecting Nm 8 8
01H coolant feed line to
turbocharger
BA09.40-P-1006- Bolt, oil return flow Nm 8 8
01H line to crankcase
BA09.40-P-1007- Banjo bolt, coolant Nm 25 -
01H feed line to crankcase
BA09.40-P-1008- Connection of Nm 7 -
01H turbocharger to front
catalytic converter
BA09.40-P-1009- Bolt, support to Nm 30 30
01H turbocharger
BA09.40-P-1010- Bolt, turbocharger Nm 20 20
01H support to crankcase
BA09.40-P-1011- Exhaust manifold to Nm 15 -
01H cylinder head
BA09.40-P-1012- Shield to turbocharger Nm 9 -
01H
BA09.40-P-1013- Banjo bolt of coolant Nm - 25
01H feed line to crankcase
BA09.40-P-1014- Bolt of deceleration Nm 7 -
01H air valve to
turbocharger
BA09.40-P-1015- Bolt, oil feed line to Nm 8 -
01H cylinder head
CHARGE AIR PIPE/CHARGE AIR COOLING - BA09.41-P-1000

Charge Air Pipe/Charge Air Cooling - Ba09.41-P-1000-01C
Engines 112, 113, 155B

Number Designation Engines Engines Engines Engine 155
112.960/961 113.990/991 113.992/993/995
AMG
BA09.41-P- Bolt, upper Nm 10 9 10 -
air distributor
to bottom part
of charge air
distributor
BA09.41-P- Bolt, bottom Nm 23 20 20 20
air distributor
to cylinder
head
BA09.41-P- Nut for pump Nm - 5 - -
1003-01C for low
temperature
water circuit
on bracket
Charge Air Pipe/Charge Air Cooling - Ba09.41-P-1000-01G
Engines 275, 285

BA09.41-P-1001-01G Bolt, charge air cooler to Nm 8
cylinder head cover
BA09.41-P-1002-01G Bolt, filler neck for low Nm 8
to bracket
BA09.41-P-1003-01G Bolt, pump for low Nm 5
to bracket
BA09.41-P-1004-01G Hose clamps at pump for Nm 3
circuit
BA09.41-P-1005-01G Bolt, cable duct to charge Nm 8
air distribution pipe
BA09.41-P-1006-01G Bolt, ground line to charge Nm 8
air distribution pipe
BA09.41-P-1007-01G Bolt, connecting pipe Nm 8
bracket for low
to cylinder head cover
BA09.41-P-1008-01G Bolt, connecting pipe Nm 8
bracket for low
to connecting pipe for low
Charge Air Duct - Ba09.41-P-1000-02B
Engines 271, 275, 285
Charge Air Duct

Number Designation Engine 271 Engine 275, 285
BA09.41-P-1001- Bolt, charge air Nm - 8
02B channel before charge
air cooler to
turbocharger
BA09.41-P-1002- Hose clamp of charge Nm - 3
02B air hose at engine
charge air channel
and at charge air
cooler
BA09.41-P-1003- Hose clamp of charge Nm - 3
02B air channel as
required charge air
cooler at charge air
cooler and at
electronic accelerator
actuator
BA09.41-P-1004- Bolt, charge air duct Nm 8 -
02B downstream of charge
air cooler to pressure
damper
Charge Air Cooler - Ba09.41-P-1000-03A
Engines 275, 285
Charge Air Cooler

BA09.41-P-1001-03A Bolt charge air cooler to Nm 8
cylinder head cover
BA09.41-P-1002-03A Bolt of pressure sensor in Nm 6
front of throttle valve
actuator at bracket
BA09.41-P-1003-03A Bolt of radiator of low Nm 5
temperature circuit to
condenser
BA09.41-P-1004-03A Bolt cooler for low Nm 5
temperature cooling circuit
to radiator
BA09.41-P-1005-03A Nut of condenser to Nm 5
radiator low temperature
circuit
COMPRESSOR - BA09.50-P-1000-01B
Engine 112, 113, 155
Supercharger
Number Designation Engine Engine Engine Engine
112.960/961 113.990 113.991 113.992/995
AMG
BA09.50-P- Bolt of Nm 20 20 20 20
1001-01B supercharger to
charge air
cooler
BA09.50-P- Torx bolt for air Nm - 7 7 7
1002-01B recirculation
flap actuator
BA09.50-P- Bolt, Nm - - - -
1003-01B compressor to
cylinder head
BA09.50-P- Bolt, bracket to Nm - - - -
1004-01B cylinder head
cover
BA09.50-P- Bolt, expansion Nm - - - -
1005-01B reservoir to
charge air
cooler
BA09.50-P- Bolt, charge air Nm - - - -
1006-01B cooler to
compressor
BA09.50-P- Center bolt to Nm 20 60 60 60
1007-01B compressor belt
pulley
Supercharger
Number Designation Engine 113.993 Engine 155
BA09.50-P-1001- Bolt of supercharger Nm 20 -
01B to charge air cooler
BA09.50-P-1002- Torx bolt for air Nm 7 -
01B recirculation flap
actuator
BA09.50-P-1003- Bolt, compressor to Nm - 20
01B cylinder head
BA09.50-P-1004- Bolt, bracket to Nm - 20
01B cylinder head cover
BA09.50-P-1005- Bolt, expansion Nm - 9
01B reservoir to charge air
cooler
BA09.50-P-1006- Bolt, charge air cooler Nm - 9
01B to compressor
BA09.50-P-1007- Center bolt to Nm 60 -
01B compressor belt
pulley
OIL CIRCUIT DIAGRAMS
Mercedes 722.6
Fig. 1: Power Flow In 1St Gear, Function

Fig. 2: Power Flow In 2nd Gear Function
Fig. 3: Power Flow In 3rd Gear Function
Fig. 4: Power Flow In 4th Gear Function
Fig. 5: Power Flow In 5th Gear Function
Fig. 6: Power Flow In Reverse Gear, Program Selection "W", Function
Fig. 7: Power Flow In Reverse Gear, Program Selection "C", Function
Fig. 8: Function Of Power Flow In Reverse Gear Function Of Program Selection "S"
Fig. 9: Shifting N To D (1st Gear), Function (Engine Started)
Fig. 10: Shifting N To D (1st Gear), Function (Activation Sequence Avtive)
Fig. 11: Shifting N To D (1st Gear), Function (1St Gear Engaged)
Fig. 12: Shift From 1 To 2, Function (1st Gear Engaged)
Fig. 13: Shift From 1 To 2, Function (Shift Phase)
Fig. 14: Shift From 1 To 2, Function (Second Gear Engaged)
OIL CIRCUIT DIAGRAMS
Mercedes 722.9
Fig. 1: Power Flow In 1st gear, Function

Fig. 2: Power Flow In 2nd Gear, Function
Fig. 3: Power Flow In 3rd Gear, Function

Fig. 4: Power Flow In 4th Gear, Function



Fig. 8: Function Of Power Flow In Reverse Gear Function Of Program Selection "S"
Fig. 9: Power Flow In Reverse Gear, Program Selection "C", Function
TRANSMISSION
Automatic Transmission - Torque Specifications - 215 & 220 Chassis
TIGHTENING TORQUES: PASSENGER CARS: AUTOMATIC TRANSMISSION - BA27.00-Z-
9999AZ
MODEL all
Vacuum unit TRANSMISSION 722.3 /4 /5 BA27.10-

P-1000-
01A
Secondary TRANSMISSION 722.3 /4, 722.5## ## up to 3652930 BA27.10-
pump P-1000-
02A
Oil pan, TRANSMISSION BA27.10-
automatic 722.3 /372 /382 /396 /397 /398 /399 /4 /5 /6 /610 /611 /630 /637 /638 /645 /7 /9 P-1000-
transmission 03A
Oil pan, TRANSMISSION 722.800 /801 BA27.10-
automatic P-1000-
transmission 03C
Complete TRANSMISSION 722.3 /4 /5 BA27.10-
automatic P-1000-
transmission 04A
Complete TRANSMISSION 722.700 /701 /702 in MODEL 168 TRANSMISSION BA27.10-
automatic 722.750 /751 in MODEL 414 P-1000-
transmission 04B
Complete TRANSMISSION 722.648 in MODEL 199 BA27.10-
automatic P-1000-
transmission 04C
Complete TRANSMISSION 722.800 /801 BA27.10-
automatic P-1000-
transmission 04D
Complete TRANSMISSION 722.9 /9 BA27.10-
automatic P-1000-
transmission 04E
Primary pump TRANSMISSION 722.7 BA27.10-
P-1000-
05A
Electrohydraulic TRANSMISSION 722.6 /6 /6 /9 /9 BA27.19-
control unit P-1000-
01A
Electric control TRANSMISSION 722.800 /801 BA27.19-
unit P-1000-
03A
Torque TRANSMISSION 720.1, 722.3 /4 /5 /7 BA27.20-
converter P-1000-
01A
Torque TRANSMISSION 722.800 /801 BA27.20-
converter P-1000-
01B
Torque TRANSMISSION 722.6 /6 /9 /9 BA27.20-
converter P-1000-
01C
Front TRANSMISSION 722.3 /4 /5 BA27.30-
transmission P-1000-
cover 01A
Rear TRANSMISSION 722.3 /4 /5 BA27.30-
cover 02A
Rear TRANSMISSION 722.800 /801 BA27.30-
cover 02B
Shift valve body TRANSMISSION 722.3 /4 /5 /7 BA27.35-
P-1000-
01A
Lower cover TRANSMISSION 722.3 /4 /5 BA27.35-
P-1000-
02A
Shift valve body TRANSMISSION 722.6 BA27.35-
P-1000-
03A
Housing TRANSMISSION 722.3 /5 /6 /7 /9 BA27.40-
P-1000-
01A
Housing TRANSMISSION 722 ... BA27.40-
P-1000-
01B
Housing TRANSMISSION 722.800 /801 BA27.40-
P-1000-
01C
Housing TRANSMISSION 722.643 /901 in MODEL 219 BA27.40-
P-1000-
01D
Housing TRANSMISSION 722.9 in MODEL 216, 221 BA27.40-
TRANSMISSION 722.6 in MODEL 216, 221 P-1000-
01E
Housing TRANSMISSION 722.6 /9 in MODEL 204 BA27.40-
P-1000-
01F
Gear assembly TRANSMISSION 722.3 /4 /5 /6 /9 BA27.50-
P-1000-
01A
Gear assembly TRANSMISSION 722.800 /801 BA27.50-
P-1000-
01B
Transmission TRANSMISSION 722 ... BA27.55-
oil cooling P-1000-
01A
Transmission TRANSMISSION 722 ... BA27.55-
oil cooling P-1000-
01B
Transmission TRANSMISSION 722.800 /801 BA27.55-
oil cooling P-1000-
01C
Transmission TRANSMISSION 722.9 BA27.55-
oil cooling P-1000-
01D
Transmission TRANSMISSION 722.6 in MODEL 216, 221 BA27.55-
oil cooling P-1000-
01E
Parking shift TRANSMISSION 722.5 /9 BA27.60-
lock P-1000-
01A
Floor-mounted TRANSMISSION 722.6 /7 /9 BA27.60-
shift P-1000-
02A
Floor shift TRANSMISSION 722.5 in MODEL 210 BA27.60-
P-1000-
02B
Floor-mounted TRANSMISSION 722.800 /801 BA27.60-
shift P-1000-
02C
Linkage for TRANSMISSION 722.6 BA27.60-
parking lock P-1000-
interlock 03A
Shift rod TRANSMISSION 722.6 /9 BA27.60-
P-1000-
04A
OIL PAN, AUTOMATIC TRANSMISSION - BA27.10-P-1000-03A
Transmission 722
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission Transmission Transmissions Transmissions Tr
722.3 722.372/382/396/397/398/399 722.4/5/7 722.6 except 72
722.628/648/649
BA27.10- Drain plug Nm 14 14 22 20 20
P-1001- on
03A transmission
oil pan
BA27.10- Bolt, oil pan Nm 8 8 8 8 8
P-1002- to
03A transmission Angle° - - - - -
housing
BA27.10- Bolt, oil Nm 8 8 - 8 -
P-1003- filler pipe to
03A cylinder
head
BA27.10- Bolt, oil Nm 8 8 - 8 8
03A transmission
housing
BA27.10- Bolt, oil Nm - - - 8 8
03A heat shield
BA27.10- Bolt, oil Nm - - - 8 8
03A oil dipstick
guide tube
BA27.10- Bolt, oil Nm - - - - -
P-1007- filler pipe
03A bracket
BA27.10- Bolt of oil Nm - - - 8 -
P-1008- filler pipe
03A retaining
clamp to
bracket
BA27.10- Bolt, oil Nm - - - 8 -
03A bracket

Number Designation Transmission Transmission Transmission
722.648 722.649 722.9
BA27.10-P- Drain plug on Nm 20 22 22
1001-03A transmission oil
pan
BA27.10-P- Bolt, oil pan to Nm 8 8 4
1002-03A transmission Angle° - - 180
housing
BA27.10-P- Bolt, oil filler Nm - - -
1003-03A pipe to cylinder
head
BA27.10-P- Bolt, oil filler Nm - 8 -
1004-03A pipe to
transmission
housing
1005-03A pipe to heat
shield
1006-03A pipe to oil
dipstick guide
tube
BA27.10-P- Bolt, oil filler Nm - 8 -
1007-03A pipe
BA27.10-P- Bolt of oil filler Nm - - -
1008-03A pipe retaining
clamp to bracket
1009-03A pipe to bracket
ELECTROHYDRAULIC CONTROL UNIT - BA27.19-P-1000-01A
Transmission 722.6/9
ELECTROHYDRAULIC CONTROL UNIT

Number Designation Transmission Transmission
722.6 722.9
BA27.19-P- Bolt, 1st stage Nm 8 4
1001-01A electrohydraulic
control unit to
transmission Stage 2 Angle ° - 90
housing
BA27.19-P- Bolt, solenoid Nm 8 8
1002-01A valve to shift plate
BA27.19-P- Bolt, pilot bushing Nm 3 -
1003-01A to
electrohydraulic
control unit
BA27.19-P- Shift shaft clamp Nm 8 8
1004-01A screw to detent
plate
BA27.19-P- Bolt of spring Nm 8 9
1005-01A element of detent
plate to
electrohydraulic
control unit
TORQUE CONVERTER - BA27.20-P-1000-01A
Transmission 720, 722.3/4/5/7
TORQUE CONVERTER
720.1 722.3 722.4
BA27.20-P- Oil drain Nm 14 14 14
1001-01A plug to
torque
converter
BA27.20-P- Bolt, torque Stage 1 Nm - 42 42
1002-01A converter to Stage 2 Nm - - -
drive plate Stage 3 Angle° - - -
TORQUE CONVERTER
722.5 722.7
BA27.20-P- Oil drain plug to Nm 14 -
1001-01A torque converter
BA27.20-P- Bolt, torque Stage 1 Nm 42 42
1002-01A converter to Stage 2 Nm - -
drive plate Stage 3 Angle° - -
SHIFT VALVE BODY - BA27.35-P-1000-03A
Transmission 722.6
TIGHTENING TORQUES OF SHIFT VALVE BODY

Number Designation Transmission 722.6
BA27.35-P-1001- Bolt, valve housing M6x30 Nm 8
03A to shift valve body
BA27.35-P-1002- Bolt, side cover to M4x12 Nm 4
03A valve housing and
shift valve body
HOUSING - BA27.40-P-1000
Housing - BA27.40-P-1000-01A
Transmission 722
HOUSING
Number Designation Transmission Transmission Transmission 722.6 except
722.3 722.5 722.660/661/662/663/666/674
BA27.40- Transmission Nm 70 70 -
P-1001- overload
01A protection
pressure
switch to
transmission
housing
BA27.40- Bolt, Nm - - 20
P-1002- transmission
01A housing to
converter
housing
BA27.40- Bolt, oil Nm - - 20
P-1003- pump with
01A multi-disk
brake B1 to
torque
converter
housing
BA27.40- Bolt, multi- Nm - - 10
P-1004- disk brake B1
01A to converter
housing
BA27.40- Bolt, multi- 1st stage Nm - - 16
01A to
transmission 2nd stage Angle° - - -
housing
BA27.40- Bolt, detent Nm 8 - 8
P-1006- plate to range
01A selector lever
BA27.40- Bolt, locking Nm - - -
P-1007- pawl to shift
01A lock lever
BA27.40- Bolt, M10x40 Nm 55 - -
P-1008- automatic M10x90 Nm 45 - -
01A transmission
to engine M12 Nm 65 - -
BA27.40- Screw plug Nm 13 - -
P-1009- for
01A measuring
point for
modulating
pressure,
control
pressure and
working
pressure
BA27.40- Bolt of Nm - - -
01A housing to
reverse idler
shaft
BA27.40- Bolt, Nm - - -
P-1011- expansion
01A reservoir to
transmission
housing
BA27.40- Bolt, Nm - - -
P-1012- expansion
01A reservoir to
torque
converter
casing
BA27.40- Bolt, ground Nm - - 20
P-1013- line to
01A transmission
housing
BA27.40- Bolt, heat Nm - - 6
P-1014- shield to
01A transmission
housing
BA27.40- Bolt, 1st stage Nm - - -
01A housing to
converter 2nd stage Angle° - - -
housing
BA27.40- Screw plug, Nm - - -
P-1016- pilot bushing
01A of park pawl
mechanism
BA27.40- Screw plug, Nm - - -
P-1017- bearing bolt
01A of park detent
BA27.40- Bolt, bracket 1st stage Nm - - -
P-1018- for rear 2nd stage Angle° - - -
01A engine mount
to
transmission
BA27.40- Bolt, leaf Nm - - 8
P-1019- spring to
01A transmission
housing
01A housing of
all-wheel
drive to 2nd stage Angle° - - -
adapter
housing
01A housing to 2nd stage Angle° - - -
servo module
HOUSING
722.660/661/662/663/666/674 722.7 722.9
BA27.40- Transmission Nm - - -
P-1001- overload
01A protection
pressure
switch to
transmission
housing
BA27.40- Bolt, Nm 20 25 -
01A housing to
converter
housing
BA27.40- Bolt, oil Nm 20 - 20
P-1003- pump with
01A multi-disk
brake B1 to
torque
converter
housing
BA27.40- Bolt, multi- Nm 10 - 11
01A to converter
housing
BA27.40- Bolt, multi- 1st stage Nm 16 - 10
01A to 2nd stage Angle° - - 90
transmission
housing
BA27.40- Bolt, detent Nm 8 8 8
P-1006- plate to range
01A selector lever
BA27.40- Bolt, locking Nm - 8 -
P-1007- pawl to shift
01A lock lever
BA27.40- Bolt, M10x40 Nm 40 - 38
P-1008- automatic M10x90 Nm 40 - 38
01A transmission
to engine M12 Nm - - -
BA27.40- Screw plug Nm - - -
P-1009- for
01A measuring
point for
modulating
pressure,
control
pressure and
working
pressure
BA27.40- Bolt of Nm - 20 -
01A housing to
reverse idler
shaft
BA27.40- Bolt, Nm - 5 -
P-1011- expansion
01A reservoir to
transmission
housing
BA27.40- Bolt, Nm - 5 -
P-1012- expansion
01A reservoir to
torque
converter
casing
BA27.40- Bolt, ground Nm 20 - 9
P-1013- line to
01A transmission
housing
BA27.40- Bolt, heat Nm 6 - 9
P-1014- shield to
01A transmission
housing
BA27.40- Bolt, 1st stage Nm - - 10
01A housing to
converter 2nd stage Angle° - - 90
housing
BA27.40- Screw plug, Nm - - 70
P-1016- pilot bushing
01A of park pawl
mechanism
BA27.40- Screw plug, Nm - - 22
P-1017- bearing bolt
01A of park detent
BA27.40- Bolt, bracket 1st stage Nm - - 10
P-1018- for rear
01A engine mount
to 2nd stage Angle° - - 90
transmission
BA27.40- Bolt, leaf Nm - - 5
P-1019- spring to
01A transmission
housing
01A housing of
all-wheel
drive to 2nd stage Angle° - - 90
adapter
housing
01A housing to 2nd stage Angle° - - 90
servo module
Housing - BA27.40-P-1000-01B
Transmission - 722.6
MODIFICATION NOTES
Bolt, automatic transmission to crankcase
20.4.06 Bolt, automatic transmission to engine oil pan Transmission 722.6 in model 211
Bolt, heat shield to transmission housing
HOUSING
Number Designation Transmission Transmission Transmission Transmission
722.6 in model 722.6 in model 722.648 in 722.6 in model
163 171 model 199 203
BA27.40- Bolt, automatic
P-1001- transmission to Nm 40 38 35 38
01B crankcase
01B engine oil pan
BA27.40- Bolt, heat shield to
P-1003- transmission Nm 8 8 - 8
01B housing
Bolt, shield to
BA27.40-
hexagon special
P-1004- Nm - - - -
bolt for shift
01B
module (ISM)
Hexagon special
BA27.40- bolt, shift module
P-1005- (ISM) to Nm - - - -
01B transmission
housing
Standard bolt, shift
BA27.40-
module (ISM) to
P-1006- Nm - - - -
transmission
01B
housing
HOUSING
722.6 in model 209 722.6 in model 211 722.6 in model 215
BA27.40-P- Bolt, automatic
Nm 38 38 40
1001-01B transmission to crankcase
Bolt, automatic
BA27.40-P-
transmission to engine oil Nm 38 38 40
1002-01B
pan
BA27.40-P- Bolt, heat shield to
Nm 8 8 8
1003-01B transmission housing
Bolt, shield to hexagon
BA27.40-P-
special bolt for shift Nm - - -
1004-01B
module (ISM)
Hexagon special bolt, shift
BA27.40-P-
module (ISM) to Nm - - -
1005-01B
transmission housing
Standard bolt, shift
BA27.40-P-
module (ISM) to Nm - - -
1006-01B
HOUSING
Number Designation Transmission Transmission Transmission 722.649 Transmission
722.6 in model 722.649 in model in model 722.6 in model
220 230.476/477/479 240.078/079/178/179 461, 463
01B crankcase
01B engine oil pan
Bolt, heat
BA27.40-
shield to
P-1003- Nm 8 8 8 8
transmission
01B
housing
Bolt, shield to
BA27.40- hexagon
P-1004- special bolt for Nm - - - -
01B shift module
(ISM)
Hexagon
special bolt,
BA27.40-
shift module
P-1005- Nm - - - -
(ISM) to
01B
transmission
housing
Standard bolt,
BA27.40- shift module
P-1006- (ISM) to Nm - - - -
01B transmission
housing
GEAR ASSEMBLY - BA27.50-P-1000-01A
Transmission 722
GEAR SET
Number Designation Transmission Transmission 722.6
722.3/4/5 722.9
BA27.50-P-1001- Collared nut, output NM 120 200
01A flange to output
shaft
BA27.50-P-1002- Bolt, detent plate to NM 8 -
01A transmission
housing
BA27.50-P-1003- Bolt, support flange NM 11 -
01A K2 to transmission
housing
TRANSMISSION OIL COOLING - BA27.55-P-1000
Transmission oil cooling - BA27.55-P-1000-01A
Transmission 722
MODIFICATION NOTES
Banjo bolt or union nut, oil cooler line to torque converter and Transmission 722.6 in model
21.1.05
transmission housing, 1st stage 211
Banjo bolt or union nut, oil cooler line to torque converter and Transmission 722.6 in model
21.1.05
transmission housing, 1st stage 220
Banjo bolt or union nut, oil cooler line to converter housing and Transmission 722.7 except
21.1.05
transmission housing 2nd stage 722.750/751
TRANSMISSION, OIL COOLER

Number Designation Transmission Transmissions Transmission
722.372/382/396/397/398/399 722.610/611/630/637/638/645 722.7 except
722.750/751
Union nut
BA27.55-
connecting
P-1001- Nm - 25 -
transmission oil
01A
line to cooler
Banjo bolt
or union Stage
nut, oil Nm 34 20 30
1
BA27.55- cooler line
P-1002- to torque
01A converter
and Stage
Angle° - - -
transmission 2
housing
BA27.55- Banjo bolt
P-1003- connecting ATF Nm - 25 -
01A line to oil cooler
BA27.55- Bolt, clamp of oil
P-1004- cooler line to oil Nm - 8 -
01A pan
BA27.55- Bolt, auxiliary oil
P-1005- cooler bracket on Nm - - -
01A front end
BA27.55- Bolt, bracket to Nm - - -

P-1006- auxiliary oil
01A cooler
Union nut,
BA27.55-
transmission oil
P-1007- Nm - - -
line to automatic
01A
transmission
BA27.55- Bolt, transmission
P-1008- oil line clamp to Nm - - -
01A engine

722.662/663/666/673/674 722.6 in model 722.6 in model
in model 163 171 211
BA27.55- Union nut connecting
P-1001- transmission oil line to Nm 18 - 25
01A cooler
Banjo bolt or
Stage
union nut, oil Nm 20 5 5
BA27.55- 1
cooler line to
P-1002-
torque converter
01A Stage
and transmission Angle° - 95 95
2
housing
BA27.55-
Banjo bolt connecting
P-1003- Nm 30 - 25
ATF line to oil cooler
01A
BA27.55-
Bolt, clamp of oil cooler
P-1004- Nm 8 8 8
line to oil pan
01A
BA27.55-
Bolt, auxiliary oil cooler
P-1005- Nm - - -
bracket on front end
01A
BA27.55-
Bolt, bracket to
P-1006- Nm - - -
auxiliary oil cooler
01A
BA27.55- Union nut, transmission
P-1007- oil line to automatic Nm - - -
01A transmission
BA27.55-
Bolt, transmission oil
P-1008- Nm - - 12
line clamp to engine
01A

722.6 in model 220 722.750/751 in model
414
BA27.55-P- Union nut connecting transmission oil
Nm 25 -
1001-01A line to cooler
Stage
Banjo bolt or union nut, oil Nm 5 25
BA27.55-P- 1
cooler line to torque converter
1002-01A Stage
and transmission housing Angle° 95 -
2
BA27.55-P- Banjo bolt connecting ATF line to oil
Nm 25 -
1003-01A cooler
BA27.55-P-
Bolt, clamp of oil cooler line to oil pan Nm 8 -
1004-01A
BA27.55-P- Bolt, auxiliary oil cooler bracket on
Nm - 10
1005-01A front end
BA27.55-P-
Bolt, bracket to auxiliary oil cooler Nm - 8
1006-01A
BA27.55-P- Union nut, transmission oil line to
Nm - 25
1007-01A automatic transmission
BA27.55-P- Bolt, transmission oil line clamp to
Nm - -
1008-01A engine
Transmission oil cooling - BA27.55-P-1000-01B
Transmission 722

722.626/628 722.633/636/643 722.648 722.649
except in
model
230.477
BA27.55- Union nut Nm 25 25 - 25
P-1001- connecting
01B transmission
oil line to
cooler
BA27.55- Banjo bolt, Stage 1 Nm 5 5 20 5
01B oil line to
transmission Stage 2 Angle° 90 90 - 95
housing
BA27.55- Bolt, oil Nm 11 11 - 11
P-1003- cooler line to
01B engine oil
pan
BA27.55- Bolt, dual Nm 11 11 - 11
P-1004- clamp to oil
01B line
BA27.55- Line Nm 25 25 - -
P-1005- connectors
01B to dual
clamp
BA27.55- Bolt, Stage 1 Nm - - 20 -
01B oil line to
transmission Stage 2 Angle° - - - -
housing

722.649 in model 722.695
230.477
BA27.55-P- Union nut Nm - 25
1001-01B connecting
transmission oil
line to cooler
BA27.55-P- Banjo bolt, Stage 1 Nm 5 5
1002-01B transmission oil
line to
transmission Stage 2 Angle° 95 90
housing
BA27.55-P- Bolt, oil cooler Nm 11 11
1003-01B line to engine oil
pan
BA27.55-P- Bolt, dual clamp Nm 11 8
1004-01B to oil line
BA27.55-P- Line connectors Nm - -
1005-01B to dual clamp
BA27.55-P- Bolt, Stage 1 Nm - -
1006-01B transmission oil
line to
transmission Stage 2 Angle° - -
housing
SHIFT LOCK - BA27.60-P-1000
Parking shift lock - BA27.60-P-1000-01A
Transmission 722.5/9
PARKING SHIFT LOCK

Number Designation Model 124, 129, 140 with Transmission
automatic transmission 722.9
BA27.60-P- Nut, operating lever for parking
NM 5 -
1001-01A shift lock to brake pedal
BA27.60-P- Nut, support plate on shift bracket
NM 5 -
1002-01A housing of parking shift lock
BA27.60-P- Bolt, clamp connection of detent
NM - 8
1003-01A plate to range selector lever
BA27.60-P- Screw plug, pilot bushing for park
NM - 70
1004-01A pawl mechanism
BA27.60-P- Screw plug, bearing pin for park
NM - 22
1005-01A detent
Floor-mounted shift - BA27.60-P-1000-02A
Transmission 722
FLOOR SELECTOR TIGHTENING TORQUE

722.6 722.7 722.9
BA27.60-P- Bolt, floor Nm 6 8 6
1001-02A selector to body
BA27.60-P- Bolt, shift gate Nm 6 - -
1002-02A to lower part of
bearing bracket
BA27.60-P- Bolt, shift lock Nm 3.5 - -
1003-02A bracket to upper
part of bearing
bracket
Linkage for parking lock interlock - BA27.60-P-1000-03A
Transmission 722.6
TIGHTENING TORQUES OF LINKAGE FOR PARKING LOCK INTERLOCK

BA27.60-P-1001-03A Bolt, parking lock Nm 8
interlock linkage to
Shift rod - BA27.60-P-1000-04A
Transmission 722.6, 9
TIGHTENING TORQUES FOR SHIFT ROD

722.6 722.9
BA27.60-P- Bolt in rod head M8x10 Nm 12 12
1001-04A
TRANSMISSION
Automatic Transmission - Testing & Repair - 215 & 220 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
engine as it is running
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
run in selector lever and 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
must be 45°C .
must be 35°C .
6 Carefully unscrew the With an oil flow of thickness (arrow a)
oil drain screw (3) or thickness (arrow b) the transmission
from the oil level is OK and does not have to be
transmission's oil pan corrected. With an oil flow of thickness
and observe the fluid (arrow c) the transmission oil level must
as it emerges, then be corrected and in addition must be
screw the oil drain 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) within
transmission fluid the oil pan is designed for operation at the
temperature using specified fluid temperature, this
STAR DIAGNOSIS temperature should never exceed the level
indicated.
must be 45°C .
must be 35°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
oil using filling pump and 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
fluid for the indicated and the specified transmission oil
fluid temperature to temperature must be reached in each case,
drain, continuing until too much transmission oil is drained at a
only a small flow higher transmission oil temperature.
(arrow B) emerges
must be 45°C .
must be 35°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
except 722.901 with code
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 - - -
INSPECT ATF LEVEL IN AUTOMATIC TRANSMISSION, ADD ATF IF NECESSARY - AR27.00-P-

0101A
Transmission 722.6 in MODELS 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230, 240
Transmission 722.6 in MODEL 461, 463 (except, 463.270 /271)

Fig. 3: Identifying ATF Level Components
Adding transmission oil

procedure or when
engine
1 Drive vehicle to level
surface
2 Open engine hood
3 Remove locking pin (93a) Remove locking pin by
breaking off the plate of
the locking pin (93a) with
a suitable tool and
pressing out the pin
remaining in the cap (93)
downwards.
4 Remove cap (93) from oil
filler pipe
5 Fill with transmission oil After a complete
refill and after changing
the transmission oil, pour
in approx. 5 liters of
transmission oil before
starting the engine.
Insufficient and excessive
quantities of oil result in
malfunctions and
transmission damage.
*BF27.00-P-1001-01C
Fig. 4
Fig. 6
6 Start engine and allow it to
idle in drive position "P"
7 Fill with remaining Initial charge
quantity of transmission
oil
8 Apply service brake and
shift through drive
positions several times
with vehicle stationary and
engine running at idle
speed
9 Insert oil dipstick all When the transmission
the way into oil filler pipe, is cold (approx. 25 °C),
pull it out again and read the transmission oil level
off transmission oil level must be between the
"min" and "max" mark of
the marking (A). The
exact transmission oil
level can only be
determined at a
transmission oil
temperature of 80 °C.
Fig. 5
10 Warm up transmission oil
to operating temperature
Check transmission fluid
level
11 Apply service brake and
shift through drive
positions several times
with vehicle stationary and
engine running at idle
speed
12 Connect STAR Wait for 2 minutes
DIAGNOSIS and check until the exact
transmission oil transmission oil
temperature in drive temperature can be
position "D" measured.
Operate service brakes
at the same time. The
exact transmission oil
level can only be
determined at a
transmission oil
temperature of 80 °C.
diagnosis system
13 Insert oil dipstick all If too much
the way into the oil filler transmission oil is added,
pipe, pull out again, read it is absolutely essential to
off transmission oil level drain off or extract the
and correct if necessary surplus. Insufficient and
excessive quantities of oil
result in malfunctions and
transmission damage.
The transmission oil
level must be between the
"min" and "max" mark of
the marking (B).
Fig. 5
Fig. 7
14 Check transmission oil After filling with
level again transmission oil
15 Mount cap (93) on oil
filler pipe and press in
new locking pin (93a)
until it latches
16 Perform engine test run
and, with engine running,
check transmission for
leaks and that it is
functioning correctly
722.600/601/604/605/ 722.602/603/615 722.610/638
606/607/608/609/611/
613/614/616/617/618/
629/634/639/660/661/
662/664/665/689/695/
696/699
For new filling
BF27.00-P- Filling Initial charge Liters 7.5 (+0.5) 7,0 (+0,5) 8.0
1001-01C capacity Oil change Liters - - -
Specifications Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-
for Operating 10A 0236-10A 0236-10A
Fluids Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-
12A 0236-12A 0236-12A
722.620/621 in 722.620/621 in
model 129 model 140,
transmission
722.622/623/
624/625/626/627/628/
630/631/632/633/635/
636/663/666/669
For new filling
BF27.00-P- Filling Initial charge Liters 8,2 (+0,5) 8,6 (+0,5)
1001-01C capacity Oil change Liters - -
Specifications for Sheet BB00.40-P-0236- BB00.40-P-0236-10A
Operating Fluids 10A
Sheet BB00.40-P-0236- BB00.40-P-0236-12A
12A
Number Designation Transmissions Transmission Transmission
722.640/644 722.640/64472 722.667/668/67
2/676/690
For new filling
BF27.00-P- Filling Initial charge Liters 7.5 7,3 (+0,5) 9
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
for Operating 0236-10A 0236-10A 0236-10A
Fluids Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0236-12A 0236-12A 0236-12A
Number Designation Transmission 722.637 in Transmission Transmission
model 722.637 in 722.649
461.302/331/332 /342//345 model
463.322/323
For new filling
BF27.00- Filling Initial charge Liters 7.9 7.9 7.5
P-1001- capacity
01C Oil change Liters - - -
Specifications Sheet BB00.40-P-0236-10A BB00.40-P- BB00.40-P-
for Operating 0236-10A 0236-10A
Fluids Sheet BB00.40-P-0236-12A BB00.40-P- BB00.40-P-
0236-12A 0236-12A
722.673 in model 722.674 in model
163 163
For new filling
BF27.00-P- Filling capacity Initial charge Liters 7,6-8,0 8,8-9,2
1001-01C Oil change Liters - -
- -
Sheet
722.641 in 722.612/697/ 722.612/ in
model 170 698 in model model 202
202
For new filling
BF27.00-P- Filling Initial charge Liters 7,3-7,7 7,3-7,7 8,5-8,9
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
for Operating 0236-12A 0236-12A 0236-12A
Fluids Sheet - -
Fig. 4: Identifying Funnel (126 589 12 63 00)

Fig. 5: Identifying Dipstick (140 589 15 21 00)
Fig. 6: Identifying Filling Pipe (140 589 49 63 00)
Fig. 7: Identifying Hand Pump (210 589 00 71 00)
COMMERCIALLY AVAILABLE TOOLS

Number Designation
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. 8: Filling Automatic Transmission With Fluid - Transmission Oil Pan Without Sloped Surface
Fig. 9: 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
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
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 can
screw (3) and mount 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.
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 and
oil using oil dispenser 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) within
transmission fluid the oil pan is designed for operation at the
temperature using specified fluid temperature, this
STAR DIAGNOSIS 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.
transmission oil pan and with white
overflow pipe, the transmission oil
temperature must be 30°C.
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 temperature
must be 40°C.
For transmissions with chamfered
transmission oil pan and black overflow
pipe the transmission oil temperature
must be 30°C.
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
Number Designation Transmission 722.9 Transmission
except 722.901 with
722.960/961/962 /963/964, code A25
except 722.901 with code
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-
for Operating 0236-12A
Fluids Sheet - -
REMOVE/INSTALL OIL PUMP - AR27.10-P-0400A
TRANSMISSION 722.6
Fig. 10: Identifying Oil Pump Components
Remove/Install
1 Remove transmission with Model 129, 140, 170, AR27.10-P-0500B
torque converter 202, 208, 210
Model 163 AR27.10-P-0500GH
Model 203 without AR27.10-P-0500P
4MATIC, 209
Model 203 with 4MATIC AR27.10-P-0500PW
Model 211 with 4MATIC AR27.10-P-0500TW
Model 215, 220 without AR27.10-P-0500I
4MATIC
Model 220 with 4MATIC AR27.10-P-0500IW
2 Put transmission down on
workbench
3 Take transmission housing Internal Torx drive
(1) off torque converter bolts (2a) 15 bolts and
housing (2) internal Torx drive bolts
(1a) 2 bolts.
Installation: The
intermediate panel (6)on
the torque converter
housing (2) can usually be
used several times. The
panel must not be coated
with sealant.
Bolt, transmission *BA27.40-P-1002-01A
housing to converter
housing
4 Pull torque converter Ensure that the multi-
housing (2) off disk clutch K1 (3) does
transmission housing (1) not fall out.
5 Unscrew internal Torx Bolt, oil pump with *BA27.40-P-1003-01A
drive bolts (4a) of oil multi-disk brake B1 to
pump (4) converter housing
6 Screw two opposed bolts
(a) into the oil pump
housing (4) and press the
oil pump (4) out of the
converter housing (2) by
applying light blows with a
plastic hammer.
Inspect
7 Check oil pump (4) According to AR27.50-P-0720-01A
condition: ?
Dismantle and assemble
oil pump
8 Check teflon rings (5a) of Installation: Insert
multi-disk brake B1 (5), both teflon rings (5a) into
replace if necessary groove with grease so that
the joint stays together.
HOUSING
Number Designation Transmission
Transmission 722.6 except 722.660/661/66
722.660/661/662 /663/666/674 2/663/666/674
BA27.40-P- Bolt, transmission Nm 20 20
1002-01A housing to torque
converter housing
BA27.40-P- Bolt, oil pump Nm 20 20
1003-01A with multi-disk
brake B1 to torque
converter housing
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500

Remove/install transmission with torque converter - AR27.10-P-0500I
TRANSMISSION 722.6 in MODEL 215
TRANSMISSION 722.6 in MODEL 220 (except 220.083 /084 /087 /183 /184 /187)
Fig. 11: Identifying Transmission With Torque Converter Remove/Install Components - Transmission
722.6 In Model 215 & Transmission 722.6 In Model 220 (Except 220.083 /084 /087 /183 /184 /187)
Fig. 12: Identifying Active Body Control Hydraulic Line, Torque Converter And Bolts
Fig. 13: Identifying Retaining Clamp And Drain Hose
MODIFICATION NOTES
13.1.06 Oil drain screw to torque converter Transmission 722.6 *BA27.20-P-1001-01C
Bolt, torque converter to drive plate Transmission 722.6 *BA27.20-P-1002-01C
Remove/install
AH00.00-
Notes on self-locking nuts and
N-0001-
bolts
01A
Before starting the work the area
around the oil cooling lines (49)
must be thoroughly cleaned in
the area around the separation
points on the transmission. Even
the smallest dirt particles,
introduced into the hydraulic
components, can lead to
malfunctions and a total failure
of the transmission
Move selector lever to position
1
"D".
With TELE AID emergency call system, code 347
or code 855 AR82.95-
Switch TELE AID to Service
2.1 As a result the additional battery is not P-0005-
mode
discharged and no emergency call signal is 03AM
transmitted, see operator's manual.
AH82.95-
Notes regarding the Tele-Aid
P-0001-
emergency call system
01AM
Risk of explosion caused by
oxyhydrogen gas. Risk of
poisoning and caustic burns
No fire, sparks, open flames or smoking. Wear
caused by swallowing battery AS54.10-
acid-resistant gloves,
acid. Risk of injury with caustic Z-0001-
clothing and goggles. Only pour battery acid into
burns to eyes and skin from 01A
suitable and appropriately marked containers.
battery electrolyte or from
handling damaged lead-acid
batteries
Insulate ground line as a protection against
Disconnect ground cable of AR54.10-
3 unintentional contact of detached ground line with
battery P-0003I
ground point of battery.
AH54.10-
Notes on battery P-0001-
01A
Risk of death caused by vehicle Align vehicle between columns of vehicle lift and AS00.00-
slipping or toppling off of the position four support plates at vehicle lift support Z-0010-
lifting platform. points specified by vehicle manufacturer. 01A
Raise vehicle with lifting
4
platform
Remove lower engine AR61.20-
5.1 Vehicles with gasoline engine
compartment paneling P-1105M
Remove bottom sections of AR94.30-
5.2 Vehicles with diesel engines
soundproofing capsule P-5300M
AR27.10-
Only detach oil filler pipe (61)
6.1 Except model 220.028/ 128/ 176 P-0500-
from the engine
04A
6.2 Remove oil filler pipe (61) Model 220.176
AR27.10-
Model 220.028/ 128
P-7010M
Unscrew oil drain screw (4) If the transmission fluid is burnt or contains
7 from the transmission oil pan wear particles, the oil cooler lines (49) and the oil
and drain transmission oil cooler must be flushed out: ?
Flush oil cooler and oil cooling lines AR27.55-
Installation: Replace sealing ring. P-0001A
*BA27.10-
P-1001-
03A
Vehicles with oil drain screw (9) on torque

converter (82)
Remove oil drain screw (9) from If the transmission oil pan contains metal
8.1 torque converter (82) and drain shavings, drain the transmission fluid from the
transmission oil torque converter (82) via the drain hole through a
clean cloth.
If there are metal shavings in the cloth after
draining the transmission fluid, the torque
converter (82) must be replaced.
In cases of doubt only flush the torque converter
(82) with automatic transmission fluid. Metal
shavings lead to transmission damage.
*BA27.20-
P-1001-
01C
BT27.20-
Oil drain screw at torque
Transmission 722.6 P-0001-
converter no longer required
01A
Remove shield (62) and AR27.10-
9 disconnect electrical connector P-0500-
(26) 01A
Remove complete exhaust AR49.10-
10.1 Engine 628
system P-7000MB
AR49.10-
10.2 Remove catalytic converters Engine 275
P-5500M
Remove complete exhaust AR49.10-
10.3 Engine 137
system P-7000L
Unscrew bolts (95) from torque
converter (82) on driven plate
11.1 Model 220.074/ 174
and detach cover from torque
converter (82)
*BA27.20-
P-1002-
01C
Remove cover (81) and unscrew
11.2 bolts (95) from torque converter Except model 220.074 /174
(82) at driven plate
Model 220.028/ 128/ 176: AR01.00-
Crank the engine at the torque converter (82). P-0100M
*BA27.20-
P-1002-
01C
12 Detach oil cooling lines (49) Seal connections with plugs.
Installation: Replace sealing rings. Fig. 14

TRANSMISSION 722.6 in MODEL 220
Banjo bolt or union nut, oil cooler line to *BA27.55-
torque converter and transmission housing P-1002-
Transmission 722.6 in model 215 01A
*BA27.55-
Banjo bolt or union nut, oil cooler line to P-1002-
torque converter and transmission housing
01B
Remove retaining clamps of oil
13.1 cooling lines (49) from engine Model 220.028/ 128
oil pan
*BA27.55-
P-1004-
01A
Remove securing clip and
AR27.60-
14 unhook shift rod (63) from range
P-0990I
selector lever (33)
15 Remove exhaust bracket (64).
Support transmission using
16 transmission lift and
transmission plate
Transmission platform, see GOTIS
Remove rear engine
17 crossmember (65) with engine Model 215.373/ 375
mount
Except model 220.028/ 128/ 176, model 215.373/ AR22.10-
375 P-1160AB
AR22.10-
Model 220.028 /128 /176
P-1170M
18.1 Remove flexible coupling Model 220.028 /128 /176
*BA41.10-
P-1001-
01A
Except model 220.028/ 128/ 176
The flexible coupling remains on the front
Disconnect front driveshaft
18.2 propeller shaft (66).
section (66) from transmission
Installation: Mount front propeller shaft (66)
on output flange of transmission:
AR41.10-
Model 215 except model 215.373 /374 P-0050-
07N
AR41.10-
Models 215.373/ 374, 220
P-0050-07I
*BA41.10-
P-1001-
01A
Loosen fitting sleeves of flexible
AR41.10-
19.1 coupling and slide back front If the fitted sleeves are jammed: ?
P-0050-09I
propeller shaft (66).
WF58.50-
Prepare drift for loosening fitted sleeves in
P-4110-
flexible couplings.
01A
Except model 220.028/ 074/ 128/ 174 Vehicles
Unscrew bolts (10) on hydraulic with Active Body Control code 487: In order to
20.1
line of Active Body Control (12) guarantee access to the bolt (11) connecting the
automatic transmission to the crankcase.
Detach retaining clamp (50) of Model 220.028/ 128 with Active Body Control
21.1
high-pressure line code 487
Model 220.028/ 128 with Active Body Control
22.1 Remove screw (51)
code 487
Unhook drain hoses (52) from
23.1 the brackets on the transmission Model 220.028/ 128
and set aside
Secure torque converter to prevent it from
Detach transmission from
falling out.
24 crankcase and remove
downwards at an angle Installation: Align bolt holes in the torque
converter with the holes in the driven plate.
*BA27.40-
Bolt, automatic transmission to crankcase P-1001-
01B
*BA27.40-
Bolt, automatic transmission to engine oil pan P-1002-
01B
If necessary AR27.20-
Remove torque converter using
25.1 Installation: Grease crankshaft journals at the P-0500-
grab handles
torque converter lightly. 01B
*BR00.45-
Multi-purpose paste Z-1009-
06A
*BE27.20-
Installed height of torque converter P-1001-
01B
Fig. 15
Deactivate service mode in AR82.95-
With TELE AID emergency call system, code 347
27.1 TELE AID emergency call P-0005-
or code 855
system 03AM
Check oil level in transmission AR27.00-
28
and correct if necessary P-0101A
AR00.19-
29 Perform basic programming
P-0200M
Read out fault memory with
30 STAR DIAGNOSIS and erase if
necessary
A transmission adaptation must be carried out
31.1 Perform transmission adaptation
after replacing or repairing the transmission.
Risk of accident caused by
vehicle starting off by itself
when engine is running. Risk of Secure vehicle to prevent it from moving by itself. AS00.00-
injury caused by contusions and Wear closed and snug-fitting work clothes. Z-0005-
burns during starting procedure Do not touch hot or rotating parts. 01A
or when working near the engine
as it is running
Perform engine test run and
32 check transmission for leaks and
that it is functioning correctly
TORQUE CONVERTER TEST VALUES

722.600/601/602/603/604/605/608/611/614/616/619/626/629/634/637/640/
Installed Distance
BE27.20-
height of from
P-1001- mm 7 (-2)
torque transmission
01B
converter housing

722.635/639/644 722.649
BE27.20-P- Installed height of Distance from
mm 21 (-2) 20 (-2)
1001-01B torque converter transmission housing

Number Designation Transmission 722.6 except Transmission Transmission
722.628/648/649 722.649 722.628
BA27.10-P- Oil drain screw
Nm 20 22 20
1001-03A to oil pan
TORQUE CONVERTER
Number Designation Transmission 722.6 except
722.648
BA27.20-P- Oil drain screw to torque M8 Nm 10
1001-01C converter M10 Nm 15
Straight threaded
Nm 42
connection
BA27.20-P- Bolt, torque converter to Stage 1 Nm 4
1002-01C drive plate Stage 2 Nm 30
Helical cut
Angle
Stage 3 90
°
HOUSING
Number Designation Transmission 722.6 in Transmission 722.6 in
model 215 model 220
BA27.40-P- Bolt, automatic transmission to
Nm 40 40
1001-01B crankcase
BA27.40-P- Bolt, automatic transmission to
Nm 40 40
1002-01B engine oil pan
TRANSMISSION OIL COOLING

Number Designation Transmission 722.6 in
model 220
Stage
Nm 5
BA27.55-P- Banjo bolt or union nut, oil cooler line to torque 1
1002-01A converter and transmission housing Stage Angle
95
2 °
BA27.55-P-
Bolt, oil cooler line retaining clamp to oil pan Nm 8
1004-01A

722.626/628 722.633/636/643 722.649 except in
model 230.477
Banjo bolt, Stage
Nm 5 5 5
BA27.55-P- transmission oil line 1
1002-01B to transmission Stage Angle
housing 90 90 95
2 °
PROPELLER SHAFT
Number Designation Model Model
215 220
BA41.10-P-1001- Self-locking nut, flexible coupling to transmission or M10 Nm - -
01A front propeller shaft M12 Nm 60 60

Fig. 15: Identifying Grab Handle (168 589 00 62 00)
REPAIR MATERIALS
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Disconnecting and connecting plug connector - AR27.10-P-0500-01A
HOUSING
722.660/661/662/663/666/674
BA27.40-P-1014- Bolt, heat shield to
Nm 6
01A transmission housing
1. Unscrew bolt (62a) .

2. Undo bolt (62b)
3. Remove heat shield (62)
Heat shield (62) not installed on model 463.
Fig. 16: Identifying Heat Shield And Bolts
4. Turn bayonet fitting of pilot bushing (21) 90° to the left and detach electrical connector (26).
Replace O-ring of electrical connector (26).

5. Install in the reverse order.
Fig. 17: Identifying Pilot Bushing And Electrical Connector
Remove/install oil filler pipe - AR27.10-P-0500-04A
1. Unscrew bolts (62, 63, 64)

2. Release wiring harness from oil filler pipe (61)
3. Use a suitable tool to lever the oil filler tube (61) out of the housing bore of the transmission housing.
Installation: Replace O-ring on oil filler pipe (61).
Fig. 18: Identifying Oil Filler Pipe And Bolts
4.
1. Remove exhaust gas recirculation pipe (51) on exhaust manifold.
Engine 606.964.
The exhaust gas recirculation pipe (51) need only be removed in a case of total removal. The oil
filler tube (61) is only swung to one side for work such as transmission removal.
2. Remove transverse exhaust pipe.

Engines 112, 113 except engine 113.993.
Fig. 19: Identifying Exhaust Gas Recirculation Pipe And Oil Filler Tube
Remove/install transmission with torque converter - AR27.10-P-0500IA
TRANSMISSION 722.901 in MODEL 215.375, 220.070 /075 /170 /175

Fig. 20: Identifying Transmission With Torque Converter Remove/Install Components
MODIFICATION NOTES
*BA27.55-P-
12.4.06 Bolt, oil cooler line to engine oil pan
1003-01D
Model 722.9 transmissions, with
7.6.06 Installed height of torque converter
exception of model 722.906
Measurement for determining installed AR27.20-P-
13.6.06 Step 22
height of torque converter changed 0500-01W
Remove/install
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
Before starting work the area around the
oil cooler lines (7) must be thoroughly
cleaned in the area around the separation
points. Even the smallest dirt particles,
introduced into the hydraulic components,
can lead to malfunctions and a total failure
of the transmission
1 Move selector lever into position "N"
With TELE AID emergency call
system, code 347 or code 855
As a result the additional battery is AR82.95-P-
2 Switch TELE AID to Service mode
not discharged and no emergency call 0005-03AM
signal is transmitted, see operator's
manual.
Notes on TELE AID emergency call AH82.95-P-
system 0001-01AM
Vehicles with Keyless Go code 889:
Press the Keyless-Go start and stop
button repeatedly until the ignition is
Switch ignition off, remove ignition key
3 switched off. Remove the Keyless Go
(transmitter key).
transmitter card or transmitter key from
the vehicle and store beyond the reach
of the transmitter (min. 2 m).
AR88.40-P-
4 Open engine hood
1000M
AR54.10-P-
5 Disconnect ground cable of battery
0003I
AH54.10-P-
Notes on battery
0001-01A
6 Raise vehicle with lifting platform
Remove bottom engine compartment AR61.20-P-
7
paneling 1105M
Detach shield (1) and separate electrical *BA27.40-P-
8
connector (2) 1014-01A
Remove right O2 sensor downstream of
AR14.00-P-
9 CAT (G3/6) and left O2 sensor
5303AA
downstream of CAT (G3/5)
If bolts are sluggish or thread is
Detach catalytic converter (3) on the left
10 damaged:
and right of the exhaust manifolds
?
Replace rivet nuts in the exhaust AR49.10-P-
manifold. 5531-01DA
*BA14.10-P-
1002-01B
Rotate engine at the crankshaft in
the direction of rotation of the engine
Remove cover (4) from the engine oil pan until the bolts (5) are accessible through
11
and unscrew bolts (5) the recess in the engine oil pan. After
unscrewing the bolts (5), press the
torque converter (6) backwards.
*BA27.20-P-
1002-01C
Detach oil cooling lines (7) from
12 Seal connections with plugs.
transmission
Installation: Replace sealing rings.
Fig. 14
*BA27.55-P-
1002-01D
Detach oil cooling lines (7) from engine Do not bend or kink oil cooling
13
and place to one side lines (7).
*BA27.55-P-
1003-01D
AR27.60-P-
14 Detach shift rod (8) at the transmission.
0990I
Check rubber mount of exhaust
15 Remove the exhaust bracket (9) bracket (9) for wear and replace if
necessary.
*BA49.10-P-
1007-01A
*BA49.10-P-
1008-01A
Support k transmission with
transmission jack and transmission *WE58.40-
16
platform (10) and secure with tensioning Z-1030-11A
strap
*WE58.40-
Z-1018-11A
Installation: Screw bolts of
Remove rear engine crossmember (11) rear engine crossmember (11) into
17
together with the rear engine mount underbody by hand to prevent damage
to tapped holes.
Installation: Secure ground strap on
rear engine mount.
*BA22.10-P-
1003-01L
*BA22.10-P-
1006-01L
Detach flexible coupling (12) from
18 transmission and propeller shaft and If the fitted sleeves are jammed: ?
remove
Loosen fitted sleeves of the flexible AR41.10-P-
coupling on the flange. 0050-09I
Fabricate drift for loosening fitting WF58.50-P-
sleeves in flexible coupling (12). 4110-01A
*BA41.10-P-
1001-01A
Detach hydraulic line (13) of steering
19
from transmission
*BA27.40-P-
20 Detach bracket (14) from transmission
1019-01A
Secure torque converter (6) to
prevent it from falling out.
Detach transmission from crankcase and
21 Installation: Align threaded holes
remove downwards at an angle
of torque converter (6) with the holes in
the driven plate.
*BA27.40-P-
1008-01A
Remove l torque converter (6) with AR27.20-P-
22 If necessary
grab handles 0500-01W
When installing new transmission or if AR27.00-P-
24 Fill transmission with gear oil
the transmission oil has been drained. 0270W
Check oil level in transmission and correct AR27.00-P-
25
if necessary 0100W
AR00.19-P-
0200M
Read out fault memory with STAR *WH58.30-
27 STAR DIAGNOSIS diagnosis system
DIAGNOSIS and erase if necessary. Z-1048-13A
28 Perform transmission adaptation After replacing or repairing

transmission, perform transmission
adaptation.
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 touch hot or rotating parts.
Perform engine test run and check
29 transmission for leaks and that it is
HOUSING
M10x40 Nm 38
BA27.40-P-1008-01A Bolt, automatic transmission to engine M10x90 Nm 38
M12 Nm -
BA27.40-P-1014-01A Bolt, heat shield to transmission housing Nm 9
BA27.40-P-1019-01A Bolt, leaf spring to transmission housing Nm 5
EXHAUST MANIFOLD
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969
Flange
BA14.10- connection,
P-1002- exhaust Nm 20
01B manifold/front
exhaust pipes
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

722.9
Stage
BA27.55-P-1002- Bolt, transmission oil line to transmission Banjo Nm 5
1
01D housing bolt
Stage Angle° 90
2
Hex. screw Nm 12
BA27.55-P-1003-
Bolt, oil cooler line to engine oil pan Nm 12
01D
EXHAUST SYSTEM
Number Designation Engine 113 in model 215, 220
BA49.10-P-1007-01A Bolt of exhaust bracket to transmission Nm 20
BA49.10-P-1008-01A Self-locking nut to front exhaust pipe Nm 20
ENGINE MOUNTS, ENGINE SUPPORTS

Number Designation Engine 112.922/944/972, Engine 275.950/980
113.941/960, 137.970 in model in model 220
220
BA22.10-P- Bolt, rear engine
Nm 40 40
1003-01L crossmember to body
BA22.10-P- Bolt or nut, rear engine M8 Nm - -
1006-01L mount to transmission M10 Nm 40 40

Number Designation Engine 113.960 in model
215
BA22.10-P-1003-
Bolt, rear engine crossmember to body Nm 40
01L
BA22.10-P-1006- Bolt or nut, rear engine mount to M8 Nm -
01L transmission M10 Nm 45
PROPELLER SHAFT
215 220
BA41.10-P-1001- Self-locking nut of flexible joint to transmission or M10 Nm - -

Number Designation
WORKSHOP EQUIPMENT
WE58.40-Z-1018-11A Transmission platform
WE58.40-Z-1030-11A Transmission jack
Remove/install transmission with torque converter - AR27.10-P-0500IW
TRANSMISSION 722.6 in MODEL 220.083 /084 /087 /183 /184 /187
Shown on model 220
Fig. 22: Identifying Transmission With Torque Converter Remove/Install Components (Shown On
Model 220)
Shown on model 220 with 4MATIC

Fig. 23: Identifying Transmission With Torque Converter Remove/Install Components (Shown On
Model 220 With 4MATIC)
MODIFICATION NOTES
13.1.06 Oil drain screw to torque converter Transmission 722.6 *BA27.20-P-1001-01C
Bolt, torque converter to drive plate Transmission 722.6 *BA27.20-P-1002-01C
Remove/install
AH00.00-
Notes on self-locking nuts and
N-0001-
bolts
01A
Before starting work the area
surrounding the oil cooling lines
in the vicinity of the separation
points on the transmission must
be thoroughly cleaned. Even the
smallest dirt particles, introduced
into the hydraulic components,
can lead to malfunctions and a
total failure of the transmission
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.
battery acid or when handling
damaged lead-acid batteries
Insulate ground line as a protection
1 against unintentional contact of detached ground P-0003I
battery
line with ground point of battery.
AH54.10-
01A
Remove hot film mass air flow AR07.07-
2
sensor P-1454AA
Risk of death caused by vehicle Align vehicle between columns of vehicle lift and AS00.00-
slipping or toppling off of the position four support plates at vehicle lift support Z-0010-
lifting platform. points specified by vehicle manufacturer. 01A
Raise vehicle with lifting
3
platform
4
compartment paneling P-1105M
Drain transmission oil at the If the transmission oil is burnt or interspersed
5 transmission oil pan and at the with abrasion, the oil cooler lines and oil cooler
torque converter must be flushed out: ?
AR27.55-
Flush oil cooler lines and oil cooler.
P-0001A
Installation: Replace sealing ring.
*BA27.10-
P-1001-
03A
*BA27.20-
P-1001-
01C
Remove right O2 sensor AR14.00-
6
downstream of CAT (G3/6) P-5303AA
Disconnect connector O2 left
AR14.00-
7 probe upstream of catalytic
P-5303AA
converter
AR27.10-
Disconnect plug on To do this, detach shield (10) over plug and
8 P-0500-
electrohydraulic controller unit unclip line.
01A
*BA27.40-
P-1014-
01A
Detach bracket (11) of connectors
9 O2-oxygen sensor at bottom of
transmission (5)
Installation: Check tapping plates (4) and
10 Remove exhaust bracket (6)
Mark front axle gear propeller
11 shaft (3) in relation to transfer
case flange
Detach front axle gear propeller
12 Installation: Observe marking.
shaft (3) from transfer case flange
*BA33.30-
P-1005-
02C
Remove shift rod (14) from To unhook, press the locking device (14a)
13 upwards until the bolts of the shift rod (14) can be
transmission (5)
moved out
Remove bolts (13); to do this, *BA27.20-
14 turn the torque converter into the P-1002-
appropriate position 01C
Detach exhaust shielding plate (1)
15 for front propeller shaft behind
transfer case (16)
Detach front propeller shaft from
16 Flexible disk remains on propeller shaft.
transfer case (16)
Installation: Attach front propeller shaft to AR41.10-
transfer case (16). P-0050-07I
*BA41.10-
P-1001-
01A
Loosen fitted sleeves on flexible AR41.10-
17 If the fitted sleeves are jammed: ?
coupling. P-0050-09I
WF58.50-
Prepare drift for loosening fitted sleeves in
P-4110-
flexible couplings.
01A
Detach ground line from transfer
18
case (16)
*BA61.10-
Dismount reinforcement bridge
19 P-1002-
(8)
01D
Unhook rear exhaust system (7)
from the rubber mounts, lower
20
slightly and secure to prevent it
from falling down
Support transmission (5) with
Transmission platform, see GOTIS
21 assembly lift and transmission
platform
Remove rear engine cross AR22.10-
22 Rear engine mount remains installed.
member (2) P-1160IW
Undo banjo bolt (12) on left oil
23 Seal off line connections using plugs.
cooling line from transmission (5)
Fig. 14
24 Remove banjo bolt (9) from right Seal off line connections using plugs.
oil cooling line on transmission
(5)
Fig. 14
25 Lower transmission (5) slightly
Remove bolts (5a) from Installation: Pay attention to different
26
transmission (5) brackets.
Detach and remove oil filler pipe
(15) on the right of the Installation: Replace oil filler pipe O-ring
27
transmission (5) and on the (15).
cylinder head
Remove automatic transmission
Secure torque converter to prevent it from
28 (5) diagonally downwards using
falling out.
assembly lift
AR27.20-
Remove l torque converter using
29.1 If necessary P-0500-
grab handles 01B
Installation: Grease crankshaft journals at the
torque converter lightly.
*BE27.20-
Test values for torque converter P-1001-
01B
Fig. 15
*BR00.45-
Multi-purpose paste Z-1009-
06A
Check oil level in automatic
AR27.00-
31 transmission (5); correct if
P-0100AC
necessary
AR00.19-
P-0200M
Read out fault memory with
33 STAR DIAGNOSIS and erase if
necessary
Transmission adaptation must be performed after
34.1 Perform transmission adaptation
the transmission is changed or repaired.
Risk of accident caused by
vehicle starting off by itself when
Secure vehicle to prevent it from moving by
engine is running. Risk of injury AS00.00-
itself.
caused by contusions and burns Z-0005-
Wear closed and snug-fitting work clothes.
during starting procedure or when 01A
working near the engine as it is
running
Carry out engine test run and

check transmission (5) for
35
function and leaks

722.606/607/609/610/617/618/623/624/628/630/631/632/633/636/643/645/
Installed Distance
BE27.20-
height of from
P-1001- mm 19.5 (-2)
torque transmission
01B
converter housing

Number Designation Transmission 722.6 except 722.628/648/649
BA27.10-P-1001-03A Oil drain screw to oil pan Nm 20
HOUSING
722.660/661/662/663/666/674
BA27.40-P-1014- Bolt, heat shield to
Nm 6
01A transmission housing
TORQUE CONVERTER
722.648
BA27.20-P- M8 Nm 10
Oil drain screw to torque converter
1001-01C M10 Nm 15
Straight threaded
Nm 42
connection
BA27.20-P- Bolt, torque converter to Stage 1 Nm 4
1002-01C drive plate
Helical cut Stage 2 Nm 30
Stage 3 Angle° 90
PROPELLER SHAFT
Number Designation Model
220
BA41.10-P-1001- Self-locking nut, flexible coupling to transmission or front M10 Nm -
01A propeller shaft M12 Nm 60
FRONT AXLE SHAFT

220.08/18
Stage
M8 Nm 15
1
Stage
Angle° 30
2
BA33.30-P-1005- Bolt of front axle gear propeller shaft to transfer Stage
M10 Nm -
02C case flange 1
Stage
Angle° -
2
FRAME FLOOR ASSEMBLY

Number Designation Model 220
BA61.10-P-1002-01D Collar bolt of rear reinforcement bridge to frame floor Nm 23
AUXILIARY REPAIR MATERIALS

FASTEN TRANSMISSION ON ASSEMBLY STAND - AR27.10-P-0600
Fasten transmission to assembly stand Support plate for mounting transmission - AR27.10-P-0600-01B
Only for transmission 722.626

Fig. 26: Identifying Assembly Stand (140 589 34 63 00)
Fig. 27: Identifying Support Plate (140 589 34 63 00)
1. Bolt support plate (071) to assembly stand (070).

2. Insert transmission into support plate (071) and secure with three bolts (arrows).
Fig. 28: Identifying Support Plate & Bolts

Fig. 29: Identifying Transmission & Support Plate
Fasten transmission on assembly stand - AR27.10-P-0600-01W
Transmission 722.9
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. 32: Identifying Transmission Fastened On Assembly Stand
REMOVE/INSTALL AUTOMATIC TRANSMISSION OIL PAN - AR27.10-P-7030W
Fig. 33: Identifying Automatic Transmission Oil Pan Remove/Install 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 oil
pan (3) pan (3) and the overflow
pipe (31) have been
redesigned to optimize the
oil feed of the
transmission. After
removal, replace the old
transmission oil pan (3)
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
2 Clean the transmission oil
pan (3) and its
surroundings thoroughly
3 Drain the transmission oil Unscrew drain plug
and collect for and pry overflow pipe (31)
determining the quantity off base (arrow) using
of transmission drift. The remaining
transmission oil drains out
immediately after prying
off.
Installation: Replace
sealing ring.
*BA27.10-P-1001-03A
Fig. 34
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: Replace
(31) from the transmission overflow pipe (31) and
oil pan (3) 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 (32)
magnet (32) from the for damage and replace if
transmission oil pan (3) necessary
7 Remove and clean seal A seal (33) which is
(33) not damaged can be used
again.
8 Clean the transmission oil
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.
caused by contusions and Do not touch hot or
procedure or when
working near the engine
as it is running
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
Fig. 34: Identifying Drift (722 589 03 15 00)
REMOVE/INSTALL ELECTROHYDRAULIC CONTROLLER UNIT (TRANSMISSION

INSTALLED) - AR27.19-P-0200
Remove/install electrohydraulic controller unit (transmission installed) - AR27.19-P-0200A
TRANSMISSION 722.6 in MODEL 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230 (except,
220.874/876)
TRANSMISSION 722.6 in MODEL 461, 463 (except 461.331, 463.270 /271)

Fig. 35: Identifying Electrohydraulic Controller Unit Components
MODIFICATION NOTES
10.5.05 Carry out transmission Step 15.1
adaptation inserted
Remove/install
Before starting work, the
area around the
transmission separation
points must be thoroughly
cleaned. Even the smallest
dirt particles, introduced
into the hydraulic
malfunctions and a total
failure of the transmission
1 Switch ignition off, Vehicles with Keyless Go
remove ignition key code 889: Press the Keyless-
(transmitter key). Go 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 (min.
2 m).
2.1 Raise vehicle with lifting Models 461,463 AR00.60-P-1000G
platform
2.2 Remove rear part section Model 140 with gasoline
of engine compartment engine: Detach rear section
paneling of the lower engine
compartment paneling on the
vehicle underbody and
remove downwards.
Model 170 AR61.20-P-1105A
Model 163.172/174/175 AR61.20-P-1105GH
Model 211 with gasoline AR61.20-P-1105T
engine
Model 215, 220 with AR61.20-P-1105M
gasoline engine
Model 129, 202, 208, 210 AR61.20-P-1105AB
with gasoline engine
Model 230 with gasoline AR61.20-P-1105R
engine
2.3 Remove rear part of Model 140, 163 with diesel
bottom sections of engine: Detach rear section
soundproofing of noise bottom section of
soundproofing on vehicle
underbody and remove
downwards.
Model 202 with diesel AR94.30-P-5300A
engine
Model 210 with diesel AR94.30-P-5300AB
engine
Model 211 with diesel AR94.30-P-5300T
engine
Model 220 with diesel AR94.30-P-5300M
engine
3 Detach front retaining Model 230
bracket of rear engine
4.1 Disconnect plug Model 163, 463
connector (26)
4.2 Detach heat shield (62) Except model 163, 463 AR27.10-P-0500-01A
and unplug connector (26) *BA27.40-P-1014-01A
5 Loosen pilot bushing (21), AR27.19-P-0230A
remove from transmission
housing (2) and replace if
necessary
*BA27.19-P-1003-01A
Pilot bushing modified BT27.19-P-0004-01A
6 Drain transmission oil; to Installation: Replace
do this, unscrew oil drain sealing ring.
screw (4) *BA27.10-P-1001-03A
If the transmission oil is
burnt or contains particles,
the oil cooling lines and oil
cooler must be flushed:
Except model 461, 463 AR27.55-P-0001A
Models 461,463 AR27.55-P-0001GA
7 Remove transmission oil Installation: Install new
pan (3) gasket
*BA27.10-P-1002-03A
8 Remove magnet (69) from Vehicles as of approx.
transmission oil pan (3) 04/2001
Clean magnet (69).
Magnet (69) in Passenger cars only BT27.40-P-0003-01A
transmission oil pan (3),
added for the first time
9 Remove oil filter (5)
10 Remove bolt (19a) and Pay attention to the
detach electric controller positions of the punched
unit (Y3/6) windows in the pulse rings
through the rpm sensor n3
hole (a) and the rpm sensor
n2 hole(b).
If plastic part of selector
valve does not engage in
driver of detent plate: ?
Insert selector valve in driver AR27.19-P-0200-01A
of detent plate.
Disassemble/assemble AR27.19-P-0220A
electric controller unit
(Y3/6).
*BA27.19-P-1001-01A
12 Add oil to transmission AR27.00-P-0101A
and check oil level
with STAR DIAGNOSIS
and erase if necessary
14 Perform transmission After replacing or repairing
adaptation transmission, perform
transmission adaptation.
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A
by vehicle starting off by from moving by itself.
itself when engine is Wear closed and snug-fitting
running. Risk of injury work clothes.
caused by contusions and Do not touch hot or rotating
burns during starting parts.
procedure or when
as it is running
for leaks and that it is

722.6 except 722.628 722.649
722.628/ 648/649
BA27.10-P- Oil drain screw Nm 20 20 22
1001-03A to oil pan
BA27.10-P- Bolt, oil pan to Nm 8 8 8
1002-03A transmission
housing Angle° - - -
ELECTROHYDRAULIC CONTROLLER UNIT

BA27.19-P-1001- Bolt, electrohydraulic Stage 1 Nm 8
01A controller unit to
transmission housing Stage 2 Angle° -
BA27.19-P-1003- Bolt, pilot bushing to electrohydraulic Nm 3
01A controller unit
HOUSING
Number Designation Transmission 722.6 except Transmission
722.660/661/662 /663/666/674 722.660/661/66
2/663/666/674
BA27.40-P- Bolt, heat shield to Nm 6 6
housing
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. 36: Identifying Plastic Part Of Selector Valve, Driver Of Detent Plate
Remove/install electrohydraulic controller unit (transmission installed) - AR27.19-P-0200W
TRANSMISSION 722.9
Fig. 37: Identifying Electrohydraulic Controller Unit Remove/Install 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
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
1 Switch off ignition, On vehicles with code
remove ignition key or 889 Keyless-Go: Press the
transmitter key 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
4 Remove heat shield above
the transmission connector
(4e)
5 Unplug 5-pin connector at Clean the transmission
transmission connector connector (4e) and
(4e) connector on the electric
controller unit (VGS) and
fully integrated
transmission control
controller unit (Y3/8).
6 Unscrew bolts (4s) and Installation: Replace
remove electric controller 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
transmission control
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 AR27.00-P-0100W
correct if necessary
9 Read out fault memory STAR DIAGNOSIS
and erase 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
fault memory
10 Perform transmission After replacing or
adaptation repairing transmission,
perform transmission
adaptation.
procedure or when
as it is running
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
DISASSEMBLE AND ASSEMBLE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0220A

Transmission 722.6 in MODELS 129, 140, 163, 170, 199, 202, 208, 210, 211, 215, 220, 230, 240
Transmission 722.6 in MODELS 461.302 /332 /342 /345,

463.206 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /308 /309 /322 /323 /33
Shown on the electrohydraulic control unit in model 163
Fig. 38: Identifying Shift Plate, Electrical Control Unit & Components
MODIFICATION NOTES
24.9.97 Remove caps Step 1 new
24.9.97 Caps for solenoid valves, Step 1 BT27.19-P-0003-01A
new
Disassemble/assemble
1 Take off caps of solenoid Only on transmission
valves 722.6 as of 1.8.97
Caps for solenoid valve, new Transmission 722.6 BT27.19-P-0003-01A
2 Unscrew bolts (17a, 17b) and Installation: Note the
remove leaf springs (17) different lengths of the
bolts (17a, 17b).
*BA27.19-P-1002-01A
3 Use pliers to pull modulating Installation: Check
pressure control solenoid the O-rings on the
valve (Y3/6y1) and shift modulating pressure
pressure control solenoid control solenoid valve
valve (Y3/6y2) out of shift (Y3/6y1) and on the shift
plate (16) pressure control solenoid
valve (Y3/6y2); fit a new
valve if necessary.
Pliers Fig. 39
4 Use pliers to pull 1-2 and 4-5 Installation: Check
shift solenoid valve the O-rings on the 1-2
(Y3/6y3), 3-4 shift solenoid and 4-5 shift solenoid
valve (Y3/6y4) and 2-3 shift valve (Y3/6y3), 3-4 shift
solenoid valve (Y3/6y5) out solenoid valve (Y3/6y4)
of shift plate (16) and 2-3 shift solenoid
valve (Y3/6y5); fit a new
valve if necessary.
Pliers Fig. 39
5.1 Remove electric control unit Transmission 722.6 up to
(Y3/6) from shift plate (16) end no. 0026194
Installation: Make
sure that the two
centering pins of the
electric control unit
(Y3/6) engage in the shift
plate (16).
5.2 Bend retaining lug on Transmission 722.6 as of
stiffening rib on oil- end no. 0026195
temperature sensor to one
side and remove electric
control unit (Y3/6) from shift
plate (16)
Retaining lug added to 722.6 BT27.19-P-0001-01A
electrohydraulic control unit
6 Disassemble shift plate (16) Only when the shift AR27.35-P-0350A
plate (16) is dirty or
metal shavings are
present in the
transmission oil.
7 Assemble in the reverse
order

BA27.19-P-1002-01A Bolt, solenoid valve to Nm 8
shift plate
Fig. 39: Identifying Pliers (606 589 00 37 00)
REPLACE PILOT BUSHING IN THE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0230A
TRANSMISSIONS 722.6
Fig. 40: Identifying Electrohydraulic Control Unit Components
Remove/Install
In order to prevent damage
to the electric control unit,
the transmission oil
temperature must be < 50 °
C when removing and
installing the pilot bushing
(21).
1.1 Switch off ignition, Vehicles without Keyless
remove ignition key from Go
the EIS [EZS] control unit
1.2 Remove Keyless Go Vehicles with Keyless Go
transmitter (ignition key/ Code 889
card) from the vehicle and Switch off engine.
store outside the
transmitter range
2.1 Detach rear section of Vehicles with gasoline
engine compartment engine except model 461
paneling and 463
Model 129,202,208,210 AR61.20-P-1105AB
Model 140
Model Series 163 AR61.20-P-1105GH
Model 170, 202.0 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 199 AR61.20-P-1105SLR
Model 203, 209 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
Model 240 AR61.20-P-1105H
2.2 Detach rear section of Vehicles with diesel
bottom sections of engines except model 461
soundproofing and 463
Model Series 163 AR94.30-P-5400GH
Model 202.1 AR94.30-P-5300A
Model 203, 209 AR94.30-P-5300P
Model 211 AR94.30-P-5300T
Model 220 AR94.30-P-5300M
3.1 Disconnect plug connector Model 163, 463
(26)
3.2 Detach heat shield (62) Except model 163, 463 AR27.10-P-0500-01A
and unplug connector (26) *BA27.40-P-1014-01A
4 Unscrew bolt (22) and When pulling out the
remove pilot bushing (21) pilot bushing (21), pay
from the electrohydraulic attention to transmission
control unit (19) oil which runs out.
If there is a green spot
on the pilot bushing (21),
only the sealing rings need
to be replaced and not the
complete pilot bushing.
*BA27.19-P-1003-01A
6 Pour ATF into automatic Except model 171, 199, AR27.00-P-0101A
transmission and inspect 203, 209, 219,
ATF level 463.270/271
Model 171 AR27.00-P-0101V
Model 203, 209 AR27.00-P-0101P
Model 219 AR27.00-P-0101TZ
Model 463.270/271 AR27.00-P-0101GX

BA27.19-P-1003-01A Bolt, pilot bushing to Nm 3
electrohydraulic control
unit
HOUSING
Transmission
Transmission 722.6 except 722.660/661/66
Number Designation 722.660/661/662 /663/666/674 2/663/666/674
BA27.40-P- Bolt, heat shield to Nm 6 6
housing
REMOVE/INSTALL ELECTRONIC TRANSMISSION CONTROL (ETC) CONTROL MODULE -

AR27.19-P-1719I
TRANSMISSION 722.6 in MODEL 215, 220
Shown on MODEL 220
Fig. 41: Identifying Electronic Transmission Control (ETC) Control Module Remove/Install Components
(Shown On Model 220)
MODIFICATION NOTES
Step
28.4.03 Read out variant coding of ETC control unit (N15/3), replaces "Disconnecting battery"
1.1
Turn key in electronic ignition switch control unit to "0", replaces "Connecting quiescent Step
28.4.03
current retention unit" 1.2
Remove/Install
When installing new ETC control unit
(N15/3)
Connect STAR DIAGNOSIS and read
Read out variant coding of ETC
1.1 data of ETC control unit (N15/3) into
control unit (N15/3)
STAR DIAGNOSIS.
Installation: Transfer stored data into
new ETC control unit (N15/3)
*WH58.30-Z-
Diagnosis system STAR DIAGNOSIS
1048-13A
Turn key in electronic ignition
1.2 switch control module in position When reusing ETC control unit (N15/3)
"0"
Vehicles with Keyless-Go Code 889:
press Start/Stop button repeatedly until
Open engine hood and raise to AR88.40-P-
2
vertical position 1000M
Release and remove cover on right
3
fuse box (F1/1)
Unplug electrical connectors (1) Push wiring harnesses hanging over
4
from ETC control unit (N15/3) ETC control unit (N15/3) to one side.
Remove ETC control module
5 (N15/3) upwards out of right fuse
box (F1/1)
AR00.19-P-
0200M
8 Read out DTC memory

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500
Remove/install torque converter - AR27.20-P-0500-01B

TEST VALUES FOR TORQUE CONVERTER
Transmission
722.620/622/ Transmission
Number Designation 625/627 722.621
BE27.20-P- Installed height Distance from mm 26 (-2) 19 (-2)
1001-01B of torque transmission
converter housing

722.600/601/602/603/ 722.606/607/609/610/
604/605/608/611/614/ 617/618/623/624/628/
616/619/626/629/634/ 630/631/632/633/636/
637/640/642/660/661/ 643/645/662/663/664/
682/683/695/699 665/666/667/668/669/
672/676/680/690/696/
698
BE27.20-P- Installed Distance from mm 7 (-2) 19.5 (-2)
1001-01B height of transmission
torque housing
converter

722.635/639/ 722.638 722.649
644
BE27.20-P- Installed Distance from mm 21 (-2) 26 (-2) 20 (-2)
1001-01B height of transmission
torque housing
converter

REPAIR MATERIALS
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!
5.1 If transmission oil is burnt or interspersed with abrasive particles: Flush oil cooler lines and oil cooler.
Fig. 44: Identifying Grab Handles & Torque Converter
Install torque converter

6 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. 45: Identifying Torque Converter And Transmission Housing
Measure installed height of torque converter in transmission housing
7 Measure dimension "A" between transmission housing and torque converter mounting using a depth
gauge.
Torque converter and primary pump will be damaged if torque converter is seated incorrectly in
transmission housing.
Fig. 46: Measuring Between Transmission Housing And Torque Converter Mounting
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
TEST VALUES FOR TORQUE CONVERTER

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
Fig. 48: Identifying Parallel Support (126 589 04 31 00)
REPAIR MATERIALS
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. 49: 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. 50: 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. 51: Measuring Installed Height Dimension Between Parallel Support And Converter Mount
DISMANTLE AND ASSEMBLE SHIFT PLATE - AR27.35-P-0350A
TRANSMISSION 722.6
TRANSMISSION 722.610 in MODELS 463.209 /232 /233 /244 /245 /250

TRANSMISSION 722.611 in MODEL 463.308 /330 /331
TRANSMISSION 722.630 in MODEL 463.206 /240 /241 /243 /246 /247 /248 /249 /254
TRANSMISSION 722.637 in MODEL 461.302 /331 /332 /342 /345, 463.322 /323
TRANSMISSION 722.638 in MODEL 463.309 /332 /333 722.645 in MODEL 463.270 /271
Location of regulating valve
Fig. 52: Identifying Shift Assembly
Fig. 53: Identifying Valve Body, Sealing Plate, Valve Housing

Fig. 54: Identifying Dowel Pin, Plastic Valve Body, Central Filter Screen
Fig. 55: Identifying Valve Body, Selector Valve & Components

Fig. 56: Identifying Valve Housing, Shift Pressure Regulating Valve
1 Remove leaf spring (82)
2 Remove valve body (72) Assembly: Insert
from valve housing (74) locating pin (59) into valve
housing (74) (arrow).
*BA27.35-P-1001-03A
Assembly: Observe for
transmission 722.6 as of
end number 0538312:
Strainer for modulating Transmission 722.6 BT27.35-P-0004-01A
pressure and shift pressure
control solenoid valve, new
end number 0485895:
Strainer in inlet to converter Transmission 722.6 BT27.35-P-0005-01A
lock-up control solenoid
valve, new
3 Remove gasket (73) Located in the valve
housing (74) are four
plastic valve balls (75) and
eight steel valve balls (76).
4 Remove side cover from All the valves are only
valve housing (74) and valve to be checked for easy
body (72) movement and swarf in
case of requirement
*BA27.35-P-1002-03A
Assembly:
The sleeves and pistons of
the components
 regulating valve, "2-

3" overlap with
sleeve and piston
(72.2),
 "3-4" overlap
regulating valve with
sleeve and piston
(72.8)
 and "1-2" and "4-5"
overlap regulating
valve with sleeve
and piston (74.18)
must not be
interchanged as
otherwise
malfunctions will
occur.
The shift valve "multi-

disk brake B2" (74.27) can
only be removed and
installed if the valve body
(72) has been removed.
end number 0027083:
Installation of a pressure BT27.35-P-0002-01A
feed valve
5 Wash all parts and blow Ensure that parts are not
them clean using compressed blown away. Only rags
air made of leather should be
used to clean parts.
6 Assemble in reverse order
TIGHTENING TORQUES OF VALVE HOUSING

BA27.35-P-1001- Bolt, valve body to M6x30 Nm 8
03A valve housing
BA27.35-P-1002- Bolt, side cover to M4x12 Nm 4
03A valve body and
valve housing
REMOVE/INSTALL RADIAL SHAFT SEALING RING AT OUTPUT FLANGE - AR27.40-P-0205I
Transmission 722.901 in MODEL 215.375, 220.070 /075 /170 /175
Fig. 57: Identifying Three Way Catalytic Converter Bracket, Shift Rod And Flex Disk
Fig. 58: Identifying Radial Shaft Sealing Ring Remove/Install Components
Removing
Notes on self-locking nuts and AH00.00-N-
bolts 0001-01A
Move selector lever into position
1
"N"
Align vehicle between the columns of the lifting
Risk of death caused by vehicle
platform and position the four support plates at AS00.00-Z-
slipping or toppling off of the
the lifting platform support points specified by 0010-01A
lifting platform.
the vehicle manufacturer.
2 Raise vehicle
Remove rear part section of AR61.20-P-
3 engine compartment paneling 1105M
Detach catalytic converter
*BA49.10-P-
4 bracket (1) from catalytic
1008-01A
converter
Support transmission with
*WE58.40-
5 transmission jack and Telescoping / transmission jack Z-1030-11A
transmission plate
*WE58.40-
Transmission platform.Passenger car Z-1018-11A
Installation: Fit bolts of rear engine
Remove rear engine crossmember to underbody by hand in order to
6 crossmember (2) together with prevent damage to the tapped holes.
rear engine mount (3) Installation: Secure ground strap on rear
engine mount.
*BA22.10-P-
Bolt, rear engine crossmember to body 1003-01L
Bolt or nut, rear engine mount to *BA22.10-P-
transmission 1006-01L
Detach shift rod (4) from
7
transmission
Detach flexible coupling (5)
from output flange (8), pull off
8 Flexible disk remains on propeller shaft.
backwards and put down on
output flange (8)
If the fitted sleeves are jammed: ?
Slacken flexible coupling fitted sleeves on AR41.10-P-
flange. 0050-09I
WF58.50-P-
Drift for loosening fitting sleeves in flex disks.
4110-01A
*BA41.10-P-
1001-01A
9 Lower transmission slightly
Check sealing surface of output flange for AR27.50-P-
10 Remove output flange (8) galling, corrosion and damage, and replace 0620-02W
output flange if necessary.
*BA27.50-P-
1001-01A
Do not damage the seat of the radial
shaft seal in the transmission housing.
Using a wide screwdriver, lever
11 radial shaft sealing ring (9) out Installation: Using drift (09), press new
of the transmission housing (10) radial shaft sealing ring into the transmission
housing until the drift (09) abuts the
Driver Fig. 59
Risk of accident due to vehicle
starting off when engine is
Secure vehicle to prevent it from moving by
running.
itself. AS00.00-Z-
Risk of injury caused by
Wear closed and snug-fitting work clothes. 0005-01A
contusions and burns during
Do not grasp hot or rotating parts.
starting procedure or when
working near the running engine
Check for leaks with engine
13
running
EXHAUST SYSTEM
Number Designation Engine 113 in model 215, 220
BA49.10-P-1008-01A Self-locking nut to front exhaust pipe Nm 20

Number Designation Engine 112.922/944, Engine 275.950/980
113.941/960, 137.970 in model in model 220
220
BA22.10-P- Bolt, rear engine crossmember
Nm 40 40
1003-01L to body
BA22.10-P- Bolt or nut, rear engine M8 Nm - -
1006-01L mount to transmission M10 Nm 40 40
PROPELLER SHAFT
215 220
BA41.10-P-1001- Self-locking nut of flexible joint to transmission or M10 Nm - -
GEAR ASSEMBLY
Number Designation Transmission 722.6 722.9
BA27.50-P-1001-01A Collar nut, output flange to output shaft Nm 200

WORKSHOP EQUIPMENT
WE58.40-Z-1018-11A Transmission platform
REMOVE/INSTALL OIL PUMP RADIAL SHAFT SEALING RING - AR27.40-P-0300A
TRANSMISSION 722.6 /9 /9
Torque Converter Developed
Fig. 60: Identifying Radial Shaft Sealing Ring, Oil Pump Housing Components
Remove
1 Lever radial shaft sealing Do not damage
ring (1) out of oil pump seat of radial shaft sealing
housing (2). ring (1) to prevent oil loss
and therefore damage to
the transmission (3).
Install
2 Install radial shaft sealing Install new radial shaft
ring (1) flush using sealing ring (1).
drift (01). Coat radial shaft
sealing ring (1) between
lips with multi-purpose
paste.
Drift Fig. 61
Multi-purpose paste *BR00.45-Z-1009-06A
REPAIR MATERIALS
GROOVED BALL BEARING - AR27.50-P-0600
Screw on and secure twelve-point collared nut and secure - AR27.50-P-0600-04B
GEAR SET
BA27.50-P-1001-01A Collared nut, output NM 200
flange to output shaft
Fig. 62: Identifying Wrench Socket (126 589 02 09 00)
1. Block transmission gear assembly by engaging park pawl.

2. Push output flange (48) onto the output shaft.
Transmission 722.611: On this model the output flange is not designed as a three-arm flange, the
attachment to the output shaft with the aid of a twelve-point collar nut corresponds to that on the three-
arm flange.
3. Fasten twelve-point collar nut (47) using the socket wrench bit 126 589 02 09 00.
Replace twelve-point collar nut (47).
4. Secure twelve-point collar nut (47) by hammering the collar into the recess in the output shaft. (Arrow)
Fig. 63: Identifying Twelve-Point Collar Nut, Output Flange
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. 64: 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. 66: 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. 67: 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-0601
Detach/attach transmission housing on torque converter housing. - AR27.50-P-0601A
TRANSMISSION 722.6
Fig. 68: Identifying Transmission Housing & Torque Converter Housing Components
MODIFICATION NOTES
27.7.01 Magnet in oil pan, newly Step 4 and 26 added BT27.40-P-0003-01A
included
Disassemble
1 Fasten transmission on AR27.10-P-0600-01B
assembly stand
Assembly stand Fig. 30
Support plate Fig. 26
Support plate for WF58.50-P-2750-04A
transmission mount
2 Loosen guide bush (21)
and remove from
3 Detach oil pan (3)
4 Remove magnet (69) from Vehicles as of 04/2001. BT27.40-P-0003-01A
oil pan Magnet in oil pan, newly
included
6 Unscrew Torx socket According to AR27.19-P-0220A
bolts (19a) and remove condition:
electrohydraulic control Disassemble and assemble
unit (19) electrohydraulic control
unit
7 Detach output flange (48) Socket wrench bit Fig. 62
Model 463: The output
flange is not designed as a
three-arm flange but as a
cylindrical flange
8 Press out radial seal ring
(20)
9 Remove shim (67a) As of transmission no.
1658778.
10 Remove circlip (68)
11 Remove deep-groove ball AR27.50-P-0601-01A
bearing (67) from Puller Fig. 76
transmission housing Tensioning clamp Fig. 77
12 Remove shim (18)
13 Unscrew Torx socket Torx insert for Torx *WH58.30-Z-1039-06A
bolts (1 a, 2a) from bolts
converter housing and
14 Remove transmission Continued operations
housing (2) from according to findings: ?
converter housing (1) Remove/install multi-disc AR27.50-P-0621A
clutch K1, K2 and K3 AR27.50-P-0781A
Remove/install multiple-
disc brake B2, multiple-
disk pack B3 and park
pawl gear
Assemble
15 Using grease, install both
Teflon rings (12a) in the
groove so that the joint
stays together
16 Mount transmission Align discs of
housing (2) on converter multiple-disc brakes B2
housing (1) and B3.
17 Screw in Torx socket *BA27.40-P-1002-01A
bolts (1a, 2a)
18 Measure end play between Only necessary when AR27.50-P-0600-06A
park pawl gear and installing new parts, e.g.
grooved ball bearing gear set, output shaft etc.
Steel straightedge Fig. 48
*BE27.50-P-1004-01A
19 Install shim (18)
20 Install grooved ball AR27.50-P-0600-05A
bearing in rear
21 Insert shim (67a) As of transmission no.
1658778.
Additional shim between Transmission 722.6 BT27.10-P-0005-01A
grooved ball bearing and
output flange
22 Drive radial seal ring (20) Drift Fig. 59
into transmission housing
23 Install output flange (48) AR27.50-P-0600-04B
Socket wrench bit Fig. 62
*BA27.50-P-1001-01A
24 Install and tighten BA27.19-P-1001-01A
unit (19)
25 Install oil filter (5)
26 Insert magnet (69) in oil Vehicles as of 04/2001. BT27.40-P-0003-01A
pan Clean abrasion
particles from magnet.
Magnet in oil pan, newly
included
27 Mount oil pan (3) *BA27.10-P-1002-03A
28 Insert guide bush (21) in
transmission housing and
tighten

BE27.50-P-1004-01A End play between park mm 0,3-0,5
pawl gear and grooved
ball bearing
HOUSING
except 722.660/661/66
2/663/666/674
BA27.40-P-1002-01A Bolt, transmission housing Nm 20
to torque converter
housing
AUTOMATIC TRANSMISSION OIL PAN
Transmission 722.6
Number Designation except 722.628/ 648/649
BA27.10-P-1002-03A Bolt, oil pan to Nm 8
transmission housing Angle -
GEAR ASSEMBLY
BA27.50-P-1001-01A Collar nut, output flange Nm 200
to output shaft

BA27.19-P-1001- Bolt, electrohydraulic 1st stage Nm 8
01A control unit to
transmission housing 2nd stage Angle -

Fig. 71: Identifying Socket Wrench Bit (126 589 02 09 00)
Fig. 74: Identifying Collet Chuck (140 589 06 34 00)


Number Designation
WH58.30-Z-1039-06A Torx insert for Torx bolts
Remove grooved ball bearing in rear of transmission housing - AR27.50-P-0601-01A
Fig. 77: 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. 78: Turning Top Part Of Puller Counterclockwise
Fig. 79: Pulling Grooved Ball Bearing Out Of Transmission Housing
Detach/attach transmission housing on torque converter housing. - AR27.50-P-0601W
TRANSMISSION 722.9
Transmission removed
Fig. 80: Identifying Transmission Housing And Torque Converter Housing Components - Transmission
722.9
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
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: Replace the AR27.50-P-0620-02W
collar nut.
Socket Fig. 62
Pin wrench Fig. 84
Puller Fig. 85
*BA27.50-P-1001-01A
6 Remove radial sealing ring Installation: Use drift.
(1r)
Drift Fig. 59
7 Remove grooved ball AR27.50-P-0601-01A
bearing (1l)
Puller Fig. 76
Clamping pliers Fig. 77
Installation: Check the AR27.50-P-0600-05A
play and insert the circlip.
8 Remove shim between Installation: Measure
grooved ball bearing (1l) and adjust the axial play
and park pawl gear 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. 48
End play between park pawl *BE27.50-P-1004-01A
gear and grooved ball
bearing
9 Detach rear engine mount Installation: Install new
bearing bracket (1h) bolts.
*BA27.40-P-1018-01A
10 Attach support plate (P1) Position the transmission
and valve lifter (H) to pry so that it is vertical with the
off transmission housing torque converter housing
(1) (1w) facing downward.
Valve lifter Fig. 91
11 Remove internal Torx bolts Position the
(11w, 12w) transmission so that it is
vertical with the torque
converter housing (1w)
facing downward. The
transmission housing (1)
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:
housing (1) from torque Carefully mount the
converter housing (1w) transmission housing (1).
using lever (H) The disks of 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

BE27.50-P-1004-01A End play between park mm 0.20 to 0.40
pawl gear and grooved
ball bearing
GEAR ASSEMBLY
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. 83: Identifying Wrench Socket (126 589 02 09 00)
Fig. 84: Identifying Pin Wrench (129 589 01 07 00)
Fig. 85: Identifying Two-Armed Puller (000 589 88 33 00)

Fig. 91: Identifying Valve Lifter (442 589 00 31 00)
REMOVE/INSTALL MAIN COMPONENTS OF THE TRANSMISSION - AR27.50-P-0610W
TRANSMISSION 722.9
Fig. 92: Identifying Transmission Remove/Install Main Components - Transmission 722.9
MODIFICATION NOTES
1.7.03 Reference to Step 1
"disassembling
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 consists AR27.50-P-0612W
of drive shaft, multi-disk
clutch K2, front planet
carrier, 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 Remove/Install
Components - Transmission 722.9 (1 Of 2)
Fig. 94: Identifying K3, Rear Hollow Shaft, Rear Planet Carrier And Output Shaft Remove/Install
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: Replace
from output shaft (24) the Torlon rings (2a).
Fig. 95
3 Remove circlip (2b), shim Installation: Check the
(2c), axial needle roller axial play between the shim
bearing (2d) and thrust (2c) and circlip (2b):?
plate (2e) from output
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: Replace
rings from output shaft 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
Remove/Install 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 consists of AR27.50-P-0611W
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: Install
from drive shaft (11) 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: Align
B3 (15) 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
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
4. Push output flange (1) onto output shaft (3).

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
REMOVING AND INSTALLING MULTIPLE-DISC CLUTCHES K1, K2 AND K3 - AR27.50-P-0621A
TRANSMISSION 722.6
Fig. 104: Identifying Output Shaft With Center And Rear Gear Set And Clutch K3 Components
Dismantling
1 Remove transmission AR27.50-P-0601A
housing from converter
housing
2 Remove output shaft with According to
center and rear gear set findings ?
and clutch K3 (12) Dismantle and assemble AR27.50-P-0810A
output shaft with center
and rear gear set and K3
Dismantle and assemble AR27.51-P-0830A
clutch K3
3 Remove thrust needle
bearing (13) and thrust
washer (13a)
4 Remove drive shaft with According to
clutch K2 and front gear findings ?
set (58)
drive shaft with clutch
K2 and front gear set
5 Remove clutch K1 (83) According to
findings ?
Remove, install multiple- AR27.50-P-0721A
disc brake B1 and oil
pump
Dismantle and assemble AR27.51-P-0800B
clutch K1
Assembly
6 Using grease, insert *BR00.45-Z-1007-06A
Teflon rings in the
multiple-disc brake B1 in
the groove so that the joint
remains together
7 Mount clutch K1 (83)
8 Using grease, insert
Teflon rings (58a) in the
groove so that the joint
remains together
9 Install drive shaft with
clutch K2 and front gear
set (58)
10 Install front washer (13a)
and thrust needle bearing
(13)
11 Install output shaft with
center and rear gear set
and clutch K3 (12)
12 Install transmission AR27.50-P-0601A
housing on converter
housing
REPAIR MATERIALS
BR00.45-Z-1007-06A Grease A 001 989 37 51
DISMANTLING AND ASSEMBLING OIL PUMP - AR27.50-P-0720-01A
1. Remove pump gears (22 and 23) from pump housing

2. Check radial seal ring (24), replace if necessary
3. Replace O-ring (25)
4. Lubricate pump gears and place in the pump housing. Insert pump gear (22) so that the chamfer (arrow)
points towards the pump housing.
Use ATF oil

Fig. 105: Identifying Pump Gears From Pump Housing
Fig. 106: Identifying Radial Seal Ring And O-Ring
REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721
Remove/install multi-disk brake B1 and oil pump - AR27.50-P-0721A
TRANSMISSION 722.6
Fig. 107: Identifying Multi-Disk Brake B1 And Oil Pump Components
Fig. 108: Identifying Oil Pressure For Clutch K1
MODIFICATION NOTES
2.8.00 Figure modified from 8 Value modified in *BA27.40-P-1004-01A
Nm to 10 Nm BA27.40-P-1004-01A for
transmission 722.6
Dismantle
1 Remove multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
2 Unscrew Torx socket Removal: Screw two
bolts (7a) and remove oil opposed bolts into the oil
pump (7) pump housing and press
the oil pump out of the
converter housing by
applying light blows with
a plastic hammer.
According to
findings ?
Dismantle and assemble AR27.50-P-0720-01A
oil pump
3 Unscrew Torx socket Removal: Screw two
bolts (6a) and remove opposed bolts into the
multi-disk brake B1 (6) multi-disk brake B1 and
from converter housing separate from the
converter housing by
applying light blows with
a plastic hammer.
According to
findings ?
multi-disk brake B1
4 Detach intermediate Use a suitable tool for
panel (8) from converter loosening
housing (1) Additional work ?
Remove/install multi-disk AR27.50-P-0781A
brake B2, multi-disk pack
B3 and park pawl gear
Assembling
5 Place intermediate panel The intermediate
(8) on converter housing panel can generally be
(1) and align used several times. The
panel must not be coated
with sealant
6 Securely tighten multi- Installed position of
disk brake B1 (6) on multi-disk brake B1 in
converter housing (1) relation to converter
housing is specified by a
plain dowel pin in the
multi-disk brake B1
(arrow).
*BA27.40-P-1004-01A
7 Install oil pump (7) and *BA27.40-P-1003-01A
securely tighten
8 Install multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
HOUSING
Transmission 722.6
except 722.660/661/66
Number Designation 2/663/666/674
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 10
to converter housing
Remove/install multi-disk brake B1 and oil pump - AR27.50-P-0721W
TRANSMISSION 722.9
Fig. 109: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components - Transmission
722.9 (1 Of 2)
Fig. 110: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install 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 consists of AR27.50-P-0612W
drive shaft, multi-disk
clutch K2, front planet
carrier, internal plate
carrier, multi-disk clutch
K1 and multi-disk brake
B3
2 Unscrew bolts (17a) and Screw two opposing
remove oil pump (17) 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-disk
remove multi-disk brake 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 possible
torque converter housing to use gasket (1d) several
(1w) and align times. Gasket (1d) must
not have any scratches
and must not be coated
with sealing compound.
6 Attach multi-disk brake Installation position is
(16) to torque converter determined by a dowel
housing (1w) 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
INSERTING AND MEASURING MULTIPLE-DISC PACK B3 - AR27.50-P-0780-11A
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH

Transmission
Number Designation 722.6
BE27.50-P-1003- Play in multiple-disc brake B3 mm 1,0...1,4
02B Number of 3 mm -
multiple-discs 4 mm -
Fig. 111: Identifying Transmission Housing (External Plate Carrier/B3)

Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B3 in the sequence shown in the picture and insert
individually.
2. Using a feeler gage, measure the clearance "L" at three points between the snap ring (133a) and externally
toothed plate (133c).
For the measuring procedure the snap ring (133a) must abut the upper contact surface of the
groove in the external plate carrier.
3. with snap ring (133a), adjust if necessary.
Snap rings are available in thicknesses of 3.2, 3.5, 3.8, 4.1, 4.4 and 4.7 mm
Fig. 112: Identifying Externally Toothed Plate, Snap Ring
REMOVING AND INSTALLING MULTI-DISK BRAKE B2, DISK PACK B3 AND PARK PAWL
GEAR - AR27.50-P-0781A
TRANSMISSION 722.6
Fig. 113: Identifying Multi-Disk Brake B2, Disk Pack B3 And Park Pawl Gear Components
Disassembling
1 Detach transmission AR27.50-P-0601A
housing from torque Bracket for transmission
WF58.50-P-2750-03A
converter housing housing
This bracket may only
be used if the torque
converter housing with
gear sets has been
detached from the
2 Remove disk pack B3 To facilitate removal of
(133) and disk spring the snap ring (133a),
(133b) by removing snap compress the disk pack B3
ring (133a) in transmission (133).
housing Check disks for
scorch marks and wear.
3 Unscrew torx socket bolts
(11)
4 Remove multi-disk brake The externally toothed AR27.50-P-0880A
B2 (14) from transmission disk carrier for multi-disk
housing brake B2 is also the piston
for multi-disk brake B3
According to findings: ?
Disassembling and
assembling multi-disk
brake B2.
5 Remove park pawl gear
(15)
Assembling
6 Insert park pawl gear (15)
7 Install multi-disk brake B2
(14) in transmission
housing (2)
8 Screw in torx socket bolts *BA27.40-P-1005-01A
(11)
9 Insert and measure disk Pay attention to AR27.50-P-0780-11A
spring (133b) and disk sequence of disks.
pack B3 (133)
Survey of multiple-disk Transmission 722.6 GF27.51-P-5200A
components, production
details
10 Fit snap ring (133a)
11 Attach transmission AR27.50-P-0601A
housing to torque
converter housing
HOUSING
except
722.660/661/66
2/663/666/674
BA27.40-P-1005- Bolt, multi-disk 1st stage Nm 16
01A brake B2 to
transmission housing 2nd stage Angle -
REMOVE/INSTALL BPC CLUTCH PACK, MULTI-DISK BRAKE B2 AND PARK PAWL GEAR -
AR27.50-P-0782W
TRANSMISSION 722.9
Fig. 114: Identifying BPC Clutch Pack, Multi-Disk Brake B2 And Park Pawl Gear Remove/Install
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 the
this step press together circlip (5s) determines the
BPC clutch pack (5) clearance.
Installation: Measure AR27.51-P-7229-01W
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
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).
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)

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
DISMANTLING AND ASSEMBLING OUTPUT SHAFT WITH CENTER AND REAR GEAR SET -
AR27.50-P-0810A
TRANSMISSION 722.6
Fig. 115: Identifying Output Shaft With Center And Rear Gear Set Components
Disassembling
housing from torque
converter housing
2 Remove multi-plate clutch AR27.50-P-0621A
K1, K2 and K3
3 Remove upper two visible
Teflon rings (42b) from
output shaft
4 Remove circlip (42f), shim
(42e), thrust needle
bearing (42d) and thrust
washer (42c) from output
shaft
5 Remove clutch K3 (44) According to
condition: ?
Disassemble clutch K3 AR27.51-P-0830A
and assemble
6 Remove rear tubular shaft According to
(45) from output shaft condition: ?
rear tubular shaft
N Remove rear gear set (43)
with integrated tubular
shaft of center gear set
from output shaft
Conversion from 18° to Transmission 722.6 BT27.50-P-0012-01A
23° teeth in front and rear
planetary gear set
8 Remove thrust washer
(43a)
9 Remove multi-disk brake AR27.50-P-0721A
B1 and oil pump, install
Assembling
10 Mount thrust washer (43a)
with the collar pointing
towards the planet carrier
11 Mount rear gear set (43)
with integrated tubular
shaft of the center gear set
on output shaft
12 Using grease, install lower *BR00.45-Z-1007-06A
three Teflon rings (42b) in
the groove so that the joint
stays together
13 Put rear tubular shaft (45) Inspect O-rings on
on output shaft hollow shaft, replace if
necessary.
14 Install clutch K3 (44)
15 Mount circlip, shim, thrust
needle bearing and thrust
washer (42c - 42f)
16 Using grease, insert the
upper two Teflon rings
(42b) in the groove so that
the joint remains together
17 Inspect axial play between AR27.50-P-0810-01A
shim (42e) and circlip *BE27.50-P-1005-01A
(42f)
18 Install multiple-disc clutch AR27.50-P-0621A
K1, K2 and K3
MULTI-DISK CLUTCH
BE27.50-P-1005-01A Axial play between shim mm 0.15- 0.6
and circlip
REPAIR MATERIALS
BR00.45-Z-1007-06A Grease A 001 989 37 51
Checking and adjusting end play between shim and circlip - AR27.50-P-0810-01A

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. 116: Identifying Multi-Disk Clutch K3
DISASSEMBLING AND ASSEMBLING REAR HOLLOW SHAFT WITH REAR FREEWHEEL -

AR27.50-P-0850A
TRANSMISSION 722.6
Fig. 117: Identifying Rear Hollow Shaft With Rear Freewheel Components
1 Detach transmission housing AR27.50-P-0601A
from torque converter
housing
2 Remove multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
3 Remove circlip (45h), shim Installation:
(45g), axle needle roller Check that circlip is
bearing (45f) from hollow correctly seated.
shaft (45a). Check O-rings (45b),
If using BT27.50-P-
0011-01A, axial needle
roller bearing and shim are
no longer required.
4 Remove rear sun gear (45e) Installation: Install
with internally toothed disk hollow shaft (45a) on
carrier/ K3 and rear freewheel and press in
freewheel (45d). while turning
counterclockwise
Friction bearing in sun gear Transmission 722.6 BT27.50-P-0011-01A
of rear planetary gearset
converted to anti-friction
bearing
5 Remove snap ring (45c) for
freewheel
6 Press freewheel out of sun Installation: The thrust
gear. plate of the freewheel
(45d) must face the snap
ring (45c).
DISMANTLE AND ASSEMBLE REAR TUBULAR SHAFT - AR27.50-P-0851W
TRANSMISSION 722.9
Fig. 118: Identifying Rear Tubular Shaft Dismantle/Assemble 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: Replace
hollow shaft (22w) O-rings (22d).
3 Remove bearing (22l)
DISMANTLING AND ASSEMBLING MULTI-DISK BRAKE B1 - AR27.50-P-0870
Dismantling and assembling multi-disk brake B1 - AR27.50-P-0870A

TRANSMISSION 722.6
Fig. 119: Identifying Multi-Disk Brake B1 Components
MODIFICATION NOTES
25.8.98 New special tool for AR27.50-P-0870-01A
setting clearance
16.9.02 Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02, refer to step 10.
Dismantling
1 Remove snap ring (6h)
2 Remove multi-disk pack Check multi-disks
(6g) and spring washer for scorch marks and wear.
(6f) from external plate
carrier
3 Place assembly device Assembly device Fig. 120
(073) on spring washer
(6d) and tension until the
snap ring (6e) is exposed
4 Remove snap ring (6e)
5 Remove piston (6c) from
the external plate carrier
by carefully blowing
compressed air into the
bore (A).
Assemble
6 Install piston (6c) in Inspect molded gasket,
external plate carrier replace if necessary.
Press in the piston with
the assistance of the spring
washer (6d) and the
assembly device (073).
7 Insert spring washer (6d) Insert spring washer
with the curvature towards
the multi-disk pack.
(073) on spring washer
(6d) and tension until the
groove of the snap ring is
exposed
9 Insert snap ring (6e) The collar of the
snap ring must point
towards the multi-disk
pack.
After installing, check snap
ring for correct seat
10 Insert spring washer (6f) Observe outer
and multi-disk pack (6g) multi-disk sequence
in the external plate Inserting and measuring
carrier and measure multi-disk pack B1: ?
TRANSMISSION 722.6 up AR27.50-P-0870-01A
to 01.09.02
Pressing tool Fig. 122
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Transmission 722.6 as of AR27.50-P-0870-01AA
02.09.02
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Thickness of steel multi- Transmission 722.6 BT27.51-P-0002-01A
disks B1, K1 and K2
changed
External plate carrier B1 Transmission 722.6 BT27.50-P-0008-01A
modified
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
Survey of multi-disk Transmission 722.6 GF27.51-P-5200A
details
11 Insert snap ring (6h) For additional work, AR27.50-P-0721A
see: ?
Remove/install multi-disk
brake B1 and oil pump

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided
multi-disks multi-disks
BE27.50-P- Clearance of Number of 2 mm 2.30...2.70 2.20...2.60
1001-02B multi-disk multi-disks 3 mm 2.70...3.10 2.40...2.80
brake B1 4 mm 3.00...3.40 2.60...3.00
Fig. 120: Identifying Assembly Device (140 589 13 43 00)
Fig. 121: Identifying Pressing Tool (208 589 00 21 00)
Inserting and measuring multi-disk pack B1 - AR27.50-P-0870-01A
Thickness steel multi- BT27.51-P-0002-01A

disks B1, K1 and K2
changed
MODIFICATION NOTES
25.8.98 New special tool for Point 2 and 3 added
setting clearance
30.3.99 New values for clearance
of multi-disk brake

722.6 up to
01.09.02 with
double sided
multi-disks
BE27.50-P-1001- Play in multi- Number of multi- 2 mm 2.30...2.70
02B disk brake B1 disks 3 mm 2.70...3.10
4 mm 3.00...3.40
Fig. 123: Identifying External Plate Carrier/B1, Spring Washer And Friction Multi-Disks
Soak new friction multi-disks in automatic transmission fluid for 1 hour before installation.
1. Assemble the disks for multi-disk brake B1 in the sequence shown in the diagram and insert one at a time.
2. Place pressing tool (078) on externally toothed plate (70c).
3. Press together multi-disk pack by pressing together pressing tool as far as stop using a lever press (the
marking ring can then still be seen, refer to small arrow ).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (6h) and the
externally toothed plate (70c).
During the measuring procedure, the snap ring (6h) must touch the upper contact surface of the groove in
the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (6h).
Snap rings are available in thicknesses of 2.6, 2.9, 3.2, 3.5, 3.8 and 4.1 mm.
Fig. 124: Identifying Place Pressing Tool (078) On Externally Toothed Plate
Inserting and measuring multiple-disc pack B1 - AR27.50-P-0870-01AA

722.6 as of
02.09.02 with
single sided
multiple discs
BE27.50-P- Play in multiple- Number of 2 mm 2.20...2.60
1001-02B disc brake B1 multiple discs 3 mm 2.40...2.80
4 mm 2,60...3,00
Fig. 125: Identifying Thrust Device (208 589 00 21 00)
1. Assemble the new disks for the multi-disk brake B1 in the sequence shown and dismantle individually.
Insert the new disks in ATF oil before installation for 1 h.
Fig. 126: Identifying Assembling Sequence Of Disks For Multi-Disk Brake B1
2. Mount pressure device (078) onto end disk (70c).

3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
The marking ring (smaller arrow) is then still visible.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (6h) and end disk
(70c).
During the measuring procedure, the snap ring (6h) must lie against the upper contact surface of the
groove in the external plate carrier (6b).
5. Use corresponding snap ring (6h) to adjust clearance (L) if necessary.
The snap rings (6h) are available at sizes 2.6 mm, 2.9 mm, 3.2 mm, 3.5 mm, 3.8 mm and 4.1 mm.
Fig. 127: Pressing Tool Placed On Externally Toothed Plate
Disassemble/assemble multi-disk brake B1 - AR27.50-P-0870W
TRANSMISSION 722.9
Fig. 128: Identifying Multi-Disk Brake B1 Disassemble/Assemble Components - Transmission 722.9 (1 Of

3)

3)

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
disk spring (5t) scorch marks and wear.
Replace if necessary.
6 Place multidisk brake in
lever press
7 Place clamping device on Position the clamping
disk spring (16t) device precisely (see
arrow in picture 2) to
enable later removal of
the circlip (16s).
Fig. 132
Fig. 131
8 Operate lever press until Stop lever press
circlip (16s) is exposed stoke 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
from external plate carrier vulcanized-on seal.
(16a)
Checking
15 Check external plate If an external plate
carrier (16a) 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 (see
with the following
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. 132
Fig. 131
groove of circlip (16s) is stoke as soon as
exposed accessibility to groove is
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 spring
disk pack (5) in external (5t) in such a way that the
plate carrier (16a) camber of the inner
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. 131: Identifying Drift Set (722 589 04 15 00)

DISMANTLING AND ASSEMBLING MULTIPLE-DISC BRAKE B2 - AR27.50-P-0880
Dismantling and assembling multiple-disc brake B2 - AR27.50-P-0880A
TRANSMISSION 722.6
Fig. 133: Identifying Outer Multiple-Disc Carrier B2 Or Piston B3 Components (1 Of 2)

Fig. 134: Identifying Outer Multiple-Disc Carrier B2 Or Piston B3 Components (2 Of 2)
Fig. 135: Identifying Snap Ring, Assembly Device

Fig. 136: Identifying Piston B2, Piston Guide Ring And Valve
Fig. 137: Identifying Oil Pressure Supply
MODIFICATION NOTES
clearance adjustment
Dismantling
1 Remove snap ring (134a)
2 Take multiple-disc pack The outer
B2 (134) and disc spring multiple-disc carrier for
(134b) out of outer the multi-disc brake B2 is
multiple-disc carrier B2 the piston for the
multiple-disc brake B3 at
the same time.
Check multiple-discs for
burnt spots and wear.
3 Place assembly device Fig. 120
(074) on disc spring (29)
and tension until the
groove for the snap ring is
exposed (figure C)
4 Remove snap ring (31)
5 Remove spring plate (30)
and disc spring (29)
6 Separate piston guide ring
(28) and piston/ multiple-
disc brake B2 (27) from
piston B3 (14a) by blowing
bore (D) (figure E) .
7 Press piston guide ring
(28) out of piston B2 (27)
Peak-to-valley height on Transmission 722.6 BT27.50-P-0009-01A
piston B2 modified
Piston B2 modified Transmission 722.6 BT27.50-P-0010-01A
8 Separate piston guide (32)
from piston B3 (14a) by
blowing compressed air
into the bore (A) (figure
E) .
Assembling
9 Assemble piston guide AR27.50-P-0880-01A
(32) and piston B3 (14a) in
the correct position
10 Insert piston/multiple-disc Check all sealing
brake B2 (27) in piston B3 rings, replace if necessary.
(14a) The rounded off
edges on the sealing rings
(14c), (28a) and (28b)
must point outwards The
rounded off edges on the
sealing ring (14d) must
point inwards (figure B)
11 Insert piston guide ring The valve (137) in
(28) the piston guide ring must
be on top (figure D)
12 Insert disc spring (29) and Insert disc spring
spring plate (30) with the curvature
towards the spring plate
(074) on disc spring (29)
groove for the snap ring is
exposed
14 Insert snap ring (31)
15 Insert disc spring (134b) Observe outer AR27.50-P-0880-02A
and multiple-disc pack multiple-disc sequence.
(134) in the outer multiple-
disc carrier B2 and
measure
Survey of multiple-disc Transmission 722.6 GF27.51-P-5200A
pack components, as-built
16 Insert snap ring (134a)
Follow up work ?
Remove, install multiple- AR27.50-P-0781A
disc brake B2 and
multiple-disc pack B3
Assembling piston guide and outer multiple-disc carrier of multiple-disc brake - AR27.50-P-0880-01A
Fig. 139: Identifying Piston Guide And Outer Multiple-Disc Carrier Of Multiple-Disc Brake
1. Insert piston guide (32) in transmission housing (2) and tighten securely.
2. Press in outer multiple-disc carrier/B2 (14a) up to the stop in the piston guide (32).
The recess in the external splines or the opening in the outer multiple-disc carrier/B2 (14a) must
point downwards (arrow).
3. Remove assembled component from transmission housing again for further assembly work.
Inserting and measuring multiple-disc pack B2 - AR27.50-P-0880-02A
MODIFICATION NOTES
25.8.98 New special tool for Item 2 and 3 incorporated
clearance adjustment for the first time
30.3.99 New adjustment values for
clearance of multi-disk
brake

Transmission
Number Designation 722.6
BE27.50-P-1002- Play in multiple- Number of 4 mm 1,90...2,30
02B disc brake B2 multiple-discs 5 mm 2,00...2,40
6 m- -
Fig. 141: Identifying External Plate Carrier/B2, Piston/B2
Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B2 in the sequence shown in the picture an insert individually.
2. Mount the pressure device (078) on the externally toothed plate (134a).
3. Compress the clutch pack; to do this, compress the pressure device as far as the stop using a lever press
(the marking ring is still visible, see small arrow ).
4. Using a feeler gage, measure the clearance "L" at three points between the snap ring (144a) and externally
toothed plate (134a).
For the measuring procedure the snap ring (144a) must abut the upper contact surface of the
groove in the external plate carrier.
5. with snap ring (144a), adjust if necessary.
Snap rings are available in thicknesses of 2.9, 3.2, 3.5, 3.8 and 4.1 mm
Fig. 142: Identifying Mount Pressure Device (078) On Externally Toothed Plate
Disassemble/assemble multi-disk brake B2 - AR27.50-P-0880W
TRANSMISSION 722.9
2)

2)
Disassemble
and end disk (105)
2 Remove disk pack (5), Check disks for
externally toothed plate scorch marks and wear.
(105a) and spring washer
(5t)
on spring washer (61t)
circlip (61s) is exposed.
5 Remove assembly
device.
6 Remove spring plate (61f)
and spring washer (61t)
7 Remove guide ring (61r) Blow compressed air
and piston (61k) by in carefully.
blowing compressed air
into bore (B) of piston
guide (61b)
8 Detach piston guide (61b) Blow compressed air
from external plate carrier in carefully.
(61a) by blowing The external plate
compressed air into bore carrier (61a) is also the
(A) piston for multi-disk
brake B3
Assemble
9 Assemble piston guide Install new sealing AR27.50-P-0880-01W
(61b) and external plate rings (161a, 161b, 161i).
carrier (61a) 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
must point outwards.
11 Insert guide ring (61r) Install new sealing
ring (161r)
The rounded off edges
must point outwards.
12 Insert spring washer (61t) Insert spring washer
and spring plate (61f). (61t) with the curvature
towards the spring plate
(61f)
on spring washer (61t)
groove for the circlip
(61s) is exposed.
14 Install circlip (61s)
15 Remove assembly
device.
16 Install spring washer (5t), Insert spring washer
externally toothed plate (5t) such that the inward
(105a) and disk pack (5). curvature is towards the
piston (61k)
Observe disk
sequence: ?
Survey of multi-disk GF27.51-P-5200W
details
circlip (105s)
clearance
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. 146: Identifying Piston Guide And External Plate Carrier Of Multi-Disk Brake B2
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B3 - AR27.50-P-0890W
TRANSMISSION 722.9

3)
3)

3)
Disassemble
and end disk (105)
lever press
disk spring (15t) in device precisely (see
external plate carrier arrow in picture 2) to
(15a) enable later removal of
the circlip (15s).
Fig. 132
Fig. 131
circlip (15s) is exposed stoke as soon as
from groove
lever press
11 Remove piston (15k) Check the
from external plate carrier vulcanized-on seal.
(15a)
Checking
12 Check external plate If an external plate
carrier (15a) carrier (15a) without outer
phase (1) is fitted (see
with the following
must be used when
installing:
220 994 03 40
If an external plate
carrier (15a) with outer
phase (2) is fitted (see
with the following
must be used when
installing:
001 994 18 40
Assemble
14 Install disk spring (15t) Insert the disk spring
the camber of the inner
piston (15k).
15 Position circlip (15s)
Final installation only
after actuation of the lever
press.
lever press
enable installation of the
circlip (15s).
Fig. 132
Fig. 131
groove of circlip (15s) is stoke as soon as
exposed accessibility to groove is
19 Install circlip (15s) Observe the
installation position of the
incorrectly, the disk
spring (5t) will jam.
lever press
disk pack (5) in external (5t) in such a way that the
plate carrier (15a) camber of the inner
piston (15k).
Observe disk
sequence:
See Overview of GF27.51-P-5200W
multidisk components, as-
built configuration
circlip (105s)
clearance
DISASSEMBLE/ASSEMBLE CLUTCH K1 - AR27.51-P-0800
Disassemble/assemble clutch K1 - AR27.51-P-0800B
TRANSMISSIONS 722.6
Fig. 152: Identifying Clutch K1 Components
Fig. 153: Identifying Snap Ring, Assembly Tool
MODIFICATION NOTES
clearance adjustment
16.9.02 Disks for B1, K1 and K3 Transmission 722.6 as BT27.50-P-0013-01A
changed from 02.09.02, see work
step 12.
Disassemble
from outer multiple-disc
carrier
2 Take multiple-disc pack Check multi-disks
(89) out of outer multiple- for scorch marks and wear.
disc carrier
(072) on spring plate (87)
and tension until the snap
ring (88) is exposed
(figure A)
5 Take out disk spring (86b)
and remove piston (86) by
carefully blowing
bore (A) (figure B) .
6 Remove snap ring (91) According to condition.
and take out front
freewheel (92).
Assemble
7 Install piston (86) in outer Check sealing rings
multiple-disc carrier (83b and 86a), replace if
necessary.
The rounded off
edges of the sealing rings
must face outwards
8 Insert disc spring (86b). Insert disk spring
with the curvature towards
the piston
9 Insert spring plate (87). Insert spring cup
with curvature towards sun
gear.
(072) on spring plate (87) Check sealing ring
and tension until the (87a), replace if necessary
exposed
11 Insert snap ring (88) After installing,
check snap ring for correct
seating
12 Insert multiple-disc pack Observe
(89) in the outer multiple- externally-toothed plate
disc carrier and measure
sequence. Insert and
measure disk pack K1: ?
Transmission 722.6 up to AR27.51-P-0800-02AA
01.09.02
Thrust device Fig. 122
Play in multiple-disc *BE27.51-P-1001-01B
clutch K1
Transmission 722.6 as of AR27.51-P-0800-02A
02.09.02
Play in multiple-disc *BE27.51-P-1001-01B
clutch K1
Strength of steel disks B1, Transmission 722.6 BT27.51-P-0002-01A
K1 and K2 changed
Disks for B1, K1 and K3 Transmission 722.6 as of BT27.50-P-0013-01A
changed 02.09.02
details
14 Insert front freewheel (92) The freewheel (92)
and fit snap ring (91) must be installed in
direction of arrow
Continuing operation,
see: ?
Remove/install K1, K2 AR27.50-P-0621A
and K3

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
multiple-discs multiple-discs
BE27.51-P- Play in Number of 3 mm 2.70...3.10 2.40...2.80
1001-01B multiple-disc multiple-discs 4 mm 3.00...3.40 2.60...3.00
clutch K1 5 mm 3.30...3.70 2.80...3.20
6 mm 3.60...4.00 2.90...3.30
Fig. 154: Identifying Assembly Tool (140 589 13 43 00)
Insert and measure multi-disk pack K1 - AR27.51-P-0800-02A
Thickness of steel multi- BT27.51-P-0002-01A

disks B1, K1 and K2
changed
MODIFICATION NOTES
setting clearance
of multi-disk clutch

722.6 up to
01.09.02 with
double sided
multi-disks
BE27.51-P-1001- Clearance of Number of 3 mm 2.70...3.10
01B multi-disk clutch multi-disks 4 mm 3.00...3.40
K1 5 mm 3.30...3.70
6 mm 3.60...4.00
Fig. 157: Identifying External Plate Carrier/K1, Spring Washer
1. Assemble the disks for multi-disk clutch K1 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (89c).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (90) and the
externally toothed plate (89c).
During the measuring procedure, the snap ring (90) must touch the upper contact surface of the groove in
the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (90).
Fig. 158: Identifying Place Pressing Tool On Externally Toothed Plate
Insert and measure multi-disk pack K1 - AR27.51-P-0800-02AA

722.6 as of
02.09.02 with
single-sided
multiple-discs
BE27.51-P-1001- Play in multiple- Number of 3 mm 2.40...2.80
01B disc clutch K1 multiple- discs 4 mm 2,60...3,00
5 mm 2.80...3.20
6 mm 2.90...3.30

1. Assemble and install the disks for the multi-disk clutch K1 in the sequence shown in the picture
individually.
Fig. 160: Identifying External Plate Carrier, Internally Toothed Plate
2. Mount pressure device (078) onto end disk (89c).

3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (90h) and end disk
(89c).
During the measuring procedure, the snap ring (90) must lie against the upper contact surface of the
groove in the external plate carrier (83a).
5. Use corresponding snap ring (90h) to adjust clearance (L) if necessary.
The snap rings (90) are available at sizes 2.6 mm, 2.9 mm, 3.2 mm, 3.5 mm, 3.8 mm and 4.1 mm.
Fig. 161: Identifying Mount Pressure Device Onto End Disk
Dismantling and assembling clutch K1 - AR27.51-P-0800W
TRANSMISSION 722.9
Fig. 162: Identifying Clutch K1 Dismantle/Assemble Components - Transmission 722.9 (1 Of 2)

Fig. 163: Identifying Clutch K1 Dismantle/Assemble Components - Transmission 722.9 (2 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. 122
5 Operate the lever press Stop the lever
until the circlip (14s) is press 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. 122
18 Operate lever press until Stop the lever
the groove (arrow) is free press 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 (5t)
and clutch pack (5) in so that the curvature of
external plate carrier the inner circumference
(14a) points towards the piston
(14k).
Observe lamella-
sequence: ?
components
circlip (105s)
clearance
DISASSEMBLE/ASSEMBLE K2 CLUTCH - AR27.51-P-0820W
TRANSMISSION 722.9
Fig. 165: Identifying K2 Clutch Disassemble/Assemble Components - Transmission 722.9 (1 Of 2)

Fig. 166: Identifying K2 Clutch Disassemble/Assemble 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
and disk spring (5t) scorch marks and wear.
6 Place multidisk clutch
(11) in lever press
7 Fit assembly device (076) Fig. 120
on spring cup (11f)
8 Operate lever press and Stop lever press
expose circlip groove stoke as soon as
(104) accessibility to 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 spring
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
on spring cup (11f)
20 Operate lever press and Position the spring
expose circlip groove cup (11f) precisely in
(104) order to prevent it from
canting.
Stop lever press
stoke as soon as
sufficient. Excess force
can cause damage.
21 Install circlip (11s)
(076) and multidisk
clutch (11) from lever
press
clutch pack (5) (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)
Inserting and measuring multiple-disc pack K2 - AR27.51-P-0820-02A
Thickness of steel discs BT27.51-P-0002-01A

B1, K1 and K2 revised
Additional disc spring in BT27.51-P-0003-01A
multiple-disc pack K2
MODIFICATION NOTES
25.8.98 Special new tool for Items 2 and 3 incorporated
adjusting play for the first time
30.3.99 New adjustment values for
multi-disc clutch release
clearance
Fig. 169: Identifying Presser (208 589 00 21 00)
ADJUSTMENT VALUES - MULTIPLE-DISC CLUTCH

722.6 without 722.6 with
diaphragm diaphragm
spring spring
BE27.51-P- Play in Number of 3 mm 1.40-1.80 2.30-2.70
1002-01B multiple-disc discs 4 mm 1.50-1.90 2.40-2.80
clutch K2 5 mm 1.70-2.10 2.50-2.90
6 mm 1.80-2.20 2.70-3.10
Fig. 170: Identifying Outer Multiple-Disc Carrier/K2, Piston
Place new friction multiple-discs in ATF fluid for one hour before installing.
1. Put discs for multiple-disc clutch K2 together in the sequence shown in the illustration and insert
individually.
2. Mount presser (078) on outer multiple disc (105c).
3. Compress multiple-disc pack, using a lever press compress presser as far as the stop (then the marking
ring is still visible, see small arrow ).
4. Using a feeler gauge, determine the play "L" at three points between the snap ring (106) and outer
multiple-disc (105c).
During the measurement the snap ring (106) must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
5. Adjust with snap ring (106), if necessary.
Fig. 171: Identifying Mount Presser On Outer Multiple Disc
DISMANTLING AND ASSEMBLING DRIVE SHAFT WITH CLUTCH K2 AND FRONT GEAR SET -
AR27.51-P-0825A
TRANSMISSION 722.6
Fig. 172: Identifying Drive Shaft With Clutch K2 And Front Gear Set Components
Fig. 173: Identifying Snap Ring, Assembly Device
MODIFICATION NOTES
1.8.97 New assembly device Special tool for steps 8
and 13 modified
setting loose play
Disassembling
housing from torque
converter housing, fit on
2 Remove multiple-disk AR27.50-P-0621A
clutch K1, K2 and K3,
install
3 Remove snap ring (84b)
from the inner multiple-
disc carrier / clutch K1
with integrated front gear
set (84) and take off
hollow gear (84a)
Conversion from 18° to Transmission 722.6 BT27.50-P-0012-01A
23° teeth in front and rear
planetary gear set
4 Remove drive shaft with
clutch K2 (100)
Plain bearings of input Transmission 722.6 BT27.50-P-0002-02A
shaft converted to anti-
friction bearings
5 Remove needle thrust
bearing (85)
from outer multiple-disc
carrier / clutch K2
7 Take out multiple-disc Inspect disks for
pack (105) scorch points and wear
8 Take out disk spring As of transmission no.
(107) 1596205
Additional disk spring in Transmission 722.6
multiple-disk set K2 BT27.51-P-0003-01A
onto spring retainer (103)
and press until snap ring Operate assembly
device with a lever press.
(104) is released (Fig. A)
11 Take out disc spring Further work
(102) and pull piston according to condition: ?
(101) out of outer Remove multiple-disk AR27.50-P-0721A
multiple-disc carrier brake B1 and oil pump,
install
Assembling
12 Install piston (101) in Inspect seals (101a
outer multiple-disc carrier and 101b), replace if
necessary.
The rounded
edges of the seals must
point to the outside.
13 Insert disk spring (102) Insert disk spring
and spring retainer(103) (102) with curved side
pointing toward spring
retainer (103).
Inspect seal (103a),
(076) on spring plate
(103) and press until the
exposed
16 Insert disk spring (107). As of transmission no.
1596205
Additional disk spring in Transmission 722.6 BT27.51-P-0003-01A
multiple-disk set K2
17 Insert multiple-disk set Pay attention to AR27.51-P-0820-02A
(105) into outer multiple- order of outer disks.
disk carrier and measure
Thickness of steel disks Transmission 722.6 BT27.51-P-0002-01A
B1, K1 and K2 modified
Survey of disks fitted as- Transmission 722.6 GF27.51-P-5200A
built configuration
18 Fit snap ring (106)
19 Insert axial needle Insert axial needle *BR00.45-Z-1007-06A
bearing (85) into inner bearing (85) with a little
multiple-disk carrier/K1 grease to prevent it
slipping.
20 Install drive shaft in inner
multiple-disc carrier/
clutch K1 with integrated
front gear set
21 Fit internally-geared Pay attention to
wheel (84a) installation position.
Further work: ?
Remove multiple-disk AR27.50-P-0621A
clutch K1, K2 and K3,
install
REPAIR MATERIALS
BR00.45-Z-1007-06A Grease A 001 989 37 51
DISASSEMBLE AND ASSEMBLE CLUTCH K3. - AR27.51-P-0830
Disassemble and assemble clutch K3. - AR27.51-P-0830A
TRANSMISSION 722.6
Fig. 175: Identifying Clutch K3 Components
MODIFICATION NOTES
setting clearance
16.9.02 Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02, refer to step 10.
Dismantling
1 Remove snap ring (44h)
from external plate
carrier
2 Remove multi-disk pack Check multi-disks
(44g) and spring washer for scorch marks and
(44f) from external plate wear.
carrier
(072) on spring plate
(44d) and tension until
the snap ring (44e) is
exposed
4 Remove snap ring (44e)
5 Remove spring plate
(44d) and piston (44c)
from the external plate
carrier
Assemble
6 Install piston (44c) in the Check sealing ring
external plate carrier (44b) and replace if
necessary.
The rounded off
edges of the sealing ring
must point outwards
7 Insert spring plate (44d) Insert spring
washer with the curvature
towards the piston
(072) on spring plate and
tension until the groove
of the snap ring is
exposed
9 Insert snap ring (44e) The collar of the
snap ring must point
towards the multi-disk
pack.
10 Insert spring washer (44f) Observe outer
and multi-disk pack (44g) multi-disk sequence
in the external plate Inserting and measuring
carrier and measure clutch pack K3: ?
Transmission 722.6 up to AR27.51-P-0830-01A
01.09.02
Play in multi-disk clutch *BE27.51-P-1003-01B
K3
Transmission 722.6 as of AR27.51-P-0830-01AA
02.09.02
Play in multi-disk clutch *BE27.51-P-1003-01B
K3
Thickness of friction and Transmission 722.6 BT27.51-P-0001-01A
steel multi-disks changed
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
details
11 Insert snap ring (44h) For additional work,
see: ?
Install clutch K3 AR27.50-P-0810A

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
multi-disks multi-disks
BE27.51-P- Play in multi- Number of 3 mm 2.30...2.70 2.30...2.70
1003-01B disk clutch multi-disks 4 mm 2.40...2.80 2.40...2.80
K3 5 mm 2.50...2.90 2.50...2.90

Inserting and measuring multi-disk pack K3 - AR27.51-P-0830-01A
Thickness of friction and BT27.51-P-0001-01A

steel multi-disks K3
changed
MODIFICATION NOTES
setting clearance
of multi-disk clutch

722.6 up to
01.09.02 with
double sided
multi-disks
BE27.51-P-1003- Play in multi- Number of multi- 3 mm 2.30...2.70
01B disk clutch K3 disks 4 mm 2.40...2.80
5 mm 2.50...2.90

Fig. 179: Identifying Measuring Multi-Disk Pack K3 Thickness Of Friction And Steel Multi-Disks
1. Assemble the disks for multi-disk clutch K3 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (41a).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (44g) and the
externally toothed plate (41a).
During the measuring procedure, the snap ring (44g) must touch the upper contact surface of the groove
in the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (44g).
Snap rings are available in thicknesses of 2.0, 2.3, 2.6, 2.9, 3.2, and 3.5 mm.
Fig. 180: Place Pressing Tool On Externally Toothed Plate
Inserting and measuring multiple-disc pack K3 - AR27.51-P-0830-01AA

722.6 as of
02.09.02 with
single-sided
multiple-discs
BE27.51-P-1003- Play in multiple- Number of 3 mm 2,30...2,70
01B disc clutch K3 multiple- discs 4 mm 2.40...2.80
5 mm 2.50...2.90
Fig. 181: Identifying Thrust Device(208 589 00 21 00)
1. Assemble and install the disks for the multi-disk clutch K3 in the sequence shown in the picture
individually.
Fig. 182: Identifying Multiple-Disc Pack K3
2. Mount pressure device (078) onto end disk (41a).

3. Compress the disk pack, to do so l press the pressure device (078) together using a lever press up to
stop.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (44g) and end disk
(41a).
During the measuring procedure, the snap ring (44g) must lie against the upper contact surface of the
groove in the external plate carrier (44a).
5. Use corresponding snap ring (44g) to adjust clearance (L) if necessary.
The snap rings (44g)are available at sizes 2.0 mm, 2.3 mm, 2.6 mm, 2.9 mm, 3.2 mm and 3.5 mm.
Fig. 183: Identifying Mount Pressure Device Onto End Disk
Disassemble/assemble clutch K3 - AR27.51-P-0830W
TRANSMISSION 722.9
Fig. 184: Identifying Clutch K3 Disassemble/Assemble Components - Transmission 722.9 (1 Of 2)

Fig. 185: Identifying Clutch K3 Disassemble/Assemble Components - Transmission 722.9 (2 Of 2)
Dismantling
and end disk (105)
3 Place assembly device on Assembly device Fig. 120
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. 120
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 (5t)
disk pack (5) such that curvature of
inner circumference faces
piston (21k)
Make sure that disks
are installed in correct
sequence: ?
details
13 Installed end disk (105)
and circlip (105s)
clearance
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. 187: Identifying Distance Between Upper Edge Of Parallel Support And End Disk (1 Of 2)
Fig. 188: 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
device on end disk (105) end disk (105) such that
they cannot slip off during
pressing procedure.
Drift set Fig. 131
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)
Multi-disk clutch K1:
(M2)
(M4)
(M1)
4 Position parallel support Fig. 48
5 Using depth gage (T), Measure distance at
measure distance between two points on
upper edge of parallel circumference of end disk
support and end disk (105) and note down mean
(105) value as value "a"
6 Return lever press to
original position
7 Push end disk (105) Carefully insert
against circlip (105s) tool (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 at
measure distance between two points on
upper edge of parallel circumference of end disk
support and end disk (105) and note down mean
(105) 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) are
so, install circlip (105s) of available in graduations of
appropriate thickness 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
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. 192: Identifying Clearance Between Circlip (133a) And Externally Toothed Plate (133c)
FLUSH OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001
Flush out oil cooler lines and oil cooler - AR27.55-P-0001A
Fig. 193: Flushing Out Oil Cooler Lines And Oil Cooler Components
Shown on model 168

Fig. 194: Flushing Out Oil Cooler Lines And Oil Cooler Components - Shown On Model 168
Extracting oil
1 Connect pump (2) to See: Fig. A
vacuum connection on
reservoir (3)
2 Attach plastic hose to
connection fitting (1) and
push all the way down the
oil filler pipe into the oil
pan
3 Actuate pump The extracted oil runs
into the reservoir (3).
Flushing
4 Connect pump (2) to See: Fig. B
pressure connection on
reservoir (3)
5 Fill reservoir (3) with
kerosene
6 Attach plastic hose to Ensure that the
connection fitting (1), kerosene can flow through
screw onto one of the two freely. Blow out oil cooler
oil cooler lines using the and oil cooler line
appropriate connection thoroughly with
piece (4) and flush out with compressed air.
kerosene
7 Connect the second plastic Secure the plastic hose
hose to the second oil on the connection fitting
cooler line and collect the
escaping transmission fluid with a hose clamp if
necessary.
Flushing out oil cooler lines and oil cooler - AR27.55-P-0001R
TRANSMISSION 722.9 in MODEL 211, 215, 220, 230 with ENGINE 113
Fig. 196: Flushing Out Oil Cooler Lines And Oil Cooler Components
Fig. 197: Identifying Oil Cooling Line
MODIFICATION NOTES
Kerosene cleaning agent replaced by 7-speed automatic transmission fluids (ATF, Step
30.5.07
specification 236.12) for the flushing process. 6
Remove/install
Depressurize the hydraulic
Risk of injury to skin or eyes caused by
system completely before
hydraulic fluid spraying out under high pressure. AS00.00-Z-
starting any work on the system.
Risk of poisoning caused by swallowing 0013-01A
Wear protective clothing and
hydraulic fluid.
safety glasses.
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
AR61.20-P-
1 Remove bottom engine compartment paneling Model 211
1105T
AR61.20-P-
Model 215, 220
1105M
AR61.20-P-
Model 230
1105R
Unscrew drain plug from transmission oil pan *BA27.10-
2 and drain transmission oil P-1001-03A
*BA27.55-
3 Remove bolts (5, 6) from oil cooling lines (7, 8)
P-1002-01D
Detach retaining clamps of the oil cooling lines *BA27.55-
4
(7, 8) on the engine oil pan P-1003-01D
Do not kink or bend oil
cooling lines (7, 8) otherwise
damage will occur.
5 Pull oil cooling lines (7, 8) out of transmission Collect transmission oil
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
6 Fig. 7
transmission oil
7-gear automatic transmission fluids (ATF, BB00.40-P-
specification 236.12) 0236-12A
Connect hand pump (2) with pressure fitting to
7
reservoir (3)
Connect plastic hose to connection fitting (1) and Secure plastic hose to
8 connect appropriate connector (4) to oil cooler connection fitting (1) using hose
line (7) clamp if necessary.
9 Connect plastic hose to 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
10 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.
11 Remove hand pump (2)
Always observe work
procedure and Specifications for AR27.00-P-
13 Fill transmission with gear oil
Operating Fluids, otherwise 0270W
transmission will be damaged.
STAR DIAGNOSIS diagnosis
14 Read out fault memory and erase if necessary
system
Secure vehicle to prevent it
Risk of accident caused by vehicle starting off
from 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.
Carry out engine test run, checking the
15
transmission for function and oil leaks

722.9
Stage
Nm 5
1
Banjo bolt
BA27.55-P-1002- Bolt, transmission oil line to Stage
Angle° 90
01D transmission housing 2
hex. head
Nm 12
screw
BA27.55-P-1003-
Bolt, oil cooler line to engine oil pan Nm 12
01D

BA27.10-P-1001-03A Oil drain screw to oil pan Nm 22
FLUSH OUT AUTOMATIC TRANSMISSION AND CONVERTER - AR27.55-P-0100A
TRANSMISSION 722.6
Fig. 199: Identifying Convertor Plate Locking Pin
Fig. 200: Identifying Oil Cooling Line Connection, Banjo Bolt

Fig. 201: Identifying Right Oil Cooling Line, Hose Clamp
Remove/install
Risk of injury to skin or Depressurize the hydraulic AS00.00-Z-0013-01A
eyes caused by hydraulic system completely before
fluid spraying out under starting any work on the
high pressure. Risk of system. Wear protective
poisoning caused by clothing and safety glasses.
swallowing hydraulic
fluid.
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A
by vehicle starting off by from moving by itself.
procedure or when
engine
toppling off of the liftingplatform and position the
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
Before opening the
hydraulic system,
thoroughly clean the area
surrounding the separation
point. Even the smallest
dirt particles, introduced
into the hydraulic
malfunctions and a total
failure of the hydraulic
system
1.1 Remove the rear section of Vehicles with gasoline
the engine compartment engine except model 461
paneling and 463
Model 129,202,208,210 AR61.20-P-1105AB
Model 140
Model 163 except AR61.20-P-1105GH
163.136/154/157
Model 163.136/154/157
Model 170 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 209, 203 with AR61.20-P-1105P
gasoline engine
Model 211 AR61.20-P-1105T
Model 219 AR61.20-P-1105TX
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
Model 240 AR61.20-P-1105H
1.2 Remove rear part of Vehicles with diesel engine
bottom sections of except model 461 and 463
soundproofing Model 140
Model 163 AR94.30-P-5400GH
Model 202.1 AR94.30-P-5300A
Model 209, 203 with diesel AR94.30-P-5300P
engine
Model 210 AR94.30-P-5300AB
Model 211 date service. AR94.30-P-5300T
Model 220 AR94.30-P-5300M
2 Unscrew drain plug from The transmission oil
the transmission oil pan should have an operating
and drain transmission oil temperature of 80 °C.
*BA27.10-P-1001-03A
3 Detach transmission oil Caution: when
pan and install a new removing the transmission
transmission oil filter oil pan, approx. 2.5 liters
of transmission oil will still
be in the transmission oil
pan.
4 Mount transmission oil Install new gasket.
pan *BA27.10-P-1002-03A
5 Detach clamps for right oil Model 163, 171, 211, *BA27.55-P-1004-01A
cooling line (2) from 219, 220, 461, 463
engine oil pan Model 199, 203, 209, *BA27.55-P-1003-01B
215, 230
6 Unscrew banjo bolt (3) Model 163, 171, 211, *BA27.55-P-1002-01A
from connection (1) on 219, 220, 461, 463
right oil cooling line (2) Model 199, 203, 209, *BA27.55-P-1002-01B
215, 230
7 Join connection fitting (4) Remove the connection
with an approx. 1.5 meter fitting (4) from the l hand
long hose using a hose pump.
clamp (5) Fig. 7
8 Mount banjo bolt (3) and
oil cooling line (2) to
connection fitting (4)
9 Hold hose into a bucket The bucket should have
with a scale on it a capacity of 10 liters.
10 Unlock cap (93) Break off plate (93a)
using a suitable tool and
press out locking pin (93b)
remaining in cap (93)
downwards.
11 Detach cap (93) from oil
filler pipe
12 Fit funnel to oil filler The entire flushing
pipe and pour 5 liters of procedure requires 14 liters
oil into transmission of transmission oil.
Fig. 4
Flushing
An assistant is required for
the flushing procedure
13 Start the engine and drain Always observe
transmission oil via the work procedure and
hose into the bucket operating fluid
specifications, otherwise
transmission will be
damaged.
14 Once 3 liters of
transmission oil are in the
bucket stop the engine
immediately
15 Pour in 3 liters of
transmission oil
16 Repeat flushing process
twice
17 Add remaining Model 129, 140, 163, 170, AR27.00-P-0101A
transmission oil (3 liters) 202, 208, 210, 211, 215,
and check transmission oil 220, 230, 240, 461, 463
level except 463.270/ 271
Model 171 AR27.00-P-0101V
Model 203, 209 AR27.00-P-0101P
Model 219 AR27.00-P-0101TZ
Model 463.270/271 AR27.00-P-0101GX
19 Carry out engine test run,
checking the transmission
for function and oil leaks

722.6 except 722.628 722.648 722.649
722.628/
648/649
BA27.10-P- Oil drain plug Nm 20 20 20 22
1001-03A to oil pan
BA27.10-P- Bolt, oil pan Nm 8 8 8 8
1002-03A to
transmission Angle° - - - -
housing

722.660/ 661 in 722.662/ 722.6 in model
model 163 663/666/ 171
673/674 in
model 163
BA27.55-P- Banjo bolt or Stage 1 Nm 20 20 5
1002-01A union nut, oil
cooler line to
torque
Stage 2 Angle° - - 95
converter and
transmission
housing
BA27.55-P- Bolt, clamp of Nm 8 8 8
1004-01A oil cooler line
to oil pan

Transmissions
Transmission Transmission Transmission 722.610/
722.6 in 722.643 in 722.6 in 611/630/
Number Designation model 211 model 219 model 220 637/638/ 645
BA27.55- Banjo bolt or Stage 1 Nm 5 20 5 20
P-1002- union nut, oil
01A cooler line to
torque
converter Stage 2 Angle° 95 - 95 -
and
transmission
housing
BA27.55- Bolt, clamp of oil Nm 8 8 8 8
P-1004- cooler line to oil pan
01A

722.648 722.649 except 722.695
in model
230.477
BA27.55-P- Banjo bolt, Stage 1 Nm 20 5 5
1002-01B transmission
oil line to
transmission Stage 2 Angle° - 95 90
housing
BA27.55-P- Bolt, oil cooler Nm - 11 11
1003-01B line to engine
oil pan
Fig. 202: Identifying Funnel (126 589 12 63 00)
REMOVE/INSTALL IGNITION LOCK CONTROL CABLE - AR27.60-P-0122I
TRANSMISSION 722.6 /9 in MODEL 215, 220
Shown on model 220
Fig. 204: Identifying Ignition Lock Control Cable Remove/Install Components (Shown On Model 220)
Remove/Install
Connect quiescent current retention device AR54.10-
1
(trickle charger) P-1030-07I
Key cannot be withdrawn.
Turn key in electronic ignition lock EIS With Keyless Go, code 889: Press
2
into position "0". start/stop button repeatedly until the
Risk of explosion from explosive gas. Risk No fire, sparks, open flames or
of poisoning and caustic burns from smoking. Wear protective gloves, acid-
AS54.10-
swallowing battery electrolyte. Risk of resistant clothing and safety glasses.
Z-0001-
injury through burns to skin and eyes from Pour battery electrolyte only into
01A
battery acid or when handling damaged suitable and appropriately marked
leadacid batteries containers.
AR54.10-
3 Disconnect ground cable from battery
P-0003I
AH54.10-
01A
AR68.20-
4.1 Remove cover on center console Model 215
P-2350N
AR68.20-
5.1 Remove cover on shift lever Model 220
P-2310M
Remove operating / display unit with Model 220 with COMAND operating AR82.85-
6.1
control module and display system, code 352a. P-7472I
AR68.20-
7 Remove center console Model 215
P-2000N
AR68.20-
Model 220 except 220.074 /174
P-2000M
AR68.20-
Model 220.074/ 174
P-2000AM
Unscrew fixing rosette on electronic
8 ignition switch control unit (N73) using Fig. 205
claw-type wrench
Pull electronic ignition switch control
9
module (N73) out of instrument panel
Installation: Switch ignition

Compress retaining lugs (arrows) and push switch to position "0".
out cable (1) of ignition switch on
10  It must only be possible to move
electronic ignition switch control unit (N73)
in the direction of the arrow the selector lever out of position
"P" when the transmitter key is in
position "2" and the brake pedal
is depressed.
 It must only be possible to
withdraw the ignition key when
the selector lever is in position
"P".
Unlatch cable (1) from ignition switch on Press locking tab (1b), twist
11 coupling (1c) through 90° in direction
electronic selector lever module control unit
(N15/5) of arrow and pull off ignition switch
cable (1).
Remove ignition switch cable (1) from When removing do not damage
12
instrument panel sound insulating mat.
AR00.19-
P-0200M
Fig. 205: Identifying Claw-Type Wrench For Rosette On Ignition/Starter Switch (210 589 00 07 00)
REMOVING AND INSTALLING WIRE CABLE / TRANSMISSION FOR PARKING SHIFT LOCK
ON TRANSMISSION - AR27.60-P-0500-05B
For removal and installation, move selector lever or range selector lever to position "P" and, with control
cable / gears removed, leave in position "P".
Removing
1. Turn cable/transmission (80) on transmission counterclockwise and remove.

Fig. 206: Turning Cable/Transmission On Transmission Counterclockwise
Installation
2. Install cable/transmission (80) and turn clockwise
After installation, adjust cable for parking shift lock and check for proper operation.
Fig. 207: Identifying Cable/Transmission
REMOVE/INSTALL FLOOR SHIFT - AR27.60-P-0900I
TRANSMISSION 722.6 in MODEL 215.373 /375 /376 /378 /379,

220.025 /026 /028 /063 /065 /067 /070 /073 /075 /083 /084 /087 /125 /126 /128 /165 /167 /170 /173 /175 /176 /17
Fig. 208: Identifying Floor Shift Remove/Install Components
Remove/Install
Disconnect shift rod from intermediate AR27.60-P-
1
lever 0990I
AR68.20-P-
2 Remove center console Model 215
2000N
AR68.20-P-
Model 220
2000M
Does not apply to air
Remove air duct for center rear
3.1 conditioning system in rear, code
compartment air nozzle
582.
Hexagon socket head bolts, *BA27.60-P-
4 Unscrew hexagon socket head bolts (40)
floor shift to body 1001-02A
Disconnect couplings at electronic
5
selector lever module control unit (N15/5)
Unclip ignition switch control cable from
AR27.60-P-
6 ignition switch control cable connecting Models 215, 220
0122I
pipe (1)
Remove electronic selector lever module
7
After installing the floor shift,
8 Install in the reverse order erase fault code with STAR
DIAGNOSIS.
STAR DIAGNOSIS diagnosis *WH58.30-Z-
system 1048-13A
TIGHTENING TORQUES FOR FLOOR SHIFT

BA27.60-P-1001-02A Hexagon socket head bolts, floor shift to body Nm 6

Number Designation
REMOVING AND INSTALLING ELECTRONIC SELECTOR LEVER MODULE (ESM) - AR27.60-P-

0901
Removing and installing electronic selector lever module (ESM) - AR27.60-P-0901AM
TRANSMISSION 722.643 in MODEL 215.374, 220.074 /174

Fig. 209: Identifying Electronic Selector Lever Module Connector Pin And Electronic Selector Lever
Module Control Module
Fig. 210: Identifying Electronic Selector Lever Module (ESM) Remove/Install Components
Remove/Install
AR61.20-P-
1 Remove engine compartment paneling Only remove rear part. 1105T
2 Disconnect shift rod from floor shift Move selector lever to position
"D"
Remove securing clip for this step.
AR82.95-
Activate the service mode in the TELE AID
3.1 Only with code 347, 855. P-0005-
03AM
AH82.95-
Notes regarding the Tele-Aid emergency call
Only with code 347, 855. P-0001-
system
01AM
Risk of explosion from explosive gas. Risk No fire, sparks, naked flames or
of poisoning and caustic burns from smoking. Wear protective gloves,
swallowing battery electrolyte. Risk of acid-resistant clothing and safety AS54.10-Z-
injury through burns to skin and eyes from glasses. Pour battery electrolyte only 0001-01A
battery acid or when handling damaged into suitable and appropriately
leadacid batteries marked containers.
Turn key in electronic ignition AR54.10-
4 Disconnect ground cable of battery switch EIS into position "0". Key P-0003I
cannot be withdrawn.
Vehicle fitted with code (889)
Keyless-Go:
Switch off engine, remove Keyless
Go cards from the vehicle and keep
outside the range of the transmitter.
Installation: Read out fault
memory after connecting, adjust time
display on combination instrument,
code radio, normalize power window
and activate steering angle sensor.
Vehicles with stationary heater:
adjust time display on stationary
heater.
Ensure that ground cable will not
come into renewed contact with the
battery terminal as you are working.
AH54.10-
Notes on battery All models P-0001-
01A
AR68.20-
5 Remove selector lever cover
P-2310M
AR68.20-
6 Remove center console
P-2000AM
Press locking tab (1b), twist
Release ignition lock cable (1) at electronic
coupling (1c) through 90° in the
7 selector lever module control module
direction of the arrow and pull off
(N15/5)
ignition lock cable (1).
Unplug electronic selector lever module
8
connector (2)
Pull locking plate off pin (3) and
9 Remove selector lever module press pin (3) backwards to access the
front bolt.
AR82.95-
Deactivate service mode in TELE AID
11.1 Only with code 347, 855. P-0005-
03AM
Perform basic programming AR00.19-
12 Render electrical system operational (normalize windows and sliding roof, P-0200M
etc.).
13 Perform function check If result is negative: ?
AR27.60-
Adjust shift rod.
P-0990I
Remove/install electronic selector lever module (ESM) - AR27.60-P-0901R
Transmission 722.617 in MODEL 220.063
Transmission 722.618 in MODEL 220.065 /165
Transmission 722.626 in MODEL 220.026
Transmission 722.628 in MODELS 215.378, 220.178 /878
Transmission 722.633 in MODELS 215.375, 220.075 /175 /875
Transmission 722.636 in MODELS 215.373, 220.073 /173
Transmission 722.6 in MODEL 230

(Transmission 722.6 In Model 230)
Remove/install
AH00.00-N-
0001-01A
Information on preventing damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
See ?
1 Unhook head on intermediate lever Remove/install and
adjust shift rod:
AR27.60-P-
Model 230
0990R
AR27.60-P-
Model 215, 220
0990I
Model 230 up to AR68.20-P-
2.1 Remove cover on center console
14.1.04 2350R
Model 230 as of AR68.20-P-
15.1.04 2350RA
AR68.20-P-
2.2 Remove center console Model 215
2000N
AR68.20-P-
Model 220
2000M
Only on model 215,
3.1 Remove air duct for center rear compartment air nozzle 220 without rear air
conditioner, code 582
4.1 Remove bolts (5) Only for model 230
On model 230 use
Allen wrench with ball
head.
5 Remove bolts (6)
Installation:
Replace self-locking
bolts (6).
*BA27.60-P-
1001-02A
Detach electric plugs on electronic selector lever module
6
Raise locking lug (2), press coupling (3) over the cable
connection fitting (4) against the spring force, turn the
7 coupling (3) through 90° (arrow) and detach ignition
switch cable (1) from electronic selector lever module
On model 230 raise
rear center console
Remove electronic selector lever module control unit
8 Installation: Pay
(N15/5).
attention to electrical
lines.
Read out fault memory with STAR DIAGNOSIS and STAR DIAGNOSIS *WH58.30-
10
erase if necessary. diagnosis system Z-1048-13A
Carry out function check of electronic selector lever
11
module control unit (N15/5)
TIGHTENING TORQUES FOR FLOOR SHIFT

BA27.60-P-1001-02A Bolt, floor selector to body Nm 6

Number Designation
Removing and installing electronic selector lever module (ESM) - AR27.60-P-0901RB
TRANSMISSION 722.901 in MODEL 215.375, 220.070 /075 /170 /175

(Transmission 722.901 In Model 215.375)
Remove/Install
Risk of death. Death may
result if vehicle slips or topples
from the lifting platform.
Notes on self-locking nuts and AH00.00-N-
bolts 0001-01A
The vehicle must be horizontal Position vehicle on the lifting platform.
Carry out control unit
When replacing the electronic selector lever
1.1 adaptation using STAR
module control unit (N15/5).
DIAGNOSIS
*WH58.30-
Z-1048-13A
2
"R".
Turn key in electronic ignition With Keyless Go, code 889:
3
lock EIS into position "0". Press start/stop button repeatedly until the
Lift the vehicle and unhook
shift rod from electronic AR27.60-P-
4
selector lever module control 0990I
unit (N15/5)
AR68.20-P-
5 Remove center console Model 215 2000N
AR68.20-P-
Model 220
2000M
6 Unscrew screw (2)
Unscrew hexagon socket bolts
7 Use Allen wrench with ball head.
(3)
*BA27.60-P-
1001-02A
Disconnect electrical plug
sockets from electronic
8
selector lever module control
unit (N15/5)
Lift up locking lug (5) and press coupling (6)
Unlatch cable (4) from ignition
against the spring force into the electronic
switch on electronic selector
9 selector lever module control unit (N15/5), rotate
lever module control unit
through 90° (arrow) and disconnect ignition lock
(N15/5)
cable (4).
Lift up center console at rear
and remove electronic selector Installation: Do not jam any electric cables in
10
lever module control unit between.
(N15/5)
12 Read out DTC memory
Connect STAR DIAGNOSIS AD00.00-P-
and read out fault memory 2000-04A
13 Perform function check If in bad condition: ?
AR27.60-P-
Adjusting shift rod
0990I
FLOOR SELECTOR TIGHTENING TORQUE

BA27.60-P-1001-02A Bolt, floor selector to body Nm 6

Number Designation
REMOVING AND INSTALLING SELECTOR LEVER HANDLE - AR27.60-P-0920-01A
STAR Remove
1. Loosen clamp (3) by turning anticlockwise (arrow A).

2. Pull selector lever handle (1) off selector lever (4).
Install
3. Push selector lever handle (1) onto the selector lever (4) and tighten the clamping piece (3) in clockwise
direction (arrow B).
Fig. 213: Identifying Selector Lever Handle Components
REMOVE/INSTALL PARK PAWL MECHANISM - AR27.60-P-0950
Remove/install park pawl mechanism - AR27.60-P-0950A
TRANSMISSION 722.6
Fig. 214: Identifying Park Pawl Mechanism Components
Remove
1 Remove range selector
lever; unscrew bolt (60) to
do this
2 Remove detent plate with
tapered rod (35, 34)
3.1 Undo bolt (36) Except model 215, 220
4.1 Remove bolt (141) Except model 215, 220
Bolt is caulked
5.1 Pull linkage (50) out of Except model 215, 220
detach lock pawl (139)
6 Remove circlip (52) of
pilot bushing (51)
7 Press park detent (53)
against spring (54) and
press pilot bushing (51)
out of transmission
housing using a suitable
tool
8 Remove circlip (56) and
bearing pin (55)
9 Remove park detent (53)
with spring (54)
Install
10 Insert park detent (53) and Check O-ring (55a)
spring (54) into and replace if necessary
install bearing pin (55)
with circlip (56)
11 Press park detent (53) Press in pilot
against spring (54) as far bushing until it snaps into
as stop and insert pilot place
bushing (51) into Check O-ring (51 a)
transmission housing so and replace if necessary
that the park detent snaps
into the recess of the pilot
bushing
12 Install circlip (52).
13.1 Insert linkage (50) into Except model 215, 220
attach lock pawl (139)
14.1 Install bolt (141) Except model 215, 220
Bolt must be
caulked on transmission
housing side
Check O-ring (141a)
and replace if necessary
15.1 Tighten bolt (36) Except model 215, 220
*BA27.60-P-1001-03A
16 Insert detent plate with
tapered rod (35 and 34)
17 Mount range selector Check sealing ring
lever (33) (33a), replace if necessary
*BA27.40-P-1006-01A
HOUSING
Transmission 722.6 except
722.660/661/66
Number Designation 2/663/666/674
BA27.40-P-1006-01A Bolt, detent plate to Nm 8
range selector lever
TIGHTENING TORQUES OF LINKAGE FOR PARKING SHIFT LOCK

BA27.60-P-1001-03A Bolt, parking shift lock Nm 8
linkage to transmission
housing
Remove, install park pawl mechanism - AR27.60-P-0950W
TRANSMISSION 722.9
Transmission removed
Fig. 215: Identifying Park Pawl Mechanism Remove/Install 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
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: Install
bearing bracket new bolts.
*BA27.40-P-1018-01A
6 Remove range selector Check the sealing
lever (81); to do so, ring (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 bearing
to do so, unscrew screw pin (85) using a bar
plug (85s) magnet.
*BA27.40-P-1017-01A
9 Remove pilot bushing Press the park detent
(84); to do so, unscrew (83) as far as possible
screw plug (84s) 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: Push the
together with spring (83f) 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
ADJUSTING WIRE CABLES FOR PARKING LOCK INTERLOCK - AR27.60-P-0965B
TRANSMISSION 722.60/61,
722.620 ## as of 1681,
722.621 ## as of 1977,
722.622 ## as of 16287,
722.623 /624 /625 /626 /627 /628 /629 /63 /66 /69
Fig. 218: Identifying Wire Cables For Parking Lock Interlock Components
MODIFICATION NOTES
15.10.97 Sequence of work steps
revised
The selector lever must be in

position "P" for all
adjustment work.
Adjusting wire The wire
cable/steering lock cable/transmission must be
installed to adjust the wire
cable/steering lock.
1 Pretension spring on
adjusting button (79a)
2 Turn key in steering lock to
position "0"
3 Adjust wire cable/steering
lock (79) by pressing
(arrow)
Adjusting wire
cable/transmission
4 Pretension spring on
5 Turn key in steering lock to
position "0"
6 Adjust wire
cable/transmission (80) by
pressing the adjusting button
(80a) (arrow) Figure A
REMOVE/INSTALL AND SET SHIFT ROD - AR27.60-P-0990I
TRANSMISSION 722.6 in MODEL 215, 220, 240
TRANSMISSION 722.9 in MODEL 215, 220
Fig. 219: Identifying Set Shift Rod Remove/Install Components
Remove
Risk of death. Death may result
if vehicle slips or topples from
the lifting platform.
The vehicle must be horizontal Position vehicle on the lifting platform.
1
"D".
2 Raise vehicle.
Remove shield in the area of the
3.1 electronic selector lever module Models 215, 220
3.2 Remove cover from shield Model 240
Unclip locking plates (1) using a
4
screwdriver
Detach rod head (98) from
5 intermediate lever (97)
Position range selector lever (33)
6
in position "R"
Detach shift rod (63) at range
7
selector lever (33)
Remove shift rod (63) together
8
with rod head (98)
Inspect
Check bushes in range selector
lever (33) and in intermediate
9
lever (97) for damage and replace
if necessary
Setting, installing
Saw slot in bolt head of locking
10.1 bolt (2) and unscrew locking bolt Vehicles with locking bolt
(2) from rod head (98)
10.2 Loosen grub screw (99) Vehicles with grub screw
Attach shift rod (63) at range
11
selector lever (33)
Move range selector lever (33) to
12
position "D"
Attach rod head (98) to
13
intermediate lever (97)
14 Clip in locking plates (1) Install new locking plates (1)
Vehicles with locking bolt
Replace locking bolt (2).
Screw in locking bolt (2) at rod
15.1 For tightening, counter-press at rod head (98)
head (98)
Do not move range selector lever (33) from
position "D".
*BA27.60-P-
1001-04A
Vehicles with grub screw
Replace grub screw (99).
15.2 Tighten grub screw (99) For tightening, counter-press at rod head (98)
Do not move range selector lever (33) from
position "D".
*BA27.60-P-
1001-04A
16 Perform function check
Install shield in the area of the
17.1 electronic selector lever module Models 215, 220
17.2 Install cover in the shield Model 240
TIGHTENING TORQUES FOR SHIFT ROD
BA27.60-P-1001-04A Bolt in rod head M8x10 Nm 12 12
REMOVING AND INSTALLING WIRE CABLE FOR PARKING LOCK INTERLOCK - AR27.60-P-
1000B
TRANSMISSION 722.60/61,
722.620 ## as of 1681,
722.621 ## as of 1977,
722.622 ## as of 16287,
722.623 /624 /625 /626 /627 /628 /629 /63 /66 /69
Fig. 220: Identifying Wire Cable For Parking Lock Interlock Components
Removing and installing

wire cable/ steering lock
1 Remove cover below left of ra68001400150x
instrument panel
2 Unhook wire cable/steering Installation : Position
lock (79) by pressing in the key in steering lock in
locking tongues and at the position "1"
same time pressing
(arrows) against the
steering lock (figure A)
3 Remove stop lamp switch AR42.10-P-0040A
4 Unhook wire cable/steering
lock (79) at the release
lever (77) (arrow) (figure
B)
5 Compress locking device
(arrows) and at the same
time push the wire
cable/steering lock upwards
out of the mount on the
pedal bearing bracket
(figure C)
6 Remove wire cable/steering
lock
7 Install in reverse order
8 Adjust wire cables for AR27.60-P-0965A
parking lock interlock
Removing wire
cable/transmission
9 Remove cover below left of ra68001400150x
instrument panel
10 Pull off entrance strip
upwards
11 Remove A-pillar footwell
cover
12 Unscrew accelerator pedal
from floor panel
13 Remove driver side floor Do not fold up
lining complete floor carpet, foamed
insulating material
cracks.
14 Remove air duct for rear
compartment heating
15 Unhook wire
cable/transmission (80) at
release lever (77) (arrow)
(figure B)
16 Compress locking device
(arrows) and at the same
time push the wire
cable/transmission upwards
out of the mount on the
pedal bearing bracket
(figure C)
17 Turn wire To install and AR27.60-P-0500-05B
cable/transmission (80) remove, position selector
counterclockwise and pull lever or range selector
off (figure D) lever in position "P" and
leave in position "P"
when wire cable/
transmission is removed.
Installation : Attach
wire cable/ transmission
and turn clockwise
(figure E)
18 Remove rubber boot on
tunnel
19 Open cable straps behind Installation : Attach
cover on left of tunnel and wire cable/ transmission
remove wire in the bracket on the
cable/transmission jacket tube
21 Adjust wire cables for AR27.60-P-0965A
parking lock interlock
AXLE SHAFTS
Axle Shafts - Rear - 215 & 220 Chassis
NOTE: The following tables identify applicable models covered in this article.
MODEL IDENTIFICATION 215 CHASSIS (2000-04)

Model (Year) Chassis Number
CL55 AMG (2003-04) 215.374
CL500 AMG (2001-02) 215.373
CL500 (2000-04) 215.375
CL600 (2001-03) 215.378
CL600 (2004) 215.376
MODEL IDENTIFICATION 220 CHASSIS (2000-04)

Model (Year) Chassis Number
S55 AMG (2001-02) 220.173
S55 AMG (2003-04) 220.174
S430 (2000-04) 220.170
S430 4MATIC (2003-04) 220.183
S500 (2000-04) 220.175
S500 4MATIC (2003-04) 220.184
S600 (2001-03) 220.178
S600 (2004) 220.176

All models are equipped with separate half axle shafts with inner and outer Constant Velocity (CV) joints.
Axles are serviceable separately. Outer CV joint is not serviceable. Inner CV joint is serviceable. Rubber boot is
serviceable for both inner and outer CV joints.
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

REAR AXLE SHAFTS
CAUTION: DO NOT move vehicle on its wheels with axle shaft(s) removed, damage to
wheel bearing will occur.
NOTE: Numbers in parenthesis correspond to numbers in illustrations.

Removal
1. Raise and support vehicle.

2. Remove rear wheel(s).
3. Remove axle shaft collard nut (12). See Fig. 1 .
4. Remove exhaust system as necessary to facilitate axle shaft removal.
5. Remove axle shaft bolts and washers from axle shaft (37) and connecting flange.
6. Move axle shaft into roughly horizontal position, push together and remove downwards at an angle from
the connecting flange.
Fig. 1: Removing Rear Axle Shaft

Disassembly
Outer CV joint is not serviceable. Inner CV joint can be disassembled and inspected for wear. Rubber boot is
serviceable for both inner and outer CV joints. For disassembly:
1. Remove large clamp on inner CV joint. See Fig. 2 .

2. Remove inner CV joint end cap and cup seal.
3. Remove inner CV joint circlip.
4. Push inner CV joint off axle shaft.
5. Remove small clamp on inner CV boot.
6. Remove inner CV boot.
7. Remove outer CV joint clamps.
8. Remove outer CV boot.
Fig. 2: Rear Axle Shaft Component Identification

Inspection
Clean and inspect all components of axle shaft. Inspect ball bearings and races of CV joints for scoring and
excessive wear. Inspect axle shaft splines for wear. Inspect condition of CV boots. Replace CV boots if worn.
Replace axle shaft assembly if CV joint(s) are worn. CV joints are not serviceable.
Reassembly
To reassemble axle shaft, reverse disassembly procedure. Fill CV joint with proper amount of NEW grease. See
CV JOINT GREASE QUANTITY table.
Installation
To install, reverse removal procedure. Oil rear axle flange bolt threads and bolt head contact surface prior to
installation. Torque all bolts to specification. See TORQUE SPECIFICATIONS .
CV JOINT GREASE QUANTITY
CV JOINT GREASE QUANTITY

Application Oz. (g)
Inner CV Joint 5.3 (150)
Outer CV Joint 4.2 (120)
Application Ft. Lbs. (N.m)
Rear Axle Collared Nut 236 (320)
Rear Axle Flange Bolt (1) 52 (70)
Wheel Lug Bolt (Alloy Or Steel Wheel) 81 (110)
(1) Oil rear axle flange bolt threads and bolt head contact surface prior to installation.
ACCESSORIES & BODY, CAB
Body Sealing, Corrosion Protection - 215 & 220 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: BODY SEALING, CORROSION PROTECTION - AH97.00-
Z-9999AZ
MODEL all
Notes on sprayable AH97.10-P-

MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0
seam sealing 0002-01FF
Notes on cavity AH97.20-P-
MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0
preservation 0001-01FF
Notes on applying
AH97.20-P-
permanent underfloor MODEL 454.0
9409-01FF
protection
Notes on
MODEL 129, 163, 164, 168, 169, 170, 171, 202, 203, 204, 208, AH97.20-P-
transportation
209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414 ... 9409-03A
sheeting
MODEL all
joint sealant 0002-01A
Notes on hollow AH97.20-P-
MODEL 168,414,639
cavity preservation 0001-01A
MODEL 124, 126, 129, 140, 164, 168, 169, 170, 171, 201, 202,
203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240,
245, 251, 463, 638, 639, 671, 690, 901, 902, 903, 904, 905, 906,
preservation 0001-01B
WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5,
XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 ...
Special notes
AH97.20-P-
regarding wax MODEL all with fire-extinguishing system
1000-02PV
preservation
MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 201,
Underfloor AH97.20-P-
202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230,
preservation 2000-01A
240, 245, 251, 414, 463, 638, 671, 906 ...
Underbody AH97.20-P-
MODEL 454.0, 450, 452
preservation 2000-01FF
MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199,
Instructions for
201, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221,
processing AH97.20-P-
230, 240, 245, 251, 414, 461, 463, 671, 690, 901, 902, 903, 904,
permanent 9409-01A
905, 906, WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4,
underbody protection
XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 ...
NOTES ON SPRAYABLE JOINT SEALANT - AH97.10-P-0002-01A

All models
Application areas:
With this material, when applied over large surfaces on areas such as the wheelhouses, longitudinal members
(rocker panels) and vehicle floor elements, the characteristics are visually equivalent to the standard or plant
seals in terms of the processing.
When applying the material from the standard cartridge (300 ml), a special compressed air gun is required
which allows different types of application for structured joints, surface coatings, stone-impact protection and
sound deadening in combination with the associated plastic injection nozzles.
Processing:
 Wet-in-wet painting possible between 30 min. and 8 h after application without paint additives. Forced
drying is necessary between 8 h and 72 h. Longer standing times should be avoided to exclude paint
adhesion losses.
 Adhesion surfaces must be clean, dry and free of grease.
 Spray filler/filler primer before application of sprayable joint sealing agent.
 Never apply the sprayable joint sealing agent to fresh (unhardened) 1K polyurethane material.
Specific material advantages of "sprayable joint sealing agent":
 Does not contain any isocyanates, silicone, PVCs and no dangerous agent.
 The replaceable nozzle makes cleaning unnecessary.
 Visual repair of the plant seals and underbody coating.
 Good stability.
 UV-resistant.
 Material offers a number of application possibilities.
 With the proper gun setting, the sprayable joint seal can be applied as joint seal and surface coating in
sequence.
 It is necessary, however, to wait for the end of the skin formation period of about 15 min. for the sprayed
seam.
 Can be painted over well.
NOTES ON CAVITY PRESERVATION - AH97.20-P-0001-01B
Model 124, 126, 129, 140, 164.1/8, 168, 169, 170, 171, 201, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219,
220, 221, 230, 240, 245.2, 251, 463, 638, 639, 671, 690.6, 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
The cavity preservation with wax already performed at the factory completes the corrosion prevention
measures.
No repetition of this preservation work is necessary.
Repair preservation
After accident repair spray cavities with wax in machined areas. When replacing detachable body components,
e.g. front fender, engine hood, doors, trunk lid as well as during welding, riveting and soldering work, also
perform repair preservation.
Always apply repair preservation agent twice with a drying time of 5 minutes in between.
After drying, ensure that drain holes are not plugged.
It is important that the wax preservation agent is applied following sealing and paintwork, however, before
assembly. Otherwise paint damage can occur or installation parts can be soiled with wax.
Also apply preservation agent to replacement bodies twice after they have been painted.
Replacement body shells top-coated in the factory have already been treated with the standard cavity
preservation.
Processing instructions
The processing temperature for the wax should not be less than +15 °C
The cavities should be dry for preservation. Before starting preservation work, check spray pattern of spraying
hose or spray can.
The wax must spray uniformly from the openings in a circular pattern.
Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear.
The spraying hose of the hand-held lance must be "stiff". Hoses that tend to roll up are not suitable.
When preserving, insert spraying hose as far as possible to all sides in the hollow cavities. Spray while slowly
inserting and pulling out hose.
Clean spray nozzle and spray hose together with spray equipment.
SPECIAL NOTES REGARDING WAX PRESERVATION - AH97.20-P-1000-02PV
All models with fire extinguishing system
When applying preservation wax, pressurize the entire extinguishing pipe system (approx. 10 bars) during
the spraying operation to prevent clogging the exit holes for extinguishing agent. Start by disconnecting the
extinguishing agent reservoir from the extinguishing pipe.
UNDERFLOOR PRESERVATION - AH97.20-P-2000-01A
Model 124, 126, 129, 140, 163, 164.1/8, 168, 169, 170, 171, 201, 202, 203, 204, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245.2, 251, 414, 463, 671, 638, 906
Repair damage on underbody protection as well as paint damage on door bottom edges, wheelhouse edges
and entrance.
Preserve underbody in area to be repaired following accident repair. Replacement body shells must have their
underbodies preserved when the vehicle is fully assembled.
The underside of the vehicle is to be cleaned before waxing. Spray the preservation wax on the dry underbody.
Do not spray following parts with preservation wax and cover if possible to prevent damage and extensive
cleaning work:
 Brake linings and brake discs

 Exhaust pipes and mufflers
 Propeller shafts
NOTES ON TRANSPORTATION SHEETING - AH97.20-P-9409
Instructions for processing permanent underbody protection - AH97.20-P-9409-01A
Model 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 201, 202, 203, 204, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245.2, 251, 414, 461, 463, 671, 690.6, 901, 902, 903, 904, 905, 906, WD1, WD2,
WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
The frame floor is coated with PVC permanent underbody protection as standard, see "Paintwork and Corrosion
Protection Manual". PVC is used as a standard material for sealing work in areas such as spot welds, door folds.
When PVC materials burn, they release a highly corrosive hydrochloric acid.
The new underbody protection agent does not adhere well to the burned PVC allowing rust to form later.
For this reason, always remove PVC underbody protection as well as PVC joint seals before starting any
brazing or welding work.
This also applies for work such as cutting or grinding
For the same reasons, it is preferable to separate damaged body parts using "cold" separating methods.
Notes on transportation sheeting - AH97.20-P-9409-03A
Model 129, 163, 164, 168, 169, 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240,
245.2, 251, 414
Since 1 July 1995, the exterior surface preservation has been eliminated on all vehicle models with code (524)
Paint protection. Instead, a protective sheeting is applied to the following surfaces on the vehicle in the factory:
 Horizontal surfaces (engine hood, roof, trunk lid)

 Front and rear fenders
 Front and rear doors on driver's side
 Outside mirror housings
 Bumper (with code (494) USA version)
In general, the transport foil remains on the painted exterior surface until the vehicle is prepared for sale
Remove transport foil 24 h before preparing for sale.
Time transport foil remains on vehicle.
The time the foil remains on the vehicle is limited to 180 days (new). The sheeting therefore carries a label on
the engine hood which specifies the latest removal date for the sheeting. After expiration date, it is necessary to
remove the foil by pulling off of the vehicle.
Removal of transport foil
In exceptional cases (transport foil missing or damaged, useful life expired or paintwork rectification
necessary), the entire vehicle or portions of the originally protected surfaces must be re-covered with transport
foil. To do this, the old sheeting and adhesive tape must be pulled off by hand.
If the temperature is too high (>50°C), adhesive residues may be left behind on the painted surfaces.
On icy vehicles the foil can tear when removing due to the effect of ice and snow.
Snow and ice residues can be thawed by heating up the surface temperature of the vehicle in a heated hall or
with the help of a hot air gun.
Heating also makes it easier to remove stubborn tape/adhesive residues.
Heat sources and cleaning fluid must not be used simultaneously.
In rare cases, localized swellings of the paintwork may be visible after the sheeting is removed. However,
this corrects itself within a few days.
Disposal of transport foil
The transport foil, the safety adhesive tape and the label for marking the expiration date consist of polyolefin
materials (PE/PP).
Dispose of separated foil waste properly. Observe legal regulations applicable in country.
SAFETY PRECAUTIONS
RISK OF EXPLOSION, POISONING AND RISK OF INJURY - AS97.00-Z-0001-01A
Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all
potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.
Potential risks
Risk of explosion
The solvents contained in anticorrosion agents (such as underfloor protective coatings, cavity wax, engine
compartment wax) are flammable, and may burst into flame if sprayed onto glowing hot components or open
flames.
Risk of poisoning
Inhaling spray and solvent vapors can lead to damage of the respiratory system and lungs. Symptoms of
poisoning include headache, breathing difficulty, nausea and loss of consciousness.
Underfloor protective coating materials further pose the following risks:
 Risk of damage to liver and kidneys.

 Central nervous system disorders, loss of consciousness.
 When these substances burn they produce toxic gases with a noxious odor; these gases are dangerous in
high concentrations.
Risk of injury
If anticorrosion coatings come in contact with the eyes they can cause severe eye damage.
In the event of frequent or prolonged contact with the skin, these substances can drain the skin of natural oils
and lead to inflammation.
Safety instructions/precautions
 Always remove all PVC undercoating and PVC seam sealer from the areas to be treated before
performing any welding or soldering. This also applies for work such as cutting, sanding or similar work.
 When removing damaged bodywork sections use "cold" separating methods when possible. With these
methods, smoke and toxic fumes are avoided.
 Do not expose containers to direct sunlight or to temperatures in excess of 50°C.
 Always apply at the prescribed pressure.
 Never spray corrosion inhibitor into flames or onto hot objects; keep well away from sparks and all
potential sources of ignition, and do not smoke.
 Take precautions to avoid sparks from electrostatic discharge.
 Avoid all contact with eyes and skin.
 Wear tight-fitting safety glasses and solvent-resistant gloves.
 Wear respiratory protection and apply only in well ventilated areas.
 If clothing becomes soaked or contaminated, remove and wash it immediately.
 Keep well away from food and drinks.
 Seal containers tightly and store them in a well-ventilated area.
First aid measures
In case of eye contact
 Flush thoroughly with water and consult a physician (eye doctor) immediately.
In case of ingestion
 Give medicinal activated charcoal, do not induce vomiting, consult a physician immediately.
In case of inhalation
 Move victim to fresh air, have victim lie down and remain calm, avoid strenuous activity.
In case of skin contact
 Immediately wash with soap and water, apply protective skin ointment.
Fire protection measures
Rescue, extinguishing and cleanup operations in areas contaminated by fumes should only be undertaken by
individuals wearing respiratory protection. Do not inhale fumes from flames or explosions.
Suitable extinguishing agents:
 Indirect water spray

 Foam
 Extinguishing powder
 Carbon dioxide
Non-suitable extinguishing agents:
 Direct high-pressure water spray
SAFETY INFORMATION: BODY SEALING, CORROSION PROTECTION - AS97.00-Z-9999ZZ
MODEL all
Risk of explosion and MODEL 100, 107, 108, 109, 111, 112, 113, 114, 115,
poisoning caused by 116, 123, 124, 126, 129, 140, 163, 164, 168, 169, 170,
AS97.00-
solvent vapors and gasses. 171, 201, 202, 203, 208, 209, 210, 211, 215, 216, 219,
Z-0001-
Risk of injury to skin and 220, 221, 230, 240, 245, 251, 405, 414, 436, 437, 450,
01A
eyes when working with 451, 452, 454, 461, 463, 613, 638, 639, 671, 690,
anticorrosion agents 901,902,903,904,905,906...
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: BODY SEALING, CORROSION
PROTECTION - AR97.00-Z-9215AA
MODEL 215
Seam seal following AR97.10-

MODEL 215
repair P-4000A
Sealing joints AR97.10-
MODEL 215
following repairs P-4000N
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209,
Process corrosion
210, 211, 215, 220, 230, 240, 463, 690, 901, 902, 903, 904, 905, AR97.20-
protection materials
WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, P-0500A
before painting
Cavity preservation AR97.20-
MODEL 215
following repair work P-1500A
MODEL 129, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, AR97.20-
Install transport foil
230, 240, 414 ... P-4000A
TESTING AND REPAIR WORK: PASSENGER CARS: BODY SEALING, CORROSION

PROTECTION - AR97.00-Z-9220AA
MODEL 220
Seam seal following AR97.10-

MODEL 220
repair P-4000B
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209,
Process corrosion
210, 211, 215, 220, 230, 240, 463, 690, 901, 902, 903, 904, 905, AR97.20-
protection materials
WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, P-0500A
before painting
Cavity preservation AR97.20-
MODEL 220
following repair work P-1500B
MODEL 129, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, AR97.20-
Install transport foil
230, 240, 414 ... P-4000A
PROCESSING OF BODY SEALANT (PAINTABLE) BEFORE PAINTING - AR97.10-P-0500-02A

1. Carefully clean affected body parts.
2. Apply body sealant uniformly.
3. Spread body sealant evenly.
4. Maintain drying time for overpainting.
When replacing sheet attached parts (doors, trunk lid, etc.) and also body parts welded in place, carefully
seal the folds and openings with body sealant in order to avoid corrosion and leaks. The spot weld seams and
the rivets must be sealed on both sides.
The brushes, wooden spatulas, etc. used to spread the body sealant should generally be cleaned only with
pure benzine. If these objects are cleaned with paint thinner or other alcoholic liquids before applying the body
sealant, the sealant does not cure and remains sticky.
SEAM SEAL FOLLOWING REPAIR - AR97.10-P-4000
Seam seal following repair - AR97.10-P-4000A
MODEL 215
Fig. Work instructions

item,
etc.
Risk of explosion and poisoning Never spray anticorrosion agents on flames or
caused by solvent vapors and glowing hot objects and keep them well away
AS97.00-Z-
gasses. Risk of injury to skin and from all potential sources of ignition. Use them
0001-01A
eyes when handling anticorrosion only in well-ventilated rooms; wear respiratory
agents. protection.
Model 124, 126, 129, 140, 163, 168, 169, 170,
AH97.20-
Underbody preservation 171, 201, 202, 203, 208, 209, 210, 211, 215,
P-2000-01A
219, 220, 230, 240, 414, 463, 671
Cavity preservation following AR97.20-P-
repair work 1500A
Application of body sealant AR97.10-P-
(paintable) before painting 0500-02A
Seam sealing following repair, front AR97.10-P-
end damage 4000-01A
Seam sealing following repair, rear AR97.10-P-
end damage 4000-02A
Seam sealing following repair, side AR97.10-P-
damage 4000-03A
Seam sealing following repair, AR97.10-P-
detachable body components 4000-04A
Service Information sprayable seam SI97.10-P-
seal 0001A
Seam seal following repair, front end damage - AR97.10-P-4000-01A
Fig. 1: Identifying Seal Spot Welding Area - Engine Compartment And Wheelhouse (Shown On Model
220)
Shown on model 220
Engine compartment and wheelhouse area
Fig. 2: Identifying Seal Spot Welding Area - Footwell And Inner A-Pillar (Shown On Model 220)
Shown on model 220
Footwell and inner A-pillar area
Fig. 3: Identifying Seal Spot Welding Area - Overall Underfloor
Overall underfloor area
1. Seal spot welds of area to be repaired with seam sealing material
Insert plastic plugs and grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle mounts, windows and detachable body components free
of sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side only seal corresponding surface.
Observe standard seals!
Seam seal following repair, rear end damage - AR97.10-P-4000-02A

Fig. 4: Identifying Seal Spot Welding Area - Wheelhouse And Rear Longitudinal Member
Wheelhouse and rear longitudinal member area
Fig. 5: Identifying Seal Spot Welding Area - Rear And Inner Trunk
Rear and inner trunk area

Fig. 6: Identifying Seal Spot Welding Area - Rear Longitudinal Member
Rear longitudinal member area
Fig. 7: Identifying Seal Spot Welding Area - Underfloor
Underfloor area, general
of sealant.
Seam seal following repair, side damage - AR97.10-P-4000-03A
Fig. 8: Identifying Seal Spot Welding Area - Outer A-Pillar (Shown On Model 220)
Outer A-pillar area, shown on model 220
Outer A-pillar and front longitudinal member area

Fig. 9: Identifying Seal Spot Welding Area - Outer A-Pillar And Front Longitudinal Member Area
Inner A-pillar area
Fig. 10: Identifying Seal Spot Welding Area - Inner A-Pillar

Fig. 11: Identifying Seal Spot Welding Area - Rear Fender
Rear fender area
Fig. 12: Identifying Seal Spot Welding Area - Wheelhouse And Rear Longitudinal Member

of sealant.
Seam seal following repair, detachable body components - AR97.10-P-4000-04A
Engine hood area

Fig. 14: Identifying Seal Spot Welding Area - Engine Hood
Front door area
Fig. 15: Identifying Seal Spot Welding Area - Front Door
Trunk lid cover and tank recess area

Fig. 16: Identifying Seal Spot Welding Area - Trunk Lid Cover And Tank Recess
Trunk lid area
Fig. 17: Identifying Seal Spot Welding Area - Trunk Lid
of sealant.
Seam seal following repair - AR97.10-P-4000B
MODEL 220
Fig. Work instructions

item,
etc.
AS97.00-Z-
0001-01A
agents. protection.
Model 124, 126, 129, 140, 163, 168, 169, 170,
AH97.20-
Underbody preservation 171, 201, 202, 203, 208, 209, 210, 211, 215,
P-2000-01A
219, 220, 230, 240, 414, 463, 671
Cavity preservation following AR97.20-P-
repair work 1500B
Application of body sealant AR97.10-P-
(paintable) before painting 0500-02A
Seam sealing following repair, front AR97.10-P-
end damage 4000-01B
Seam sealing following repair, rear AR97.10-P-
end damage 4000-02B
Seam sealing following repair, side AR97.10-P-
damage 4000-03B
Seam sealing following repair, AR97.10-P-
detachable body components 4000-04B
Service Information sprayable seam SI97.10-P-
seal 0001A
Seam seal following repair, front end damage - AR97.10-P-4000-01B

Fig. 18: Identifying Seal Spot Welding Area - Engine Compartment And Wheelhouse
Area of engine compartment and wheelhouse
Fig. 19: Identifying Seal Spot Welding Area - Footwell And Inner A-Pillar
Area of footwell and inner A-pillar

Fig. 20: Identifying Seal Spot Welding Area - Overall Underfloor
1. Seal spot welds of area to be repaired with seam sealing material.
of sealant.
Seam seal following repair, rear end damage - AR97.10-P-4000-02B
Area of rear, sidewall and C-pillar

Fig. 21: Identifying Seal Spot Welding Area - Sidewall And C-Pillar
Area of rear wheelhouse, rear fender and rear end
Fig. 22: Identifying Seal Spot Welding Area - Rear Wheelhouse, Rear Fender And Rear End (1 Of 2)
Fig. 23: Identifying Seal Spot Welding Area - Rear Wheelhouse, Rear Fender And Rear End (2 Of 2)
Area of rear end and left and right inner trunk
Fig. 24: Identifying Seal Spot Welding Area - Rear End And Left/Right Inner Trunk
Area of inner rear passenger compartment

Fig. 25: Identifying Seal Spot Welding Area - Inner Rear Passenger Compartment
Area of longitudinal member on rear cross member
Fig. 26: Identifying Seal Spot Welding Area - Longitudinal Member On Rear Cross Member
of sealant.
Seam seal following repair, side damage - AR97.10-P-4000-03B
Fig. 27: Identifying Seal Spot Welding Area - Outer A-Pillar
Area of outer A-pillar
Area of outer A-pillar and front longitudinal member

Fig. 28: Identifying Seal Spot Welding Area - Outer A-Pillar And Front Longitudinal Member
Inner A-pillar area
Fig. 29: Identifying Seal Spot Welding Area - Inner A-Pillar

Area of rear, sidewall and C-pillar
Fig. 30: Identifying Seal Spot Welding Area - Sidewall And C-Pillar
Area of sidewall and rear wheelhouse
Fig. 31: Identifying Seal Spot Welding Area - Sidewall And Rear Wheelhouse
of sealant.
Seam seal following repair, detachable body components - AR97.10-P-4000-04B
Engine hood area

Fig. 33: Identifying Seal Spot Welding Area - Engine Hood
Area of front door
Fig. 34: Identifying Seal Spot Welding Area - Front Door
Area of rear door

Fig. 35: Identifying Seal Spot Welding Area - Rear Door
Fig. 36: Identifying Seal Spot Welding Area - Sidewall And Doors
Area of sidewall and doors
Area of trunk lid, license plate recess and tank recess

Fig. 37: Identifying Seal Spot Welding Area - Trunk Lid, License Plate Recess And Tank Recess
of sealant.
Sealing joints following repairs - AR97.10-P-4000N
MODEL 215
Sealing
Following repairs on hybrid body, spot weld and welding
flanges are to be sealed on both sides in repair area.
Riveted and bonded joints are only to be additionally
sealed if the adhesive does not perform this sealing AR97.10-P-
1 Sealing following repairs function.
0500-02A
Do not apply sealant to unprimed repair areas.
When replacing components such as doors, engine
hood, trunk lid, etc. seams and folds are also to be sealed
Notes on sprayable joint AH97.10-P-
sealant 0002-01A
Service information on SI97.10-P-
All models
sprayable seam sealing 0001A
PROCESS CORROSION PROTECTION MATERIALS BEFORE PAINTING - AR97.20-P-0500A
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463
MODEL 690.6, 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
Fig.
item, Work instructions
etc.
Model 124, 126, 129, 140, 163, 168, 169, 170, 201, 202, 203,
Notes on processing 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 671, 690.6,
AH97.20-P-
permanent underbody 901, 902, 903, 904, 905, WD1, WD2, WD3, WD6, WD7,
9409-01A
protection agent XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3,
YD4, YD5, YD6, YD7
Application of body
For sealing plans see paint and corrosion protection AR97.10-P-
sealant (paintable)
manual. 0500-02A
before painting
Do not use zinc dust paint for painting outer surface
Process zinc dust AR97.20-P-
paint before painting All bare sheet metal parts must be free of dirt, rust, oil and 0500-01A
wax.
Process permanent
AR97.20-P-
underbody protection
0500-03A
agent for painting
Processing zinc dust paint before painting - AR97.20-P-0500-01A
Zinc dust paint serves for preventing corrosion on welds, sheet metal contact points and surfaces, which
cannot be painted or are difficult to paint following assembly. Do not use zinc dust paint for painting the
exterior surface
1. Thoroughly clean body parts to be painted
All bare sheet metal parts must be completely clean and free of rust, oil and wax.
2. Uniformly apply zinc dust paint with brush or paint spray gun.
Maintain drying time of zinc dust paint before overpainting.

Processing permanent underbody protection agent for painting - AR97.20-P-0500-03A
Permanent underbody protection agent (synthetic rubber), dark gray
The permanent underbody protection agent is designed on a synthetic rubber basis and is suited for processing
fender bottom sections, underbody as well as transitions to original standard PVC underbody protection.
Not suited for sealing work (seam sealing). Blow through spray gun with solvent after use. Ensure that air
hole on screw-in thread is free.
Permanent underbody protection (water-base dispersion), gray
This permanent underbody protection agent is a water-base dispersion suitable for use on the underbody, fender
bottom sections as well as outer surface For processing on the outer surface (e.g. front fender below bumper,
longitudinal members at entry) thin material with 5 % water to achieve better coverage.
This underbody protection agent is not suited for the transitions to the original standard PVC underbody
protection agent and to the sealing work (seam sealing) because it can result in insufficient adhesion and crack
formation
After finishing work, clean equipment thoroughly with water and moisten air flap with mineral oil before
reusing, otherwise the spray mist can dry affecting the function
Processing permanent underbody protection agent for painting
 All areas to which permanent underbody protection agent is to be applied must be thoroughly cleaned
(steam cleaner). In particular, remove wax and oil residues as well as loose pieces of PVC thoroughly.
Grind corroded points down to bare metal and prime.
A hot air gun and flat nozzle with integrated scraper or rotating wire brushes are suitable for removing the
PVC material.
 Apply permanent underbody protection agent uniformly with spray gun.
Do not spray permanent underfloor protection on equipment, otherwise, the function could be impaired.
 Observe drying time before overpainting.
CAVITY PRESERVATION FOLLOWING REPAIR WORK - AR97.20-P-1500
Cavity preservation following repair work - AR97.20-P-1500A
MODEL 215
Engine hood area

Fig. 38: Identifying Engine Hood Area For Cavity Preservation (Model 215)
Front longitudinal member area
Fig. 39: Identifying Front Longitudinal Member Area For Cavity Preservation (Model 215)
Wheelhouse liner and front longitudinal member area

Fig. 40: Identifying Wheelhouse Liner And Front Longitudinal Member Area For Cavity Preservation
(Model 215)
A-pillar area
Fig. 41: Identifying A-Pillar Area For Cavity Preservation (Model 215)
Fig. 42: Identifying Wheelhouse And Rear Longitudinal Member Area For Cavity Preservation (Model
215)
Fig. 43: Identifying Longitudinal Member, Rear End And Rear Cross Member Area For Cavity
Preservation (Model 215)
Longitudinal member, rear end and rear cross member area
Front door area

Fig. 44: Identifying Front Door Area For Cavity Preservation (Model 215)
Rear fender area
Fig. 45: Identifying Rear Fender Area For Cavity Preservation (Model 215)
Trunk lid area

Fig. 46: Identifying Trunk Lid Area For Cavity Preservation (Model 215)
Fig. 47: Identifying Underfloor Area For Cavity Preservation (Model 215)

AS97.00-Z-
0001-01A
agents. protection.
Model 124, 126, 129, 140, 168, 169, 170, 171,
201, 202, 203, 208, 209, 210, 211, 215, 219,
Notes on cavity preservation 220, 230, 240, 463, 639, 671, 690.6, 901, 902, AH97.20-P-
903, 904, 905 0001-01B
Model WD1, WD2, WD3, WD6, WD7, XD1,
XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2,
YD3, YD4, YD5, YD6, YD7
Apply cavity preservation agent in colored
areas, from inside, only after completing sealing
and paintwork, however, before assembly work.
Apply repair preservation agent twice with a
drying time of 5 minutes in between.
1 Perform repair preservation The spraying hose should be stiff and the
nozzles should spray at angle to the front and
rear. The cavities should be dry.
Insert spray hoses as far as possible into
cavities. Spray while inserting and pulling out
slowly.
Processing instructions for cavity AP97.20-P-
preservation agent 0640-01A
GF98.00-P-
Cavity protection, general
2045A
*WE58.40-
Cavity preservation gun Sata HRS no. 11072
Z-1006-08A
*BR00.45-Z-
MB cavity wax preservation, 1 l
1003-05A
The processing temperature should not be
Remove cavity sealant from drain less than 15 °C. Additional preservation
2 measures may be required depending on the
holes
repair area deviating from the standard cavity
preservation illustrated.
WORKSHOP EQUIPMENT DESCRIPTION

WE58.40-Z-1006-08A Cavity preservation gun
REPAIR MATERIALS SPECIFICATION

BR00.45-Z-1003-05A Preservation agent A 000 986 72 70 05
Cavity preservation following repair work - AR97.20-P-1500B
MODEL 220
Engine hood area

Fig. 48: Identifying Engine Hood Area For Cavity Preservation (Model 220)
Area of front longitudinal member
Fig. 49: Identifying Front Longitudinal Member Area For Cavity Preservation (Model 220)
Wheelhouse liner and front longitudinal member area

Fig. 50: Identifying Wheelhouse Liner And Front Longitudinal Member Area For Cavity Preservation
(Model 220)
A-pillar area
Fig. 51: Identifying A-Pillar Area For Cavity Preservation (Model 220)
Area of wheelhouse and inner longitudinal member
Fig. 52: Identifying Wheelhouse And Inner Longitudinal Member Area For Cavity Preservation (Model
220)
Fig. 53: Identifying Longitudinal Member, Rear End And Rear Cross Member Area For Cavity
Preservation (Model 220)
Area of longitudinal member, rear end and rear cross member
Area of front door

Fig. 54: Identifying Front Door Area For Cavity Preservation (Model 220)
Area of B-pillar
Fig. 55: Identifying B-Pillar Area For Cavity Preservation (Model 220)
Area of rear door

Fig. 56: Identifying Rear Door Area For Cavity Preservation (Model 220)
Rear fender area
Fig. 57: Identifying Rear Fender Area For Cavity Preservation (Model 220)
Trunk lid area

Fig. 58: Identifying Trunk Lid Area For Cavity Preservation (Model 220)
Fig. 59: Identifying Underfloor Area For Cavity Preservation (Model 220)

AS97.00-Z-
0001-01A
agents. protection.
Model 124, 126, 129, 140, 168, 169, 170, 171,

201, 202, 203, 208, 209, 210, 211, 215, 219, AH97.20-P-
Notes on cavity preservation
220, 230, 240, 463, 639, 671, 690.6, 901, 902, 0001-01B
903, 904, 905
Model WD1, WD2, WD3, WD6, WD7, XD1,
XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2,
YD3, YD4, YD5, YD6, YD7
Apply cavity preservation agent in colored
areas, from inside, only after completing sealing
and paintwork, however, before assembly work.
Apply repair preservation agent twice with a
drying time of 5 minutes in between.
1 Perform repair preservation The spraying hose should be stiff and the
nozzles should spray at angle to the front and
rear. The cavities should be dry.
Insert spray hoses as far as possible into
cavities. Spray while inserting and pulling out
slowly.
Processing instructions for cavity AP97.20-P-
preservation agent 0640-01A
GF98.00-P-
Cavity protection, general
2045A
*WE58.40-
Cavity preservation gun Sata HRS no. 11072
Z-1006-08A
*BR00.45-Z-
MB cavity wax preservation, 1 l
1003-05A
The processing temperature should not be
Remove cavity sealant from drain less than 15 °C. Additional preservation
2 measures may be required depending on the
holes
repair area deviating from the standard cavity
preservation illustrated.
WORKSHOP EQUIPMENT DESCRIPTION

WE58.40-Z-1006-08A Cavity preservation gun
REPAIR MATERIALS
INSTALL TRANSPORT FOIL - AR97.20-P-4000A
MODEL 129, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414 with CODE (524) Paint
protection
Notes on
Model 129, 163, 168, 169, 170, 202, 203, 208, 209, 210, 211, AH97.20-P-
transportation
215, 220, 230, 240, 414 9409-03A
sheeting
1.1
Remove old If old transport foil is present. Using heat simplifies removal
transport foil of transport foil. Do not heat transport foil too much to prevent
paint damage
2 Clean the vehicle Chamois the vehicle dry.
Visible adhesive tape marks from repainting can remain
because they are removed before the vehicle is shipped.
Check paint surface
3 It is not necessary to take swelling into consideration when
on vehicle
repainting. The new transport foil can be installed on these paint
surfaces
Install new transport Do not mask plastic parts and rubber profiles not with new
4
foil by hand transport foil
MAINTENANCE
PRESERVATION - AP97.20-P-0640A
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202.0 /1, 203, 208.3 /4, 209, 210.0 /2, 211, 215, 220, 230,
240, 414.700
MODEL 461.302 /332 /342 /345
MODEL 463
Application
1 Apply seam seal
Seam sealing Model 124, 126, 129, 140, 163, 168, 201,
following repair 230.456/467/471/472/476/477/479, 461.302/332/342/345, 463
Seam sealing AR97.10-P-
Model 202
following repair 4000E
AR97.10-P-
Model 203
4000P
AR97.10-P-
Type 208.3
4000K
AR97.10-P-
Type 208.4
4000KA
AR97.10-P-
Model 209
4000Q
AR97.10-P-
Model 210
4000F
AR97.10-P-
Model 211
4000T
AR97.10-P-
Model 215
4000A
AR97.10-P-
Model 170
4000G
AR97.10-P-
Model 220
4000B
AR97.10-P-
Model 230.474/475
4000R
AR97.10-P-
Model 240
4000H
AR97.10-L-
Model 414.700
4000VA
All models
seam sealing 0002-01A
Apply hollow cavity
2 Before use shake or stir preservation wax thoroughly.
preservation
Cavity preservation Model 124, 126, 129, 140, 163, 168, 201, 203, 209,
following repair 230.456/467/471/472/474/ 476/477/479, 461.302/332/342/345,
work 463
Cavity preservation
AR97.20-P-
following repair Model 202.0/1
1500E
work
AR97.20-P-
Model 210
1500F
AR97.20-P-
Model 211
1500T
AR97.20-P-
Model 215
1500A
AR97.20-P-
Model 170
1500G
AR97.20-P-
Model 220
1500B
AR97.20-P-
Model 208.3/4
1500K
AR97.20-P-
Type 230.475
1500R
AR97.20-L-
Model 414.700
1500VA
Model 168, 414, 639
preservation 0001-01A
Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203,
208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6,
preservation 0001-01B
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
Processing AP97.20-P-
instructions for 0640-01A
cavity preservation
agent
Model 461, 463: During subsequent preservation work on
Apply underbody the underbody cover brake parts such as brake discs and brake
3
preservation agent hoses in a suitable manner to prevent them from being sprayed
resulting in subsequent extensive cleaning.
Processing
permanent
AR97.20-P-
underbody
0500-03A
protection agent for
painting
Underfloor Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, AH97.20-P-
preservation 209, 210, 211, 215, 220, 230, 240, 414, 463, 671 2000-01A
Instructions for
processing
Model 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, AH97.20-P-
permanent
210, 215, 220, 230, 414, 461, 463 9409-01A
underbody
protection
Remove wax fog
residues on outer
4
surface with silicon
remover
Treat outer surface
with polish and *BR00.45-
5 Polish
gloss preservation Z-1013-04A
agent
*BR00.45-
Gloss preserver
Z-1014-04A
Install transport
6 As replacement for exterior preservation.
protection foil
Installing transport AR97.20-P-
Except model 124, 126, 140, 201, 461, 463
foil 4000A
Notes on
Models 129, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, AH97.20-P-
transportation
220, 230, 240, 414 9409-03A
sheeting
REPAIR MATERIALS
BR00.45-Z-1013-04A Polish A 000 986 45 74
BR00.45-Z-1014-04A Gloss preserver A 000 986 44 74
Processing instructions for cavity preservation agent - AP97.20-P-0640-01A
The cavity preservation with wax already performed at the factory completes the corrosion prevention
measures.
No repetition of this preservation work is necessary.
Repair preservation
Following accident repairs, spray hollow cavities with wax in the repaired area. When replacing detachable
body components, e.g. front fender, engine hood, doors, trunk lid as well as during welding, riveting and
soldering work, also perform repair preservation.
Always apply two coats of repair preservation agent, one after another with an air drying time of 5 min. in
between.
After drying, ensure that drain holes are not plugged.
It is important that the wax preservation agent is applied following sealing and paintwork, however, before
assembly. Otherwise painting defects can occur or attached parts may be contaminated with wax.
It is also necessary to preserve replacement bodies twice after painting.
Replacement bodyshells top-coated in the factory have already been treated with the standard cavity
preservation.
Working instructions
The cavities must be dry before preserving. Before commencing preservation work, check the spray pattern
from the spraying hose or spray can. The wax must spray uniformly from the openings in a circular pattern.
Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear.
The spraying hose of the hand-held lance must be "stiff". Hoses that tend to roll up are not suitable.
When preserving, insert spraying hose as far as possible to all sides in the hollow cavities. Spray while slowly
inserting and retracting the hose (processing temperature not below +15°C). Clean spray nozzle and spray hose
together with spray equipment.
BRAKES
Brakes - Testing & Repair - 215 & 220 Chassis
TESTING & REPAIR

INSTALLING PROTECTIVE WASHERS TO PROTECT BRAKE DISK DUST SHIELDS - AR42.00-P-
0100-01A
Fig. 1: Identifying Guard Plate (220 589 01 31 00)
The wheel bolts on light-alloy rims are too long; only use short bolts.
1. Attach guard plate (060) to wheel hub with 3 wheel bolts.
Fig. 2: Identifying Guard Plate
TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND

MECHANICAL SYSTEMS - AR42.00-Z-9215AA
MODEL 215
Bleed brake system MODEL 215, 220 AR42.10-P-0010I

Replace brake hoses Models 215, 220 AR42.10-P-0013I
Test brake system with MODEL 215, 220 AR42.10-P-0015I
pressure tester for leaks
Remove/install mechanical MODEL 211, 215, 220, AR42.10-P-0040I
stop lamp switch 230
Remove/install front axle MODEL 215, 220 AR42.10-P-0070I
brake caliper
Remove/install rear axle MODEL 215, 220 AR42.10-P-0080I
brake caliper
Remove/install brake pads MODEL 215, 220 AR42.10-P-0161I
on fixed caliper
Remove/install brake disc MODEL 215, 220 AR42.10-P-0220I
Remove/install master Models 215, 220 AR42.10-P-0300I
brake cylinder
Remove/install parking Models 215, 220 AR42.20-P-0510I
brake pedal assembly
Remove/install front brake MODEL 215, 220 ... AR42.20-P-0520I
cable
Remove/install rear brake MODELS 215, 220 AR42.20-P-0525I
control cable
Removing and installing MODEL 215 (except AR42.20-P-0530I
brake shoes of parking 215.379) MODEL 220
brake (except 220.179) MODEL
230
Removing and installing MODEL 215.379, AR42.20-P-0530IM
brake shoes of parking 220.179
brake
Adjusting parking brake MODELS 215, 220 AR42.20-P-0540I
(except 215.379, 220.179)
Adjusting parking brake MODEL 215.379, AR42.20-P-0540IM
220.179 with ENGINE
275.980
Remove/install left front or MODEL 215, 220, 230 AR42.30-P-0712I
right rpm sensor
Removing and installing MODEL 215, 220 AR42.31-P-6002I
BAS diaphragm travel
sensor
Remove/install Models 215, 220 AR42.40-P-0816I
ETS/ASR/ESP hydraulic
unit
Removing and installing Models 215, 220 AR42.40-P-0820I
left or right rear axle speed
sensor
Remove/install yaw rate MODEL 163, 168, 170, AR42.45-P-0841A
and lateral acceleration 202, 208, 210, 215, 220
sensor
TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND
MECHANICAL SYSTEMS - AR42.00-Z-9220AA
MODEL 220
Bleed brake system MODEL 215, 220 AR42.10-P-0010I

Bleed brake system MODEL 220 with CODE AR42.10-P-0010MB
(979) Special protection
version with CODE (Z07)
Top protection
Replace brake hoses Models 215, 220 AR42.10-P-0013I
Test brake system with MODEL 215, 220 AR42.10-P-0015I
pressure tester for leaks
Remove/install mechanical MODEL 211, 215, 220, AR42.10-P-0040I
stop lamp switch 230
Remove/install front axle MODEL 215, 220 AR42.10-P-0070I
brake caliper
Remove/install rear axle MODEL 215, 220 AR42.10-P-0080I
brake caliper
Remove/install brake pad Model 220 AR42.10-P-0160I
on floating brake caliper
Remove/install brake pads MODEL 215, 220 AR42.10-P-0161I
on fixed caliper
Remove/install brake disc MODEL 215, 220 AR42.10-P-0220I
Remove/install master Models 215, 220 AR42.10-P-0300I
brake cylinder
Remove, install brake MODELS 220.175 /178 AR42.10-P-0302MB
booster hydraulic unit with CODE (Z07)
maximum protection
Remove, install motor-and- MODELS 220.175 /178 AR42.10-P-0303MB
pump assembly with CODE (Z07)
maximum protection
Remove, install motor-and- MODEL 220.175 /178 AR42.10-P-0304MB
pump assembly pressure with CODE (Z07) Top
reservoir protection
Remove, install brake MODEL 220.175 /178 AR42.10-P-0305MB
booster hydraulic unit with CODE (Z07) Top
pressure reservoir protection
Remove/install parking Models 215, 220 AR42.20-P-0510I
Remove/install front brake MODEL 215, 220 ... AR42.20-P-0520I
cable
Remove/install rear brake MODELS 215, 220 AR42.20-P-0525I
control cable
Removing and installing MODEL 215 (except AR42.20-P-0530I
brake shoes of parking 215.379) MODEL 220
brake (except 220.179) MODEL
230
Removing and installing MODEL 215.379, 220.179 AR42.20-P-0530IM
brake shoes of parking
brake
Adjusting parking brake MODELS 215, 220 AR42.20-P-0540I
(except 215.379, 220.179)
Adjusting parking brake MODEL 215.379, 220.179 AR42.20-P-0540IM
with ENGINE 275.980
Remove/install left front or MODEL 215, 220, 230 AR42.30-P-0712I
right rpm sensor
BAS diaphragm travel
sensor
Remove/install Models 215, 220 AR42.40-P-0816I
ETS/ASR/ESP hydraulic
unit
Removing and installing Models 215, 220 AR42.40-P-0820I
left or right rear axle speed
sensor
Remove/install yaw rate MODEL 163, 168, 170, AR42.45-P-0841A
and lateral acceleration 202, 208, 210, 215, 220
sensor
Checking brake booster MODEL 220.175 /178 AR42.50-P-0001MB
hydraulic unit with CODE (Z07) Top
protection
BLEED BRAKE SYSTEM - AR42.10-P-0010
Bleed brake system - AR42.10-P-0010I
MODEL 215, 220
Sequence of bleeding operation for brake calipers with one bleed screw, shown on model 220.
Fig. 3: Identifying Sequence Of Bleeding Operation For Brake Calipers With Bleed Screw
Sequence of bleeding operation for 8-piston brake calipers at front axle with two bleed screws
Observe different sequence of bleeding operation for left-hand and right-hand drive vehicles.
Fig. 4: Locating Bleeding Operation For Left-Hand And Right-Hand Drive Vehicles
MODIFICATION NOTES
11.8.05 Bleed screw on rear axle Model 215.379
fixed brake caliper
Remove/install
Risk of death caused Align vehicle between the columns of the AS00.00-Z-0010-
by vehicle slipping or lifting platform and position the four 01A
toppling off of the support plates at the lifting platform
lifting platform. support points specified by the vehicle
manufacturer.
Risk of poisoning Only pour brake fluid into suitable and AS42.50-Z-0001-
caused by swallowing appropriately marked containers. Wear 01A
brake fluid. Risk of protective clothing and eye protection
injury caused by when handling brake fluid.
brake fluid coming
into contact with skin
and eyes.
Notes on handling AH42.50-P-0001-
brake fluid 01A
Notes on externally AH42.10-P-9406-
invisible brake fluid 02A
loss
Notes on repairs to AH42.00-P-0003-
brake system 01A
1 Connect filling and Pay attention to manufacturer's
bleeding device operating instructions. Bleeding pressure
> or =2 bar.
Brake fluid changer, see GOTIS
Brake fluid *BF42.10-P-1001-
01A
2 Carrying out bleeding To assist the bleeding operation, press AR42.10-P-0010-
operation the brake pedal for high-pressure 02I
bleeding.
Bleed screw to brake caliper *BA42.10-P-1002-
10G
12G
Socket wrench Fig. 6
3 Install in the reverse
order
4 Inspect fluid level in Brake fluid *BF42.10-P-1001-
brake fluid reservoir, 01A
adjust to correct level
if necessary
FRONT AXLE BRAKE CALIPER
BA42.10-P-1002-10G Bleed screw to brake Nm 7
caliper

Number Designation Model 220 except Model 220 with special
model protection, model
08/18/074/174/ 179, 220.08/18/074/174/179
model 220 without
special protection
BA42.10-P-1002- Bleed screw to Nm 7 14
10G brake caliper
REAR AXLE BRAKE CALIPER

Number Designation Model 215 except Model 215.374
215.374
12G brake caliper

Number Designation Model 220 without Model 220 with
special protection, special protection,
except model model 220.074/174
074/174
12G brake caliper
BRAKE FLUID
Number Designation Model 215 Model 220
BF42.10-P- Brake fluid Filling capacity Liters approx. 0.7...0.9 approx. 0.7...0.9
1001-01A Specifications for Sheet BB00.40-P- BB00.40-P-
Operating Fluids 0330-01A 0330-01A
Sheet BB00.40-P- BB00.40-P-
0331-00A 0331-00A
Fig. 5: Identifying Socket Wrench (140 589 03 09 00)
Carrying out bleeding operation - AR42.10-P-0010-02I
MODIFICATION NOTES
11.8.05 Bleed screw on rear axle Type 215.379 *BA42.10-P-1002-01A
fixed brake caliper
FRONT AXLE FIXED BRAKE CALIPER

Number Designation Model 215.373/ Model
375/378, Model 215.374/376/379
215.376 except 215.376
BA42.10-P-1002- Bleed screw at Nm 7 14
02A front axle fixed
brake caliper

Number Designation Model 220 except Model Model 220.176
220.074/174/ 220.074/174/ 179,
176/179, Model model 220.176
220.175 without without ,
code Z07 +979 model 220.175
with code Z07
+979
BA42.10-P- Bleed screw at Nm 7 14 7
1002-02A front axle fixed
brake caliper
FRONT AXLE FLOATING BRAKE CALIPER

Number Designation Model 163.113 up Type 163.11316
to VIN A289564,
X754619 163.154
up to VIN A289564
except
BA42.10-P-1002- Bleed screw at front Nm 18 18
03A axle floating caliper

Number Designation Model 163.113 Model 163.128/ Model
as of VIN 172/174/ 175 163.128/except
A289565,
X754620
163.154 as of
VIN A289565
except
1002-02A front axle fixed
brake caliper
FRONT AXLE FLOATING BRAKE CALIPER

Number Designation Models 163.128/ Model 163.154/157
157/172/ 174/175
BA42.10-P-1002- Bleed screw at front Nm 18 18
03A axle floating caliper
FIXED CALIPER AT REAR

Number Designation Model 215.373/ Model 215.374/ 376
375/378/ 379
BA42.10-P-1002- Bleed screw on rear Nm 7 14
01A axle fixed brake
caliper

Number Designation Model 220.073/173/ Model 220.074/174/
178/179/874/ 176, Model 220.175
875/876/878, Model with codes Z07,
220.070/075/ 170/175 Model 220.175 with
with code 494 or 498 code 494+Z04
or 625
BA42.10-P-1002- Bleed screw on rear Nm 7 14
01A axle fixed brake
caliper

Model 163.113 as of VIN
A289565, X754620
163.154 as of VIN
Number Designation A289565
BA42.10-P-1002-01A Bleed screw on rear axle Nm 18
fixed brake caliper
REAR AXLE FLOATING CALIPER

Model 163.113
to VIN
A289564,
X754619
Models 163.154 to VIN
Number Designation Model 163.136 163.154/157 A289564
1001-17A rear axle
floating caliper
CLUTCH ACTUATION
BA25.20-P-1001-01B Bleed screw to central Nm 6
clutch operator

Number Designation
WH58.30-Z-1008-11A Brake bleeder wrench WAF 8
WH58.30-Z-1009-11A Brake bleeder wrench WAF 10
Sequence of bleeding operation for brake calipers with one bleed screw, shown on model 220.
Fig. 7: Identifying Sequence Of Bleeding Operation For Brake Calipers With Bleed Screw
Sequence of bleeding operation for 8-piston brake calipers at front axle with two bleed screws
Observe different sequence of bleeding operation for left-hand and right-hand drive vehicles.
Fig. 8: Locating Bleeding Operation For Left-Hand And Right-Hand Drive Vehicles
1. Open bleed screw at brake caliper (1), allow approx. 80 cm3 of brake fluid to drain out free of bubbles ,
bleeding pressure 2 bar.
2. Repeat bleeding procedure at the brake calipers (2, 3, 4), allowing approx. 80 cm3 of brake fluid to drain
out free of bubbles at each caliper.
On vehicles with 8-piston brake calipers at the front axle, observe the sequence shown in the figure.
3.1 Model 163
Repeat bleeding procedure at bleed screw of clutch slave cylinder, allow approx. 80 cm3 of brake fluid to drain
out free of bubbles .
Model 163, 215, 220
If the brake pedal travel is still too long, an additional high-pressure bleeding operation is to be performed:
a) Start engine.
B) Open bleed screw on brake caliper (1), depressing the brake pedal in jerks in the process, hold down for
approx. 3 seconds and release slowly (carry out the process approx. 5 times).
On model 163 the bleed screw should be opened with the commercially available tool listed above
Bleed brake system - AR42.10-P-0010MB
MODEL 220 with CODE (979) Special protection version with CODE (Z07) Top protection
Fig. 9: Identifying Brake Bleeding Operation
brake fluid coming
and eyes.
brake fluid 01A
brake system 01A
The brake fluid
expansion reservoir
must not be
completely drained to
ensure that air does not
enter the system. If the
brake fluid reservoir is
completely emptied,
the entire bleeding
procedure must be
repeated. The brake
system can only be
bled with two people
attending.
1 Remove wiper arms AR82.30-P-6100M
2 Remove water Fastened with 4 expansion rivets.
repellent
Pre-ventilation
3 Switch off ignition
4 Reduce pressure in Fully depress brake pedal 30 times.
pressure reservoir
5 Unscrew brake circuit Do not connect the filling and
closure cap (10c) on bleeding unit yet.
brake circuit
expansion reservoir
and fill expansion
reservoir when
unpressurized
bleeding device to operating instructions.
plug of expansion Brake fluid changer, see GOTIS
reservoir and switch http://gotis.aftersales.daimlerchrysler.com
on
Bleed pressure approx. 2 bar.
7 Perform the bleed Start at the brake caliper with the
procedure at all brake longest feed line.
calipers At each brake caliper allow approx. 80
cm3 brake fluid to escape free of
bubbles .
If necessary close the bleed screw once or
twice in the process in order to create a
short-term pressure build-up to force out
any hidden air pockets.
10G
12G
8 Bleed brake booster Allow approx. 80 cm3 brake fluid to
hydraulic unit via the escape free of bubbles .
brake circuit bleed If necessary close the bleed screw once or
screw (11b) twice in the process in order to create a
short-term pressure build-up to force out
any hidden air pockets.
Brake circuit bleed screw (11b) *BA42.50-P-1001-
01B
9 Switch off filling and
bleeding device and
remove cap on brake
circuit
Bleeding booster
circuit
1 Unscrew booster Do not connect the filling and
circuit closure cap bleeding unit yet.
(10d) and fill booster
circuit expansion
reservoir when not
pressurized
booster circuit Bleed pressure approx. 2 bar.
expansion reservoir
and switch on
12 Switch on ignition and The booster circuit pump starts up.
simultaneously switch
off filling and bleeding
unit
13 When the booster Booster circuit pump starts up again.
circuit pump has been
switched off, fully
depress the brake
pedal approx. 10 times
14 After switching off the Carefully open bleed screw (high
hydraulic unit booster pressure). Secure bleed hose to prevent it
circuit pump again, from slipping.
bleed via booster
circuit bleed screw
(11a) with brake pedal
pressed down
15 Close booster circuit Repeat this procedure until brake fluid
bleed screw (11a) emerges free of bubbles (approx. 80
again and slowly ease cm3 ).
off brake pedal
Booster circuit bleed screw (11a) *BA42.50-P-1001-
01B
Bleeding brake circuit
brake circuit plug and Bleed pressure approx. 2 bar.
switch on
18 Switch on ignition The booster circuit pump starts up.
Wait for the pump to cut out: do not
switch off the ignition.
19 Bleed brake calipers at Start at the brake caliper with the
the rear axle longest feed line.
Exert pressure on brake pedal and open
bleed screw while fully depressing the
brake pedal. Close bleed screw again and
gradually release brake pedal. Repeat this
procedure until brake fluid emerges free
of bubbles .
12G
20 Bleed brake calipers Start at the brake caliper with the
on front axle longest feed line.
Exert pressure on brake pedal and open
bleed screw while fully depressing the
brake pedal. Close bleed screw again and
of bubbles (approx. 80 cm 3 ).
10G
21 Bleed brake booster Exert pressure on brake pedal and open
hydraulic unit via the brake circuit bleed screw (11b) while
brake circuit bleed fully depressing the brake pedal. Close
screw (11b) brake circuit bleed screw (11b) again and
of bubbles (approx. 80 cm3 ).
Brake circuit bleed screw (11b) *BA42.50-P-1001-
01B
23 Switch off and
disconnect filling and
bleeding unit
24 Reduce pressure in While pressing the brake pedal, check
reservoir by fully the fluid level in the expansion reservoir;
depressing brake pedal stop pressing brake pedal and extract
up to 30 times brake fluid, if necessary.
25 Correct brake fluid Fill booster circuit up to "MAX"
level in expansion mark. The fluid level may drop below the
reservoir of booster "MIN" mark when the ignition is
circuit switched on.
26 Correct brake fluid Fill brake circuit to between the
level in expansion "MAX" and "MIN" marks depending on
reservoir of brake the condition of the brake disks and
circuit linings.
27 Screw on cap

Number Designation Model 220 except Model 220 with
model 08/18/074/174/ special protection,
179, model 220 model 179,
without special 220.08/18/074/
protection 174/179
10G brake caliper

074/174
12G brake caliper
BRAKE SYSTEM HYDRAULICS
Number Designation Model 220 with code
Z07
BA42.50-P-1001-01B Bleed screw on brake Nm 12
booster hydraulic unit
REPLACE BRAKE HOSES - AR42.10-P-0013I
Models 215, 220
Fig. 10: Identifying Brake Hoses Remove/Install Components
Remove/Install
Risk of poisoning from Pour brake fluid only into AS42.50-Z-0001-01A
swallowing brake fluid. suitable and appropriately
Risk of injury from brake marked containers. Wear
fluid coming into contact protective clothing and
with skin and eyes. eye protection when
handling brake fluid.
Notes on handling brake AH42.50-P-0001-01A
fluid
Notes on repairs to brake AH42.00-P-0003-01A
system
Notes on installing brake AH42.10-P-9406-01A
hoses
Risk of death. Death may Align vehicle between the AS00.00-Z-0010-01A
result if vehicle slips or columns of the lifting
topples from the lifting platform and position the
1 Raise vehicle.
2 Unscrew brake line (5) When loosening or
from brake hose (51) and tightening the brake line
seal off openings (5) on the brake hose (51),
take care not to twist the
bracket (arrows).
Counterhold at two flats
of brake hose using open-
end wrench if necessary.
Seal off line
connections immediately
with plugs. The brake
fluid reservoir must not be
allowed to empty
completely.
Box wrench bit Fig. 11
Brake line at brake *BA42.10-P-1001-04A
hose
3 Unscrew brake hose (51) Box wrench Fig. 12
from floating caliper.
i Only front axle:
Pull out brake hose
through rubber grommet
at bracket.
Brake hose to fixed *BA42.10-P-1002-04A
caliper
5 Bleed brake system. Model 215, model 220 AR42.10-P-0010I
without special protection
code Z07
Model 220 with special AR42.10-P-0010MB
protection code Z07
BRAKE LINES, BRAKE HOSES

BA42.10-P-1001- Brake pipe to brake NM 14 14
04A hose
BA42.10-P-1002- Brake hose to fixed NM 18 18
04A or floating caliper
Fig. 11: Identifying Ring Wrench Socket (000 589 75 03 00)
Fig. 12: Identifying Ring Wrench (000 589 76 03 00)
TEST BRAKE SYSTEM WITH PRESSURE TESTER FOR LEAKS - AR42.10-P-0015I
MODEL 215, 220
Shows model 220
Fig. 13: Testing Brake System With Pressure Tester For Leaks (Shows Model 220)
MODIFICATION NOTES
11.8.05 Bleed screw on rear axle Model 215.379
fixed brake caliper
Checking
brake fluid coming
and eyes.
Notes on externally AH42.10-P-9406-
invisible brake fluid 02A
loss
brake system 01A
brake fluid 01A
1 Raise vehicle
2 Unscrew bleed screw Pressure testers for hydraulic fluid
at brake caliper and systems must not be used for systems
connect pressure with brake fluid, otherwise brake fluid
tester (051) may be mixed with mineral oil which
may cause the brakes to fail.
Pressure tester
After testing, only bleed the brake
caliper to which the pressure tester was
connected.
10G
12G
3 Bleed pressure tester Pressure tester, see GOTIS
(051). http://gotis.aftersales.daimlerchrysler.com
4.1 Switch off easy Vehicles with memory function
entry/exit function for Otherwise, move driver seat and
driver seat and steering wheel to a different position, e.g.
steering wheel if the driver door is opened/closed. The
seat may be damaged if the brake pedal
winch is installed.
It is switched off using the buttons on
the multifunction steering wheel in the
"Comfort" menu on the multifunction
display, see vehicle owner's manual.
High-pressure check
5 Run engine at
moderate speed then
create as great a
vacuum as possible
by suddenly releasing
the accelerator pedal
6 Install brake pedal Brake pedal jack Fig. 14
winch (080) with
adapter for brake
pedal winch between
brake pedal and seat
Adapter for brake pedal winch Fig. 15
Protect brake pedal and seat against
damage.
7 Depress brake pedal The pressure loss during the test duration
as far as possible with of 5 minutes must not exceed 5 % of the
the brake pedal winch regulated value.
(080)
Brake pedal winch Fig. 14
Low-pressure
testing
8 Switch off engine and
operate brake pedal
until vacuum is
reduced
9 Turn back brake The line pressure must not fall
pedal winch (080) throughout the duration of the test (2
until a line pressure minutes).
of approx. 3 bar
overpressure is still
indicated on the
pressure gauge
Brake pedal winch Fig. 14
10 Disconnect pressure Pressure tester, see GOTIS
tester (051) http://gotis.aftersales.daimlerchrysler.com
11 Bleed brake system Model 215, model 220 without special- AR42.10-P-0010I
protection package code Z07
Model 220 with special-protection AR42.10-P-
package code Z07 0010MB
BA42.10-P-1002-10G Bleed screw to brake Nm 7
caliper

179, model 220 model
without special 220.08/18/074/220
protection 174/179
10G brake caliper

215.374
12G brake caliper

074/174
BA42.10-P-1001- Self-locking bolt, Nm 115 180
12G brake caliper to
wheel carrier
12G brake caliper
BA42.10-P-1003- Guide pin to caliper Nm 28 28
12G support
BA42.10-P-1004- Bolt, brake pad Nm 8 8
12G contact sensor to
brake caliper
Fig. 14: Identifying Brake Pedal Winch (000 589 18 31 00)
Fig. 15: Identifying Adapter For Brake Pedal Winch (211 589 00 31 00)
REMOVE/INSTALL MECHANICAL STOP LAMP SWITCH - AR42.10-P-0040I
MODEL 211, 215, 220, 230
Model 211, 230
Fig. 16: Identifying Mechanical Stop Lamp Switch Remove/Install Components (Model 211, 230)
Model 215, 220
Fig. 17: Identifying Mechanical Stop Lamp Switch Remove/Install Components (Model 215, 220)
Remove/Install
1 Remove left cover below Model 211 AR68.10-P-1500T
instrument panel
Model 215 AR68.10-P-1500N
Model 220 AR68.10-P-1500M
Model 230 AR68.10-P-1500R
2 Unplug electric connector
at stop lamp switch (S9/1)
3 Press catch (1)
4 Turn and withdraw stop Installation: Pull out
lamp switch (S9/1). actuating pin (2)
completely. Depress brake
pedal (24), insert stop
lamp switch (S9/1) and
rotate until the catch (1) is
latched. The actuating
path is adjusted
automatically.
REMOVE/INSTALL FRONT AXLE BRAKE CALIPER - AR42.10-P-0070I
MODEL 215, 220
Shown on 4-piston brake caliper
Fig. 18: Identifying Front Axle Brake Caliper Remove/Install Components (4-Piston Brake Caliper)
Shown on 8-piston brake caliper

Fig. 19: Identifying Front Axle Brake Caliper Remove/Install Components (8-Piston Brake Caliper)
Remove/install
toppling off of the lifting platform and position the
Risk of poisoning caused Only pour brake fluid into AS42.50-Z-0001-01A
by swallowing brake fluid. suitable and appropriately
Risk of injury caused by marked containers. Wear
brake fluid coming into protective clothing and
contact with skin and eyes. eye protection when
When working on vehicles
with 8-piston brake caliper,
the bolts (1) of the radial
bolted connection should
not be released under any
circumstances as this leads
to malfunctions in the
brake system
1 Raise vehicle with lifting
platform
2 Remove front wheel
Remove/install wheels AP40.10-P-4050Z
3 Remove brake hose (51) Seal line connections
from brake line (5) and immediately with
seal line terminals with plugs. The expansion
stop plugs reservoir for brake fluid
may not become entirely
empty to prevent bubbles
from getting into the brake
system.
system
Brake fluid notes AH42.50-P-0001-01A
hoses
*BA42.10-P-1001-04A
4 Detach brake hose (51)
from brake caliper (31a)
When loosening or
tightening brake line (5) on
brake hose (51), take care
not to twist its bracket. If
necessary, counterhold the
two flats of the brake hose
(51) using an open wrench.
*BA42.10-P-1002-04A
Box wrench Fig. 12
5 Detach left front brake pad
contact sensor (S10/1) or
right front brake pad
contact sensor (S10/2)
from the left front brake
pad contact sensor
connector (S10/1x1) or
contact sensor connector
(S10/2x1)
wear indicator contact
sensors
6 Disconnect left front brake Installation: Replace
pad contact sensor self-locking bolt.
connector (S10/1x1) and
contact sensor connector
(S10/2x1) from brake
caliper (31a)
Bolt, brake pad contact *BA42.10-P-1004-10G
sensor to brake caliper
7 Detach front axle brake Installation: Replace
caliper; to do so, remove self-locking bolts (35).
bolts (35)
Self-locking bolt, *BA42.10-P-1001-10G
brake caliper to steering
knuckle
Guide pin on caliper *BA42.10-P-1003-10G
support
9 Bleed brake system Model 215, model 220 AR42.10-P-0010I
version, without top
protection
protection version code
979, with top protection
code Z07
Risk of accident when Before starting engine, AS42.50-Z-0002-01A
commissioning the vehicle actuate brake pedal
due to a lack of braking several times until the
effect when the service pressure is built up and
brake is operated for the maintained in the brake
first time after repair work system.
10 Operate brake pedal
several times until the
brake pads make contact
with the brake disks (firm
resistance can be felt)
Checking
11 Check brake system for AR42.10-P-0100-01A
leaks

BA42.10-P-1001-10G Self-locking bolt, brake Nm 180
caliper to steering knuckle
BA42.10-P-1004-10G Bolt, brake pad contact Nm 10
sensor to brake caliper

179, model 220 Model 220.08/18/074/
without special 174/179
protection
steering knuckle
brake caliper
BA42.10-P-1003- Guide pin to Nm - 25
10G caliper support

BA42.10-P-1001- Brake pipe to brake Nm 14 14
04A hose
BA42.10-P-1002- Brake hose to fixed Nm 18 18

REMOVE/INSTALL REAR AXLE BRAKE CALIPER - AR42.10-P-0080I
MODEL 215, 220
Shown on vehicle with fixed brake caliper
Fig. 23: Identifying Rear Axle Brake Caliper Remove/Install Components (Fixed Brake Caliper)
MODIFICATION NOTES
11.8.05 Self-locking bolt, fixed Model 215.379 *BA42.10-P-1001-12G
caliper to wheel carrier
Remove/install
and bolts
platform
2 Remove rear wheel
3 Remove brake hose (51) Seal off line terminals AR42.10-P-0013I
from brake line (5) and immediately with
seal line terminals with stop plugs. The expansion
stop plugs reservoir for brake fluid
may not become entirely
empty to prevent bubbles
from getting into the brake
system.
system
hoses
*BA42.10-P-1001-04A
4 Remove brake hose (51) AR42.10-P-0013I
from brake caliper (31b)
hoses
*BA42.10-P-1002-04A
Box wrench Fig. 12
5 Detach right rear brake pad Installation: Damaged
contact sensor (S10/4) or defective contact
from the right rear brake sensors must be replaced
pad contact sensor with new sensors.
connector (S10/4x1)
pad wear sensor contact
sensors
6 Remove right rear brake Removal on left side is
pad contact sensor same as on right side.
connector (S10/4x1) from Installation: Replace
brake caliper (31b) self-locking bolt.
Brake caliper *BA42.10-P-1004-12G
7 Remove brake linings from Vehicles with fixed brake AR42.10-P-0161I
brake caliper (31b) caliper
Vehicles with floating AR42.10-P-0160I
brake caliper
8 Remove brake caliper Installation: Replace
(31b) from wheel carrier bolts (35).
*BA42.10-P-1001-12G
*BA42.10-P-1003-12G
10 Bleed brake system Model 215, model 220 AR42.10-P-0010I
version, without top
protection
protection version code
979, with top protection
code Z07
11 Operate brake pedal
several times until the
brake linings make contact
with the brake disks (firm
resistance can be felt)
Checking
procedure or when
working near the engine as
it is running
and check brake system for
function and leaks In
the event of a leak,
determine and eliminate
cause, otherwise
malfunctions of the brake
system and serious
environmental pollution
may occur.

215.374
wheel carrier
brake caliper

except model Model 220.074/174
074/174
wheel carrier
12G support
brake caliper

BA42.10-P-1001- Brake pipe to brake Nm 14 14
04A hose
BA42.10-P-1002- Brake hose to fixed Nm 18 18
CHECK BRAKE SYSTEM FOR LEAKS - AR42.10-P-0100-01A
1. After bleeding, depress the brake pedal firmly several times in order to set the correct clearance between
the brake disc and the brake pad.
2. Then, with the engine running, carry out a leak test on the brake system; to do this, press the brake pedal
firmly.
3. The pressure built up must be maintained without it being possible to depress the brake pedal further.
4. Check all connections for leaks.
5. Check the brake fluid level in the brake fluid reservoir and correct if necessary.
REMOVE/INSTALL BRAKE PAD ON FLOATING BRAKE CALIPER - AR42.10-P-0160I
MODEL 220
Front axle
Fig. 27: Identifying Brake Pad On Floating Brake Caliper Remove/Install Components (Front Axle)
Rear axle
Fig. 28: Identifying Brake Pad On Floating Brake Caliper Remove/Install Components (Rear Axle)
MODIFICATION NOTES
8.11.06 Section on repeated Step 16
application of brake pedal
has been added
Remove/install
contact with skin and eyes.eye protection when
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.
system
and bolts
1 Lower brake fluid level in In order to prevent the
brake fluid reservoir down expansion reservoir
to "MIN" mark overflowing when
pressing back the brake
pistons.
2 Remove wheels
3.1 Disconnect left and right Installation: Replace
front brake pad contact defective contact sensors.
sensor connectors
(S10/1x1, S10/2x1) and
pull contact sensors out of
brake lining
pad wear sensor contact
sensors
3.2 Disconnect right rear brake Installation: Replace
pad contact sensor (S10/4) defective contact sensors.
and pull contact sensor out
of brake lining
4 Unclip electrical feed line
of contact sensor from
retaining clip on
longitudinal member
5 Pry out clip (10)
6 Detach protective caps Installation: Replace
from bolts (31c) and bolts (31c).
remove bolts (31c)
*BA42.10-P-1003-10G
BA42.10-P-1003-12G
7 Detach brake caliper (31) Do not tension or kink
with brake pads (31g) and brake hose. To relieve the
hang up to one side load on the brake hose,
attach the brake caliper
(31) to the vehicle so that
it is free of tension,
otherwise the brake hose
will be damaged.
8 Remove brake pads (31g)
from brake caliper (31)
Brake pads (31g) are to be
disposed of as special
waste. The local authorities
can provide information
regarding whether disposal
is also permitted as
industrial waste similar to
domestic waste.
Only brake pad kits
(31g) approved by
Mercedes Benz must be
installed.
Installation: Install
brake pads (31g) without
grease.
Checking
9 Check brake lining Replace brake pads
thickness and brake disks (31g) and brake disks in
complete sets if
necessary.
Check brake lining AP42.10-P-4253A
thickness
Inspect condition of brake AP42.10-P-4258I
disks
10 Check upper and lower Replace defective
bellows for damage and parts.
upper and lower guide pins
for ease of movement
11 Check brake caliper (31) If the brake caliper
for leaks and dust boot for (31) is leaky or the dust
damage boot is damaged:
?
Install new front axle AR42.10-P-0070I
brake caliper.
Replace rear axle brake AR42.10-P-0080I
caliper.
12 Press back brake piston If the brake piston is
using pusher tool difficult to move:
(031) ?
Install new front axle AR42.10-P-0070I
brake caliper.
Replace rear axle brake AR42.10-P-0080I
caliper.
Check for creases
forming in the dust boot:
If the dust boot
projects out beyond the
brake piston after the
piston is pressed back,
move the dust boot into
the correct position.
Fig. 29
Clean
13 Clean contact surfaces of Installation: Do not
brake pads (31g) at brake use any sharp-edged or
caliper (31) pointed tools to prevent
damage.
14 If necessary, clean the AR42.10-P-2260-01I
perforation of brake disks
16 Operate the brake pedal Firm resistance should
several times until the be noticeable at the brake
brake pads (31g) contact pedal.
the brake disks
17 Check brake fluid level,
Brake system - inspect AP42.10-P-4210Z
fluid level

Number Designation Model 220 except Model 220 with special
model protection, Model
08/18/074/174/179, 220.08/18/074/174/179
model 220 without
special protection
BA42.10-P-1003- Guide pin to Nm - 25
10G caliper support

except model Model 220.074/174
074/174
12G support
Fig. 29: Identifying Pusher Tool (000 589 52 43 00)
REMOVE/INSTALL BRAKE PADS ON FIXED CALIPER - AR42.10-P-0161I
MODEL 215, 220
Front axle
Fig. 30: Identifying Brake Pads On Fixed Caliper Remove/Install Components (Front Axle)
Fig. 31: Identifying Brake Pads On Fixed Caliper Remove/Install Components (Rear Axle)
Rear axle
Remove/install
contact with skin and eyes eye protection when
necessary.
system
and bolts
1 Unscrew the cap on the In order to prevent the
brake fluid expansion expansion reservoir
reservoir and suction off overflowing when
some brake fluid pressing back the brake
pistons.
2 Remove wheels
Checking
3 Check brake lining Replace brake pads
thickness and brake disks (43) and brake disks in
complete sets if necessary.
disks
Check brake lining If the brake pads (43) AP42.10-P-4253A
thickness have worn down to
beyond the wear limit, the
bar between the sealing
groove and dust cap may
be damaged; therefore:
?
Check brake system for AR42.10-P-0015I
leaks with pressure tester.
4 Check brake calipers (31a, If the brake calipers
31b) for leaks and dust (31a, 31b) are leaky or the
boots for damage dust boots damaged:
?
Replace brake caliper on AR42.10-P-0070I
front axle.
Install new brake caliper AR42.10-P-0080I
at rear axle.
5 Remove brake pad contact
sensors
wear indicator contact
sensors
6 Knock out retaining pins Installation: Knock
(41) with punch (035) retaining pins (41) all the
way in.
7 Pull brake pads (43) out of Press out brake pads
brake calipers (31a, 31b) (43) using lever
(034) if they are stuck.
Insert wedge between
lever (034) and
brake caliper (31a, 31b)
to prevent
damage.
Installation: Install
front axle brake pads (43)
with panel (43a) dry. The
marking (see arrow) on
the panel (43a) must point
in the direction of rotation
of the wheel during
forward travel.
Only complete sets of
brake pads (43) approved
by Mercedes-Benz may
be installed.
Brake pads (43) are to
be disposed of as special
waste. The local
authorities can provide
information regarding
whether disposal is also
permitted as industrial
waste similar to domestic
waste.
Fig. 33
Fig. 34
8 Press back brake piston On 4-piston fixed
using pusher tool brake calipers, secure one
(031) pair of opposing pistons
with wedges to
prevent them from
slipping out. Then push
back other piston pair
using pusher tool
(031).
Fig. 33
Fig. 29
If the piston is difficult to
move: ?
Replace brake caliper on AR42.10-P-0070I
front axle.
Install new brake caliper AR42.10-P-0080I
at rear axle.
Clean
9 Clean brake pad guides Do not use any sharp-
edged or pointed tools to
prevent damage.
perforation of brake disks
first time after repair work. system.
12 Operate the brake pedal A firm resistance must
several times until the be noticeable at the brake
brake pads (43) contact the pedal.
brake disks
Checking
13 Check brake fluid level,
Brake system - inspect Vehicles with top AP42.10-P-4210M
fluid level protection
Vehicles without code AP42.10-P-4210Z
Z07 Top protection
Fig. 32: Identifying Pusher Tool (000 589 52 43 00)
Fig. 33: Identifying Wedge (601 589 07 63 00)
Fig. 34: Identifying Lever (123 589 13 33 00)

REMOVE/INSTALL BRAKE DISC - AR42.10-P-0220I
MODEL 215, 220
Fig. 35: Identifying Brake Disc And Bolt
MODIFICATION NOTES
17.12.02 Notes on safety for brake AS42.50-Z-0001-01A
fluid, included for the first
time
17.12.02 Check version of pedal Step 10.1 BT42.20-P-0510-01A
assembly, added
Remove/install
necessary.
system
1 Remove wheels
Remove/install wheels, AP40.10-P-4050Z
rotate if necessary
2 Release parking brake When removing the brake
disks (61) on the rear axle
Checking
3 Check brake lining Only replace brake
thickness and brake disks pads and brake disks (61)
(61) in complete sets if
necessary.
disks
Check brake lining If the brake pads have AP42.10-P-4253A
thickness worn down to beyond the
wear limit, the bar
between the sealing
groove and dust cap may
be damaged; therefore:
?
Check brake system for AR42.10-P-0015I
leaks with pressure tester.
Clean
perforation in the brake
disks (61)
5 Remove brake disk Do not detach brake
hose, instead attach brake
caliper to vehicle so that it
is free of tension. Do not
kink or tension brake
hose, as otherwise it will
be damaged.
Remove/install front axle AR42.10-P-0070I
brake caliper.
Remove/install rear axle AR42.10-P-0080I
brake caliper.
6.1 Preloading automatic When removing the brake
cable slack adjuster disks (61) on the rear axle
Model 215 except AR42.20-P-0520-01A
215.379, Model 220
except 220.179
6.2 Release cable slack When removing the brake
adjuster disks (61) on the rear axle
Model 215.379, model AR42.20-P-0520-03IM
220.179
*BA42.20-P-1005-01A
*129589116300
7 Unscrew locking bolt (64) When removing brake
and remove brake disk disk (61) on rear axle: If
(61) parking brake drums are
run in, turn back the
adjusting mechanism of
the parking brake
beforehand. Otherwise the
brake shoes will be
damaged:
See Adjust parking brake:
Model 215 except AR42.20-P-0540I
215.379, Model 220
except 220.179
Model 215.379, Model AR42.20-P-0540IM
220.179
securing bolt (64)
*BA42.10-P-1001-06A
*BA42.10-P-1002-06A
Clean
8 Clean contact surfaces and
seat of brake disk (61) if
necessary
9 Lightly grease seat of Long-life grease *BR00.45-Z-1001-06A
brake disk (61)
Checking
10 Check condition of brake After removing rear axle
shoes of parking brake brake disk (61), if
necessary: ?
Replace parking brake
shoes:
215.379, Model 220
except 220.179
220.179
Checking
12 Check version of pedal After installing brake disk
assembly (61) on the rear axle
Parking brake pedal BT42.20-P-0510-01A
assembly modified
13 Adjust parking brake After installing brake
disks (61) on rear axle
215.379, Model 220
except 220.179
220.179
14 Release automatic slack After installing brake
adjuster disks (61) on rear axle
Model 215 except AR42.20-P-0520-02A
215.379, Model 220
except 220.179
BRAKE DISCS, BRAKE COVER PLATE

Number Designation Model 215.373/ Model 220.02/06/07/0
374/375/ 376/378/ 8/12/16/17/18/87
379
BA42.10-P-1001- Locking bolt of rear Nm 10 10
06A axle brake disk
BA42.10-P-1002- Locking bolt of Nm 10 10
06A front axle brake
disk
PARKING BRAKE
BA42.20-P-1005- Bolt, brake cable at Nm 12 12
01A cable slack adjuster
Fig. 36: Identifying Snap-Release Tool (129 589 11 63 00)
REPAIR MATERIALS
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51
REMOVE/INSTALL MASTER BRAKE CYLINDER - AR42.10-P-0300I
MODELS 215, 220

Fig. 37: Identifying Master Brake Cylinder Remove/Install Components
MODIFICATION NOTES
11.3.04 Note on disposal of brake
fluid which has escaped,
added
Remove/Install
Risk of poisoning caused Pour brake fluid only into AS42.50-Z-0001-01A
fluid
system
Notes on externally AH42.10-P-9406-02A
invisible brake fluid loss
In order to prevent paint
damage, brake fluid which
has escaped must be rinsed
off immediately with water
2 Suction off brake fluid
from the reservoir (10)
3 Detach plug (10b)
4 Unscrew bolt (10a)
5 Remove reservoir (10) Replace gaskets (9).
from master brake cylinder
(1)
Detach brake lines (5) from Box wrench bit Fig. 38
master brake cylinder (1)
and seal connections with
plugs
*BA42.10-P-1003-04A
7 Detach pendulum support AR42.10-P-0300-02N
(113) from master brake
cylinder (1)
*BA42.10-P-1003-05A
8 Unscrew hexagon nuts (19, *BA42.10-P-1001-05A
2 pieces)
9 Remove master brake Do not tilt master
cylinder (1). brake cylinder but pull out
straight forwards
otherwise the thrust rod is
pressed out off its axial
position.
sealing ring (1a).
11 Bleed brake system AR42.10-P-0010I
Check
12 Check brake system for AR42.10-P-0100-01A
leaks

BA42.10-P-1003- Brake pipe to master Nm 16 16
04A brake cylinder
MASTER BRAKE CYLINDER

BA42.10-P-1001- Nut, brake master Nm 20 20
05A cylinder to brake
booster
BA42.10-P-1003- Bolt, pendulum Nm 9 9
05A support to master
brake cylinder
Fig. 40: Identifying Set Of Plugs (129 589 00 91 00)
Removing and installing hinged support on master brake cylinder - AR42.10-P-0300-02N
MASTER BRAKE CYLINDER

BA42.10-P-1003- Bolt, hinged support Nm 9 9
05A on master brake
cylinder
Loosen bolt (113b) and remove hinged support (113) with rubber ring (113a) from master brake cylinder (1).
The hinged support (113) is inserted in a suitable hole in the bottom of the longitudinal frame member.
Fig. 41: Identifying Hinged Support On Master Brake Cylinder Remove/Install Components
REMOVE, INSTALL BRAKE BOOSTER HYDRAULIC UNIT - AR42.10-P-0302MB
MODELS 220.175 /178 with CODE (Z07) maximum protection
Fig. 42: Identifying Brake Booster Hydraulic Unit Remove/Install Components

Remove/install
Risk of injury from skin marked containers. Wear
and eye contact with brake protective clothing and
fluid eye protection when
Notes on handling brake All models AH42.50-P-0001-01A
fluid
Notes on repairs to brake All models AH42.00-P-0003-01A
system
2 Reduce pressure in Fully depress brake
pressure reservoir pedal 30 times to the stop.
3 Remove mechanical stop AR42.10-P-0040I
lamp switch (S9/1)
4 Remove cover (3)
5 Pull out retainer (6) and
bolt (5)
6 Remove wiper system AR82.30-P-6100M
7 Draw off brake fluid from
the reservoir (10)
8 Remove bracket (15)
9 Unplug connection (11)
10 Detach hoses (9) and cable Collect escaping brake
(8) from reservoir (10) fluid.
11 Unscrew bolts (12)
12 Pull reservoir (10) out of
brake booster hydraulic
unit (A7/6)
13 Detach brake lines (14) *BA42.50-P-1003-01B
14 Detach cable (8) from *BA42.50-P-1005-01B
charge plunger unit (7)
15 Release brake line (13) *BA42.50-P-1003-01B
16 Unscrew screws (2) *BA42.50-P-1004-01B
17 Detach brake line (13) Push brake booster
hydraulic unit (A7/6)
toward the driver's side.
18 Remove brake booster Installation: Replace
hydraulic unit (A7/6) gasket (1).
upward
20 Bleed brake system AR42.10-P-0010MB
BRAKE SYSTEM - HYDRAULIC CIRCUITS
Z07
BA42.50-P-1003-01B Brake line to brake Nm 16
BA42.50-P-1004-01B Bolt, brake booster Nm 17
hydraulic unit to firewall
BA42.50-P-1005-01B Brake line to charge Nm 16
piston unit
REMOVE, INSTALL MOTOR-AND-PUMP ASSEMBLY - AR42.10-P-0303MB
MODELS 220.175 /178 with CODE (Z07) maximum protection
Fig. 43: Identifying Motor-And-Pump Assembly Remove/Install Components
Remove/install
fluid eye protection when
fluid
system
pressure reservoir pedal 30 times to the stop.
3 Remove fender liner in left AR88.10-P-1300M
front fender
4 Disconnect connector for
pressure switch (2) and
connector for motor-and-
pump assembly (3)
5 Detach hydraulic line (4) Plug hydraulic line.
from motor-and-pump
assembly (1)
6 Unscrew bolt (5). Installation: Fit
washer (6) between body
bracket and rubber mount.
*BA42.50-P-1002-01B
7 Remove motor-and-pump Installation: Ensure
assembly (1) correct seating of the bolt
(arrow) in the rubber
mount.
8 Unclamp hose (7) with Fig. 44
clamp and detach

Z07
BA42.50-P-1002-01B Bolt for motor-and-pump Nm 10
assembly to bracket
Fig. 44: Identifying Clamp (000 589 40 37 00)
REMOVE, INSTALL MOTOR-AND-PUMP ASSEMBLY PRESSURE RESERVOIR - AR42.10-P-

0304MB
MODEL 220.175 /178 with CODE (Z07) Top protection

Fig. 45: Identifying Motor-And-Pump Assembly And Pressure Reservoir
Remove/install
1 Remove motor-and-pump AR42.10-P-0303MB
assembly (1)
2 Unscrew pressure reservoir Installation: lubricate
(2). pre-mounted sealing ring
(arrow) with brake fluid.
Screw in pressure
reservoir by hand then
tighten.
*BA42.50-P-1006-01B

Z07
BA42.50-P-1006-01B Motor-and-pump Nm 40
assembly pressure
reservoir
REMOVE, INSTALL BRAKE BOOSTER HYDRAULIC UNIT PRESSURE RESERVOIR - AR42.10-P-

0305MB

Fig. 46: Identifying Brake Booster Hydraulic Unit, Water Deflector And Pressure Reservoir
Remove/install
fluid. eye protection when
fluid
system
pressure reservoir pedal 30 times as far as
the stop.
4 Remove water deflector (1) Fastened with 4 body-
bound rivets.
5 Unscrew pressure reservoir Installation: lubricate
(2). pre-mounted sealing ring
(arrow) with brake fluid.
Screw in pressure
reservoir by hand then
tighten.
*BA42.50-P-1007-01B

Z07
BA42.50-P-1007-01B Pressure reservoir at brake Nm 40
CLEANING PERFORATIONS IN BRAKE DISCS - AR42.10-P-2260-01I

Number Designation
WH58.30-Z-1007-20A Cordless drill/driver
The bores in the perforated brake disks (61) may become clogged with brake dust. If this is the case the
brake disks (61) must be cleaned.
1. Clear brake dust from holes in brake disk (61) using a suitable drift.
If the brake dust cannot be removed by means of a drift, use cordless drill/driver and 4.3 mm dia
drill bit. In doing so no chips from the brake disks may be detached, the bores in the brake disks (61)
must on no account be enlarged!
Fig. 47: Identifying Brake Discs Cleaning Procedure (1 Of 2)

Fig. 48: Identifying Brake Discs Cleaning Procedure (2 Of 2)
REMOVE/INSTALL PARKING BRAKE PEDAL ASSEMBLY - AR42.20-P-0510I
Models 215, 220
Fig. 49: Identifying Parking Brake Pedal Assembly Remove/Install Components (Models 215, 220)
Fig. 50: Identifying Parking Brake Pedal
MODIFICATION NOTES
2.12.02 Notes on self-locking AH00.00-N-0001-01A
bolts, incorporated for the
first time
2.12.02 Check version of pedal Step 12 BT42.20-P-0510-01A
assembly, included for the
first time
Remove/Install
Risk of death. Death may Align vehicle between the AS00.00-Z-0010-01A
result if vehicle slips or columns of the hydraulic
topples from the lifting hoist and position the four
platform. support plates below the
hoist support points
manufacturer.
and bolts
1 Lift vehicle with lifting
platform
2 Preload automatic cable AR42.20-P-0520-01A
slack adjuster (92)
3 Unscrew bolt (93) from
intermediate lever (91) of
automatic cable slack
adjuster (92)
4 Remove left cover below Model 215 AR68.10-P-1500N
instrument panel
Model 220 AR68.10-P-1500M
5 Remove front left floor AR68.20-P-2050M
covering
6 Loosen clamps (arrows) The rear clamp is only
and remove cover (76) of accessible when the
pedal assembly (71) defroster nozzle with
rosette is removed.
7 Unhook brake cable (85) Use snap-release *129589116300
from the tensioning tool (043).
shackle on the parking
brake pedal (75) and
unclip from the pedal
assembly (71)
Installation: Pay
attention to correct
seating of rubber ring
(85c).
8 Unscrew bolts (72) and Push pedal assembly
take off pedal assembly (71) inwards slightly and
(71) remove from cover (76a).
Do not loosen Torx *BA42.20-P-1001-01A
bolts on the back of the
pedal assembly (71),
otherwise the pedal
assembly (71) will be
damaged beyond repair.
Friction brake foot GF42.20-P-1000A

controls / parking brake,
function
9 Detach control cable (79) To do so, first remove
for releasing parking the bracket (77a) and then
brake. detach the control cable
(79) from the release
lever (77). Unclip control
cable (79) from pedal
assembly (71) using tool
(010).
Tool for releasing parking WF58.50-P-4220-01A
brake control cable
11 Slacken automatic cable AR42.20-P-0520-02A
slack adjuster (92)
12 Check version of pedal See ?
assembly (71)
assembly modified
13 Operate parking brake If the pedal travel is
pedal (75) and check pedal not within the tolerance
travel of parking brake range: ?
pedal (75)
Adjust parking brake AR42.20-P-0540I
Control force on parking *BE42.20-P-1001-01C
brake pedal
Number of notches that *BE42.20-P-1002-01C
parking brake pedal has
to be pressed
ADJUSTING VALUES FOR PARKING BRAKE

Number Designation Model 215, Pedal Model 215, Pedal
assembly with assembly with
pulled notch pushed notch
BE42.20-P-1001- Control force on N 170 (-50/+70) 170 (-50/+70)
01C parking brake pedal
BE42.20-P-1002- Number of notches Quantity 1 5
01C that parking brake
See fig. BT42.20-P-0510- BT42.20-P-0510-
pedal has to be
01A 01A
pressed
ADJUSTING VALUES FOR PARKING BRAKE

Number Designation Model 220, Pedal Model 220, Pedal
pulled notch pushed notch
BE42.20-P-1001- Control force on N 170 (-50/+70) 170 (-50/+70)
BE42.20-P-1002- Number of notches Quantity 1 5
01C that parking brake
See fig. BT42.20-P-0510- &.2.(BT42.20P-
pedal has to be
01A 0510-01A)
pressed
PARKING BRAKE
BA42.20-P-1001- Bolt, foot-operated Nm 12 12
01A parking brake pedal
assembly to front
wall pillar
REMOVE/INSTALL FRONT BRAKE CABLE - AR42.20-P-0520I
MODEL 215.373 /374 /375 /376 /378 /379,

220.025 /026 /028 /063 /065 /067 /070 /073 /074 /075 /083 /084 /087 /125 /126 /128 /165 /167 /170 /173 /174 /17
Fig. 52: Identifying Front Brake Cable Remove/Install Components
MODIFICATION NOTES
2.12.02 Notes on self-locking nuts AH00.00-N-0001-01A
and bolts, included for the
first time
2.12.02 Check version of pedal Step 17 BT42.20-P-0510-01A
assembly, included for the
first time
Remove/Install
Risk of death cased by Align vehicle between the AS00.00-Z-0010-01A
vehicle slipping or columns of the hydraulic
toppling off of the lifting hoist and position the four
manufacturer.
Notes on self-locking nuts All models AH00.00-N-0001-01A
and bolts
platform
2 Remove rear cross strut at
frame floor
3 Lower rear exhaust system Detach rear bracket
between center and rear
muffler at rear axle and
remove bracket of rear
muffler at frame floor.
Detach exhaust system
until heat shield below
propeller shaft can be
removed. Refer to
Removing exhaust system
complete: ?
Engine 113 except AR49.10-P-7000AA
113.960 in model
220.875
Engine 113.960 220.875 AR49.10-P-7000MP
Engine 137 in model AR49.10-P-7000L
215.378, 220.178
Engine 137 220.878 AR49.10-P-7000MPL
Engine 275 AR49.10-P-7000IM
Engine 613 AR49.10-P-7000M
Engine 648
Engine 628 AR49.10-P-7000MB
4 Remove heat shield below
propeller shaft
5.1 Pre-tension automatic Model 215 except AR42.20-P-0520-01A
cable slack adjuster (92) 215.379, 220 except
220.179
5.2 Relieve load on cable Model 215.379, 220.179 AR42.20-P-0520-03IM
slack adjuster
Self-locking bolt, *BA42.20-P-1002-01A
brake cable to rear wheel
carrier
Snap-release tool *129589116300
6 Unhook retracting spring
(94)
7 Detach brake cable (85) at Model 215 except
intermediate lever (91) by 215.379, 220 except 220.
unscrewing bolt (93) 179: ?
Bolt, brake cable to *BA42.20-P-1004-01A
automatic cable slack
adjuster
Models 215.379,
220.179:?
Bolt, brake cable to *BA42.20-P-1005-01A
cable slack adjuster
8 Remove left cover below Model 215 AR68.10-P-1500N
instrument panel
Model 220 AR68.10-P-1500M
9 Remove accelerator pedal AR30.12-P-1321I
10 Remove floor covering in AR68.20-P-2050M
driver footwell
11 Detach brake cable (85) Use snap-release tool
from parking brake pedal (043)
(75) Installation: Check
that rubber ring (85c) is
seated correctly on the
nipple.
12.1 Detach lower engine Engines 112, 113, 137, AR61.20-P-1105M
compartment paneling 275
Loosen heat shield at
transmission until brake
cable (85) can be
threaded through.
12.2 Remove bottom parts of Engines 613, 628, 648 AR94.30-P-5300M
noise encapsulation Loosen heat shield at
transmission until brake
cable (85) can be
threaded through.
13 Unclip brake cable (85) Installation: Install
from retaining clips (85a) new retaining clips (85a)
in driver footwell, unclip
on outside of frame floor
and pull out through
grommet (85b) at
transmission tunnel.
14 Detach brake cable (85) Use snap-release tool
from frame floor (043)
16.1 Slacken automatic cable Model 215 except AR42.20-P-0520-02A
slack adjuster (92) 215.379, 220 except
220.179
17 Check version of pedal
assembly (71)
assembly modified
pedal (75) several times not within the tolerance
and check pedal travel of range: ?
parking brake pedal (75) Adjust parking brake
215.379, 220 except
220.179
Model 215.379, 220.179 AR42.20-P-0540IM
Actuating force on *BE42.20-P-1001-01C
parking brake pedal
Notches through which *BE42.20-P-1002-01C
the parking brake pedal
must be depressed
ADJUSTMENT VALUES FOR PARKING BRAKE

Number Designation Model 215, pedal Model 215, pedal
pulled detent pushed detent
BE42.20-P-1001- Actuating force on N 170 (-50/+70) 170 (-50/+70)
BE42.20-P-1002- Notches through Quantity 1 5
01C which the parking
See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed
PARKING BRAKE
BA42.20-P-1004- Bolt, brake cable to Nm 12 12
01A automatic cable slack
adjuster
PARKING BRAKE
01A brake cable to rear
wheel carrier
PARKING BRAKE
BA42.20-P-1005- Bolt, brake cable to Nm 12 12
01A cable slack adjuster
Pre-tension automatic cable slack adjuster - AR42.20-P-0520-01A
1. Model 140: Detach exhaust system (only as far as necessary).

2. Turn detent eccentric bolt (g) to the left using the Allen wrench (approximately half a turn) and
simultaneously push backwards in slot until the spring-loaded detent eccentric (b) engages with the raised
section (h) in the holddown clip (d).
Fig. 54: Identifying Pre-Tension Automatic Cable Slack Adjuster

Relieve load on automatic slack adjuster. - AR42.20-P-0520-02A
1. Lift center holddown clip (arrow) using a screwdriver so that the cable slack adjuster sets itself
automatically.
Fig. 55: Locating Relieve Load On Automatic Slack Adjuster
Detach brake cables - AR42.20-P-0520-03IM
PARKING BRAKE
wheel carrier
1. Unscrew adjusting screw (89) several turns.

2. Detach the retracting spring (94) from its mount.
3. Detach front brake cable (85) from cable slack adjuster (91)
4. Unhook cable slack adjuster (91) from frame floor.
5. Unhook rear brake cables (86) from cable slack adjuster (91).
6. Detach rear brake cables (86) from bracket at frame floor using snap-release tool.
Fig. 57: Identifying Brake Cables
REMOVE/INSTALL REAR BRAKE CONTROL CABLE - AR42.20-P-0525I
MODELS 215, 220
Fig. 58: Identifying Rear Brake Control Cable Remove/Install Components
Remove/Install
manufacturer.
system
1 Raise vehicle.
2 Remove parking brake Model 215 except AR42.20-P-0530I
shoes 215.379, 220 except
220.179
Model 215.379, 220.179 AR42.20-P-0530IM
3 Detach front brake cable Installation: Install
(85) at intermediate lever new self-locking bolt (93)
(91)
4 Detach brake cables (86)
from equalizer arm (92)
5 Detach brake cables (86) Use snap-release tool
from bracket on rear axle (043)
carrier
6 Unscrew self-locking bolt Installation: Install
(98) on wheel carrier. new self-locking bolt (98)
carrier
7 Remove brake cables (86)
from wheel carrier
8 Install in the reverse order Installation: Install
new grommet if
necessary.
PARKING BRAKE
wheel carrier

REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
REMOVING AND INSTALLING BRAKE SHOES OF PARKING BRAKE - AR42.20-P-0530
Removing and installing brake shoes of parking brake - AR42.20-P-0530I
MODEL 215 (except 215.379)
MODEL 220 (except 220.179)
MODEL 230
Shown on model 220
Fig. 60: Identifying Brake Shoes Of Parking Brake Remove/Install Components (Model 220)
MODIFICATION NOTES
2.12.02 Check version of pedal Work step 15 BT42.20-P-0510-01A
assembly, added
Remove/install
Risk of injury caused by Deactivate SBC brake AS42.46-Z-0001-01A
body parts being jammed system using STAR
or crushed. Risk of injury DIAGNOSIS.
to skin and eyes caused by
brake fluid spraying out at
high pressure when
working on the SBC brake
system
1.1 Deactivate SBC brake Model 230
system using STAR The following steps
DIAGNOSIS. should be run through in
STAR DIAGNOSIS:
Select menu item "SBC-
Sensotronic Brake
Control"/"Deactivate 'SBC'
system".
Then process all the
individual steps from top to
bottom.
system
diagnosis system
2 Remove rear wheels.
rotate if necessary
3 Remove brake disks on Model 215, 220 AR42.10-P-0220I
rear axle
Model 230 AR42.10-P-0220R
4.1 Preloading automatic Model 215, 220 AR42.20-P-0520-01A
4.2 Release cable slack Model 230
adjuster
5 Detach lower retracting Installation: Ensure that
spring (111) using the lower retracting spring
removal and installation (111) is seated correctly!
tool (040).
Fig. 61
6 Remove retaining springs Installation: Pay
(107) with installation tool attention to correct seat of
(041) retaining springs (107).
Fig. 62
7 Remove brake shoes (103) If brakes shoes (103) are
over rear axle shaft flange burnt or brake disk surfaces
(68) are damaged, replace brake
shoes (103), lower and
upper retracting springs
(111, 112), retaining springs
(107) and brake disks.
Installation: Turn back
adjusting mechanism (105)
and insert into both brake
shoes (103) with the
adjusting wheel (c) pointing
toward front of vehicle.
8 Detach upper retracting Installation: Ensure that
spring (112). the upper retracting spring
(112) is seated correctly!
Lightly grease thread of
thrust piece (104) and
cylindrical part of
adjustment wheel (c) with
MB long-life grease.
Long-life grease *BR00.45-Z-1001-06A
9 Remove expanding lock Installation: Lightly
(109) grease all bearing and slide
surfaces on expansion lock
(109) with MB long-life
grease.
Checking
10.1 Inspect cap (110). Model 230
Check cap (110) is seated
firmly, check for score
marks and deformation,
Notes on installing the cap AH42.20-P-0530-01T
on the brake stator
12.1 Activate SBC brake Model 230
system using STAR The following steps
DIAGNOSIS should be run through in
STAR DIAGNOSIS:
Select menu item "SBC-
Sensotronic Brake
Control"/"Initial startup after
repair"/"Remove/ install
brake shoes of parking
brake". Then process all the
individual steps from top to
bottom.
12.2 Release automatic slack Model 215, 220 AR42.20-P-0520-02A
adjuster
Checking
assembly
assembly modified
14 Adjust parking brake Model 215, 220 AR42.20-P-0540I
Model 230 AR42.20-P-0540R
Fig. 61: Identifying Removal And Installation Tool (116 589 01 62 00)
Fig. 62: Identifying Installation Tool (112 589 09 61 00)

Number Designation
REPAIR MATERIALS
Removing and installing brake shoes of parking brake - AR42.20-P-0530IM
MODEL 215.379, 220.179
Shows model 220

Fig. 63: Identifying Brake Shoes Of Parking Brake Remove/Install Components (Shows Model 220)
Remove/Install
manufacturer.
system
platform until the wheels
are clear
rotate if necessary
3 Relieve load on cable AR42.20-P-0520-03IM
slack adjuster
carrier
4 Remove brake disks on AR42.10-P-0220I
rear axle
5 Detach lower retracting Installation: Ensure
spring (111) using removal that lower retracting
and installation tool (040) spring (111) is seated
correctly.
Removal and Fig. 61
installation tool
6 Remove retaining spring Installation: Ensure
(107) using installation that retaining springs
tool (041) (107) are seated correctly.
Installation tool Fig. 62
7 Remove brake shoes (103) If the brake shoes
over rear axle shaft flange (103) are scorched or the
(68) faces of the brake disks
are damaged, the brake
shoes (103), retracting
springs, retaining springs
(107) and brake disks
must be replaced.
Installation: Turn
back adjusting
mechanism (105) and
insert into both brake
shoes (103) such that the
adjusting wheel (c) points
in the direction of travel.
8 Detach upper retracting Installation: Ensure
spring (112) that upper retracting
spring (112) is seated
correctly. Coat thread of
thrust piece (104) and
cylindrical part of
adjusting wheel (c) with
MB long-life grease.
9 Remove expanding lock Installation: Coat all
(109) bearing and sliding
surfaces on the expanding
lock (109) with MB long-
life grease.
Check
assembly
12 Adjusting parking brake AR42.20-P-0540IM
PARKING BRAKE
wheel carrier
Fig. 64: Identifying Removal And Installation Tool (116 589 01 62 00)
REPAIR MATERIALS
ADJUSTING PARKING BRAKE - AR42.20-P-0540
Adjusting parking brake - AR42.20-P-0540I
MODELS 215, 220 (except 215.379, 220.179)

Fig. 67: Identifying Adjusting Wheel
MODIFICATION NOTES
2.12.02 Checking version of Step 1 BT42.20-P-0510-01A
parking brake pedal
assembly, added
2.12.02 Operate parking brake Step 2
pedal and check pedal
travel of parking brake
pedal, included for the
first time
9.9.03 Play adjustment of brake Step 10
shoes modified
Adjust
manufacturer.
system
1 Check version of parking
assembly modified
pedal and check pedal not within the tolerance
travel of parking brake range, adjust parking
pedal brake.
parking brake pedal
must be depressed
are clear
4 Pre-tension automatic AR42.20-P-0520-01A
rotate if necessary
6 Using a suitable tool, turn Adjustment direction
the adjusting wheel (105) for applying the brake
until the brake shoes touchshoes:
the brake drum and the Right side: Turn the
rear wheel no longer turns adjusting wheel (105)
from the bottom upwards.
Left side: Turn the
adjusting wheel (105)
from the bottom upwards.
7 Turn back the adjusting When slackening the
wheel (105) until the rear adjusting wheels ensure
wheel can be turned that both sides are turned
completely freely back by the same number
of teeth (10 teeth).
8 Relieve load on automatic AR42.20-P-0520-02A
cable slack adjuster.
9 Actuate parking brake Actuating force on *BE42.20-P-1001-01C
pedal several times parking brake pedal
must be depressed
10 Check that the rear wheels
can turn freely
11 Mount rear wheels
rotate if necessary

brake pedal must be See fig. BT42.20-P-0510- BT42.20-P-0510-
depressed 01A 01A

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed
Adjusting parking brake - AR42.20-P-0540IM
MODEL 215.379, 220.179 with ENGINE 275.980
Fig. 68: Identifying Parking Brake Adjusting Components
Inspecting, setting
manufacturer.
1 Check version of parking
assembly modified
pedal and check pedal not within the tolerance
travel of parking brake range, adjust parking
pedal brake.
parking brake pedal
must be depressed
are clear
rotate if necessary
5 Loosen adjusting screw
(89)
system
6 Using a suitable tool, turn Adjustment direction
the adjusting wheel (105a) for applying the brake
until the brake shoes (103) shoes (103):
touch the brake drum and Right side: Turn the
the rear wheel no longer adjusting wheel (105a)
turns from the bottom upwards.
Left side: Turn the
adjusting wheel (105a)
from the top downwards.
7 Turn back the adjusting Ensure that the
wheel (105a) until the rear adjusting wheel (105a) is
wheel can be turned turned back by the same
completely freely number of teeth (10 to 11
teeth) on both sides.
8 Screw in adjusting screw
(89) until front brake cable
(85) and rear brake cables
(85) no longer sag
pedal several times and not within the tolerance
check pedal travel of range, readjust parking
parking brake pedal brake at adjusting screw
(89) at cable slack adjuster
(91) until the correct
number of notches is
achieved at the pedal: ?
parking brake pedal
must be depressed
10 Check that the rear wheels
can turn freely
11 Mount rear wheels
rotate if necessary

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed
MAKING HOLES FOR BRACKET OF PARKING BRAKE CABLE ON REAR AXLE CARRIER -
AR42.20-P-2001-01I
REAR AXLE SHAFT

BA35.30-P-1002- Self-locking bolt, M10 Nm 70 70
01A rear axle shaft to
connecting flange
(thread and bolt M12 Nm 100 100
head contact
surface oiled)
WORKSHOP EQUIPMENT
1. Position bracket (1) on rear axle carrier (2) and mark holes.
Attach new bracket (1) in parallel with the broken off bracket (1), displaced in the direction of the
wheel.
Fig. 69: Identifying Bracket And Rear Axle Carrier
2. Support exhaust system using a transmission jack.

3. Unhook rubber mount (3) and lower the exhaust system.
4. Detach rear axle shafts (37) from rear axle center assembly (50) and place downwards.
Fig. 70: Identifying Rubber Mount, Rear Axle Shafts And Rear Axle Center Assembly
5. Center punch markings on rear axle carrier (2) and drill using angular drill (01) and 6.5 mm dia. drill.
6. Debur holes.
7. Mount rear axle shafts (37) on rear axle center assembly (50)
8. Hook up exhaust system in rubber mount (3).
Fig. 71: Identifying Rear Axle Carrier And Angular Drill
REMOVE/INSTALL LEFT FRONT OR RIGHT RPM SENSOR - AR42.30-P-0712I
MODEL 215, 220, 230

Fig. 72: Identifying Left Front Or Right Rpm Sensor Remove/Install Components (Shown On Model 220)
Shown on model 220
Fig. 73: Identifying Left Front RPM Sensor
Remove/install
1 Unscrew bolt (6a)
and bolts
*BA42.30-P-1001-01A
2 Take out left front rpm Installation: Lightly
sensor (L6/1) or right front grease bore in steering
rpm sensor (L6/2) knuckle (2) with MB
long-life grease.
3 Unlock and disconnect left Press clip in direction
front axle multiple circuit of arrow.
junction connector, major
assembly compartment
(X62/7) or right front axle
multiple circuit junction
connector, major assembly
compartment (X62/6)
4 Install in the reverse order Installation: Ensure
that the electrical feed line
to the rpm sensor has
sufficient play. The
vehicle suspension must
be able to fully compress
and rebound without
damaging the feed line.
The feed line should not
chafe at any point, as this
could lead to system
failure.
Installation: On
model 230 installation
position must be noted:
The chafing protection (1)
must be screwed to the
front rpm sensor as
shown. It must not be
mounted between the rpm
sensor and steering
knuckle (2).
Installation: On
model 215, 220 check
rotor of wheel hub for
damage. Pay attention to
cleanliness of magnetic
tip.
5 Read out fault memory and
erase if required
fault memory
diagnosis system
FRONT AXLE RPM SENSOR

Number Designation Model 215 Model 220 Model 230
BA42.30-P-1001- Self-locking bolt, Nm 25 25 25
01A front axle rpm
sensor to steering
knuckle

Number Designation
REPAIR MATERIALS
REMOVING AND INSTALLING BAS DIAPHRAGM TRAVEL SENSOR - AR42.31-P-6002I
MODEL 215, 220

Fig. 74: Identifying BAS Diaphragm Travel Sensor Remove/Install Components
1 Disconnect vacuum line Operate brake pedal
(8) from brake booster several times to reduce the
vacuum.
2 Disconnect BAS
diaphragm travel sensor
connector (A7/7x1)
3 Remove locking ring (16b) Use suitable tool, e.g.
offset scribing iron
(arrow).
4 Pull out BAS diaphragm Installation: Rub front
travel sensor (A7/7b1) of diaphragm travel sensor
with a little spirit so that
the O-ring slides properly
when inserting.
5 Check O-ring and replace Installation: Insert O-
if necessary ring in brake booster
groove and ensure it is
seated correctly.
REMOVE/INSTALL ETS/ASR/ESP HYDRAULIC UNIT - AR42.40-P-0816I
Models 215, 220
Connections on hydraulic unit A7/3:

Fig. 75: Identifying ETS/ASR/ESP Hydraulic Unit Remove/Install Components
Fig. 76: Identifying ABC Suspension Oil Reservoir And Traction Systems Hydraulic Unit
Remove/install
tasting brake fluid. Injury suitable and appropriately
hazard due to skin and eye marked containers. Wear
contact with brake fluid protective clothing and
eye protection when
fluid
system
Ignition OFF
1 Detach intake pipe (1). Only remove intake
pipe on the left.
2 Swivel ABC suspension To do this, loosen three
oil reservoir to the side nuts at bracket for ABC
(see diagram) suspension oil reservoir.
3 Unscrew hydraulic lines Ring wrench bit Fig. 38
from hydraulic unit (A7/3)
Ring wrench bit Fig. 39
Seal off hydraulic lines
and connections with
plugs.
Do not misconnect lines.
Set of closure Fig. 20
plugs
*BA42.40-P-1001-01B
4 Unplug connector from Push bayonet lock
hydraulic unit upwards and detach plug
(see arrows).
5 Removing hydraulic Unscrew hydraulic
module unit from retainer or
remove complete with
retainer. Unscrew
mounting screws for
hydraulic unit. Pull the
retaining plate upwards
out of the rubber mounts
if necessary.
6 Install in the reverse order Flush away with water
any brake fluid which
runs out.
7 Bleeding brake system Model 215, model 220 AR42.10-P-0010I
code Z07
protection code Z07
DIAGNOSIS and
interrogate fault memory
Diagnosis system STAR *WH58.30-Z-1048-13A
DIAGNOSIS
ACCELERATION SLIP REGULATION (ASR)

BA42.40-P-1001- Brake line to NM 14 14
01B ASR/ESP hydraulic
unit
Fig. 77: Identifying Ring Wrench Bit (000 589 77 03 00)
Fig. 78: Identifying Ring Wrench Bit (140 589 00 03 00)
Fig. 79: Identifying Set Of Closure Plugs (129 589 00 91 00)

Number Designation
REMOVING AND INSTALLING LEFT OR RIGHT REAR AXLE SPEED SENSOR - AR42.40-P-0820I
Models 215, 220

Fig. 80: Identifying Left Or Right Rear Axle Speed Sensor Remove/Install Components (Shown On
Model 220)
Shown on model 220
Remove/install
1 Unscrew mounting screw Replace bolts. *BA42.40-P-1002-01B
(6a) and remove left rear
and right rear rpm sensor
2 Remove left rear and right Installation: Check
rear rpm sensor (L6/3, rotor on wheel hub for
L6/4) damage. Ensure that the
magnetic blade is clean.
Fasten lines for the rpm
sensor in retaining clamps
on the tie rod and ensure
that they are not damaged
when the vehicle
suspension moves
towards jounce and
rebound.
Grease the bore in the *BR00.45-Z-1001-06A
wheel carrier lightly with
MB long-term grease.
3 Pull off grommet (3) over For the left grommet
rpm sensor connector (3) over the rpm sensor
(L6/3x1, L6/4x1) connector (L6/3x1,
L6/4x1), in addition
unscrew nuts (1) and
remove cover (2).
4 Disconnect rpm sensor Installation: Ensure
connector (L6/3x1, that the components are
L6/4x1) correctly routed.
ACCELERATION SLIP REGULATION (ASR)

BA42.40-P-1002- Self-locking bolt of NM 8 8
01B rear axle speed
sensor
REPAIR MATERIALS
CHECKING BRAKE BOOSTER HYDRAULIC UNIT - AR42.50-P-0001MB
Fig. 81: Identifying Brake Booster Hydraulic Unit Components
Check
The battery voltage must The following test
be between 11 and 14 V operations must be
performed consecutively,
with the test results be
noted at the conclusion of
each individual operation.
This test must be All of the component
conducted at a room operations within the
temperature of between overall test procedure
18° C and 23° C must be carried out before
analysis and assessment
can start.
1 Inspect brake system for
external leaks
3 Remove inner liner in front AR88.10-P-1300M
fender
4 Pressure gauge connection AR42.50-P-0001-01MB
Distributor unit *WH58.30-Z-1003-23A
Pressure tester (single *WH58.30-Z-1012-15A
and dual-circuit hydraulic
brake systems)
5 Bleeding booster circuit AR42.50-P-0001-10MB
Bleeder screw *BA42.50-P-1001-01B
Brake fluid replacement *WE58.40-Z-1001-07A
unit
6 Checking monitoring AR42.50-P-0001-03MB
system
7 Reservoir preload test AR42.50-P-0001-04MB
8 Check cockpit warning AR42.50-P-0001-05MB
displays
9 Check charge time of AR42.50-P-0001-06MB
motor-and-pump assembly
10 Check motor-and-pump AR42.50-P-0001-07MB
assembly cycling points
11 Check warning display AR42.50-P-0001-08MB
trigger points
12 Check for leaks AR42.50-P-0001-09MB
13 Assess the results of the
individual test operations
and then replace the
components indicated ?
Remove/install
14 Remove brake booster AR42.10-P-0302MB
hydraulic unit
15 Remove motor-and-pump AR42.10-P-0303MB
assembly
16 Remove motor-and-pump
assembly pressure
reservoir
17 Remove brake booster
hydraulic unit pressure
reservoir
18 Remove ESP control unit
19 After replacing one or
several components, repeat
the entire test process.
20 Detach pressure gauge AR42.50-P-0001-02MB
Distributor unit *WH58.30-Z-1003-23A
Pressure tester (single *WH58.30-Z-1012-15A
and dual-circuit hydraulic
brake systems)

Z07

Number Designation
WH58.30-Z-1012-15A Pressure tester (hydraulic single / dual circuit brake systems)
WH58.30-Z-1003-23A Distributor A 116 990 02 72
WORKSHOP EQUIPMENT
WE58.40-Z-1001-07A Brake fluid replacement unit
Pressure gauge connection caused by swallowing brake fluid. caused by brake fluid coming into contact with skin and
eyes. - AR42.50-P-0001-01MB

by swallowing brake suitable and appropriately
fluid. Risk of injury marked containers. Wear
caused by brake fluid protective clothing and
coming into contact with eye protection when
skin and eyes. handling brake fluid.

Number Designation
1. Switch off ignition.

2. Release pressure from booster circuit (by depressing brake pedal approximately 30 times).
3. Screw out the nuts (1) on the hydraulic line (2).
4. Remove angled fitting (3) from hydraulic line.
5. Install adapter (4) and distribution module (5) between angled fitting (3) and hydraulic line.
Instead of the adapter (2 M10x1 outside threaded fittings) a short length of brake line bent to the
desired configuration can also be installed.
6. Connect test line (6) from pressure gauge to adapter (5).
Fig. 82: Identifying Pressure Gauge Connection Components
Detach pressure gauge caused by swallowing brake fluid. caused by brake fluid coming into contact with skin and eyes. -
AR42.50-P-0001-02MB
by swallowing brake suitable and appropriately
fluid. Risk of injury marked containers. Wear
caused by brake fluid protective clothing and
coming into contact with eye protection when
skin and eyes handling brake fluid.

Number Designation

3. Disconnect test line (6) from pressure gauge to adapter (5).
4. Remove adapter (4) and distribution module (5).
5. Install angled fitting (3) on hydraulic line.
6. Install nuts (1) on the hydraulic line (2).
Fig. 83: Identifying Pressure Gauge Connection Components
Check monitoring system - AR42.50-P-0001-03MB
The ignition must be switched off.

1. Remove connection plug (1) from motor-and-pump assembly.
3. Read pressure indicated on gauge.
Pressure gauge indicates 0 bar: System OK. Pressure gauge shows residual pressure (> 0 bar): Brake
booster hydraulic unit is defective.
Fig. 84: Checking Monitoring System
4. Start engine. After 60 seconds the following message should appear in the instrument cluster "BRAKE
SYSTEM - STOP, CALL FOR SERVICE."
Message appears: System OK
No message appears: ESP control unit or vehicle electrical system defective.

6. Reconnect plug (1) to motor-and-pump assembly (should audibly snap into place).
Fig. 85: Identifying Instrument Cluster

Check reservoir preload - AR42.50-P-0001-04MB
1. Release pressure from booster circuit (depress brake pedal approximately 30 times). Pressure gauge
should indicate 0 bar.
2. Switch on the ignition and simultaneously note the reading on the pressure gauge. The following message
appears in the instrument cluster: "BRAKE SYSTEM - WAIT - PRESSURIZATION".
When the ignition is switched on the pressure should jump from 30 to 85 bar. This is the reservoir
preload.
Pressure between 30 and 85 bar: System OK.
Pressure below 30 bar: Malfunction in reservoir motor-and-pump assembly and reservoir for brake
booster hydraulic unit.
Fig. 86: Checking Reservoir Preload
Check cockpit warning displays - AR42.50-P-0001-05MB
1. Release pressure from booster circuit (depress brake pedal approximately 30 times).
2. Start engine.
3. Observe pressure gauge along with the corresponding status messages displayed in the instrument cluster.
At approximately 135 bar the message "BRAKE SYSTEM - WAIT - PRESSURIZATION!" should go
out.
Message goes out: System OK.
Message remains in display: ESP control unit or vehicle electrical system defective.

Fig. 87: Checking Cockpit Warning Displays
Checking charge time of motor-and-pump assembly - AR42.50-P-0001-06MB
2. Switch on the ignition and monitor the period that elapses until the motor-and-pump assembly is
deactivated.
Time between 40 and 70 s: System OK.
Time > 70 s: Motor-and-pump assembly defective.
Time < 40 s: Brake booster hydraulic unit is defective.
Checking motor-and-pump assembly cycling points - AR42.50-P-0001-07MB
2. Switch on the ignition and wait until the motor-and-pump assembly is deactivated.
Read the motor-and-pump assembly's pressure at deactivation from the pressure gauge.
If the pressure lies between 172 and 190 bar:
System OK.
Pressure < 172 bar or >190 bar:
Malfunction in motor-and-pump assembly.

4. Depress brake pedal to reduce reservoir pressure to 138 - 144 bar.
5. Switch on ignition and note whether motor-and-pump assembly starts to run.
Motor-and-pump assembly starts: System OK.
Motor-and-pump assembly fails to start:
Malfunction in motor-and-pump assembly.
Check warning trigger points - AR42.50-P-0001-08MB
3. Remove fuse (f8, 40 ampere) for relay K37/1.
Fig. 88: Identifying Fuse
4. Quickly depress the brake pedal a number of times in succession to depressurize the booster circuit.
At 101 -107 bar the warning "BRAKE SYSTEM - WAIT-PRESSURIZATION" should appear in the
instrument cluster's display.
The motor-and-pump assembly starts to run.
At approximately 135 bar the warning display should go out again.
Conditions met: System OK
Fails to comply with conditions: ESP control unit or vehicle electrical system defective.
5. Install fuse (f8, 40 amperes) for relay K37/1.

Fig. 89: Checking Warning Trigger Points
Leakage check - AR42.50-P-0001-09MB
3. Switch off the ignition and record the pressure.
Do not operate brake pedal.
4. Wait 30 minutes then switch the ignition back on.
Pressure loss < 20 bar and motor-and-pump assembly does not restart: System OK.
Pressure loss >20 bar and motor-and-pump assembly starts to run:
Brake booster hydraulic unit is defective.
Bleeding booster circuit from swallowing brake fluid. from skin and eye contact with brake fluid - AR42.50-P-0001-
10MB

and eye contact with protective clothing and
brake fluid. eye protection when

Z07
WORKSHOP EQUIPMENT
WE58.40-Z-1001-07A Brake fluid replacement unit
1. Check level of brake fluid in booster circuit (10d) and top up as necessary.
2. Connect discharge hose to booster circuit bleed valve (11a).
3. Switch on ignition.
Secure discharge hose on booster circuit bleed valve (11a) to prevent it from slipping off (high
pressure).
4. Carefully open the booster circuit bleed valve (11a) while slowly depressing the brake pedal to the floor.
5. Continue to bleed the booster circuit until the emerging brake fluid is free of air bubbles.
6. Close booster circuit bleed valve (11a), release the brake pedal and switch off the ignition.
Fig. 90: Identifying Brake Fluid Replacement Unit Components

CABIN AIR FILTERS
Activated Charcoal Filter & Dust Filter - 215 Chassis
DESCRIPTION
ACTIVATED CHARCOAL FILTER
Some models may be equipped with activated charcoal filters. The filters are used to absorb odors and
pollutants from the air entering the passenger compartment. Both fresh air and recirculated air are filtered.The
activated charcoal filters are located in behind the right side of the instrument panel in the A/C housing. See
Fig. 1 .
Fig. 1: Locating Activated Charcoal Filters

IDENTIFICATION
215 CHASSIS MODEL IDENTIFICATION

Year Model
2000-2006 CL500
2001-2006 CL55
2001-2006 CL600
2005-2006 CL65
NOTE: Manufacturer's terminology for this filter is activated charcoal filter, dust filter
or HVAC filter.
NOTE: Numbers in parenthesis refer to numbers in illustrations.
1. The activated charcoal filters are located in the A/C housing behind the glove box. See Fig. 1 .
2. Remove cover (1) with insert plugs (2) toward front out of knee guard (3), and toward rear out of both
retainers (arrows) on heater housing (6). See Fig. 2 .
3. Unclip footwell lamp from knee guard (3) and unplug connector. See Fig. 2 . Remove screws (4). Push
knee guard (3) with hooks (5) toward bottom out of instrument panel (7).
Fig. 2: Removing Cover Under Right Side Of Instrument Panel

4. Pull back carpeting in passenger side footwell. Move locking slide (2) in the direction of the arrow and
remove activated charcoal filter cover (1). See Fig. 3 .
Fig. 3: Removing Activated Charcoal Filter

NOTE: Activated charcoal filters should never be cleaned - replace old filters.
5. Pull activated charcoal filters(3) down and out of case. See Fig. 3 . To install activated charcoal filters,
reverse removal procedure.
CABIN AIR FILTER
1. The dust filters are located behind the right side of the instrument panel. See Fig. 4 .
Fig. 4: Locating Dust Filters
2. Open glove box lid (6). Unclip glove box lamp (1) and unplug connector. See Fig. 5 .
3. Remove plugs (2) and screws (3, 4). See Fig. 5 . Pull glove box (5) completely out of instrument panel.
Unhook control cable on lock on glove box.
Fig. 5: Removing Glove Box
4. Unlock slide (2) upwards and remove cover (3) from A/C housing (4) in direction of arrow (to left). See
Fig. 6 . Pull dust filters (5) out of the A/C housing (4). Hold dust filters horizontal when removing to
prevent spilling dust into interior.
Fig. 6: Removing Dust Filters
NOTE: Dust filter should never be cleaned; replace filter if dirty.
5. To install dust filter, reverse removal procedure.

CABIN AIR FILTERS
Activated Charcoal Filter & Dust Filter - 220 Chassis
DESCRIPTION
Some models may be equipped with activated charcoal filters. The filters are used to absorb odors and
pollutants from the air entering the passenger compartment. Both fresh air and recirculated air are filtered.The
activated charcoal filters are located in behind the right side of the instrument panel in the A/C housing. See
Fig. 1 .

IDENTIFICATION
220 CHASSIS MODEL IDENTIFICATION

Year Model
2006 S350
2000-2006 S430
2000-2006 S500
2001-2006 S600
2001-2006 S55
NOTE: Manufacturer's terminology for this filter is activated charcoal filter, dust filter
or HVAC filter.
1. The activated charcoal filters are located in the A/C housing behind the glove box. See Fig. 2 .

2. Remove cover (1) under right side of instrument panel. Remove cover (1) with catch lugs (2) out of knee
protection (3) toward front and rear from both retaining brackets (arrows) on heater housing (6). See Fig.
3.
Fig. 3: Removing Cover Under Right Side Of Instrument
3. Unclip footwell illumination from knee protection (3) and unplug connector. See Fig. 3 . Remove screws
(4). Remove knee protection (3) with hooks (4) downward out of instrument panel and center console.
4. Pull back carpeting in passenger side footwell. Move locking slide (2) in the direction of the arrow and
remove activated charcoal filter cover (1). See Fig. 4 .
Fig. 4: Removing Activated Charcoal Filter
NOTE: Activated charcoal filters should never be cleaned - replace old filters.
5. Pull activated charcoal filters (3) down and out of case. See Fig. 4 . To install activated charcoal filters,
reverse removal procedure.
CABIN AIR FILTER
1. The dust filters are located behind the right side of the instrument panel. See Fig. 5 .
Fig. 5: Locating Dust Filters

2. Open glove box lid (6). Unclip glove box lamp (1) and unplug connector. See Fig. 6 .
3. Remove plugs (2) and screws (3, 4). See Fig. 6 . Pull glove box (5) completely out of instrument panel.
Unhook control cable on lock on glove box.
Fig. 6: Removing Glove Box
4. Unlock slide (2) upwards and remove cover (3) from A/C housing (4) in direction of arrow (to left) . See
Fig. 7 . Pull dust filters (5) out of the A/C housing (4). Hold dust filters horizontal when removing to
prevent spilling dust into interior.
Fig. 7: Removing Dust Filters
NOTE: Dust filter should never be cleaned; replace filter if dirty.
5. To install dust filter, reverse removal procedure.

Central Locking System - 215 & 220 Chassis
BASIC KNOWLEDGE
CENTRAL LOCKING (CL), FUNCTION - GF80.20-P-0005S
MODELS 215, 220
Interlinkage of central locking (CL), illustrated on model 220
Fig. 1: Identifying Interlinkage Components Of Central Locking (CL) - Illustrated On Model 220
The central locking controls the authorization for access to the passenger compartment. The central locking can
be operated in various manners:
 Remote control with remote control key

 Operation with the interior switch.
 Control with mechanical key.
 By opening the driver's door from the inside
 Remote control via Keyless Go card (only with code 889)
On model 215 the rear door control modules (N69/3, N69/4) are replaced by the rear control module (N22/6).
Power locking:
The power locking feature completely closes a door or trunk lid when it has only been pushed up to the first
catch.
The functions for opening the trunk lid are described in the function description for remote trunk release
(RTR)
Central locking (CL), location GF80.20-P-0005-01S

of components
Operating CL with remote GF80.20-P-2002S
control key, function
Operating CL with GF80.20-P-2004S
mechanical key, function
Unlocking by opening a door, GF80.20-P-3004S
function
Locking/unlocking vehicle GF80.20-P-3009S
with interior switch, function
Headlamp delayed switch-off, up to 31.5.00 GF80.20-P-2003S
function
as of 1.06.00 GF80.20-P-2003SA
Remote trunk release (RTR), GF80.20-P-0006S
function
Power locking for doors, GF80.40-P-3001S
function
Central locking (CL), location of components - GF80.20-P-0005-01S

Fig. 2: Identifying Central Locking (CL) Components Location
REMOTE TRUNK RELEASE (RTR), FUNCTION - GF80.20-P-0006S
MODEL 215, 220
Remote trunk release (RTR), function illustrated on model 220

Fig. 3: Identifying Remote Trunk Release (RTR), Function Diagram - Illustrated On Model 220
The following functions are described in the function description:
 Opening the trunk lid with the remote control key

 Opening the trunk lid with the remote trunk lid release switch (S20/1s6) on the driver's door
 Manual opening the trunk lid by pressing the lock cylinder in the trunk lid lock
 Trunk lid power locking feature
The state of the central locking system determines whether the trunk lid can be opened with the individual
features. Regardless of this the trunk lid can be locked or unlocked with the manual key .
Fig. 4: Remote Trunk Release (RTR) Block Diagram
Opening trunk lid with GF80.20-P-3010S

remote control key, function
Locking/unlocking trunk lid GF80.20-P-3011S
with manual key, function
Opening trunk lid with GF80.20-P-3012S
interior switch, function
Manually opening trunk lid, GF80.20-P-3013S
function
Central locking (CL), GF80.20-P-0005S
function
Trunk lid power locking, GF80.40-P-3002S
function
Remote trunk release (RTR), GF80.20-P-0006-01S
location of components
Remote trunk release (RTR), location of components - GF80.20-P-0006-01S

Fig. 5: Identifying Remote Trunk Release (RTR) Components Location
REMOTE TRUNK LOCKING (RTL) FUNCTION - GF80.20-P-0007A
MODELS 215, 220 with CODE (881b) Remote trunk locking (RTL)
Fig. 6: Remote Trunk Locking (RTL) Function Diagram
Function overview
The remote trunk lid locking (RTL) function in comparison to remote trunk release (RTR) represents an
extension to operating convenience. Remote trunk locking (RTL) makes it possible to open and close the trunk
lid hydraulically. Models fitted with remote trunk locking (RTL) are equipped with additional hydraulics, a
sensor and additional operating switches. The location and networking of the electric components corresponds
to the conditions prevalent in the remote trunk release (RTR) feature. The extensions in the remote trunk
locking (RTL) as compared with the remote trunk release (RTR) are highlighted in the block diagram. More
detailed information can be ascertained from the reference table that follows.
Hydraulic opening of the trunk lid can be started with the following controls:
 Via radio using the transmitter key (A8/1)

 From inside the car by means of the remote trunk lid release switch (S20/1s6)
 At the trunk lid using the trunk lid release switch (S15/1)
The trunk lid can be opened in this way as far as the end stop. The opening movement can also be stopped,
however, at any desired point and also continued again.
As of 06/00: opening angle limitation : If the remote trunk lid release switch (S20/s16) is operated
continuously for 5 seconds when the trunk lid is closed, the opening angle limitation is activated - and is
deactivated if the remote trunk lid release switch (S20/s16) is operated again for another 5 seconds.
When the function is active, the trunk lid opens as far as the defined position.
Hydraulic closing of the trunk lid is possible by means of the following switches:
 From inside the car by means of the remote trunk lid release switch (S20/1s6)
 At the trunk lid using the RTL push-button (S62/26)
For safety reasons, it is not possible to close the trunk lid by means of the remote control using the
transmitter key (A8/1).
During the hydraulic closing operation , the hydraulic system closes the trunk lid just far enough to enable the
trunk lid to automatically engage in the catch as a result of its own weight. The RTL hydraulic pump (M51) is
switched off before the trunk lid engages in the catch. The power closing system then performs the final closing
of the trunk lid.
The entire control process for the opening and closing functions is conducted by the pneumatic control
module (combined) (A37). The pneumatic control module (combined) (A37) scans the trunk lid opening
angle detection sensor (B24/16) and is actuated via the
 trunk lid open relay (K69/1) and

 trunk lid close relay (K69/2)
and the hydraulic pump (RTL) (M51) . The two relays are responsible for actuating the electric motor in the
hydraulic pump (RTL) (M51), switching it on and off as well as changing its direction of rotation.
When switched off the two hydraulic pump (RTL) (M51) terminals are connected to ground. To open the trunk
lid a hydraulic pump (M51) terminal is switched from ground to terminal 30 by the trunk lid open relay
(K69/1). When closing, the trunk lid close relay (K69/2) switches the corresponding connection at M51 from
ground to terminal 30.
The hydraulic pump (RTL) (M51) builds up the pressure for the hydraulic ram . A multiple-jointed hinge is
used to divert the straight-line motion of the hydraulic ram into a rotary movement, with the result that the trunk
lid can be hydraulically opened and closed. The weight of the trunk lid is relieved through means of two
installed gas-filled telescopic struts
Safety mechanism
With the trunk lid opening angle detection sensor (B24/16) the pneumatic control module (combined) (A37)
controls the limit switch position and the hydraulic operation of the trunk lid. The hydraulic pump RTL (M51)
is switched off when the specified limit stop angle position is reached.
With the aid of the trunk lid opening angle detection sensor (B24/16) the pneumatic control module (combined)
(A37) analyzes not only the actual opening angle of the trunk lid, but it also registers any changes in speed in
trunk lid movement. If the trunk lid encounters an obstacle or if a manual intervention takes place, the speed of
the trunk lid is altered. In such an event the pneumatic control module (combined) (A37) stops the hydraulic
opening motion and reverses the trunk lid's direction of movement during the closing procedure.
Manual operation of the trunk lid is also possible in an emergency, but necessitates greater physical effort as
the hydraulic system also has to be moved. The trunk lid opening angle detection sensor (B24/16) does not
require any recalibration after a manual intervention.
For safety reasons, the pneumatic control module (combined) (A37) switches the hydraulic pump RTL
(M51) off after a maximum of two minutes continuous operation .
Remote trunk locking (RTL), location GF80.20-P-0007-

of hydraulic components 01A
Remote trunk release (RTR), location GF80.20-P-0006-
of components 01S
Open trunk lid with remote control key, GF80.20-P-3010B
function
Open trunk lid with interior switch, GF80.20-P-3012B
function
Manually open trunk lid, function GF80.20-P-3013B
Close trunk lid, function GF80.20-P-2006A
Power-assisted trunk lid close, function GF80.40-P-3002S
Locking/unlocking trunk lid with GF80.20-P-3011S
Trunk lid status indicator, function GF80.20-P-4015S
Trunk lid lock, GF80.20-P-4103S
position/task/design/function
Pneumatic system equipment (PSE) GF80.20-P-4106S
control module (combined),
Hydraulic ram, position/task/design GF80.20-P-4111A
Trunk lid opening angle detection GF80.20-P-4113A
sensor, position/task/design/function
Gas-filled telescopic struts, GF80.20-P-4114A
position/task
Remote trunk locking hydraulic pump, GF80.20-P-4115A
position/task/design
Trunk lid relay, position/task/design GF80.20-P-4116A
Remote trunk locking (RTL) arrangement of hydraulic components - GF80.20-P-0007-01A
Models 215, 220 with code 881b (trunk lid remote control)
Shown on model 220
Fig. 7: Identifying Remote Trunk Locking (RTL) Hydraulic Components - Shown On Model 220
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF REMOTE TRUNK LOCKING (RTL) -

GF80.20-P-0994A
MODEL 215, 220 with CODE (881b) Remote trunk locking (RTL)
Remote trunk locking (RTL), function GF80.20-P-0007A

Remote trunk locking (RTL), location of GF80.20-P-0007-
hydraulic components 01A
Opening trunk lid with remote control key, GF80.20-P-3010B
function
Opening trunk lid with interior switch, GF80.20-P-3012B
function
Opening trunk lid manually, function GF80.20-P-3013B
Closing trunk lid, function GF80.20-P-2006A
location/purpose/design/function
Pneumatic system equipment (PSE), GF80.20-P-4106S
combined functions,
Hydraulic pump, remote trunk locking, GF80.20-P-4115A
location/purpose/design
Trunk lid relay, location/purpose/design GF80.20-P-4116A
Trunk lid opening angle detection sensor, GF80.20-P-4113A
Hydraulic cylinder, GF80.20-P-4111A
Gas pressure strut, location/purpose GF80.20-P-4114A
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF REMOTE TRUNK RELEASE (RTR) -

GF80.20-P-0995SZ
MODEL 215, 220
Remote trunk release (RTR), function GF80.20-P-0006S

Remote trunk release (RTR), location of GF80.20-P-0006-
components 01S
Opening trunk lid with remote control key, GF80.20-P-3010S
function
Locking/unlocking trunk lid with manual GF80.20-P-3011S
key, function
Opening trunk lid with interior switch, GF80.20-P-3012S
function
Manually opening trunk lid, function GF80.20-P-3013S
Trunk lid power locking, function GF80.40-P-3002S
Remote trunk release switch, GF80.20-P-4104S
CONTENTS, FUNCTION DESCRIPTION OF CENTRAL LOCKING (CL) - GF80.20-P-0996SZ
MODELS 215, 220
Central locking (CL), location of GF80.20-P-0005-

components 01S
Central locking (CL), function GF80.20-P-0005S
Operating CL with remote control key, GF80.20-P-2002S
function
Headlamp delayed switch-off, function up to 31.5.00 GF80.20-P-2003S
as of 1.6.00 GF80.20-P-
2003SA
Operating CL with mechanical key, GF80.20-P-2004S
function
Unlocking by opening a door, function GF80.20-P-3004S
Locking with remote control key, function GF80.20-P-3005S
Unlocking with remote control key, GF80.20-P-3006S
function
Actuating lock switch, function Model 220 only GF80.20-P-3007S
Locking/unlocking driver's door with GF80.20-P-3008S

Locking/unlocking vehicle with interior GF80.20-P-3009S
switch, function
Automatic locking, function GF80.20-P-4009S
Transmitting remote control signal, GF80.20-P-4010S
function
Receiving remote control signal, function GF80.20-P-4011S
Relocking, function GF80.20-P-4012S
Central locking emergency opening, GF80.20-P-4013S
function
Pneumatically locking/unlocking, function GF80.20-P-4016S
Power locking for doors, function GF80.40-P-3001S
Infrared receiver, GF80.20-P-4101S
Antenna amplifier module, GF82.62-P-3105A
CENTRAL LOCKING CONTROL WITH REMOTE CONTROL KEY, FUNCTION - GF80.20-P-2002S
MODEL 220
Operating the CL using the transmitter key
Function shown on model 220
Fig. 8: Central Locking Control Function Diagram With Remote Control Key - Shown On Model 220
The vehicle can be locked and unlocked with the remote control key . There are two operating modes for the
"Unlocking " function: "Universal unlocking" and "Selective unlocking". In the "Universal unlocking" mode all
doors, the tank flap and the trunk lid are unlocked. In the "Selective unlocking" mode only the driver's door and
the tank flap are unlocked. In both operating modes the anti-theft alarm (ATA) is deactivated.
The "Unlocking" function can be triggered by pressing the "Unlock" button on the remote control key. The
remote control key can be set in such a manner that the first actuation is either "universal" or "selective".
The turn signal lamps flash once to indicate successful unlocking. If the "Unlock" button is pressed again on
the remote control key following "selective unlocking" the vehicle is unlocked "universally".
The "Locking " function can be started by pressing the "Lock" button on the remote control key. All locking
points are locked and the ATA is activated. The turn signal lamps flash three times to indicate successful
locking.
Unlocking with remote control GF80.20-P-3006S

key, function
Locking with remote control key, GF80.20-P-3005S
function
Activation of anti-theft alarm GF80.50-P-2002S
system (ATA), function
Deactivation of anti-theft alarm GF80.50-P-2003S
system (ATA), function
Remote control key, GF80.57-P-4101S
purpose/design/function
HEADLAMP DELAYED SWITCH-OFF, FUNCTION - GF80.20-P-2003
Headlamp delayed switch-off, function - GF80.20-P-2003S
MODEL 215, 220 up to 31.5.00
The headlamp delayed switch-off function serves for illuminating the environment of the vehicle for a short
time, e.g. in an underground parking lot.
Function prerequisites:
 Light was switched on previously

 Starter switch in position "0"
Function sequence
If at least one door is unlocked and locked again the low beam (with xenon the fog lamps) is switched on for a
certain time after the last vehicle door is locked. The duration of the headlamp delayed switch-off feature can be
set to max. 60 seconds in the instrument cluster.
Interruption function (discrete exit)
Before leaving the vehicle (exterior lamp switch (S1) in position "0"), turn electronic key in starter switch to
position 0, then to position 2 and then back to position 0. The headlamp delayed switch-off function is
interrupted until the function prerequisites are present again.
When the anti-theft alarm (ATA) is triggered the headlamp delayed switch-off feature is also interrupted.
Deactivating function
When the time interval is set to "0 s " in the instrument cluster (A1) the headlamp delayed switch-off feature is
deactivated.
Anti-theft alarm system GF80.50-P-0001S

(ATA), function
Instrument cluster (KI), GF54.30-P-0002-05S
operation instructions
Contents, function GF80.20-P-0996SZ
description of central
locking (CL)
Headlamp delayed switch-off, function - GF80.20-P-2003SA
MODELS 215, 220 as of 1.6.00
The headlamp delayed switch-off function serves for illuminating the vehicle environment with parking lights,
taillamps, license plate lamps and fog lamps for a time interval set in the instrument cluster (A1) when leaving
the vehicle.
The time interval can be set in increments of 15 s from 0 s to 60 s.
 Headlamp delayed switch-off feature is activated (T>0) via instrument cluster (A1)
 Circuit 61 and circuit 15 "OFF" and
 automatic light switch daylight sensor (B32/1) signals "DARKNESS"
As of 01.06.01 (model year 2002) for USA and CANADA The exterior lamp switch should also be set to
the automatic position.
Function sequence
If the function prerequisites are present the headlamp delayed switch-off feature is active for 60 s (this time is
independent of the time interval set in the instrument cluster (A1)).
When a door is opened (also trunk lid) the time (t= 60s) is started again (this applies each time the door is
opened before the time has expired (t=60s).When the last door is locked the time interval set in the instrument
cluster (A1) is activated.
Interruption function (discrete exit)
When the ignition is switched on and off (circuit 15) the headlamp delayed switch-off feature is interrupted
until the function prerequisites are present again.
When an alarm is triggered by the anti-theft alarm (ATA) the headlamp delayed switch-off feature is also
interrupted.
Deactivating function
When the time interval is set to "0 s " in the instrument cluster (A1) the headlamp delayed switch-off feature is
deactivated.
As of 01.06.01 (model year 2002) for USA and CANADA If the exterior lamp switch is set to a position
other than "Automatic" the headlamp delayed switch-off feature is also deactivated.

(ATA), function
Instrument cluster (KI), GF54.30-P-0002-05S
operation instructions
Contents, function GF80.20-P-0996SZ
description of central
locking (CL)
CENTRAL LOCKING OPERATION WITH MECHANICAL KEY, FUNCTION - GF80.20-P-2004S
MODEL 215, 220
With the mechanical key it is only possible to lock or unlock the driver's door. This is accomplished only
mechanically, without changing the status of the central locking. This does not deactivate the anti-theft alarm.
On vehicles with anti-theft alarm (ATA) it is therefore necessary to insert the main or emergency key into the
EIS control module (N73) to switch off the alarm.
Model 220 only :
The lock switches which trigger the central locking function can be actuated with the mechanical key.
This deactivates the ATA.
The production breakpoints for the lock switches are defined in the function description "Actuating
lock switches".
The CL and ATA functions are not possible without lock switches.
Locking/unlocking driver's except GF80.20-P-3008S

door with mechanical key,
function
Actuating lock switches, only GF80.20-P-3007S
function
Deactivating anti-theft alarm, GF80.50-P-2003S
function
CLOSING TRUNK LID FUNCTION - GF80.20-P-2006A
Shown on model 220

Fig. 9: Identifying Remote Trunk Lid Release Switch And RTL Pushbutton - Shown On Model 220
Operating instructions
The hydraulic closing of the trunk lid can be controlled using the following switches:
 RTL push-button (S62/26)

 Remote trunk lid release switch (S20/1s6)
With the remote trunk lid release switch (S20/1s6) the trunk lid can be closed from inside the vehicle
hydraulically . In order for this to happen, safety reasons require that the switch be pressed constantly . As
soon as the switch is no longer pressed the trunk lid movement is stopped.
Pressing the switch again will start the trunk lid moving again.
The RTL push-button (S62/26) can be used to close the trunk lid hydraulically by pressing it once . Pressing
the RTL push-button (S62/26) repeatedly will either stop or resume the closing operation.
When the trunk lid is open this is displayed by an illuminated red LED in the remote trunk lid release switch
(S20/1s6).
Operating procedure
Operation of the remote trunk lid release switch (S20/1s6 ) is detected by the left front door control module
(N69/1).
The left front door control module (N69/1) sends the message to close the trunk lid over the interior CAN to the
pneumatic control module (combined) (A37) .
Operation of the RTL push-button (S62/26) is read in directly by the pneumatic control module (combined)
(A37).
Once the switch has been pressed the pneumatic control module (combined) (A37) will actuate the two relays
 trunk lid open relay (K69/1) and

 trunk lid close relay (K69/2)
and activate the hydraulic pump RTL (M51) . The hydraulic ram is charged with fluid and closes the trunk lid
by means of the multiple-jointed hinge.
With the trunk lid opening angle detection sensor (B24/16) the pneumatic control module (combined) (A37)
controls the hydraulic operation and the limit switch position of the hydraulic pump RTL (M51). When the
trunk lid opening angle detection sensor (B24/16) reaches the specified limit stop position, the pneumatic
control module (combined) (A37) switches off the hydraulic pump RTL (M51). The limit stop position of the
hydraulic pump RTL (M51) is selected such that after the hydraulic is switched off the weight of the trunk lid
causes it to fall into the catch.
The complete trunk lid closing procedure is conducted by the power-assisted closing feature. The power-
assisted closing function is activated by the pneumatic control module (combined) (A37), by means of opening
the trunk lid closing assist locking eye microswitch's (S88/3) contact.
Safety mechanism
The hydraulic trunk lid closing operation is constantly controlled by the pneumatic control module
(combined) (A37) via the trunk lid opening angle detection sensor (B24/16) . If the trunk lid encounters an
obstacle or if a manual intervention takes place, the speed of the trunk lid is momentarily altered. This change in
speed is analyzed by the pneumatic control module (combined) (A37). In such an event the pneumatic control
module (combined) (A37) stops the closing operation immediately and opens the trunk lid again to precisely
the position it was at when the closing operation was initiated.
Manual operation of the trunk lid is possible in an emergency, but necessitates greater physical effort as the
hydraulic system also has to be moved. The trunk lid opening angle detection sensor (B24/16) does not require
any recalibration after a manual intervention.
Power-assisted trunk lid close, function GF80.40-P-3002S

function
function
position/task
UNLOCKING BY OPENING A DOOR, FUNCTION - GF80.20-P-3004S
MODEL 220, 215
It is always possible to open any of the doors from the inside even when the vehicle is locked centrally. By
opening the driver or passenger door from the inside the vehicle can be unlocked partially or completely
in the following cases.
Opening a door, shortly after locking
If the driver or passenger door is opened within 10 seconds after locking with the remote control key, the PSE
control module (combined) (A37) unlocks pneumatically. The PSE control module (combined) (A37)
unlocks only selectively if the vehicle was unlocked selectively before locking.
Opening a door after locking with the remote control key (vehicle unlocked selectively)
1. Insert remote control key into ignition:
The anti-theft alarm (ATA) is deactivated and the interior switch released but the vehicle is not
unlocked .
2a. Opening driver's door:
The PSE control module (combined) (A37) unlocks selectively (driver's door and trunk lid)
2b. Opening passenger door:
Driver's door and trunk lid are unlocked when the pump for the PSE control module (combined) (A37)
has been running for max. 20 seconds before opening the door.
Opening a door after locking with the remote control key (vehicle unlocked universally)
1. Insert remote control key into ignition:
The anti-theft alarm (ATA) is deactivated and the interior switch released but the vehicle is not
unlocked .
2. Opening driver or passenger door:
The PSE control module (combined) (A37) unlocks the entire vehicle pneumatically.
Opening a door after locking with the interior switch, or following automatic locking
1. Opening driver's door:
The PSE control module (combined) (A37) unlocks the entire vehicle pneumatically corresponding to
the status before locking, universal or selective.
2. Opening passenger door:
The PSE control module (combined) (A37) unlocks the vehicle pneumatically if it was unlocked
universally before locking.
If selectively unlocked before locking the driver's door and the trunk lid are only unlocked when the pump for
the PSE control module (combined) (A37) was operating for max. 20 seconds before opening the door.
 Opening of a rear door does not affect the status of the central locking.
 It is not possible to unlock the vehicle when the vehicle speed is above the limit value of approx. 15
km/h.
Locking/unlocking pneumatically, GF80.20-P-4016S

function
Deactivation of anti-theft alarm (ATA), GF80.50-P-2003S
function
combined functions,
LOCKING WITH REMOTE CONTROL KEY, FUNCTION - GF80.20-P-3005S
MODEL 215, 220
Locking with remote control key, function
illustrated on model 220

Fig. 10: Locking With Remote Control Key, Function Diagram - Illustrated On Model 220
When the "Lock vehicle" button is pressed, the remote control key sends a radio frequency and infrared signal
to the corresponding receivers in the vehicle. These receive the signal and transmit the information via the CAN
bus to the electronic ignition/starter switch control module (N73) . The electronic ignition/starter switch
control module (N73) checks the access authorization of the remote control key . If the access authorization is
valid, the electronic ignition/starter switch control module (N73) sends the command "Lock" via the CAN
bus. The PSE control module (combined) (A37) receives the command and locks the doors pneumatically .
Moreover, the interior switches, i.e. the interior central locking switch (N72/1s6) and the remote trunk
release switch (S20/1s6) are locked.
If the remote control key is inserted into the electronic ignition/starter switch control module (N73) after
locking, the interior switches are activated again. The status of the central locking is the same as after locking
with the interior central locking switch (N72/1s6) .
However, the vehicle is only unlocked again when a door is opened .

function
function
switch, function
Unlocking by opening one door, function GF80.20-P-3004S
function
function
Electronic ignition switch (EIS) control GF80.57-P-4102S
module, location/purpose/design/function
combined functions,
UNLOCKING WITH REMOTE CONTROL KEY, FUNCTION - GF80.20-P-3006S
MODEL 215, 220
Unlocking with remote control key, function illustrated on model 220
Fig. 11: Unlocking With Remote Control Key Function Diagram - Illustrated On Model 220
Remote control key set to "selective unlocking" When the "Unlock vehicle" button is pressed once, the
remote control key sends a radio frequency and infrared signal to the corresponding receivers in the vehicle.
These receive the signal and transmit the information via the CAN bus to the electronic ignition/starter switch
control module (N73) . The electronic ignition/starter switch control module (N73) checks the access
authorization. If the access authorization is valid then the electronic ignition/starter switch control module
(N73) sends the command "selective unlocking " via the CAN bus. The PSE control module (combined)
(A37) receives the command and unlocks the vehicle pneumatically .
If the vehicle was locked previously, the PSE control module (combined) (A37) unlocks selectively, i.e. only
the driver's door and the tank flap. If the driver's door and the tank flap are already unlocked and another
unlocking operation is requested the PSE control module (combined) (A37) unlocks the vehicle universally so
that the remaining doors are also unlocked. The remote trunk release switch (S15/1) is enabled.
Remote control key set to "universal unlocking" When the "Unlock vehicle" button is pressed once the
remote control key sends a radio frequency and infrared signal to the corresponding receivers in the vehicle. If
the access authorization is valid, the electronic ignition/starter switch control module (N73) sends the
command "universal unlocking " via the CAN bus. The PSE control module (combined) (A37) receives the
command and unlocks all the doors and the tank flap pneumatically . The remote trunk release switch
(S15/1) is enabled.
The interior switches are released when the vehicle is unlocked universally or selectively with the remote
control key.

function
function
switch, function
function
function
combined functions,
ACTUATING LOCK SWITCHES, FUNCTION - GF80.20-P-3007S

MODEL 220 up to 1.6.00 with CODE (491) U.S. version
MODEL 220 up to 1.9.99 with CODE (498) Japanese version
Fig. 12: Actuating Lock Switches, Function Diagram
The left front lock switch (S86/1) on vehicles with left-hand steering or the right front lock switch
(convenience) (S87/2) on vehicles with right-hand steering as well as the trunk lid lock switch (S88/2) can be
actuated with the mechanical key. This unlocks or locks the vehicle. The anti-theft alarm (ATA) is also
activated or deactivated.
Function sequence for left-hand steering as an example Actuation of the left door lock switch is read in
voltage coded by The left front door control module (N69/1) and relayed to the EIS control module (N73)
via the CAN bus.
The EIS control module (N73) transmits the command to lock or unlock the vehicle to the PSE control
module (combined) (A37) . The PSE control module (combined) (A37) recognizes immediately that the trunk
lid lock switch (S88/2) is actuated.
The PSE control module (combined) (A37) locks/unlocks the vehicle pneumatically. This is confirmed by the
turn signal system and release of the interior switches is performed in the same manner as when the vehicle
is locked or unlocked with the remote control key .
Without lock switches the corresponding door/trunk lid can only be locked/unlocked mechanically.
The ATA triggers an alarm

Central locking emergency unlocking, GF80.20-P-4013S
function
Pneumatically locking/unlocking, function GF80.20-P-4016S
function
Activating anti-theft alarm, function GF80.50-P-2002S
Deactivating anti-theft alarm, function GF80.50-P-2003S
switch, function
Opening trunk lid with interior switch GF80.20-P-3012S
PSE control module (combined), GF80.20-P-4106S
LOCKING/UNLOCKING DRIVER'S DOOR WITH MECHANICAL KEY, FUNCTION - GF80.20-P-

3008S
MODEL 215, 220
The driver's door can be unlocked or locked with the manual key.
This has no effect on the status of the central locking, i.e. the other locking points are not unlocked or locked by
this operation.
The anti-theft alarm (ATA) is neither activated nor deactivated. The convenience feature is not actuated.
Manual key on remote

control key
Anti-theft alarm (ATA), GF80.50-P-0001S
function
LOCKING/UNLOCKING VEHICLE WITH INTERIOR SWITCH, FUNCTION - GF80.20-P-3009S
MODEL 215, 220

Fig. 13: Locking/Unlocking Vehicle With Interior Switch, Function Diagram
With the exception of the fuel tank flap the vehicle can be locked or unlocked centrally with the interior
central locking and ATA function display switch (N72/1s6) . Theanti-theft alarm (ATA) is not activated or
deactivated.
The command to unlock or lock is sent via CAN by operating the interior switch. The PSE control module
(combined functions) (A37) receives this command and locks or unlocks pneumatically. The interior switch is
enabled by the locking and unlocking functions of central locking via CAN.
When locking with the interior central locking switch (N72/1s6) the signals from the door contact switches
are evaluated.
Possible situations are:
 Driver's door or passenger door open:
Only unlocking is permissible.
 Locking from outside with key:
Only locking is permissible.
 Unlocking from outside with key:
If none of the doors are open, full function.

function
Unlocking with remote control key, GF80.20-P-3006
function
function
Upper control panel control module, GF54.21-P-4105S
OPENING TRUNK LID - GF80.20-P-3010
Opening trunk lid with transmitter key function - GF80.20-P-3010B
Fig. 14: Identifying Transmitter Key
Operating procedure
If the "Open trunk lid" push-button is operated the transmitter key (A8/1) sends a radio signal to the rear
window antenna (A2/32) in the vehicle. From there the radio signal is sent by the rear window antenna
amplifier module (A2/12) to the overhead control panel control module (N70). The trunk lid opening
information is sent from the overhead control panel control module (N70) to the EIS control module (N73)
over the CAN. The EIS control module (N73) checks the access authorization of the transmitter key. If access
authorization is issued, the EIS control module (N73) sends the command to open the trunk lid over the CAN to
the pneumatic control module (combined) (A37) .
If the trunk lid was not mechanically locked using the transmitter key (A8/1), the pneumatic control module
(combined) (A37) activates the following functions directly one after the other:
 An increase in excess pressure in the rear lock's pneumatic cylinder to release the trunk lid.
 Activation of the hydraulic pump RTL (M51) through driving the trunk lid open relay (K69/1).
Thehydraulic ram is then charged with fluid by the hydraulic pump RTL (M51) and opens the trunk lid by way
of the multiple-jointed hinge to its end position.
When the trunk lid reaches the end position the trunk lid opening angle detection sensor (B24/16) registers
this and informs the pneumatic control module (combined) (A37). When the trunk lid opening angle detection
sensor reaches the specified limit stop position, the pneumatic control module (combined) (A37) switches off
the hydraulic pump RTL (M51) and the trunk lid stops in the open position
If the "Open trunk lid" push-button is pressed again on the transmitter key (A8/1) the hydraulic pump RTL
(M51) is immediately stopped . The trunk lid is then held at the position that it was in. Pressing the push-button
again restarts the opening operation. An interruption to the trunk lid movement can be overridden by the trunk
lid release switch (S15/1) control or the remote trunk lid release switch (S20/1s6).
Safety mechanism
(A37) can also initiate an emergency-stop function . In the event that the trunk lid encounters an obstacle, or a
manual intervention takes place on the trunk lid, the trunk lid opening angle detection sensor (B24/16) registers
a change in speed of the trunk lid. The pneumatic control module (combined) (A37) immediately switches off
the hydraulic pump RTL (M51) and the trunk lid stops at the position it was in at that time.

function
Trunk lid close, function GF80.20-P-2006A
position/task
Opening trunk lid with remote control key, function - GF80.20-P-3010S
MODEL 215, 220

By pressing the "open trunk lid" button the transmitter key transmits a signal to the corresponding receiver in
the vehicle via radio frequency or infrared. These receive the signal and convey the contents to the EIS control
module (N73) as a CAN message.
The control module (N73) checks the access authorization. If access authorization is granted, the EIS control
module (N73) sends the command to open the trunk lid to the PSE control module (combined functions)
(A37) via CAN. The PSE control module (combined functions) (A37) opens the trunk lid pneumatically ,
unless the trunk lid lock is secured by the 90° position of the lock cylinder. The anti-theft alarm (ATA) is
only partially deactivated.

function
Opening trunk lid pneumatically, function GF80.20-P-4016S
Deactivation of anti-theft alarm (ATA), GF80.50-P-2003S
function
PSE control module (combined functions), GF80.20-P-4106S
Electronic ignition/starter switch control GF80.57-P-4102S
module (EIS),
Remote control key,
LOCKING/UNLOCKING TRUNK LID WITH MECHANICAL KEY FUNCTION - GF80.20-P-3011S
MODELS 215, 220
The mechanical key can be used to turn the lock cylinder in the trunk lock.
In the 0° position (1) the lock is mechanically unlocked. If the vehicle is not centrally locked, the trunk lid can
be manually opened.
Turning the key by 30° to the left (2) and pressing the lock cylinder enables the trunk lid lock to be
mechanically opened, even when the vehicle has been centrally locked. In this position the key can not be
withdrawn .
By turning the key to the right, the lock cylinder is moved to the 90° position (3) . In this position the key can
be withdrawn . The trunk lock is mechanically locked. It can not be opened, neither manually with the
transmitter key nor with the remote trunk lid release switch (S20/1s6) (doorman function) .
Fig. 15: Identifying Locking/Unlocking Trunk Lid With Mechanical Key Angle
Manually open trunk lid, function GF80.20-P-3013S

Open trunk lid with remote control key, GF80.20-P-3010S
function
Open trunk lid with interior switch, GF80.20-P-3012S
function
OPEN TRUNK LID WITH INTERIOR SWITCH FUNCTION - GF80.20-P-3012
Open trunk lid with interior switch function - GF80.20-P-3012B
Shown on model 220
Fig. 16: Identifying Remote Trunk Lid Release Switch - Shown On Model 220
With the remote trunk lid locking switch (S20/1s6) the trunk lid can be opened from inside the vehicle
hydraulically .
For this purpose the switch must be operated for at least 0.5s.
Operating it again serves to interrupt or continue the hydraulic trunk lid release function.
Function requirements
Operation of the remote trunk lid release switch (S20/1s6) is then possible only when:
 the vehicle is at rest and

 has been unlocked with the transmitter key (A8/1) or
 if after unlocking it with the transmitter key (A8/1) the transmitter key (A8/1) is inserted into the EIS
control module (N73).
In such cases the left front door control module (N69/1) receives a corresponding CAN message whereby the
remote trunk lid release switch (S20/1s6) is activated.
As of 06/00: opening angle limitation : If the remote trunk lid release switch (S20/s16) is operated
continuously for 5 seconds when the trunk lid is closed, the opening angle limitation is activated - and is
deactivated if the remote trunk lid release switch (S20/s16) is operated for another 5 seconds.
When the function is active, the trunk lid opens as far as the defined position.
Operating procedure
Operation of the remote trunk lid release switch (S20/1s6) is read in by the left front door control module
(N69/1). If the function of the switch has been enabled, the left front door control module (N69/1) sends a
command to open the trunk lid over the CAN to the pneumatic control module (combined) (A37) .
The pneumatic control module (combined) (A37) then activates the following functions immediately after
each other:
 An increase in excess pressure in the rear lock's pneumatic cylinder to release the trunk lid.
 Activation of the hydraulic pump RTL (M51)
The hydraulic pump RTL (M51) then charges the hydraulic ram with fluid and thus opens the trunk lid by
way of the multiple-jointed hinge to its limit position.
When the trunk lid reaches the end position the trunk lid opening angle detection sensor (B24/16) registers
this and informs the pneumatic control module (combined) (A37).
If during the opening operation the remote trunk lid release switch (S20/1s6) or the trunk lid release switch
(S15/1) is operated, the trunk lid stops in the position at that time.
Safety mechanism
a change in speed of the trunk lid.
The pneumatic control module (combined) (A37) then immediately switches off the hydraulic pump RTL
(M51). The trunk lid is then held at the position that it was in.
(S20/1s6).

function
position/task
Opening trunk lid with interior switch, function - GF80.20-P-3012S
MODEL 215, 220
With the remote trunk release switch (S20/1s6) the trunk lid can be opened from the vehicle passenger
compartment.
Function prerequisites
The function of the remote trunk release switch (S20/1s6) is enabled by the left front door control module
(N69/1)
 by actuation of the emergency unlocking function

 by unlocking the vehicle with the remote control key,
 by unlocking the vehicle with the lock switches , only),
 by unlocking the vehicle by opening a door if it was locked automatically previously or with the switch
for the interior central locking switch (N72/1s6),
 by inserting the remote control key into the ignition after locking with the remote control key.
In the above mentioned cases the left front door control module (N69/1) receives a corresponding CAN
message.
The function of the switch is disabled by the left front door control module (N69/1) when
 the automatic locking feature is actuated,

 the vehicle is locked with the remote control key or with the switch for the remote trunk release switch
(S20/1s6)
 the vehicle is locked with the lock switches ( , only).
Function sequence
Actuation of the remote trunk release switch (S20/1s6) is recognized by the left front door control module
(N69/1). If the function of the switch is released , the left front door control module (N69/1) sends a command
to open the trunk lid to the PSE control module (combined) (A37) via the CAN bus. The PSE control module
(combined) (A37) opens the trunk lid pneumatically if the trunk lid lock is not secured with the lock cylinder
in the 90° position.
Pneumatically opening trunk lid GF80.20-P-4016S

function
PSE control module (combined GF80.20-P-4106S
functions),
Trunk lid release switch GF72.29-P-4112S
MANUALLY OPENING TRUNK LID, FUNCTION - GF80.20-P-3013
Open trunk lid manually function - GF80.20-P-3013B
Fig. 17: Identifying Trunk Lid Release Switch And Trunk Lid Lock Switch
Operating procedure
When the lock cylinder in the trunk lid lock is in position 1, the lock cylinder is pushed in and the trunk lid
release switch (S15/1) is activated. Operation of the switch is detected by the pneumatic control module
(combined) (A37) . If the vehicle is centrally unlocked, then the pneumatic control module (combined) (A37)
releases the trunk lid and then starts the hydraulic pump RTL (M51) .
Thehydraulic ram is then charged with fluid by the hydraulic pump RTL (M51) and opens the trunk lid by
way of the multiple-jointed hinge to the end position. The trunk lid reaching the specified limit stop position
and the uniform opening operation of the trunk lid are registered by the trunk lid opening angle detection
sensor (B24/16) and sent to the pneumatic control module (combined) (A37).
When the trunk lid opening angle detection sensor reaches the specified limit stop position, the pneumatic
control module (combined) (A37) switches off the hydraulic pump RTL (M51) and the trunk lid stops in the
open position.
If the trunk lid release switch (S15/1) is operated several times the hydraulic trunk lid opening operation is
stopped at the position at that time or set forth. The stopping or continuation of the hydraulic opening operation
can also be conducted with the transmitter key (A8/1) or the remote trunk lid release switch (S20/1s6).
Safety mechanism
a change in speed of the trunk lid. The pneumatic control module (combined) (A37) then immediately switches
off the hydraulic pump RTL (M51). The trunk lid is then held at the position that it was in.
(S20/1s6).
function
function
Function of trunk lid status indicator GF80.20-P-4015S
position/task
Manually opening trunk lid, function - GF80.20-P-3013S
MODEL 215, 220
If the lock cylinder in the trunk lid lock is in the 0° position (1), the remote trunk release switch (S15/1) is
actuated when the lock cylinder is pressed. The PSE control module (combined) (A37) recognizes actuation of
the switch. The PSE control module (combined) (A37) opens the trunk lid pneumatically, when the vehicle is
unlocked universally .
Fig. 18: Identifying Locking/Unlocking Trunk Lid With Mechanical Key Angle

function
Trunk lid status indicator GF80.20-P-4015S
combined functions,
AUTOMATIC LOCKING, FUNCTION - GF80.20-P-4009S
MODEL 215, 220
Function prerequisite
The vehicle is unlocked with the remote control key (or on model 220, with the lock switches ).
Function sequence
The "automatic locking" function locks the vehicle centrally except the tank flap as soon as the vehicle speed
exceeds the limit value of approx. 15 km/h.
This is accomplished as soon as the PSE control module (combined) (A37) recognizes that the threshold value
is exceeded by evaluating the speed signals on the CAN bus. The PSE control module (combined) (A37) locks
the doors pneumatically.
The trunk lid is locked.
The vehicle can be unlocked by opening a door from the inside or with the interior central locking switch
(N72/1s6) if the vehicle speed is below the limit.
If the vehicle is unlocked with the interior central locking switch (N72/1s6) following automatic locking the
vehicle remains unlocked even at speeds exceeding the limit speed . The system returns to the initial status
when a door is opened or circuit 15 is switched on or off .
If a door is opened following automatic locking and is closed again while the vehicle speed is above the limit
speed the door in question is locked again after it is closed.
The automatic locking function can be deactivated or activated:
 Via diagnosis
 With the instrument cluster (A1) control menu

function
Actuation of lock switches, function Model 220 only GF80.20-P-3007S

function
Instrument cluster (IC), function GF54.30-P-0002S
combined functions,
TRANSMITTING REMOTE CONTROL SIGNAL, FUNCTION - GF80.20-P-4010S
MODEL 215, 220
When a button is pressed the remote control key first sends a radio frequency (RF) signal and then an infrared
(IR) signal. The signal contains a code for checking the access authorization and a command for executing a
function.
The radio frequency remote control has a greater transmission range . For IR transmission it is necessary to
point the remote control key at one of the door handles.
Receiving remote control signal, GF80.20-P-4011S

function
RECEIVING REMOTE CONTROL SIGNAL, FUNCTION - GF80.20-P-4011S
MODEL 215, 220
The radio frequency remote control signal is received via the rear window antenna. The receiver in the top rear
window antenna amplifier (A2/12) converts the radio signal into a data signal. The overhead control panel
control module (N70) receives this data signal via a data bus.
The infrared signal is received by the left front door IR receiver (A26/1) or by the right front door IR
receiver (A26/2) .
The control module connected to the corresponding receiver evaluates the signal.
The code for access authorization and the remote control command in the signal are transferred to the electronic
ignition/starter switch control module (N73) as a CAN message. The electronic ignition/starter switch
control module (N73) checks the code for access authorization and sends the corresponding command to the
CAN bus if the code is correct.
Antenna amplifier module, GF82.62-P-3105

Infrared receiver, GF80.20-P-4101S
Overhead control panel control module, GF82.20-P-4101S
RELOCKING, FUNCTION - GF80.20-P-4012S
MODEL 215, 220
The relocking feature prevents the vehicle from being unlocked when the remote control key is actuated
unintentionally.
After the vehicle has been unlocked with the remote control key the PSE control module (combined) (A37)
starts a waiting time of 40 seconds. After expiration of this waiting time the vehicle is again locked
pneumatically by the PSE control module (combined) (A37) if one of the following does not occur previously:
 door or trunk lid opened, or

 emergency unlocking function triggered, or
 interior CL switch actuated, or
 remote control key inserted into the key opening in the electronic ignition/starter switch control
module (N73)
 (Only , ). The relocking feature is inactive if the vehicle is unlocked before or after actuation
of the remote control key with a lock switch.
 If the "Unlock vehicle" button is pressed again on the remote control key before the waiting time has
expired the waiting time is reset and restarted (maximum 10 times).
 The anti-theft alarm (ATA) is activated by the relocking feature.
Activation of anti-theft alarm system GF80.50-P-2002S

(ATA), function
Electronic ignition/starter switch (EIS) GF80.57-P-4102S
control module,
combined functions,
CENTRAL LOCKING EMERGENCY OPENING, FUNCTION - GF80.20-P-4013S
MODEL 215, 220
The emergency unlocking feature unlocks the vehicle doors after an accident.
The PSE control module (combined) (A37) is equipped with a crash sensor. When the vehicle is decelerated
with a force of more than 6 g the emergency unlocking feature is triggered.
Deceleration of 6 g corresponds to an impact against a solid wall at a speed of approx. 25 km/h.
After a waiting time of eight to eleven seconds the PSE control module (combined) (A37) pneumatically
unlocks all of the vehicle doors . Moreover, the remote trunk release switch (S15/1) in the trunk lid lock and,
via the CAN bus, the remote trunk release switch (S20/1s6) on the driver's door are enabled.
The anti-theft alarm (ATA) is not deactivated!
The emergency unlocking feature is canceled, i.e. the previous locking status is restored if circuit 15 OFF is
recognized for at least two seconds.
The emergency unlocking feature has priority over all other central locking functions.

function
combined functions,
TRUNK LID STATUS DISPLAY FUNCTION - GF80.20-P-4015S
MODELS 215, 220
The status of the trunk lid is displayed by means of an LED in the remote trunk lid release switch (S20/1s6) .
If the trunk lid is open, the contact of the trunk lid closing assist locking eye microswitch (S88/3) is closed.
The switch is read in by the rear SAM control module (N10/8) .
The rear SAM control module (N10/8) emits an appropriate CAN message to the left front door control
module (N69/1) . The left front door control module (N69/1) drives the LED in the remote trunk lid release
switch (S20/1s6) .
If the push-button unit illumination (terminal 58d) is active, the LED is driven by a lower current (day/night
switchover).
Remote trunk release switch GF72.29-P-4112S

Pneumatic control module (combined), GF80.20-P-4106S
LOCKING/UNLOCKING PNEUMATICALLY, FUNCTION - GF80.20-P-4016S
MODEL 215, 220
The dual pressure pump driven by an electric motor is integrated into the PSE control module (combined)
(A37) . It provides pressure and vacuum as required. The pneumatic actuators in the doors, the tank flap and
the trunk lid receive pressure and vacuum from the PSE control module (combined) (A37) .
Universal unlocking :
The central locking pneumatic actuators in all doors receive vacuum and are locked.
Selective unlocking:
Only the central locking pneumatic actuators in the driver's door and the tank flap receive vacuum and are
unlocked.
Opening trunk lid
The central locking pneumatic actuator for the trunk lid lock receives vacuum , opening the trunk lid lock if it
is not secured with the lock cylinder in the 90° position.
Locking:
The central locking pneumatic actuators in the doors and the tank flap receive pressure thereby locking all
doors and the tank flap .
Power locking doors, function GF80.40-P-3001S

combined functions,
INFRARED RECEIVER, LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.20-P-4101S
MODEL 220
Infrared receiver, location GF80.20-P-4101-01S

Infrared receiver, purpose Infrared receiver signals
from remote control key.
Infrared receiver, design The infrared receiver
consists of one IR
sensitive semi-conductor
component with active
electronic actuation
circuit.
The receiver is concealed
behind a filter panel in
the door handle.
Infrared receiver, The infrared receiver
function converts the signal from
the remote control key
(A8/1) into an electrical
signal. The electrical
signal is read in by the
left front door control
module (N69/1) or right
front door control
module (N69/2) . The
information contained in
the signal is sent as a
CAN message by the
door control module.
Infrared receiver, location - GF80.20-P-4101-01S
Model 220
The infrared receiver (1) is installed in the front section of the door handle.
Fig. 19: Identifying Infrared Receiver Location
TRUNK LID LOCK POSITION/TASK/DESIGN/FUNCTION - GF80.20-P-4103S
MODELS 215, 220
Trunk lid lock, position GF80.20-P-4103-02S

Trunk lid lock, task Locking trunk lid
Trunk lid lock, design The trunk lid lock is
made up of two
components, the latch
and the lock cylinder .
The trunk lid release
switch (S15/1) is located
on the lock cylinder as is
the trunk lid lock switch
(S88/2) . The
latch holds the trunk lid
closing assist locking
eye microswitch
(S88/3) .
Function of trunk lid lock GF80.20-P-4103-01S
Trunk lid lock, function - GF80.20-P-4103-01S
Model 215, 220
The lock cylinder for the trunk lid lock is connected to the latch mechanically by a rod. The lock can be opened
pneumatically with the pneumatic actuator or mechanically with the rod. The trunk lid closing assist locking
eye microswitch (S88/3) is read in by the rear SAM control module (N10/8) . The state of the trunk lid
closing assist locking eye microswitch (S88/3) indicates whether the trunk lid is open or closed.
By moving the lock cylinder to the 0° position the remote trunk release switch (S15/1) is actuated. The
position of the switch is recognized by the PSE control module (combined) (A37) .
The pneumatic cylinder unlocks the trunk lid by pressure. The trunk lid opens.
The trunk lid is not unlocked when the lock cylinder is in the 90° position.
When the lock cylinder is moved to the 30° position the trunk lid is unlocked mechanically.
, only
The trunk lid lock switch (S88/2) can be actuated with the manual key, thereby locking or unlocking the
vehicle. The anti-theft alarm (ATA) is also activated or deactivated.
Trunk lid lock, location - GF80.20-P-4103-02S
Model 215, 220

Fig. 20: Identifying Trunk Lid Lock Components Location
REMOTE TRUNK RELEASE SWITCH, LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.20-P-

4104S
MODEL 215, 220
Remote trunk release The remote trunk release GF72.29-P-4112-01S

switch, location switch (S20/1s6) is
located in the left front
power window switch
group (S20/1) .
Remote trunk release To trigger the remote
switch, task trunk release and display
the status of the trunk lid.
Remote trunk release Consists of a sensor with
switch, design normally open contact
and built-in LED.
Remote trunk release GF80.20-P-4104-01S
switch, function
Remote trunk release switch, function - GF80.20-P-4104-01S
Model 215, 220
The position of the remote trunk release switch (S20/1s6) is read in by the left front door control module
(N69/1) on vehicles with left-hand steering and the right front door control module (N69/2) on vehicles with
right-hand steering. If the contact is closed for longer than 25 s actuation of the button is ignored.
Actuation of the button is recognized again only following recognition of the non-actuated state.
The LED for function display is actuated by the left front door control module (N69/1) on vehicles with left-
hand steering and the right front door control module (N69/2) on vehicles with right-hand steering when the
trunk lid is open.
PNEUMATIC SYSTEM EQUIPMENT WITH COMBINED FUNCTIONS

POSITION/TASK/DESIGN/FUNCTION - GF80.20-P-4106S
MODELS 215, 220
Pneumatic control GF80.20-P-4106-01S

module (combined),
position
Pneumatic control Pneumatic actuation for the
module (combined), system functions
task
 Central locking (CL)
 Retractable rear head
restraints (RHR)
 Power locking (PL)
 Multicontour seat (MCS)

control of system
functions
 Remote trunk release
(RTR) for corresponding
equipment specification
 Electric control of remote
trunk locking (RTL) for
code 881
Pneumatic control In the PSE the bi-pressure
module (combined), pump is integrated for the
design purpose of a pneumatic excess
and vacuum supply
Function
Central locking and GF80.20-P-4016S
trunk lid pneumatic
release, function
function
Remote trunk release GF80.20-P-0006S
(RTR), function
Retractable rear head GF91.16-P-0002S
restraints (RHR)
Power-assisted door GF80.40-P-3001S
closing, function
Power-assisted trunk lid GF80.40-P-3002S
close, function
Multicontour seat GF91.25-P-0001S
(MCS), function
Remote trunk locking For code 881b (remote trunk GF80.20-P-0007A
(RTL), function locking)
PSE control module (combined), location - GF80.20-P-4106-01S
Models 215, 220
The PSE control module (combined) (A37) is located behind the paneling in the trunk on the left side above the
wheelhouse. It is positioned in foam padding.
Illustrated on model 220
Fig. 21: Identifying PSE Control Module (Combined) - Illustrated On Model 220
HYDRAULIC RAM POSITION/TASK/DESIGN - GF80.20-P-4111A
Shown on model 220

Fig. 22: Identifying Hydraulic Ram - Shown On Model 220
Hydraulic ram, position In trunk behind upper

right paneling
Hydraulic ram, task Exertion of forces on to
the multiple-jointed hinge
for the hydraulic opening
and closing of the trunk
lid
Hydraulic ram, design Hydraulic ram with two
hydraulic lines
TRUNK LID OPENING ANGLE DETECTION SENSOR POSITION/TASK/DESIGN/FUNCTION -

GF80.20-P-4113A
Shown on model 220

Fig. 23: Identifying Trunk Lid Opening Angle Detection Sensor - Shown On Model 220
Trunk lid opening angle In the trunk at right below the

detection sensor, multiple-jointed hinge
position
Trunk lid opening angle  Recording of trunk lid
detection sensor, task opening angle
 Recording of speed
changes in trunk lid in
event of malfunction
Trunk lid opening angle  Plastic rod serving as
detection sensor, design connection to multiple-
joint hinge
 Potentiometer with
electric connection to
pneumatic control
module (combined)
(A37)
Trunk lid opening angle  Recording of limit stop
detection sensor, position
function
 Recording of speed
changes in trunk lid
movements
GAS-FILLED TELESCOPIC STRUTS, POSITION/TASK - GF80.20-P-4114A
Shown on model 220
Fig. 24: Identifying Gas-Filled Telescopic Struts - Shown On Model 220
Gas-filled telescopic One each on left and

struts, position right-hand sides of trunk
lid underside
Gas-filled telescopic  To relieve trunk lid
struts, task weight
 Provision of a
partial force to hold
up the trunk lid
when in opened
position
TRUNK LID REMOTE CLOSING HYDRAULIC PUMP POSITION/TASK/DESIGN - GF80.20-P-

4115A
Shown on model 220

Fig. 25: Identifying Hydraulic Pump RTL And RTL Pushbutton - Shown On Model 220
Hydraulic pump RTL, Model 215

position The hydraulic pump RTL
(M51) is located below the
battery.
Model 220
The hydraulic pump RTL
(M51) is located in a foam
padding in the trunk at
bottom right.
Hydraulic pump RTL, Supply of pressure for
task hydraulic ram for
hydraulic opening and
closing of the trunk lid.
Hydraulic pump RTL,  Hydraulic pump
design with fluid reservoir
 One power supply
cable for the
hydraulic pump
 Two hydraulic lines
TRUNK LID RELAY POSITION/TASK/DESIGN - GF80.20-P-4116A
Shown on model 220
(with hydraulic ram removed)

Fig. 26: Identifying Trunk Lid Open And Close Relay - Shown On Model 220
Trunk lid relay, position The two relays,
 trunk lid open

relay (K69/1) and
 trunk lid close
relay (K69/2)
are located in a common

plug-in socket behind the
paneling in the trunk at the
right.
Trunk lid open relay, task  Switching on and
off of the hydraulic
pump RTL (M51)
 Selection of
direction of rotation
for hydraulic pump
RTL (M51) via the
respective position
of the switching
contact.
Trunk lid open relay, Each relay consists of a
design changeover switch
between ground and
terminal 30, and a relay
coil. The relay coil is
driven directly by the
pneumatic control module
(combined) (A37).
DRIVE AUTHORIZATION SYSTEM, STAGE X, FUNCTION - GF80.30-P-2002F
MODEL 129 with ENGINE 104, 112, 113, 119, 120 (except 104.98)
MODEL 140 with ENGINE 104, 119, 120
MODEL 163 with ENGINE 112, 113
MODEL 210 with ENGINE 104, 112, 113, 119
MODEL 240 with ENGINE 285
The various drive authorization systems are interlinked with the engine control unit via CAN.
The engine control must be released by CAN bus, otherwise it is not possible to start the engine.
Checking the drive MODEL 163 GF80.57-P-3001GH

authorization, function
Table of contents, MODEL 170 as of 1.2.97 GF80.57-P-0997AZ
function description,
drive authorization MODEL 170 as of 1.3.97
system, stage 2b (DAS
2b) MODEL 170 as of 1.6.97
except
Infrared remote control MODEL 129, 140 as of GF80.30-P-0004A
for central locking 1.6.96, 210 (except
(RCL), function 210.2) as of 1.6.96 up to
28.2.97 except
MODEL 170, 210.2
(except 210.281) up to
28.2.97 except
MODEL 210.072 up to
31.5.96
MODEL 202 (except
202.083) as of 1.8.96 up
to 31.5.97 except
MODEL 202.083 to
31.5.97 except
MODEL 129, 140 as of
1.6.96, 210 /(except
210.081 /281) as of
1.6.96 up to 28.2.97
MODEL 202 as of 1.8.96
up to 31.5.97
*only valid for USA
MODEL 202 up to GF80.30-P-0004E
31.5.97 with CODE
(880a) Locking system
with infrared remote
control
MODEL 202 as of
1.12.94 up to 31.5.97
except
up to 31.5.97
MODEL 210 / (except GF80.30-P-0004F
210.081 /281) upto
28.2.97
Drive authorization MODEL 129, 140 as of
system, stage X, function 1.6.96, 210 / (except
210.081 /281) as of
1.6.96 up to 28.2.97
up to 31.5.97
*only valid for USA
Contents, function MODEL 230 GF80.57-P-0999RZ
description of drive
authorization system,
stage 3 (DAS 3)
MODEL 240 GF80.57-P-0999MX
MODEL 203, 215, 220 GF80.57-P-0999SZ
MODEL 211 GF80.57-P-0999T
MODEL 209 GF80.57-P-0999Q
MODEL 202 as of GF80.57-P-0999ZZ
1.6.97, 208,
210.081 /281, 210
(except 210.081 /281) as
of 1.3.97
PROGRAM TRANSMITTER KEY, FUNCTION - GF80.30-P-3002SM
MODEL 220, 215 as of 1.10.02 with CODE (889) Keyless go
General information
As of model update, the keyless go function has been integrated into the transmitter key (A8/1) eliminating the
keyless go transmitter card (A8/2).
Data between the transmitter key (A8/1) and the EIS control unit (N73) are transferred via the keyless go
control unit (N69/5). The access authorization and the drive authorization is accomplished between the
transmitter key (A8/1) and the EIS control unit (N73) via the overhead control panel control unit (N70).
Procedure when replacing keyless go control unit
Connect STAR DIAGNOSIS system to data link connector (X11/4).
Select menu "Keyless go" in STAR DIAGNOSIS with "Start-up" function. Then follow individual items in
menu. To complete start-up, erase DTC memory in keyless go control unit (N69/5).
Procedure for use of spare key
Case 1: Program spare key on present key track
Insert spare key to be programmed into EIS control unit (N73) A rotate enable is given after approx. 30 min.
Then switch on c. 15. After a further 90 min., the vehicle is again operational and the selector lever can be
moved out of position "P". Assignment has been successfully completed.
Case 2: Program spare key on new key track (additional key)
Insert additional key to be programmed into EIS control unit (N73). For the spare key, the authentication value,
IR signal and radio signal are synchronized at the start whereby the programming time is for at least 1 minute.
In both cases it is necessary to synchronize the transmitter key (A8/1) in the keyless go control unit (N69/5)
with an existing or new key rail with STAR DIAGNOSIS
Frequencies for central locking are:
In Europe 433.92 MHz
In USA 315.00 MHz
Transmitter key, GF80.57-P-4101S

task/design/function
POWER LOCKING DOORS, FUNCTION - GF80.40-P-3001S
MODEL 215, 220
The power locking closes a door completely when it is only touching the first catch.
Function sequence using left front door as example:
The left front door power locking drive pawl microswitch (S86/2) opens when the door is in the first catch
position. This is recognized by the left front door control module (N69/1) . The left front door control
module (N69/1) signals to the PSE control module (combined) (A37) via the CAN bus that the door is not
closed.
The PSE control module (combined) (A37) causes the left front door control module (N69/1) to switch over
the solenoid valve on the door lock. The solenoid valve switches the pneumatic line on the pneumatic actuator
for power locking. The left front door control module (N69/1) acknowledges the switchover of the solenoid
valve to the PSE control module (combined) (A37) via the CAN bus.
The power locking pneumatic actuator receives pressure from the PSE control module (combined) (A37) and
the door is moved to the end position. The air pressure is decreased again.
The left front door control module (N69/1) then switches the solenoid valve to the "central locking" position.
The PSE control module (combined) (A37) switches off when:
 the maximum pressure for power locking is reached,

 a certain safety time is expired and/or
 the request signal is no longer present.
The safety time depends on the battery voltage
with U batt >= 13 V, t= 9 s,
with U batt <= 9 V, t= 15 s.
If the safety time is exceeded twice for the trunk lid, the PSE control module (combined) (A37) recognizes a
fault and disables the power locking function for the trunk lid. The trunk lid can be locked again by the power
locking only after the PSE control module (combined) (A37) has been disconnected from circuit 30.

function
Power locking trunk lid, function GF80.40-P-3002S
Left front door control module GF72.29-P-4105S
combined functions,
POWER LOCKING TRUNK LID, FUNCTION - GF80.40-P-3002S
MODEL 215, 220
The power locking feature closes the trunk lid completely when it is in contact with the first catch. The contact
in the trunk lid closing assist locking eye microswitch (S88/3) opens when the trunk lid lock is in the first
catch. This is recognized by the rear SAM control module (N10/8) . The rear SAM control module (N10/8)
signals the status of the switch to the PSE control module (combined) (A37) via the CAN bus. The PSE
control module (combined) (A37) actuates the solenoid valve on the trunk lid lock. The solenoid valve
switches the pneumatic line to the power locking pneumatic actuator. The power locking pneumatic actuator for
the trunk lid lock receives pressure from the PSE control module (combined) (A37) . The trunk lid is moved
to the final closed position. The air pressure is reduced again.
The PSE control module (combined) (A37) switches off when:
 the maximum pressure for power locking is reached and/or

 a certain safety time is expired and/or
 the request signal is no longer present.
The safety time depends on the battery voltage,
with U batt > or = 13 V, t= 9 s,
with U batt < or = 9 V, t= 15 s.
If the safety time for the trunk lid is exceeded twice, the PSE control module (combined) (A37) recognizes a
fault and disables the trunk lid power locking feature. The trunk lid can be locked again by the power locking
only after the PSE control module (combined) (A37) has been disconnected from circuit 30.

function
Power locking doors, function GF80.40-P-3001S
Remote trunk release (RTR), location of GF80.20-P-0006-
components 01S
combined functions,
CONVENIENCE FEATURE (CF), FUNCTION - GF80.45-P-0003S

MODEL 215, 220
Function
The convenience feature includes the convenience locking and convenience opening functions. These
functions can be controlled with the remote control key or with the lock switches ( , only).
All windows and the sliding/pop-up roof can be closed with the convenience feature . The convenience
opening feature allows all vehicles windows and the sliding roof to be opened. In addition the seat ventilation
(special equipment) is switched on for five minutes.
The functions are interrupted when the remote control key or the lock switches are no longer actuated.
The excessive force limitation feature for the sliding/pop-up roof (SR) and the windows is not active when
closing.
Convenience closing/opening with GF80.45-P-2003S

Convenience closing/opening with Only on model 220 GF80.45-P-2004S
lock switches, function and
recirculated air button, function
Transmitter key, GF80.57-P-4101S
Seat ventilation mode, function GF91.30-P-2005S
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF CONVENIENCE FEATURE (CF) -

GF80.45-P-0999SZ
MODEL 215, 220
Convenience feature (CF), function GF80.45-P-0003S

Convenience closing/opening with Only model 220 GF80.45-P-2004S
lock switches, function and
recirculated air button, function
Convenience opening power GF72.29-P-3004S
windows, function
Convenience closing power GF72.29-P-3005S
windows, function
Sliding/pop-up roof convenience GF77.20-P-2000S
opening (SR), function
closing (SR), function
Automatic one-touch up/down GF72.29-P-3007S
feature, function
Automatically opening/closing GF77.20-P-2008S
sliding/pop-up roof (SR), function
CONVENIENCE CLOSING/OPENING WITH REMOTE CONTROL KEY, FUNCTION - GF80.45-P-

2003S
MODEL 215, 220
Convenience locking/closing illustrated on model 220
Fig. 27: Identifying Convenience Closing/Opening With Remote Control Key Function Diagram -
 Voltage not too low or too high

 Ignition key in position "0" or removed
 All doors closed
 Press "Lock vehicle" or "Unlock vehicle" button on remote control key for longer than 1 s
Convenience closing function
Pressing the "Lock vehicle" button on the remote control key (A8/1) triggers the corresponding function of the
central locking . If the button is pressed for more than 1 s the remote control key sends an infrared (IR) signal
for convenience closing. The signal is received by the left front door IR receiver (A26/1) or right front door
IR receiver (A26/2) .
When the function prerequisites are fulfilled the left front door control module (N69/1) or right front door
control module (N69/2) transfers the command for convenience closing to the CAN bus. The CAN messages
are received by the overhead control panel control module (N70) as well as by the other door control
modules. These control modules actuate the sliding/pop-up roof convenience closing and power window
convenience closing functions . On model 215 the left and right rear power window motors are actuated by the
rear control module (N22/6) .
Convenience opening function
When the "Unlock vehicle" button is pressed the corresponding functions for convenience opening are
accomplished. In addition the seat ventilation function (special equipment) is started by the seat control
modules for 5 minutes.
The excessive force limitation feature for the power windows and the SR is not active in combination with
the convenience closing feature.
Convenience opening power GF72.29-P-3004S

windows, function
Convenience closing power GF72.29-P-3005S
windows, function
opening (SR), function
closing (SR), function
CONVENIENCE CLOSING/OPENING WITH LOCK SWITCHES, FUNCTION - GF80.45-P-2004S

MODEL 220 with CODE (491) USA version
MODEL 220 with CODE (498) Japanese version
Fig. 28: Convenience Closing/Opening With Lock Switches Function Diagram

 Ignition key in position "0" or removed
 All doors closed
Convenience closing function with lock switch Driver/passenger door
Actuation of the left front door lock switch (CF) (S86/1)/right front door lock switch (CF) (S87/1) triggers
the central locking lock function. If the lock switch is pressed for longer than 1 s the left front door control
module (N69/1)/right front door control module (N69/2) transmits the command for convenience closing to
the CAN bus. The command is transferred as long as the lock switch is actuated. The overhead control panel
control module (N70) actuates the sliding/pop-up roof convenience closing function.
The door control modules actuate the power window convenience closing function .
Convenience closing function with trunk lid lock switch In this case the trunk lid lock switch (CF) (S88/2)
is actuated and the CAN message for convenience closing is transmitted by the PSE control module
(combined) (A37) .
Convenience opening
The convenience opening function is accomplished by actuation of the lock switch. In addition the seat
ventilation function (special equipment) is switched on for 5 minutes.
Convenience opening GF72.29-P-3004S

power windows, function
Convenience closing GF72.29-P-3005S
sliding/pop-up roof (SR),
function
sliding/pop-up roof (SR),
function
Seat ventilation mode GF91.30-P-2005S
function
CONVENIENCE CLOSING/OPENING WITH RECIRCULATED AIR BUTTON, FUNCTION -

GF80.45-P-2009S
MODEL 215, 220

Fig. 29: Convenience Closing/Opening With Recirculated Air Button Function Diagram

 Sliding/pop-up roof and power windows synchronized
Convenience closing function via recirculated air button Actuation of the recirculated air button in the
automatic AC push-button control module (N22) for t > 1 s triggers the convenience closing function. The
overhead control panel control module (N70) and the door control modules (N69/1, N69/2, N69/3, N69/4)
receive the signal to automatically close the sliding/pop-up roof and the power windows from the automatic
AC push-button control module (N22) via the CAN bus.
Simultaneously the momentary roof and window positions are stored in the corresponding control module. To
avoid excessive loads first the sliding/pop-up roof and then the windows are automatically closed.
Convenience opening function via recirculated air button When the recirculated air button is pressed again
for t > 1 s the sliding/pop-up roof and the power windows are moved to the previously stored positions.
Exception:
If some of the windows have been opened manually while the recirculated air mode was switched on, the
windows remain in the set positions after completion of the recirculated air function.
Within the scope of the convenience closing feature the roof and window positions stored when the recirculated
air button was pressed, are canceled when the ignition is switched off.

sliding/pop-up roof,
function
function
Automatic one-touch GF72.29-P-3007S
up/down feature, function
Automatic GF77.20-P-2008S
opening/closing of
function
ANTI-THEFT ALARM (ATA), FUNCTION - GF80.50-P-0001S
MODEL 215, 220 with CODE (491) US version
MODEL 215, 220 with CODE (551a) Anti-theft alarm (ATA)
ATA system interlinkage

Fig. 30: Identifying Anti-Theft Alarm (ATA) Function Diagram - Illustrated On Vehicle, Model 220
The anti-theft alarm (ATA) is a contact-controlled system with acoustic and optical alarm signal.
The left front SAM control module (N10/6) is the main control module (master) for the ATA functions.
The ATA is active when the vehicle is locked by the central locking. Exception: with automatic locking and
locking with the interior switch.
Anti-theft alarm (ATA), GF80.50-P-0001-02S

Activation of anti-theft GF80.50-P-2002S
alarm (ATA), function
Deactivation of anti-theft GF80.50-P-2003S
Alarm triggering of anti- GF80.50-P-2004S
theft alarm (ATA),
function
Anti-theft alarm (ATA), location of components - GF80.50-P-0001-02S
Models 215, 220
Location of components
Fig. 31: Identifying Anti-Theft Alarm (ATA) Components Location - Illustrated On Model 220
ANTI-THEFT ALARM (ATA) FUNCTION DESCRIPTION CONTENTS - GF80.50-P-0999SZ
MODELS 215, 220 with CODE (491) U.S. version
MODELS 215, 220 with CODE (551a) Anti-theft alarm system (ATA)
Anti-theft alarm system (ATA) - GF80.50-P-0001-

location of components 02S
Anti-theft alarm system (ATA) - GF80.50-P-0001S
function
Activating the anti-theft alarm system GF80.50-P-2002S
(ATA) - function
Deactivating the anti-theft alarm system GF80.50-P-2003S
- function
Anti-theft alarm system, alarm GF80.50-P-2004S
activation - function
Alarm activation through panic switch - GF80.50-P-3014S
function
Alarm activation through external GF80.50-P-3015S
bodywork contact - function
Alarm triggered by interior motion with code 882 GF80.50-P-3022S
sensor (IMS) (interior motion
sensor) or code 491
Alarm triggered by towing sensor (TS) GF80.50-P-3023S

Switching off anti-towing sensor - GF80.50-P-3024S
function
Switching off interior motion sensor - with code 882 GF80.50-P-3025S
function (interior motion
sensor) or code 491
Alarm activation through alarm siren - GF80.50-P-3026S

function
Activating the alarm siren - function GF80.50-P-3027S
Acoustic alarm - function GF80.50-P-4005S
Optical alarm - function GF80.50-P-4006S
Overview of system components of anti- GF80.50-P-9999S
theft alarm system (ATA) -
ACTIVATING ANTI-THEFT ALARM, FUNCTION - GF80.50-P-2002S
MODEL 215, 220 with CODE (491) USA version

Fig. 32: Identifying Activating Anti-Theft Alarm Function Diagram
The anti-theft alarm (ATA) is activated by:
 Central locking of the vehicle with the remote control key

 Central locking of the vehicle with the lock switches (model 220 only , )
 The relocking function
 Locking vehicle with KEYLESS GO (only code 889)
 Self-activation ( only): Two minutes following the last locking procedure the ATA activates
itself if the driver's door is opened and closed again after removing the remote control key.
 The ATA is not activated when the driver's door is open.

 Activation of the ATA interrupts a previously triggered alarm
 When the power supply is reactivated the ATA is automatically reactivated if it was active before
disconnected from the power supply.
 IMS and TS can be switched off separately.
Function sequence
The EIS control module (N73) transmits the command to the CAN bus to lock the vehicle. The front left SAM
control module (N10/6) transmits the message "ATA active" to the CAN bus. Then the affected control modules
activate their alarm inputs.
Activating alarm signal siren with additional battery (H3/1)

The front left SAM control module (N10/6) activates the alarm signal siren with additional battery (H3/1) via a
direct data bus.
Activating the exterior surface contacts
The rear SAM control module (N10/8) and the front right SAM control module (N10/7) activate the alarm
inputs to which the door contacts are connected individually. An input is activated as soon as it has been in the
unactuated state for min. 10 seconds.
Other functions
As soon as the front left SAM control module (N10/6) receives a message from the rear SAM control module
(N10/8) via the CAN bus that all doors and the trunk lid are closed the anti-towing sensor (TS) and the interior
motion sensor (IMS) are also activated.
The TS and IMS functions are not activated if they have been switched off previously.
Feedback after successful activation
When the ATA is active the upper control panel control module (N72) causes the indicator LED in the TS, IMS
and ATA function indicator switch (N72/1s7) to flash once per second.
only :
The alarm signal siren with additional battery (H3/1) indicates with short acoustic feedback signal three times
that the ATA has been successfully activated. If a door is not closed while activating the ATA no feedback
sounds.
Activating anti-towing sensor (TS)
The front left SAM control module (N10/6) transmits to the rear SAM control module (N10/8) the command to
activate the anti-towing sensor.
The TS input is activated by the rear SAM control module (N10/8) as soon as it has been in the unactuated state
for min. 10 seconds. only code 882:
Activating interior motion sensor (IMS)
The front left SAM control module (N10/6) transmits the command to the overhead control panel control
module (N70) to activate the interior motion sensor transmitter and receiver (A26/14). The overhead control
panel control module (N70) activates the unit via a direct data bus. The unit indicates when it is ready for
operation.
Alarm messages indicated by a unit not capable of operation are ignored by the control module.
Locking with remote GF80.20-P-3005S

control key, function
Actuating lock switches, Model 220 only GF80.20-P-3007S
function
Deactivation of anti-theft GF80.50-P-2003S
Switching off anti-towing GF80.50-P-3024S
sensor (TS), function
Switching off interior GF80.50-P-3025S
motion sensor (IMS),
function
Alarm triggering of anti- GF80.50-P-2004S
theft alarm (ATA),
function
Interior motion sensor with code 882 GF80.50-P-4104D
transmitter and receiver
DEACTIVATING ANTI-THEFT ALARM (ATA), FUNCTION - GF80.50-P-2003S
Fig. 33: Identifying Deactivating Anti-Theft Alarm (ATA), Function Diagram
The anti-theft alarm (ATA) is deactivated when:
 The vehicle is unlocked with the remote control key

 The vehicle is unlocked by opening one of the front doors from inside (possible up to max. 10 seconds
after locking with the remote control key)
 The vehicle is centrally unlocked with the lock switches (model 220 , only)
 The vehicle is unlocked with the KEYLESS GO feature (code 889 only)
 The remote control key is inserted into the EIS control module (N73) if the vehicle was previously
locked with the remote control key.
The ATA is not activated when the vehicle is unlocked
 with the interior central locking switch (N72/1s6) or

 with the emergency unlocking feature.
Function sequence
The EIS control module (N73) transmits the command to centrally unlock the vehicle on the CAN bus. The
left front SAM control module (N10/6) deletes the message "ATA active" on the CAN bus.
The corresponding control modules deactivate the alarm inputs.
only:
The alarm signal siren with additional battery (H3/1) buzzes momentarily once when the ATA is deactivated.
Moreover,
 the left front SAM control module (N10/6) deactivates the alarm signal siren with additional battery
(H3/1) .
 the overhead control panel control module (N70) deactivates the interior motion sensor (IMS) , if
connected and activated.
Partially deactivating the ATA with remote trunk release (RTR)
When the trunk lid is opened with the remote control key the TS and IMS are deactivated:
The left front SAM control module (N10/6) receives the CAN message from the EIS control module (N73)
and transmits the commands to the corresponding control modules to deactivate the TS and IMS.
After closing the trunk lid the left front SAM control module (N10/6) causes the ATA to be reactivated. TS and
IMS are only activated if they were activated before the trunk lid was opened.
Deactivation of the ATA interrupts a previously triggered alarm.
Activation of anti-theft alarm (ATA), GF80.50-P-2002S

function
Alarm triggering of anti-theft alarm GF80.50-P-2004S
(ATA), function
function
Actuation of lock switches, function GF80.20-P-3007S
Alarm signal siren, GF80.50-P-4110A
TRIGGERING OF ANTI-THEFT ALARM (ATA), FUNCTION - GF80.50-P-2004S
Fig. 34: Triggering Of Anti-Theft Alarm (ATA), Function Diagram
An anti-theft alarm (ATA) can be triggered by
 actuation of an exterior surface contact

 the anti-towing sensor (TS)
 the alarm signal siren with additional battery (H3/1)
On vehicles with code 882 or 491 ( ) in addition by
 the interior motion sensor (IMS)
ATA activated and associated inputs ready to trigger an alarm.
Function sequence
The inputs ready for alarm are checked by the control modules.
If two subsequent checks of the same input do not indicate the non-actuated state the corresponding control
module transmits the CAN message to trigger an alarm. The left front SAM control module (N10/6) triggers an
acoustic as well as optical alarm .
Moreover, on vehicles with code 491 ( ) a panic alarm can be triggered with the panic alarm switch on the
remote control key.

Alarm triggered by GF80.50-P-3015S
contact with outer skin,
function
Alarm triggered by with code 882 or 491 GF80.50-P-3022S
interior motion sensor
(IMS), function
Alarm triggered by anti- GF80.50-P-3023S
towing sensor (TS),
function
Triggering alarm via GF80.50-P-3014S
panic switch, function
Acoustic alarm, function GF80.50-P-4005S
Optical alarm, function GF80.50-P-4006S
TRIGGERING ALARM VIA PANIC SWITCH, FUNCTION - GF80.50-P-3014S

Fig. 35: Triggering Alarm Via Panic Switch, Function Diagram - Illustrated On Model 220
The panic alarm function can be triggered with the remote control key . For this purpose press the panic alarm
button on the remote control key and hold down for at least two seconds.
Function sequence
The remote control key transmits a radio frequency signal when the panic button is actuated. The signal is
received by the vehicle and, after checking the key code, transmitted to the left front SAM control module
(N10/6) via the CAN bus. The left front SAM control module (N10/6) sounds an acoustic and an optical
alarm .
The alarm can be interrupted by reactuating the panic button or by inserting the remote control key into the key
opening on the electronic ignition/starter switch control module (N73).
The duration of the panic alarm can be programmed in the control module.

function
Receiving remote control signal, GF80.20-P-4011S
function
ALARM TRIGGERED BY EXTERIOR SURFACE CONTACTS - GF80.50-P-3015S
When the anti-theft alarm (ATA) is activated actuation of an exterior surface contact triggers an alarm.
Exterior surface contacts are:
 door contact switches S17/3, S17/4 on the front doors and only on model 202 door contact switches
S17/5 and S17/6 on the rear doors
 the trunk lid closing assist locking eye microswitch (S88/3) on the trunk lid lock
 the engine hood OPEN and CLOSED switch (ATA) (S62) on the engine hood
Prerequisite for triggering an alarm is that the alarm input of the control module with correspondingly
connected contact is switched to the alarm ready mode by activating the ATA.
These are the following control modules:
 Rear SAM control module (N10/8) for door contacts and trunk lid closing assist locking eye microswitch
(S88/3).
 Front right SAM control module (N10/7) for engine hood OPEN and CLOSED switch (ATA) (S62).
It is not possible to interrupt an alarm already triggered by discontinuing actuation of the contact, e.g. by
closing a door opened previously.

Door contact switches, function GF82.20-P-4102S
ALARM TRIGGERED BY INTERIOR MOTION SENSOR, FUNCTION - GF80.50-P-3022S
MODEL 215, 220 with CODE (882b) Interior motion sensor (only with ATA)
An alarm can only be triggered by the IMS when
 the interior motion sensor transmitter and receiver (A26/14) is activated and
 the IMS function is not switched off .
When the trunk lid is opened by the remote trunk release (RTR) the alarm is not triggered by the IMS as long
as the trunk lid is open.
Function sequence
The interior motion sensor (IMS) function monitors the vehicle interior using ultrasonic signals with the aid of
the interior motion sensor transmitter and receiver (A26/14). If motion is recognized in the passenger
compartment this is indicated to the overhead control panel control module (N70) by the IMS receiver over a
data bus. The overhead control panel control module (N70) transmits the message "Alarm triggered by IMS" to
the CAN bus.
The front left SAM control module (N10/6) triggers an optical and acoustic alarm .
The IMS function can trigger max. three alarms in sequence. Then the ATA must be reactivated for
continuation of this function.

function
Switching off interior motion sensor GF80.50-P-3025S
(IMS), function
function
Interior motion sensor transmitter and GF80.50-P-4104D
receiver, location/purpose/design/function
TRIGGERING ALARM BY ANTI-TOWING SENSOR, FUNCTION - GF80.50-P-3023S
The anti-towing sensor (TS) monitors the position changes of the parked vehicle, e.g. caused by attempting to
tow the vehicle away.
An alarm can only be triggered by the TS when
 the anti-theft alarm (ATA) and the TS are activated and

 the TS function is not switched off .
When the trunk lid is opened by the remote trunk release (RTR) the alarm is not triggered by the TS as long
as the trunk lid is open.
Function sequence
The rear SAM control module (N10/8) checks several times per second the input to which the ATA inclination
sensor (B33) is connected. If a ground signal is connected to this input for longer than 1.3 s the overhead
control panel control module (N70) transmits the message "Alarm triggered by TS" to the CAN bus. The front
left SAM control module (N10/6) triggers an optical and acoustic alarm .
The TS function can trigger max. three alarms in sequence. Then the ATA must be reactivated for
continuation of this function.
Resetting the ATA inclination sensor (B33) After TS activation the ATA inclination sensor (B33) can be
reset by momentarily interrupting the power supply.
For this purpose the ATA inclination sensor (B33) is supplied with power by the anti-towing sensor relay
(K40/5kR) . This relay operates as a normally closed contact; as long as the relay coil is not under power the
ATA inclination sensor (B33) is supplied with power.
Approx. 10 s following activation of the TS the relay coil is supplied with power by the rear SAM control
module (N10/8) for 2 - 5 s. This opens the relay contact and interrupts the power supply to the ATA inclination
sensor (B33) for this time.

function
Switching off anti-towing sensor (TS), GF80.50-P-3024S
function
Inclination sensor, GF80.50-P-4105A
SWITCHING OFF ANTI-TOWING SENSOR (TS), FUNCTION - GF80.50-P-3024S
The anti-towing sensor (TS) can only be switched off when
 the anti-theft alarm (ATA) is activated previously and

 circuit 15 is OFF.
Function
Actuate the TS, IMS and ATA function indicator switch (N72/1s7) to switch off the TS . After releasing the
switch the TS is switched off.
This is indicated by the LED in the switch coming on continuously for two seconds.
The next time the ATA is activated the TS remains off.
 The TS can only be switched off for one ATA activation period. Before the ATA is activated again
switch-off must be repeated if desired.
 Further actuation of the switch for switching off the interior motion sensor (IMS) is only effective
following the confirmation signal by the LED.

TS, IMS and ATA GF54.21-P-4105S
function indicator switch
Switching off interior with code 882 GF80.50-P-3025S
motion sensor (IMS),
function
SWITCHING OFF INTERIOR MOTION SENSOR (IMS), FUNCTION - GF80.50-P-3025S
MODEL 215, 220 with CODE (882b) Interior motion sensor (only with ATA)
The interior motion sensor (IMS) can only be switched off when
 the anti-theft alarm (ATA) is activated previously and

 circuit 15 is OFF.
Function
To switch off the IMS actuate the TS, IMS and ATA function indicator switch (N72/1s7). After releasing the
switch successful switch-off is indicated by the LED in the switch flashing for two seconds. The next time the
ATA is activated the IMS remains off.
 The IMS can only be switched off for one ATA activation period. Before the ATA is activated again
switch-off must be repeated if desired.
 Further actuation of the switch for switching off the anti-towing sensor (TS) is only effective following
the confirmation signal by the LED.

Switching off anti-towing GF80.50-P-3024S
sensor (TS), function
TS, IMS and ATA GF54.21-P-4105S
function indicator switch
ALARM ACTIVATED BY ALARM SIGNAL SIREN, FUNCTION - GF80.50-P-3026S
The alarm signal siren with additional battery (H3/1) can trigger an alarm automatically . This is the case when
the ATA is activated and
 the connection lines to the siren are disconnected,

 the vehicle battery is disconnected.
The siren sounds an acoustic alarm . (Due to the rechargeable battery the siren is capable of triggering an alarm
even when the power supply is disconnected).
The siren sets the front left SAM control module (N10/6) to the alarm state and triggers an optical alarm. If the
connection between the siren and the PSE control module (combined) (A37) is interrupted, the SAM recognizes
this interruption and triggers the alarm anyway.
A triggered alarm can only be terminated by deactivating or resetting the ATA.

Activating alarm signal siren, function GF80.50-P-3027S
ACTIVATING ALARM SIGNAL SIREN FUNCTION - GF80.50-P-3027S
As soon as the anti-theft alarm system (ATA) is activated, the front left SAM control module (N10/6) also
activates the alarm signal siren with auxiliary battery (H3/1) by sending a command to the siren. The siren is
activated by this command.
As the siren, when in an activated condition, is constantly monitoring its supply and data lines, it is capable of
activating an alarm on its own .
The alarm siren, with auxiliary battery (H3/1) provides an acoustic feedback signal by sounding the
horn three times as soon as the ATA has been successfully activated. No feedback signal will be generated if
one of the doors is not closed correctly during activation of the ATA.
The siren remains active until it is deactivated again by the ATA.
Activation, Belgium
In addition to the normal "Activation" function, vehicles for the Belgian market are fitted with the function
"Self-activation".
After satisfactory completion of the preconditions
 terminal 15C "Off" and

 driver door "OPEN" and "CLOSED"
the ATA activates itself after a time of t = 120 secs. if the vehicle has not been locked. Time counting starts
with closing of the last door.
It is interrupted with opening of any one door and reset with closing of the last door as long as the ATA is not
activated.
After the command "Open" (remote control), the self-activation is started anew immediately or after
deactivation of the ATA. IMS and ATS are also activated, if not switched off. In this case there will be no
acoustic feedback signal.
Alarm activation through alarm siren - GF80.50-P-3026S

function
Alarm signal siren - GF80.50-P-4110A
Activating the anti-theft alarm system GF80.50-P-2002S
(ATA) - function
ACOUSTIC ALARM, FUNCTION - GF80.50-P-4005S
An acoustic alarm is activated by the alarm signal siren with additional battery (H3/1) by itself. The acoustic
signals differ in sequence and duration according to the national version.
The alarm can be interrupted by activating the ATA or deactivating the ATA functions. Following
interruption by activating the ATA function, the ATA remains active.
 The national version is coded in the siren with the left front SAM control module (N10/6) and can be
changed via diagnosis
 The alarm cannot be interrupted by disconnecting the connection line to the alarm signal siren with
additional battery (H3/1)!
 The alarm sequence can deviate from the coding if the connection between the alarm signal siren and the
PSE control module (combined) (A37) is interrupted.

OPTICAL ALARM, FUNCTION - GF80.50-P-4006S
The left front SAM control module (N10/6) controls the sequence of the optical signals via the CAN bus. The
optical alarm differs in sequence, duration and lamps actuated according to national versions:
 ECE: Warning hazard flasher flashes 2-3 times per second

 : Fog lamps and backup lamps flash approx. once per second
The lamps are actuated by the left front SAM control module (N10/6), right front SAM control module (N10/7),
and rear SAM control module (N10/8).
As long as the alarm is present the interior lighting is switched on. Moreover, the left turn signal indicator lamp
(A1e1) and the right turn signal indicator lamp (A1e2) flash in the instrument cluster (A1). The alarm can be
interrupted by activating the ATA function or deactivating the ATA function. After termination by activating
the ATA function the ATA remains active.
The national version is coded in the left front SAM control module (N10/6) and can be changed via
diagnosis.

Interior lighting (IL), GF82.20-P-0002S
function
INTERIOR MOTION SENSOR TRANSMITTER AND RECEIVER,

LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.50-P-4104D
MODEL 202, 210.0 (except 202.07 /08 /18) as of 1.6.98, 210.2 as of 1.6.99, 215, 220 with CODE (882b)
Interior motion sensor (only with ATA)
Interior motion sensor GF80.50-P-4104-01D

transmitter and receiver,
location
Interior motion sensor Monitoring the vehicle
transmitter and receiver, passenger compartment.
purpose
Interior motion sensor The IMS transmitter and
transmitter and receiver, receiver unit includes an
design ultrasonic transmitter and
receiver as well as a
microcontroller with data
interface.
Interior motion sensor GF80.50-P-4104-02D
transmitter and receiver,
function
Interior motion sensor transmitter and receiver, location - GF80.50-P-4104-01D
Model 202 sedan, 210.0 as of 6/98, 210.2 as of 6/99, 215, 220 with interior motion sensor
Illustrated on model 210 sedan
The interior motion sensor transmitter and receiver (A26/14) is located in the middle of the headliner.
Fig. 36: Identifying Interior Motion Sensor Transmitter And Receiver Location
Interior motion sensor transmitter and receiver, function - GF80.50-P-4104-02D
Model 202 sedan, 210.0 as of 6/98, 210.2 as of 6/99, 215, 220, sedan with ultrasonic interior protection
Function principle
The interior motion sensor transmitter and receiver (A26/14) monitors the vehicle passenger compartment with
the aid of ultrasonic signals.
Activation/deactivation
The unit is activated or deactivated with corresponding commands from the data interface.
Ultrasonic interior protection
When switched on the transmitter emits ultrasonic pulses. These pulses are reflected by the walls and objects in
the vehicle.
The reflections are recognized by the receiver in the unit and evaluated by the micro-controller. The reflection
image changes when objects are moved in the passenger compartment. In this manner the unit recognizes any
motion in the vehicle and is able to trigger an alarm.
Checking glass breakage sensors (only T-model, models 202/210)

Glass breakage sensors are connected to an additional input on the transmitter/receiver unit. A discontinuity in
the conductor loops in the glass breakage sensors is recognized as glass breakage by the logic circuitry and
transmitted to the PSE (A37) via the data bus.
INCLINATION SENSOR ARRANGEMENT/PURPOSE/DESIGN/FUNCTION - GF80.50-P-4105A
MODEL 170 up to 31.5.98 with CODE (882d) Towing sensor
MODELS 202 as of 1.6.97 up to 31.5.98, 208, 210 up to 31.5.98 with CODE (882a) Interior motion sensor
(infrared)
MODELS 170, 202, 208, 210 as of 1.6.98, 215, 220 with CODE (551a) Anti-theft alarm system (ATA)
Version up to 06/00
Fig. 37: Identifying ATA Tow Sensor (Version Up To 06/00)

Version as of 06/00
Fig. 38: Identifying ATA Tow Sensor (Version As Of 06/00)

ATA anti-towing sensor - Model 170 GF80.50-P-4105-02C

location
Models 202, 208 GF80.50-P-4105-02E
Model 210 GF80.50-P-4105-02F
Models 215, 220 GF80.50-P-4105-02S
Inclination sensor - task
Monitoring position
change of vehicle
Inclination sensor - The inclination sensor for
design ATA (B33) is fitted with
electrodes in an
electrolyte (electrically
conductive liquid).
ATA anti-towing sensor, GF80.50-P-4105-01A
function
ATA inclination sensor, function - GF80.50-P-4105-01A
Models 170, 208, 210, 215, 220
Model 202 as of 1.6.97
The electrodes in the ATA inclination sensor (B33) are partially immersed in an electrolyte (electrically
conductive liquid). If the conductive value between the electrodes changes the sensor recognizes a change in the
inclination of the vehicle. When the vehicle is parked the value for the vehicle position is stored.
If the vehicle is moved with a certain inclination in longitudinal and/or lateral direction for a certain reaction
time when the ATA is activated, the ATA inclination sensor (B33) transmits a signal to the PSE control module
(combined) (A37).
Inclination sensor, location - GF80.50-P-4105-02S
Models 215, 220
The ATA inclination sensor (B33) is located on the right below the rear seat bench.
Fig. 39: Identifying Inclination Sensor, Location - Illustrated On Model 220
ALARM SIGNAL SIREN, LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.50-P-4110A
MODEL 129, 170, 202, 208, 210 as of 1.6.98, 215, 220 with CODE (551a) Anti-theft alarm (ATA)
Alarm signal siren, Model 129 GF80.50-P-4110-01A

location
Model 170 GF80.50-P-4110-01B
Models 202, 208 GF80.50-P-4110-01C
Model 210 GF80.50-P-4110-01D
Model 215, 220 GF80.50-P-4110-01S
Alarm signal siren, The alarm signal siren with
purpose additional battery (H3/1)
transmits the acoustic signals
for the ATA alarm and the
panic alarm.
Alarm signal siren, The alarm signal siren with
design additional battery (H3/1)
consists of:
 Siren
 Electronic actuation
circuitry with data
interface
 Emergency power
supply battery
(rechargeable battery)
Alarm signal siren, GF80.50-P-4110-04A
function
Alarm signal, location - GF80.50-P-4110-01S
Models 215, 220
The alarm signal siren with additional battery (H3/1) is located concealed in the left front wheelhouse.
Fig. 40: Identifying Alarm Signal, Location - Illustrated On Model 220
Alarm signal horn, function - GF80.50-P-4110-04A
The alarm signal horn with additional battery (H3/1) is connected with the master control module of the anti-
theft alarm system (ATA) via a direct line.
Master control module for anti-theft alarm system (ATA) is:
 the combination relay (turn signal indicator with trailer hitch, heated rear window, wiper motor, ATA)
(N10/2) on model 129,
 the pneumatic control unit with combined functions (A37) on model 170, 202, 208, 210 or
 the left front SAM control module (N10/6) on model 215, 220.
Activation or deactivation
The alarm signal horn with additional battery (H3/1) is "activated" by the locking the central locking (CL) of
the vehicle.
The alarm signal horn with additional battery (H3/1) is "deactivated" by unlocking or locking the central
locking (CL) and on model 215, 220 by inserting the transmitter key (A8/1) into the EIS control module (N73).
Only model 215, 220 with code (763)Radio remote control with panic switch:
The panic alarm can also be triggered when the anti-theft alarm system (ATA) is deactivated.
Self-trigger
If the alarm signal horn with additional battery (H3/1) detects loss of the power supply or the communication, it
outputs an acoustic alarm automatically.
The alarm is not triggered in the event of a "normal" voltage drop by the vehicle battery (e.g. exterior
illumination remained switched on).
The connection to the alarm signal horn with additional battery (H3/1) can be interrupted without alarm
actuation only in the deactivated state.
Acoustic feedback ( only)
The alarm signal horn with additional battery (H3/1) outputs a feedback for activation by buzzing three times,
deactivation by buzzing once.
Battery charging condition
The additional battery installed is charged as long as "c. 15 ON" and the anti-theft alarm system (ATA) is
deactivated.
The charging state of the battery can be called via the STAR DIAGNOSIS.
TRAILER RECOGNITION CONTROL MODULE LOCATION/TASK - GF80.50-P-4111S
MODELS 215, 220 with CODE (550) Trailer coupling with CODE (551a) Anti-theft alarm system (ATA)
Shown on model 220

Fig. 41: Identifying Trailer Recognition Control Module Location - Shown On Model 220
Location On right side in trunk.

Purpose  Activation of the
trailer lights
 Monitoring of
swinging trailer hitch
(special equipment)
ANTI-THEFT ALARM (ATA) SURVEY OF SYSTEM COMPONENTS

LOCATION/TASK/DESIGN/FUNCTION - GF80.50-P-9999S
Anti-theft alarm system (ATA) - GF80.50-P-0001-

Transmitter and receiver module with code 882 GF80.50-P-4104D
interior motion sensor - (interior motion
location/task/design/function sensor) or code 491
Inclination sensor - GF80.50-P-4105A

Alarm signal siren - GF80.50-P-4110A
Control module trailer recognition - with CODE 550 GF80.50-P-4111S
location/task (trailer hitch)
Table of Contents functional GF80.50-P-0999SZ
description Anti-theft alarm system
(ATA)
DRIVE AUTHORIZATION SYSTEM STAGE 3 (DAS 3), FUNCTION - GF80.57-P-0003S
Model 215, 220
Function
The drive authorization system, stage 3 (DAS 3) releases the engine for starting. Start-up is enabled only after
the transmitter key (A8/1) is identified by the encrypted data exchange between the
 EIS control unit (N73) and the

 ME-SFI control unit (N3/10) (with gasoline engines) or the CDI control unit (N3/9) (only model 220 with
diesel engines)
This encrypted data exchange takes place over an infrared line between the transmitter key (A8/1) and the EIS
control unit (N73).
Insert transmitter key into GF80.57-P-2001S

electronic ignition/starter
switch, function
Turn electronic ignition GF80.57-P-2002S
switch to position 1 or 2,
function
Turn electronic ignition GF80.57-P-2003S
switch to position 0,
function
Check drive GF80.57-P-3001S
authorization, function
CONTENTS, FUNCTION DESCRIPTION OF DRIVE AUTHORIZATION SYSTEM STAGE 3 (DAS

3) - GF80.57-P-0999SZ
Model 215, 220
Drive authorization system stage 3 (DAS GF80.57-P-0003S

3), function
Inserting transmitter key into electronic GF80.57-P-2001S
ignition/ starter switch, function
Turning electronic ignition / starter switch GF80.57-P-2002S
to position 1 or 2, function
Turning electronic ignition/starter switch GF80.57-P-2003S
to position 0, function
Checking drive authorization, function GF80.57-P-3001S
Survey, system components, drive GF80.57-P-9999PP
authorization system, stage 3 (DAS 3),
INSERT TRANSMITTER KEY INTO ELECTRONIC IGNITION SWITCH, FUNCTION - GF80.57-P-

2001S
Model 215, 220
Function
When inserted into the electronic ignition switch control unit N73, the transmitter key (A8/1) is established
inductively via a coil in the electronic ignition switch control unit (N73) A8/1so so that the vehicle can be
started even when the key battery is discharged. The function buttons of the transmitter key (A8/1) are not
active as long as it is inserted in the EIS control unit (N73).
Mutual infrared communications occur between the transmitter key (A8/1) and the EIS control unit (N73). The
transmitter key (A8/1) is identified by the EIS control unit EZS (N73).
If the identification of the transmitter key (A8/1) is valid, the rotary lock of the EIS control unit (N73) is
enabled. The transmitter key (A8/1) can now be turned.
When the transmitter key (A8/1) is inserted into the EIS control unit (N73), the anti-theft alarm system
(ATA) with code (551) anti-theft alarm system (ATA) is deactivated and the interior CL switch and the ATA
function display (N72/1s6) (up to 31.8.02) or the 'unlock CL interior switch (N72/1s16) 'lock' CL interior switch
and the ATA function display (N72/1s17) (as of 1.9.02) of the central locking (CL) are released, however, the
vehicle is not unlocked.
Transmitter key, task/design/function GF80.57-P-4101S

Electronic ignition switch control unit, GF80.57-P-4102S
TURN ELECTRONIC IGNITION SWITCH TO POSITION 1 OR 2, FUNCTION - GF80.57-P-2002S
Model 215, 220
Function
If the verification of the transmitter key (A8/1) by the electronic ignition switch control unit (N73) is successful,
the rotary lock in the electronic ignition switch control unit (N73) is enabled. The transmitter key (A8/1) can
now be turned to position 1 or 2.
If the drive authorization is valid and the brake pedal is actuated at the same time, the selector lever lock is
canceled. The selector lever can now be moved out of the "P" position.
The transmitter key (A8/1) cannot be removed in positions 1 and 2.
Position 1
If the transmitter key (A8/1) is turned in position 1, the EIS control unit (N73) transmits the message c. ON via
the Controller Area Network bus, class B (passenger compartment) (CAN-B) 15R.
Position 2
If the transmitter key (A8/1) is turned in position 2, the EIS control unit (N73) transmits the message c. 15 ON
via the CAN-B and the Controller Area Network bus, class C (engine compartment). Drive authorization is
checked in position 2 via encrypted data exchange between the EIS control unit (N73) and the ME-SFI control
unit (N3/10) (on vehicles with gasoline engines) or CDI control unit (N3/9) (only model 220 with diesel
engines).
Position 3
If the transmitter key (A8/1) is turned in position 3, the engine is started. The transmitter key (A8/1) is
automatically turned back to position 2 after releasing.

TURN ELECTRONIC IGNITION SWITCH TO POSITION 0, FUNCTION - GF80.57-P-2003S
Model 215, 220
Function
If the transmitter key (A8/1) is turned to the left in the EIS control unit (N73), the circuit status is changed on
the Controller Area Network bus, class B (passenger compartment) (CAN-B) and on the Controller Area
Network bus, class C (engine compartment) (CAN-C).
The following function are realized in the EIS control unit (N73) when turning back the transmitter key (A8/1)
From position 2 to position 1
 Switch off c. 15 and c. 15X

 C. 15R On
 Set communication on CAN-C
From position 1 to position 0
 Voltage supply for the electric steering column lock is switched on

 Switch off c. 15R
 C. 15C ON
 Transmitter key (A8/1) can be removed
N73TThe mechanical shift lock function in the EIS control unit prevents the transmitter key (A8/1) from
being turned back to position "0" if the selector lever is not in position "P".

CHECK DRIVE AUTHORIZATION, FUNCTION - GF80.57-P-3001S
Model 215, 220
Function
After turning the transmitter key (A8/1) in the EIS control unit (N73) from position 1 to position 2, the ME-SFI
control unit (N3/10) (on vehicles with gasoline engines) or the CDI control unit (N3/9) (only model 220 with
diesel engines) are supplied with power. Following the encrypted data exchange between the
ME-SFI control unit (N3/10) or the CDI control unit (N3/9) and the EIS control unit (N73) the drive
authorization code is calculated in parallel.
This calculation is then compared in the ME-SFI control unit (N3/10) or CDI control unit (N3/9)If verification
is successful, the start authorization is issued. If the start-up is not enabled, this is stored in the DTC memory in
the ME-SFI control unit (N3/10) or CDI control unit (N3/9). If the start authorization is given, the transmitter
key receives an appropriate message via infrared from the electronic ignition switch control unit A8/1(N73).

REMOTE CONTROL KEY, PURPOSE/DESIGN/FUNCTION - GF80.57-P-4101S
MODEL 215, 220
Remote control key, Central locking (CL)

purpose remote control and
convenience feature.
Drive authorization (DAS
3).
Actuation of panic alarm.
( only)
Remote control key, GF80.57-P-4101-01S
design
Remote control key, GF80.57-P-4101-02S
function
Transmitter key design - GF80.57-P-4101-01S
Models 215, 220
Shown as up to 06/00
Location of pushbuttons on transmitter key
Fig. 42: Identifying Location Of Pushbuttons On Transmitter Key - Shown As Up To 06/00
The transmitter key consists of an electronic part and a mechanical key. The electronic part contains an FM
radio transmitter, an infrared transceiver unit, a processor chip, pushbuttons, and a battery.
Shown as of 06/00
Pushbutton assignments of transmitter key
Fig. 43: Identifying Pushbutton Assignments Of Transmitter Key - Shown As Of 06/00
The transmitter key consists of an electronic part and a mechanical key. The electronic part contains an FM
radio transmitter, an infrared transceiver unit, a processor chip, pushbuttons, and a battery.
Remote control key, function - GF80.57-P-4101-02S
Models 215, 220
Drive authorization
After inserting the remote control key (A8/1) into the key slot in the electronic ignition/starter switch
control module (N73) it is supplied with power by an inductive coil. Data is exchanged by the infrared
transmitter/receiver unit to check the drive authorization .
Locking/unlocking vehicle, remote trunk release
The remote control key transmits a radio or an infrared signal when a button is pressed. This signal is checked
for validity and the vehicle is then locked, unlocked or the trunk lid opened.
Universal/selective setting
The setting "universal/selective" for unlocking the vehicle can be changed by simultaneously actuating the
"unlock" and "lock" buttons for more than five seconds. The change is indicated by the battery indicator lamp
flashing twice.
Convenience feature
The signals for the convenience feature are transmitted in the form of infrared signals only, not as radio
frequency signals!
Mechanical key
When the release button is pressed the mechanical key can be removed completely from the remote control key.
When unlocking or locking the vehicle with the mechanical key the central locking and the anti-theft alarm
(ATA) are not actuated (except , ).
Battery control
When a button is pressed the battery indicator lamp comes on indicating the correct status of the battery in the
remote control key.
ELECTRONIC IGNITION/STARTER SWITCH CONTROL MODULE,

LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.57-P-4102S
MODELS 215, 220
Electronic GF80.57-P-4102-02S
ignition/starter switch
control module, location
Electronic GF80.57-P-4102-03S
ignition/starter switch
control module, purpose
up to 31.05.01 In GF80.57-P-4102-03I
combination with
automatic air
conditioning
as of 01.06.01 In GF80.57-P-4102-03IA
combination with
automatic air
conditioning
Electronic The EIS housing is equipped
ignition/starter switch with an opening in which the
control module, design remote control key is inserted.
An infrared
transmitter/receiver in the
opening allows data exchange
with the remote control key.
Function
function
Remote trunk release GF80.20-P-0006S
(RTR), function
(ATA), function
Drive authorization GF80.57-P-0003S
system stage 3 (DAS 3),
function
Convenience feature GF80.45-P-0003S
(CF), function
Electronic ignition/starter switch control module, location - GF80.57-P-4102-02S
Models 215, 220

Fig. 44: Identifying Electronic Ignition/Starter Switch Control Module - Illustrated On Model 220
Electronic ignition/starter switch control module, purpose - GF80.57-P-4102-03I
Purpose
The electronic ignition/starter switch control module (EIS) acts as the communication point between the
passenger compartment bus (CAN B), the electronic engine control (ME-SFI) and the electronic transmission
control (ETC).
Actuating electric suction fan
The electric suction-type fan is controlled infinitely by the electronic engine control (MF-SFI) (hardware signal
to fan control module). The cooling version is stored in the EIS electronic ignition/starter switch control
module. The signal flow is identical on both versions. The AC push-button control module calculates the
nominal fan speed depending on the refrigerant pressure and transmits the request to the electronic engine
control (ME-SFI) via the electronic ignition/starter switch (EIS) control module. In the AC mode at an outdoor
temperature of > or = 15 °C and a vehicle speed of < or = 70 km/h a basic ventilation of 40% is requested.
The electronic engine control (ME-SFI) calculates the nominal fan speed depending on the engine temperature
and compares this speed with the request from the AC push-button control module. The higher of the two
values is output by the hardware as a PWM signal.
Switch-on characteristics for AC
The AC can be switched on in two different ways:
 with circuit 15 ON (ignition)

 when residual engine heat utilization is activated (REST button ) pressed, LED illuminated)
Since some of the connected air conditioning equipment consumers represent a heavy load on the vehicle
electrical system (e.g. blower) a corresponding message is sent to the CAN B bus from the electronic engine
control via the electronic ignition/starter switch control module (EIS) control module when the starter is
actuated. As long as the starter operates the corresponding output stages (blower, hot water circulation pump,
engine fan, AC compressor) are switched off by the AC push-button control module.
A fixed program is set on in the residual engine heat utilization mode
For example a set blower control voltage is output to avoid an excessively high load on the battery. The nominal
temperatures can be varied.
Specific version coding for the automatic air conditioning is possible via the diagnosis assistance system (DAS).
The following possibilities are available:
 Refrigerant fill level control

 INACTIVE
 ACTIVE
 Pollutant-dependent recirculated air circuit

 INACTIVE
 ACTIVE (with activated charcoal filter) STANDARD
 ACTIVE (without activated charcoal filter ACTIVE (with activated charcoal filter
 Convenience locking (tunnel shift) (only on model 220)

 INACTIVE
 ACTIVE
 Beam indicator for blower in automatic mode

 Display
 Do not indicate
 REHEAT mode
 icing protection
 Standard
 100% recirculated air possible

 YES
 NO
 Display: Night design

 Automatic
 Night design
 Display: Day design

 Automatic
 Day design
 Automatic basic adjustment for rear air conditioning (only on model 220)
 ACTIVE
 INACTIVE
 Main air flap with AC switched off
 CLOSED
 OPEN
 Suction fan control

 Remaining engines
 M 137, OM 613, OM 628
 National version for AC

 Remaining world
 Hot countries
The push-button control module reads these version codings in after ignition ON via the CAN bus.
The following parameters can be changed in the EIS control module in addition.
 Country versions
 Left-hand steering
 Right-hand steering
 Engine model designation
 Vehicle models
 Stationary heater or Telestart
 PRESENT
 NOT PRESENT
 Rear air conditioning (only model 220)

 PRESENT
 NOT PRESENT
Electronic ignition/starter switch control module, purpose - GF80.57-P-4102-03IA
Purpose
The electronic ignition/starter switch control module (EIS) acts as the communication points between the
passenger compartment bus (CAN B), the electronic engine control (ME-SFI) and the electronic transmission
control (ETC).
Actuating electric suction fan
The electric suction-type fan is controlled infinitely by the electronic engine control (MF-SFI) (hardware signal
to fan control module). The cooling version is stored in the EIS electronic ignition/starter switch control
module. The signal flow is identical on both versions. The push-button control module calculates the fan speed
setting depending on the refrigerant pressure and transmits the request to the electronic engine control (ME-
SFI). The electronic ignition/starter switch (EIS) control module receives the refrigerant pressure value via the
AC push-button control module. In the AC mode at an outdoor temperature of > or = 15 °C and a vehicle speed
of < or = 70 km/h a basic ventilation of 40% is requested.
The electronic engine control (ME-SFI) calculates the nominal fan speed depending on the engine temperature
and compares this speed with the request of the AC push-button control module. The higher of the two values is
output by the hardware as a PWM signal.
Switch-on characteristics for AC
The AC can be switched on in two different ways:
 with circuit 15 ON (ignition)

 when residual engine heat utilization is activated REST button ( ) pressed, LED illuminated:
Since some of the connected air conditioning equipment consumers represent a heavy load on the vehicle
electrical system (e.g. blower) a corresponding message is sent to the CAN B bus from the electronic engine
control via the electronic ignition/starter switch control module (EIS) control module when the starter is
actuated. As long as the starter operates the corresponding output stages (blower, hot water circulation pump,
engine fan, AC compressor) are switched off by the AC push-button control module.
A fixed program is set on in the residual engine heat utilization mode
For example a set blower control voltage is output to avoid an excessively high load on the battery. The nominal
temperatures can be varied.
Specific version coding for the automatic air conditioning is possible via the diagnosis assistance system (DAS).
The following possibilities are available:
 Refrigerant fill level control

 INACTIVE
 ACTIVE
 Pollutant-dependent recirculated air circuit

 INACTIVE
 ACTIVE (with activated charcoal filter) STANDARD
 ACTIVE (without activated charcoal filter ACTIVE (with activated charcoal filter)
 Convenience locking (tunnel shift)

 INACTIVE
 ACTIVE
 Beam indicator for blower in automatic mode

 Display
 Do not indicate
 REHEAT mode
 Standard
 Icing protection
 100% recirculated air possible
 YES
 NO
 Display: Night design

 Automatic
 Night design
 Display: Day design

 Automatic
 Day design
 Automatic basic adjustment for rear air conditioning (only on model 220)
 ACTIVE
 INACTIVE
 Main air flap with AC switched off

 CLOSED
 OPEN
 Suction fan control

 Remaining engines
 M 137, OM 613, OM 628
 National version for AC

 Remaining world
 Hot countries
The push-button control module reads these version codings in after ignition ON via the CAN bus.
The following parameters can be changed in the EIS control module in addition.
 Country versions
 Left-hand steering
 Right-hand steering
 Engine model designation
 Vehicle models
 Stationary heater or Telestart
 PRESENT
 NOT PRESENT
 Rear air conditioning (only model 220)

 PRESENT
 NOT PRESENT
Electronic ignition/starter switch control module, purpose - GF80.57-P-4102-03S
Model 215, 220
 Actuation of engine fan

 Switch-on conditions for automatic air conditioning
 Interface (gateway) between interior CAN bus and engine compartment CAN bus for exchanging data
between the two bus systems
 Interface between the control modules of the passenger compartment CAN bus and the data link
connector (X11/4)
 Circuit 50 for engine control module via engine compartment CAN bus
 Checking drive authorization
 Checking access authorization
 Infrared communication with remote control key (A8/1) when inserted
 Power supply for remote control key (A8/1)
 Release of gear selector lever lockout in electronic shift lever module control module (N15/5)
 Transmitting CAN messages circuit 15, 15R
 Actuation of "universal" and "selective" central locking
The equipment versions are coded in the EIS.
SURVEY, SYSTEM COMPONENTS, DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3),

LOCATION/PURPOSE/DESIGN/FUNCTION - GF80.57-P-9999PP
Model 215, 220
Transmitter key. task/design/function GF80.57-P-4101S

Contents, function description of drive GF80.57-P-0999SZ
authorization system stage 3 (DAS 3)
KEYLESS GO, FUNCTION - GF80.61-P-0005SM
MODEL 220, 215 as of 1.10.02
General
The keyless go function allows access and starting of the vehicle without actuating the transmitter key (A8/1).
For access and drive authorization it is sufficient to carry the transmitter key (A8/1) with you.
The function of the standard central locking is maintained parallel to the keyless go functions Whereby the
use of the transmitter key (A8/1) interrupts the function of the keyless go system
The convenience opening function is not possible via keyless go.
Unlock with keyless go
The vehicle can be unlocked by:
 Pulling any door handle (global or selective opening).

 Reaching into one of the door handles
 Actuating button on transmitter key (A8/1)
The vehicle can only be locked and not unlocked with the trunk lid keyless go push-button (S62/21).
Lock with keyless go
The vehicle can be locked by:
 Actuating the left rear door push contact (S47/1s2), left front door push contact (S47s2), right rear door
push contact (S48/1s2) or right front door push contact (S48s2)
 Actuating the trunk lid keyless go button (S62/21) on trunk lid
 Actuate button on transmitter key (A8/1)
On vehicles with code (551a) anti-theft alarm (ATA) the anti-theft alarm system behaves in the same way as
if the car is unlocked and locked with the transmitter key (A8/1).
Start engine and switch off with keyless go
The engine can be started or shut off by pressing the start/stop keyless go button (S2/3) on the selector lever.
Keyless go, location of components GF80.61-P-0005-

01SM
Keyless go, block diagram GF80.61-P-0005-
02SM
Unlock, function GF80.61-P-2009SM
Lock, function GF80.61-P-2010SM
Engine start/stop, function GF80.61-P-3012SM
Communication of transmitter key with GF80.61-P-3013SM
vehicle, function
Survey of system components, keyless GF80.61-P-9996TZ
go, location/task/design/function
Keyless go, location of components - GF80.61-P-0005-01SM

Fig. 45: Identifying Keyless Go Components Location - Shown On Model 220,215 (1 Of 2)
Fig. 46: Identifying Keyless Go Components Location - Shown On Model 220,215 (2 Of 2)
Keyless go block diagram - GF80.61-P-0005-02SM

Fig. 47: Identifying Keyless Go Block Diagram
CONTENTS, FUNCTION DESCRIPTION OF KEYLESS GO - GF80.61-P-0996TZ
MODEL 220, 215 as of 1.10.02
Keyless go, function GF80.61-P-

0005SM
Keyless go, location of components GF80.61-P-0005-
01SM
Keyless go, block diagram GF80.61-P-0005-
02SM
Unlocking, function GF80.61-P-
2009SM
Locking, function GF80.61-P-
2010SM
Engine start/stop, function GF80.61-P-
3012SM
Communication of transmitter key with GF80.61-P-
vehicle, function 3013SM
Program transmitter key, function GF80.30-P-
3002SM
Survey of system components for keyless GF80.61-P-
go, location/purpose/design/function 9996TZ
UNLOCK, FUNCTION - GF80.61-P-2009SM
MODEL 220, 215 as of 1.10.02
Fig. 48: Unlock, Function Diagram - Shown On Model 220
Unlock
Requirements:
 Circuit 30
Possible control elements for system activation:
 Reach into one of the door handles

 Pull door handle
Function sequence using driver's door as example
1. Actuate left front door pull contact microswitch (S47s1) or left front door capacitive sensor (S47b1) by
lightly pulling door handle on driver's door (t >0.1 s).
The keyless go system is woken up.
2. The keyless go system (N69/5) transmits a signal to the transmitter key (A8/1) via the left front door
keyless go antenna (A2/38)
The position of the transmitter key (A8/1) in relation to the vehicle is determined via various antennas
Remote control keys in the vehicle or in the trunk are ignored
3. The transmitter key (A8/1) transmits its authorization This authorization is received by the HF antenna
and is relayed to the keyless go control module (N69/5) via the overhead control panel control module
(N70)
4. The keyless go control module (N69/5) checks whether the transmitter key (A8/1) is authorized for the
vehicle
5. Transmit access authorization code to EIS control module (N73).
6. If access authorization code is correct, the signal "Open CL "is stored on the CAN B bus.
7. Parallel to this, the EIS control module (N73) transmits the signal "Actuate lift solenoid" to the keyless go
door control module (N69/5) The left front door keyless go lift solenoid (L12) is actuated (The lift
solenoid is only actuated at the control point)
All door locks are equipped for quick unlocking with lift solenoid.
The actuation of the central locking depends on the adjustment of the transmitter key (A8/1).
Possible settings:
 Global unlocking
 Selective unlocking
Control point, driver's door: Selective unlocking
Control point, other door: Global unlocking

Function sequence using trunk lid as an example
Requirements:
 Circuit 30
 The trunk is not locked mechanically (90° switch)
1. Actuate trunk lid keyless go button (S62/21) The signal is relayed to the keyless go control module by the
pneumatic control unit (combined) (A37).
2. The keyless go control module (N69/5) requests the transmitter key (A8/1) to transmit its authorization
via the rear bumper keyless go antenna (A2/31).
The position of the transmitter key (A8/1) in relation to the vehicle is determined via various antennas
Remote control key in the vehicle or in the trunk are ignored
3. This authorization is received by the HF antenna and is relayed to the keyless go control module (N69/5)
via the overhead control panel control module (N70)
vehicle
5. Transmitting access authorization code to EIS control module (N73).
6. If the access authorization code is correct, the signal "Remote trunk release "is stored on the CAN B bus
by the EIS control module (N73) and received by the pneumatic control unit (combined) (A37).
7. The pneumatic control module with combined functions (A37) opens the trunk lid pneumatically.
Only the trunk lid is unlocked, door and filler cap remain locked.
The anti-theft alarm (ATA) behaves in the same way as if the car is unlocked and locked with the transmitter
key (A8/1).

Keyless go control module GF80.61-P-4102SM
Keyless go antenna, GF82.62-P-4100SM
Electronic ignition switch control GF80.57-P-4102S
module, location/task/design/function
LOCK, FUNCTION - GF80.61-P-2010SM
MODEL 220, 215 as of 1.10.02

Fig. 49: Lock, Function Diagram
Lock
Requirements:
 Circuit 30
 All doors are closed.
 At least one transmitter key (A8/1) is located outside the vehicle
 At least one transmitter key (A8/1) is near (<1.5m) an inductive antenna
Possible control elements for system activation:
 Actuate door handle switch

 Actuate trunk lid keyless go button (S62/21)
Function sequence using driver's door as an example
1. The left front door push contact switch (S48/s2) is actuated by pressing the door handle button on the
driver's door.
The keyless go system is woken up.
2. The keyless go control module (N69/5) transmits a signal to the transmitter key (A8/1) via the left front
door keyless go antenna (A2/38)
The position of the transmitter key (A8/1) in relation to the vehicle is determined via various antennas.
Transmitter key in the vehicle or in the trunk are ignored
(N70)
vehicle
6. If access authorization code is correct, the signal "Open CL "is stored on the CAN B bus.
7. The pneumatic control module with combined functions (A37) locks the vehicle.
As long as the transmitter key (A8/1) is located outside the vehicle, this is indicated by the instrument cluster
(A1) and the vehicle is not locked
When locking, the anti-theft alarm is also activated. Errors occurring when locking are indicated by the
instrument cluster.
Convenience locking
If the left front door push contact (S47s2) is pressed for t > 1 s the convenience closing function is started. All
windows and the tilting/sliding roof are closed
Obstruction sensor:
If a door handle is pulled within 2 s after the vehicle is locked, all power windows are actuated for approx. 2 s
in the "opening "direction depending on the version of tilting/sliding roof.

Keyless go control module, GF80.61-P-4102SM
ENGINE START/STOP, FUNCTION - GF80.61-P-3012SM

MODEL 220, 215 as of 1.10.02
Fig. 50: Engine Start/Stop, Function Diagram
Engine start-stop, function
The engine can be started or shut off by pressing the start/stop keyless go button (S2/3) on the selector lever.
Start engine
Function requirement for "Start engine"
 The transmitter key (A8/1) is located in the passenger compartment.

 The selector lever is in position "P "or "N"
 The foot brake is operated.
Function sequence
1. Press keyless go start/stop button (S2/3) on selector lever.

2. A wake-up signal is transmitted to the transmitter key (A8/1).
(N70)
vehicle
6. If the checks were positive, circuit 15R and circuit 15 - if not already switched on - are switched on, the
steering lock is unlocked and the engine is started.
If applicable, errors occurring are output by the instrument cluster (A1).
Switch off engine
Function requirements for "Switching off engine"
 The selector lever is in position "P "or "N"
The position of the transmitter key (A8/1) is not checked.
Function sequence
1. Press start/stop keyless go button (S2/3) on gear selector lever.
Circuit 15 is switched off When the driver's door is closed circuit 15c remains active and the steering lock
unlocked. Additional actuation possibilities are given in the following table.
Actuation of start/stop Status after actuation of Status after actuation of Status after actuation of
keyless go button (S2/3) keyless go start/stop keyless go start/stop keyless go start/stop
(Initial state: c. 15R, c. button (S2/3) button (S2/3) button (S2/3)
15 and engine are OFF)
Requirements: Requirements:
 Driver's door is  Driver's door

opened after button remains closed
is actuated (D), after button is
 Foot brake is not actuated (D),
operated when  Foot brake is not
operating push- operated when
button operating push-
button
1st operation Circuit 15 ON, engine is C. 15R ON C. 15R ON
started
Requirements:
 Foot brake
actuated (A),
 selector lever to
position P (B)
2nd operation Circuit 15R ON, engine Circuit 15 ON Circuit 15 ON
is switched off
Requirements:
 Selector lever in
position P or N (B)
3rd operation Circuit 15 ON, Circuit 15 OFF Circuit 15 OFF
engine is started Circuit 15R OFF Circuit 15R OFF
Circuit 15C OFF C. 15C ON
Requirements:
 Foot brake
actuated (A),
 Selector lever to
position P (B)
If a door contact switch is actuated when the engine is running and the vehicle is standing still, the EIS
control module (N73) checks the key when restarting. If a valid transmitter key (A8/1) is not recognized in the
passenger compartment of the vehicle, the instrument cluster (A1) indicates "key not recognized". The engine
remains on, but the car should be taken to a workshop without delay. If the transmitter key (A8/1) is available,
the vehicle should be restarted with the transmitter key (A8/1)
If a transmitter key (A8/1) is not recognized when starting, the instrument cluster (A1) indicates "key not
recognized "and the start attempt is interrupted (circuit 15R and 15 remain off).
If the selector lever is not in position "P "or "N "when an attempt is made to start, the following appears in the
instrument cluster (A1): "Selector lever to P or N".
If the transmitter key (A8/1) is recognized, analog circuit switching is accomplished. If the selector lever is not
in position "P "or "N "when an attempt is made to switch the engine off, the text "Selector lever to P or N
"appears in the instrument cluster (A1).
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 (A1): "Selector lever to P or N".
If the circuits described are activated through the keyless go start/stop button (S2/3) and a valid transmitter key
is then inserted into the EIS control module 1(N73), the transmitter key (A8/1) is given priority if the selector
lever in position "P". If running, the engine is switched off.

COMMUNICATION OF TRANSMITTER KEY WITH VEHICLE, FUNCTION - GF80.61-P-3013SM
MODEL 220, 215 as of 1.10.02
Shown on model 220
Fig. 51: Communication Components Of Transmitter Key With Vehicle - Shown On Model 220
Reception ranges
The inductive antennas generate fields to cover various reception ranges around the vehicle. The transmitter key
can determine its position in relation to the vehicle from the overlap of several fields. The range is approx. 1.5
m
The keyless go control module (N69/5) causes the transmitter key (A8/1) to send its authorization code via
radio and inductive antennas if
 a hand is inserted into a door handle (capacitve sensor)
the capacitive sensors are only active for 72 hours after the last locking operation and when play
protection is not active
 a door handle is pulled,

 the lock button on one of the door handles is pressed,
 the trunk lid release switch (S15/1) is pressed to open the trunk lid,
 the trunk lid keyless go button (S62/21) is pressed,
 the keyless go start/stop button (S2/3) is pressed.
Function sequence
The vehicle wakes up the transmitter key.
The transmitter key determines its position in relation to the vehicle and transmits this information to the rear
window antenna amplifier module (A2/12) with the authorization code.
The rear window antenna amplifier module (A2/12) converts the radio signal into a data signal The overhead
control panel control module (N70) receives this data signal via a data line. The code included in the signal for
authorization is transmitted to the EIS control module as CAN message.
The EIS control module (N73) checks the code and, if the code was correct, sends the corresponding command
for lock/unlock or for engine start via the CAN data bus.

KEYLESS GO CONTROL MODULE, LOCATION/TASK/DESIGN/FUNCTION - GF80.61-P-4102SM
MODEL 220, 215 as of 1.10.02
Keyless go control GF80.61-P-4102-01S

module, location
Keyless go control GF80.61-P-4102-
module, task 02SM
Keyless go control The keyless go control module
module, design contains the
actuation/evaluation electronic
of the sensors and the actuators
of the keyless go system.
Keyless go control The keyless go control module
module, function (N69/5) processes all actuator
and sensor signals of the
keyless go system.
The keyless go control
module is connected with the
EIS control module (N73) via
passenger compartment CAN
bus. The EIS control module
(N73) is an interface for the
keyless go control module with
other control modules
Keyless go control module, location - GF80.61-P-4102-01S
Models 215, 220
The keyless go control module (N69/5) is located behind the paneling in the trunk on the right above the
wheelhouse.
Fig. 52: Identifying Keyless Go Control Module
Keyless go control module, task - GF80.61-P-4102-02SM
The keyless go control module (N69/5) has the following purposes, explained using model 220 as an example:
 Control of lift solenoids in doors

 Control of keyless go inductive antennas
 Rear bumper keyless go antenna (A2/31)
 Left antenna element (A2/35a1)
 Right antenna element (A2/35a2)
 Left front door keyless go antenna (A2/38)
 Right front door keyless go antenna (A2/40)
 Left rear door keyless go antenna (A2/39)
 Right rear door keyless go antenna (A2/41)
 Locate transmitter key (A8/1) inside or outside of vehicle via antenna system
 Read in keyless go trunk lid button
 Read in keyless start/stop button (S2/3)
 Read in pull contact microswitch in doors
 Read in pressure contacts for doors
 Read in capacitive sensors for doors
Peculiarities on model 215
Since model 215 does not have rear doors, microswitches, pressure contacts and capacitive sensors for the rear
doors are eliminated The left rear door keyless go antenna (A2/39) and the right rear door keyless go antenna
(A2/41) are replaced with left rear keyless go antenna (A2/39) and right rear keyless go antenna (A2/41) on
model 215. However, the function is the same
SURVEY, SYSTEM COMPONENTS, KEYLESS GO, LOCATION/TASK/DESIGN/FUNCTION -

GF80.61-P-9996TZ
MODEL 220, 215 as of 1.10.02
Transmitter key task/design/function GF80.57-P-4101S

Table of contents, function description GF80.61-P-0996TZ
for keyless go
TROUBLE DIAGNOSIS
CARD IS NOT DETECTED BY KEYLESS GO - AF80.61-P-6000A
MODEL 215, 220
MODIFICATION NOTES
19.7.00 Supersedes STIP 80.57- Contents revised
005 dated 18.07.2000
Damage code Cause Remedy

If the malfunction
message "Card not
recognized" appears in
the instrument cluster,
observe the following
before replacing parts: ?
Cause 1: Remedy 1:
Location of card in 1. Place card in suitable
vehicle. location.
Problems with card
recognition can occur
when the card is located
in the center console or
in front of the
instrument cluster, for
example.
Cause 2: Remedy 2:
Electromagnetic 1. Avoid electromagnetic
compatibility (EMC) compatibility (EMC) and
and shielding effects. shielding effects.
Never store card together

with other electronic equipment
(e.g. cellular telephone) or
metallic items (e.g. coins or
metallic foils).
Cause 3: Remedy 3:
Both cards are located 1. Start vehicle with both
directly next to one cards one after another.
another when the engine
is started.
Hash code feedback Always ensure that only one
can be stored card is in the vehicle.
incorrectly. In this case,
the vehicle can no
longer be locked or
unlocked with one of
the cards.
Cause 4: Remedy 4:
Measures described 1. Replace control module
above do not help. (parts ordering note).
See Owner's Manual for
further instructions!
PARTS ORDERING NOTES

Part no. Designation Quantity
029 545 85 32 multifunction as req.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CENTRAL LOCKING, CONVENIENCE
FEATURE, DRIVE AUTHORIZATION SYSTEM - AR80.00-Z-9215AA
MODEL 215
Removing and installing fuel MODEL 215, 220 AR80.20-P-2300M

filler flap
Removing and installing PSE MODEL 215, 220 AR80.20-P-2700M
control module (A37/2-A37/5)
Removing and installing front MODEL 215, 220 AR80.30-P-4305M
door infrared remote control
receiver
Removing and installing MODEL 215, 220 with AR80.35-P-0001M
Keyless Go control module CODE (889) Keyless
Go
Check batteries for remote MODEL 202 as of AR80.35-P-4205E
control key 1.6.97, 208, 210 as of
1.3.97, 215, 220, 240
Remove/install batteries for MODEL 202 as of AR80.35-P-4210E
remote control key 1.6.97, 208, 210 as of
1.3.97, 215, 220, 240
inclination sensor (anti-towing CODE (551a) Anti-theft
sensor) alarm (ATA)
Remove/install interior motion MODEL 203, 210, 215, AR80.50-P-9820F
sensor transmitter/receiver 220 ...
Removing and installing ATA MODEL 215, 220 with AR80.50-P-9840M
alarm signal siren CODE (551a) Anti-theft
alarm (ATA)
Remove/install electronic MODEL 215, 220 AR80.57-P-1000M
ignition switch control unit
TESTING AND REPAIR WORK: PASSENGER CARS: CENTRAL LOCKING, CONVENIENCE

FEATURE, DRIVE AUTHORIZATION SYSTEM - AR80.00-Z-9220AA
MODEL 220
Removing and installing fuel MODEL 215, 220 AR80.20-P-2300M

filler flap
Removing and installing PSE MODEL 215, 220 AR80.20-P-2700M
control module (A37/2-A37/5)
Removing and installing front MODEL 215, 220 AR80.30-P-4305M
door infrared remote control
receiver
Keyless Go control module CODE (889) Keyless
Go
Check batteries for remote MODEL 202 as of AR80.35-P-4205E
control key 1.6.97, 208, 210 as of
1.3.97, 215, 220, 240
Remove/install batteries for MODEL 202 as of AR80.35-P-4210E
remote control key 1.6.97, 208, 210 as of
1.3.97, 215, 220, 240
inclination sensor (anti-towing CODE (551a) Anti-theft
sensor) alarm (ATA)
Remove/install interior motion MODEL 203, 210, 215, AR80.50-P-9820F
sensor transmitter/receiver 220 ...
Removing and installing ATA MODEL 215, 220 with AR80.50-P-9840M
alarm signal siren CODE (551a) Anti-theft
alarm (ATA)
Remove/install electronic MODEL 215, 220 AR80.57-P-1000M
ignition switch control unit
REMOVING AND INSTALLING FUEL FILLER FLAP - AR80.20-P-2300M
MODEL 215, 220
Fig. 53: Identifying Fuel Filler Flap Remove/Install Components - Illustrated On Model 220
Removal, installation
1 Remove paneling in trunk Right side paneling AR68.30-P-4600M
2 Turn tank flap element Removal is described
(1) to left (direction of with the tank flap element
arrow) until pneumatic (1) already removed
line connection (2a)
makes contact with body
3 Press mounting lug (3) Installation: The tank
(arrow) and pull tank flap flap element (1) can only
element (1) off of holder be installed in one
position.
Slide tank flap element
into holder until
mounting lug (3) catches
audibly
4 Remove tank flap
element (1) toward trunk
5 Carefully pry pneumatic Danger of breaking
line (2) off with open-end insert profile
wrench (7 mm)
6 Check pneumatic
function of tank flap
element (1)
7 Install in opposite order
REMOVING AND INSTALLING PSE CONTROL MODULE (A37/2-A37/5) - AR80.20-P-2700M
MODEL 215, 220

Fig. 54: Identifying PSE Control Module Remove/Install Components - Illustrated On Model 220
1 Remove paneling in trunk except right side AR68.30-P-4600M
paneling and rear wall
paneling
2 Press apart plastic lugs
(arrows) and remove
foam cap (1)
3 Unclip pneumatic strips Clips are located in
(2, 3) on pneumatic the oblong holes marked
control module with PSE with arrows. Unclip with
control module flat tool, e.g. screwdriver
(combined) (A37)
4 Loosen electrical Turn in direction of
connector (4) on PSE arrow
control module
(combined) (A37) and
remove lead
5 Remove PSE control
module (combined)
(A37)
6 Install in opposite order If the PSE is replaced
version coding must be
accomplished via STAR
DIAGNOSIS
7 Check central locking,
lumbar support or
multicontour backrest,
power locking, head
restraint extension and
retraction for proper
function
REMOVING AND INSTALLING FRONT DOOR INFRARED REMOTE CONTROL RECEIVER -

AR80.30-P-4305M
MODEL 215, 220

Fig. 55: Identifying Front Door Infrared Remote Control Receiver Remove/Install Components -
1 Pull out plug (1) in area
of door lock
2 Unscrew mounting screw Secure mounting
for left front IR receiver screw against falling
(A26/1) with Torx socket down from Torx socket
wrench (2) bolt (e.g. magnetizing
Torx socket wrench)
*BA72.10-P-1007-01E
3 Carefully remove
left/right front IR receiver
(A26/1, A26/2)
4 Disconnect electrical When installing
connector (3) ensure electrical
connector (3) is clipped
correctly
6 Check of power windows
for proper function (one-
touch window up feature)
FRONT DOOR
BA72.10-P-1007- Screw for door Nm 3 3
01E handle on front door
REMOVING AND INSTALLING KEYLESS GO CONTROL MODULE - AR80.35-P-0001M
MODEL 215, 220 with CODE (889) Keyless Go

Fig. 56: Identifying Keyless Go Control Module Remove/Install Components - Illustrated On Model 220
1 Connect quiescent current AR54.10-P-1030-07I
retention unit
2 Disconnect ground lead AR54.10-P-0003I
from battery
3 Remove paneling in trunk Right side paneling AR68.30-P-4600M
4 Unscrew screws (1) and
remove keyless Go
control module (N69/5)
5 Unlock electrical
connectors (2) on Keyless
Go control module
(N69/5) and remove
CHECK BATTERIES FOR REMOTE CONTROL KEY - AR80.35-P-4205E
MODEL 202 as of 1.6.97, 208, 210 as of 1.3.97, 215, 220, 240

Fig. 57: Identifying Remote Control Key Components - Model 202 As Of 1.6.97, 208, 210 As Of 1.3.97,
215, 220, 240
Inspect
Hold release button (1) or Light emitting diode in
lock button (2) or remote the inspection window
trunk lid opening button (4) must light up briefly,
(3) for longer than 1 if necessary: ?
second
Replace batteries for AR80.35-P-4210E
remote control key.
REMOVE/INSTALL BATTERIES FOR REMOTE CONTROL KEY - AR80.35-P-4210E
MODEL 202 as of 1.6.97, 208, 210 as of 1.3.97, 215, 220, 240
Fig. 58: Identifying Remote Control Key Components - Model 202 As Of 1.6.97, 208, 210 As Of 1.3.97,
215, 220, 240
Remove/Install
The spare key cannot be
opened, it contains no
batteries.
1 Take mechanical key (2)
out of remote control key
2 Press in retainer (1) with
mechanical key (2)
3 Lift battery compartment
(3) slightly in direction of
arrow (4)
4 Remove battery Installation: Battery
compartment (3) in compartment must catch
direction of arrow (5) in key housing.
Discharged batteries
have to be disposed of in
an environmentally
acceptable manner.
5 Insert batteries (6) below Installation: Observe
contact spring (7) polarity (plus sign toward
top)
When inserting the
batteries ensure that the
battery contacts are free of
grease.
REMOVING AND INSTALLING INCLINATION SENSOR (ANTI-TOWING SENSOR) - AR80.50-P-

0001M
Fig. 59: Identifying Inclination Sensor (Anti-Towing Sensor) Remove/Install Components - Illustrated On
Model 220
1.1 Remove front seat Model 220 AR91.12-P-1020MA
cushion
1.2 Remove individual seats Model 220 with code AR91.12-P-1020M
401, only right side
Model 215, only right AR91.12-P-1020N
side
2.1 Remove seat adjustment Model 220 with code AR91.12-P-1520M
device on rear seat 401, only right side
3 Unscrew nuts (1),
unscrew screws (2) and
remove mounting plate
(3) from vehicle floor
4 Disconnect connector Installation: After
from ATA inclination installing read out DTC
sensor (B33) memory and erase. Check
for proper function
5 Remove mounting plate
(3) from vehicle floor and
turn
6 Bend tongue (5a) on Use screwdriver
bracket (5) in direction of
arrow
7 Remove ATA inclination Installation: Rebend
sensor (B33) from mount tongue (5). The ATA
(5) toward center of inclination sensor (B33)
vehicle should catch again when
installing
REMOVE/INSTALL INTERIOR MOTION SENSOR TRANSMITTER/RECEIVER - AR80.50-P-9820F
MODEL 203, 210.0 as of 1.6.98, 210.2 as of 1.6.99, 215, 220 with code (882b) Interior motion sensor (only
with anti-theft alarm system)
Shown on model 210.0

Fig. 60: Identifying Interior Motion Sensor Transmitter/Receiver Location
Remove/Install
1 Unclip interior motion On model 203.7 with
sensor transmitter/ receiver code (413) panorama sliding
(A26/14) from headliner roof, only the side arrests are
(arrows) present
Fig. 61
Installation: If it is not
possible to clip in the
interior motion sensor
transmitter/receiver
(A26/14), because the
headliner sags, insert
spacers, e.g. foam rubber
elements between headliner
and roof (except model
203.7).
2 Remove electrical connector
from interior motion sensor
(A26/14)
Fig. 61: Identifying Assembly Wedge (110 589 03 59 00)
REMOVING AND INSTALLING ATA ALARM SIGNAL SIREN - AR80.50-P-9840M

Fig. 62: Identifying ATA Alarm Signal Siren Remove/Install Components - Illustrated On Model 220
1 Remove inner fender in AR88.10-P-1300M
front fender
2 Unscrew screw (3)
3 Unscrew nuts (2) and
loosen mount (4)
4 Disconnect connector (1) Before disconnecting
from alarm signal siren the siren ensure that the
with additional battery anti-theft alarm (ATA) is
(H3/1) deactivated because
otherwise the siren will
be triggered (internal
power supply from
rechargeable battery)
REMOVE/INSTALL ELECTRONIC IGNITION SWITCH CONTROL UNIT - AR80.57-P-1000M
MODEL 215, 220
Shown on model 220

Fig. 63: Identifying Electronic Ignition Switch Control Unit Remove/Install Components - Shown On
Model 220
Removal/installation
Risk of explosion caused by No fire, sparks, open AS54.10-Z-0001-01A
oxyhydrogen gas. Risk of flames or smoking.
poisoning and caustic burns Wear acid-resistant
caused by swallowing battery gloves, clothing and
acid. Risk of injury with caustic goggles. Pour battery
burns to eyes and skin from acid only into suitable
battery electrolyte or from and appropriately
handling damaged lead-acid marked containers.
batteries
1 Disconnect battery ground cable AR54.10-P-0003I
Notes on battery All models AH54.10-P-0001-01A
2 Remove cover on center console Model 215 AR68.20-P-2350N
Model 220 up to AR68.20-P-2350M
31.8.02
3 Remove operating and display Model 220 up to AR82.85-P-7472I
unit with control unit 31.8.02 with CODE
(352a)
COMAND operating
and display system
Model 220 as of 1.9.02 AR82.85-P-1000M
4 Move selector lever to position
"P"
5 Remove electronic ignition key
6 Unscrew rosette (1) with special *210589000700
tool
7 Remove electronic ignition
switch (N73) toward rear and
remove through cover opening
for center console.
8 Remove shift-lock control cable
(2) from electronic ignition
switch (N73)
9 Disconnect electrical connectors
(3) from electronic ignition
switch (N73)
10 Install in the reverse order Installation: When
replacing the
electronic ignition
switch (N73) program
according to
programming
instructions included
in the programming
station
Fig. 64: Identifying Claw-Type Wrench For Rosette On Ignition Switch
RETROFITTING & CONVERSION

RETROFITTING CLOSING ASSIST - AN80.40-P-0001M
MODEL 220
Figure shows left front door

Fig. 65: Identifying Retrofitting Closing Assist Components
1 Remove door locks (1) Installation: Replace
from front doors removed door locks with
new locks and connect
connector (arrows) to
door control modules
(N69/1, N69/2)
AR72.10-P-4011M
2 Remove door locks (1) Installation: Replace
from rear doors removed door locks with
new locks and connect
connector (arrows) to
control modules (N69/3,
N69/4)
AR72.12-P-2510M
Checking
4 Adapt control modules Adapt the following
for closing assist with control modules:
STAR diagnosis
 EIS closing assist
 PSE closing assist
5 Check closing assist for
proper function
6 Enter SA CODE 883 in
FDOK
KG 72 Left front door lock 1
KG 72 Right front door lock 1
KG 73 Left rear door lock 1
KG 73 Right rear door lock 1
RETROFIT ANTITHEFT ALARM SYSTEM (ATA) - AN80.50-P-0001
Retrofit antitheft alarm system (ATA) - AN80.50-P-0001M
MODEL 220
Fig. 66: Identifying Retrofit Antitheft Alarm System (ATA) Components (1 Of 6) - Model 220
Removing
1 Connect no load current
retention unit
AR54.10-P-1030-01I
2 Disconnect battery ground
cable
AR54.10-P-0003I
3.1 Remove rear seat cushion
AR91.12-P-1020MA
3.2 Install individual seats with code 401, right
side only
AR91.12-P-1020M
4.1 Remove seat adjustment with code 401, right
mechanism on rear seat side only
AR91.12-P-1520M
5 Unscrew bolts (6) and Do not disconnect
nuts (7), remove assembly electrical wiring plugs.
plate (5) from vehicle
floor and fold down
toward front.
6 Unscrew nuts (9) and Do not disconnect
remove rear fuse and relay electrical wiring plugs.
module (K40/5) from
vehicle floor
7 Remove upper control
panel control unit (N72/1)
AR54.21-P-1262M
8.1 Remove switch group (11) Only with code 220
in direction of arrow and Parktronic system or
disconnect electrical code 540 Automatic rear
connector (10). roller blind
Switch group no
longer required
9 Remove left front floor
covering.
AR68.20-P-2050M
10 Remove fender liner in
left-hand front fender
AR88.10-P-1300M
engine hood catch (12).
Install
12 Clip ATA engine hood ATA engine hood
switch (S62) into engine switch (S62) should
hood catch (12). arrest correctly (see
arrows).
13 Connect electrical Fasten connector (13)
connector (13) for ATA with cable strap (15).
engine hood switch (S62)
to present plug.
14 Screw bolts (14) into *BA88.40-P-1004-01D
engine hood catch.
15 Retrofit bracket (2) with AN80.50-P-0001-02M
alarm signal horn and
additional battery (H3/1).
16 Clip new switch group
(11) with tow-away
protection/ATA status
indicator inclination
sensor switch (S85/3) into
upper control panel
control unit (N72/1) and
connect to electrical
connector (10).
17 Install upper control panel Use new trim strip (4)
control module (N72/1) according to new switch
group (11).
AR54.21-P-1262M
18 Insert relay for tow-away
protection (K40/5kR) and
fuses (F4f51, F4f77).
Fuse assignment, as-built GF54.15-P-1256I
configuration
Relay assignment, as-built GF54.15-P-1257I
configuration
19 Install rear fuse and relay
module (K40/5) and screw
in nuts (9).
20 Loosen electrical lines (8)
from wiring harness.
21 Install assembly plate (5)
and screw in bolts (6) and
nuts (7).
22 Push ATA inclination Note direction of
sensor (B33) onto installation.
assembly plate (5) in
direction of arrow and
connect line (8) to ATA
inclination sensor (B33).
23 Retrofitting interior See installation AN80.50-P-0100M
protection instructions.
24 Install remaining parts Step 10, 9, 4, 3, 2.
onto vehicle
Checking
25 Adapt control unit for Adapt following
ATA system with STAR control units:
diagnosis.
 SAM VL- EDW
 EZS - ASS
26 Check ATA system for

proper function
27 Amend special equipment
code 551 in FDOK
ENGINE HOOD
BA88.40-P-1004-01D Bolt to engine hood catch Nm 10

kg99 Fender bolt 3
kg54 Relays 1
kg54 Fuse 5A 1
kg54 Fuse 40A 1
kg54 Cable tie 1
kg82 Anti-towing inclination sensor 1
kg82 Hood contact 1
kg82 Siren 1
kg82 Bracket (for siren) 1
kg01 Bolt (siren to bracket) 1
kg82 Tow-away protection switch 1
according to equipment variant
and color
kg 68 Wooden trim strip according to 1
equipment variant
Retrofitting alarm siren - AN80.50-P-0001-02M
Models 215, 220
1. Position holder of alarm signal siren with additional battery in left wheelhousing on the longitudinal
member, center and transfer hole pattern of holder.
2. Drill the marked holes (6) with Ø 6 mm.
Treat the newly drilled holes with corrosion protection.
Fig. 72: Identifying Sealing Plug
3. Clip open cable duct (5) at the front left and take out existing cable (4).
4. Press out sealing plug (8)
Sealing plug (8) is no longer used.

Fig. 73: Identifying Cable Duct, Sealing Plug And Existing Cable
5. Route cable (4) through existing hole and seal with rubber grommet (7).
Fig. 74: Identifying Cable And Rubber Grommet
6. Bolt alarm signal siren with additional battery (H3/1) tight to holder (2) with bolt (3).
7. Attach holder (2) in wheelhousing with fender screws (1).
8. Fit together electrical connection (4) to alarm signal siren with additional battery (H3/1).
Fig. 75: Identifying Fender Screws, Bolt, Electrical Connection And Battery
Retrofit antitheft alarm system (ATA) - AN80.50-P-0001N
MODEL 215 up to 31.8.02

Fig. 76: Identifying Retrofit Antitheft Alarm System (ATA) Components (1 Of 6) - Model 215 Up To
31.8.02
31.8.02
Fig. 78: Tightening Identifying Retrofit Antitheft Alarm System (ATA) Components (3 Of 6) - Model 215
Up To 31.8.02
31.8.02
31.8.02
31.8.02
Removing
1 Connect no load current *WH58.30-Z-1012-09A
retention unit
2 Disconnect battery
ground cable
AR54.10-P-0003I
3 Remove rear seat cushion
AR91.12-P-1020N
4 Unscrew bolts (7) and Do not disconnect
nuts (6), remove electrical wiring plugs.
assembly plate (5) from
vehicle floor and fold
down toward front.
5 Unscrew nuts (9) and Do not disconnect
remove rear fuse and electrical wiring plugs.
relay module (K40/5)
from vehicle floor
panel control unit.
AR54.21-P-1262N
If the cutout for
TS/IMS switch (N72/1s7)
is not present, send only
center console cover to
manufacturer: ?
Order for boring hole OF68.00-P-3000-01A
pattern, form sheet.
7 Remove switch group Switch group is a part
(11) in direction of arrow eliminated
and disconnect electrical
connector (10).
8 Remove front floor Left.
covering
AR68.20-P-2050M
9 Remove finder liner in Left.
front fender
AR88.10-P-1300M
left front engine hood
catch (12).
Install
11 Clip ATA engine hood ATA engine hood
switch (S62) into left switch (S62) should arrest
front engine hood catch correctly (see arrows).
(12).
12 Connect present electrical Fasten connector with
connector (13) to ATA cable straps (15).
engine hood switch
(S62).
13 Screw bolts (14) into left Bolt to engine hood *BA88.40-P-1004-01D
front engine hood catch catch.
(12).
14 Retrofit alarm siren Install alarm signal AN80.50-P-0001-02M
horn with additional
battery (H3/1) together
with alarm signal horn
bracket (2).
(11) with TS/IMS switch
(N72/1s7) onto upper
control panel (N72/1) in
connect to electrical
connector (10).
16 Install upper control
panel control module
(N72/1)
AR54.21-P-1262N
17 Insert tow-away
protection relay
(K40/5kR) and fuse 51
(K40/5f51), fuse 77
(F4f77)
Fuse assignment, as-built GF54.15-P-1256I
configuration
Relay assignment, as- GF54.15-P-1257I
built configuration
18 Install rear fuse and relay
module (K40/5) and
fasten wit nuts (9).
19 Loosen line tieout with
electrical coupling (8)
from wiring harness.
20 Install assembly plate (5)
and fasten with bolts (7)
and nuts (6).
21 Push ATA inclination Note direction of
sensor (B33) onto installation.
assembly plate (5) in
connect electrical
coupling (8) to ATA
inclination sensor (B33).
22 Retrofitting interior with CODE (551a) Anti- AN80.50-P-0100N
protection theft alarm system
(ATA).
23 Install remaining parts
onto vehicle
Checking
24 Control unit adaptation Perform following
for ATA system with control unit adaptations:$
STAR diagnosis.
 SAM VL-EDW.
 EZS-ASS.
25 Check ATA system for
proper function
26 When modifying the Anti-theft alarm
package, subsequently (ATA) code 551a.
enter code or designation
of corresponding special
equipment on vehicle
data card and FDOK
ENGINE HOOD
BA88.40-P-1004-01D Bolt to engine hood catch Nm 8

Number Designation
WH58.30-Z-1012-09A Quiescent current retention unit

kg99 Fender bolt 3
kg54 Relays 1
kg54 Fuse 5A 1
kg54 Fuse 40A 1
kg54 Cable tie 1
kg82 Anti-towing inclination sensor 1
kg82 Hood contact 1
kg82 Siren 1
kg82 Bracket (for siren) 1
kg01 Bolt (siren to bracket) 1
kg82 TS/IMS switch according to 1
equipment variant and color
group 68 Wooden trim strip according to 1
equipment variant and
requirements.
group 68 Center console cover as required 1
RETROFITTING INTERIOR MOTION SENSOR - AN80.50-P-0100
Retrofitting interior motion sensor - AN80.50-P-0100M
MODEL 220 with CODE (551a) Anti-theft alarm (ATA)
Fig. 82: Identifying Retrofitting Interior Motion Sensor Components (1 Of 3) - Model 220
1 Connect quiescent current
retention unit
AR54.10-P-1030-01I
2 Disconnect ground lead
from battery
AR54.10-P-0003I
(N72/1)
AR54.21-P-1262M
4 Remove switch group (1) Switch group is no
in direction of arrow and longer used.
disconnect electrical
connector (2)
5 Remove roof paneling Lay headliner down
on seats.
AR68.30-P-4300M
Installation
6 Install interior motion AN80.50-P-0100-01M
sensor transmitter and
receiver (A26/14)
7 Install roof paneling
AR68.30-P-4300M
(1) with ATA anti-towing
sensor/interior motion
sensor/status indicator
(S85/4) into upper control
(N72/1) and connect with
electrical connector (1)
9 Install upper control
(N72/1)
AR54.21-P-1262M
10 Assemble vehicle Work step 2
Checking
11 Adapt control modules Adapt the following
for interior motion sensor control modules:
with STAR diagnosis
 EIS interior motion
sensor
12 Check interior motion
sensor for proper function
13 Enter SA code 882 in
FDOK

KG82 Anti-towing sensor and interior 1
motion sensor switch according to
equipment version and color
KG82 Sensor cap 1
KG82 Sensor each depending on 1
equipment version and color
Retrofitting transmitter and receiver - AN80.50-P-0100-01M
Models 215, 220
1. Mark dimension (A) from recess of overhead control panel to interior protection transmitter and receiver
unit in model 215 approx. 545 mm and in model 220
approx. 660 mm on inside of roof trim (1).

Fig. 85: Identifying Dimension Mark On Overhead Control Panel
2. Fit inner frame (2) onto roof trim (1) and center at the side.
Position inner edge of inner frame (2) to dimension A, the wider cutout of the inner frame must be
pointing in direction of travel.
3. Transfer inner contour of inner frame (2) to roof trim (1).

4. Cut out roof trim (1) to match marked contour (3).
Cut out the corners slightly larger in order to ensure that the interior protection transmitter and receiver
unit (A26/14) can be installed free of stress.
5. Insert inner frame (2) from above into roof trim (1) and turn over retaining arm (4) from below.
Fig. 86: Fitting Inner Frame Onto Roof Trim And Center At Side
Models without sliding/tilting roof (code 414)
6.1 Detach cable (5) from wiring harness and connect to interior protection transmitter and receiver unit
(A26/14).
Models with sliding/tilting roof (code 414)
6.2 Detach cable (5) from wiring harness in area of vanity mirror and connect to interior protection
transmitter and receiver unit (A26/14).
Fig. 87: Identifying Cable, Inner Frame And Interior Protection Transmitter And Receiver Unit
7 Clip interior protection transmitter and receiver unit (A26/14) into inner frame (2).
8 Attach cable (5) to roof trim (1) with self-adhesive felt strips.
Retrofit interior motion sensor - AN80.50-P-0100N
MODEL 215 up to 31.8.02 with code (551a) Anti-theft alarm system (ATA)
Fig. 88: Identifying Retrofit Interior Motion Sensor Components (1 Of 2) - Model 215
Fig. 89: Identifying Retrofit Interior Motion Sensor Components (2 Of 2) - Model 215
Remove/Install
1 Connect quiescent current *WH58.30-Z-1012-
retention device 09A
2 Disconnect ground cable of
battery
AR54.10-P-0003I
3 Remove cover on center
console
AR68.20-P-2350N
If recess clearance for
TS/IRS switch (N72/1s7) is
not present, send center
console cover to
manufacturer for cutting: ?
Request form for machining OF68.00-P-3000-01A
hole
4 Remove upper control panel
control module
AR54.21-P-1262N
5 Remove switch group (11) Switch group (11) is a
from upper control panel part eliminated and is
control module (N72/1) in replaced with new switch
direction of arrow and group with TS/IRS switch
disconnect wiring connector (N72/1s7).
(10)
6 Remove headliner Lay headliner down on
seats
AR68.30-P-4300N
Install
7 Retrofit transmitter/receiver Interior motion sensor, AN80.50-P-0100-
transmitter/receiver 01M
(A26/14).
8 Install headliner
AR68.30-P-4300N
9 Install upper control panel Use new switch group
control module (11) with TS/IRS switch
(N72/1s7).
AR54.21-P-1262N
10 Fit remaining parts to
vehicle
Inspect
11 Perform control module Perform following
adaptation of interior motion control modules adaptation:
sensor with STAR
DIAGNOSIS.  EIS interior motion
sensor
12 Check infrared interior
monitoring for proper
function
13 Enter special equipment on Infrared interior
vehicle data card and in on- monitoring (only with ATA)
line vehicle data card code 882b.

Number Designation

KG82 TS/IRS switch depending on 1
series and color
KG82 Sensor cover 1
KG82 Sensor depending on series and 1
color
HVAC
Climate Control - Testing & Repair - 215 & 220 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9112AB
ENGINE 112
Correct oil level in air ENGINE 104, 111, 112, AR83.55-P-5250E

conditioning system when 113, 137, 155, 601, 602,
replacing AC compressor 604, 605, 606 ...
Correct oil level in air ENGINE 111, 112, 113, AR83.55-P-5250P
conditioning system when 271, 611, 612 ...
replacing refrigerant
compressor
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 ...
Removing and installing ENGINE 112.947 in AR83.55-P-5300GA
A/C compressor MODEL 170
Remove and install ENGINE 112 in MODEL AR83.55-P-5300GH
refrigerant compressor 163 with CODE (580) Air
conditioning or Tempmatic
for USA
Remove/install refrigerant ENGINE 113, 137 in AR83.55-P-5300M
compressor MODEL 215 ENGINE
112, 113, 137, 613 in
MODEL 220
Remove and install ENGINE 112 ... AR83.55-P-5300PV
refrigerant compressor
Remove/install refrigerant ENGINE 112, 113, 642, AR83.55-P-5300T
compressor 646, 647 ...
ENGINE 113
Correct oil level in air ENGINE 104, 111, 112, AR83.55-P-5250E
conditioning system when 113, 137, 155, 601, 602,
replacing AC compressor 604, 605, 606 ...
Correct oil level in air ENGINE 113, 156, 272, AR83.55-P-5250GZ
replacing AC compressor
Correct oil level in air ENGINE 111, 112, 113, AR83.55-P-5250P
replacing refrigerant
compressor
Remove/install refrigerant ENGINE 113 ... AR83.55-P-5300AC
compressor
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 refrigerant ENGINE 113, 156, 272, AR83.55-P-5300GZ
compressor 642 ...
Remove/install refrigerant ENGINE 113, 137 in AR83.55-P-5300M
compressor MODEL 215 ENGINE
112, 113, 137, 613 in
MODEL 220
Remove/install refrigerant ENGINE 113 ... AR83.55-P-5300Q
compressor
Remove/install refrigerant ENGINE 113.9 in AR83.55-P-5300R
compressor MODEL 230.475
Remove/install refrigerant ENGINE 113, 156, 272, AR83.55-P-5300RT
compressor 642 ...
Remove/install refrigerant ENGINE 112, 113, 642, AR83.55-P-5300T
compressor 646, 647 ...
Removing and installing ENGINE 113.967 in AR83.55-P-5300TY
A/C compressor MODEL 219.375
Remove/install refrigerant ENGINE 113, 271, 272 ... AR83.55-P-5300V
compressor
ENGINE 137
Correct oil level in air conditioning system ENGINE 104, 111, 112, 113, 137, 155, 601, AR83.55-P-
when replacing AC compressor 602, 604, 605, 606 ... 5250E
ENGINE 113, 137 in MODEL 215
AR83.55-P-
Remove/install refrigerant compressor ENGINE 112, 113, 137, 613 in MODEL
5300M
220
TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9215AA
MODEL 215
Removing and installing air collector AR83.10-P-

MODEL 215, 220
box and water collector 9998M
AR83.25-P-
Remove and install heat exchanger MODELS 215, 220
1100M
Removing and installing heater core AR83.25-P-
MODEL 215, 220
temperature sensor 1110M
Removing and installing front
AR83.25-P-
duovalve/ coolant circulation pump MODEL 215, 220
1160M
compact unit
Removing and installing blower AR83.25-P-
MODEL 215, 220
motor 1200M
Removing and installing electronic AR83.25-P-
MODEL 215, 220
blower regulator 1220M
AR83.25-P-
Removing and installing air inlet MODEL 215, 220
1401M
Removing and installing water AR83.25-P-
Models 215, 220
deflector above wiper system 1406M
Check air conditioning system for MODEL 169, 171, 199, 203, 209, 211, 215, 216, AR83.30-P-
leakage 219, 220, 221, 230, 240, 245, 461, 463 ... 1761P
leakage 219, 220, 221, 230, 245, 251, 461, 463 ... 1761PP
MODEL 164, 169, 171, 199, 203, 209, 211, 215, AR83.30-P-
Repair refrigerant circuit
216, 219, 220, 221, 230, 240, 245, 251, 461, 463 ... 1782A
Removing and installing incremental
AR83.30-P-
adjustment motor electronic control MODEL 215, 220
2005M
module
Removing and installing fresh AR83.30-P-
MODEL 215, 220
air/recirculated air flap actuator motor 2010M
Removing and installing left defroster AR83.30-P-
MODEL 215, 220
flap actuator motor 2030M
Removing and installing right AR83.30-P-
MODEL 215, 220
defroster vent flap actuator motor 2040M
Removing and installing left center AR83.30-P-
MODEL 215, 220
blend flap actuator motor 2050M
Removing and installing right center MODEL 215, 220 AR83.30-P-
vent blend flap actuator motor 2060M
MODEL 215, 220
vent diverter flap actuator motor 2070M
Removing and installing right center AR83.30-P-
MODEL 215, 220
Removing and installing actuator AR83.30-P-
MODEL 215, 220
motor for activated charcoal filter flap 2090M
Removing and installing left footwell AR83.30-P-
MODEL 215, 220
MODEL 215, 220
footwell flap actuator motor 2110M
AR83.30-P-
Remove/install AC housing Models 215, 220
5200M
Correcting oil level in air
AR83.30-P-
conditioning following repair or slow MODEL 163, 202, 208, 210, 215, 220 ...
5251E
refrigerant loss
Correct oil level in air conditioning
MODEL 169, 171, 203, 209, 211, 215, 216, 219, AR83.30-P-
system in the event of repair or slow
220, 221, 230, 245 ... 5251P
refrigerant loss
Correcting oil level in air AR83.30-P-
MODEL 163, 202, 208, 210, 215, 220 ...
conditioning after replacing parts 5252E
Correct oil level in air conditioning MODEL 169, 171, 199, 203, 209, 211, 215, 216, AR83.30-P-
system after replacing parts 219, 220, 221, 230, 240, 245 ... 5252P
Correcting oil level in air
AR83.30-P-
conditioning after system suddenly MODEL 163, 202, 208, 210, 215, 220 ...
5253E
loses all refrigerant
Correct oil level in air conditioning AR83.30-P-
MODEL 199, 203, 209, 215, 220, 240
system if system is suddenly drained 5253P
Removing and installing refrigerant AR83.30-P-
MODEL 215, 220
pressure sensor 5430M
Removing and installing expansion AR83.30-P-
MODEL 215, 220
valve 5520M
AR83.30-P-
Removing and installing evaporator MODELS 215, 220
5540M
MODEL 124, 129, 140, 168, 170, 201, 202, 208, AR83.30-P-
Check evaporator for leakage
210, 215, 220, 414, 461, 463 ... 5550A
MODEL 164, 169, 171, 203, 209, 211, 215, 219, AR83.30-P-
Cleaning the evaporator
220, 221, 230, 245, 251 ... 5555T
MODEL 215, 220
Removing and installing AR83.30-P-
MODEL 215, 220
receiver/drier 6520M
MODELS 215.379, 220.179 with ENGINE AR83.30-P-
Install/remove condenser
275.980 6540IM
MODELS 215.373 /374 /375 /376 /378, 220 AR83.30-P-
(except, 220.179) 6540M
Removing and installing evaporator AR83.30-P-
MODEL 215, 220
Remove/install pushbutton control AR83.40-P-
MODEL 215, 220 up to 31.8.02
module 6350M
AR83.40-P-
Removing and installing sun sensor MODEL 215, 220
6720M
MODEL 215, 220
multifunction sensor 6730M
Removing, installing stationary heater AR83.70-P-
MODEL 215, 220 ...
antenna 0002M
Removing, installing Telestart AR83.70-P-
MODEL 215, 220 ...
receiver 0003M
AR83.70-P-
Testing Telestart transmitter MODELS 215, 220 Telestart T61
0005I
Check emission level, adjust if AR83.70-P-
MODEL 203, 209, 211, 215, 220, 240 ...
necessary 1177M
AR83.70-P-
Remove/install heater MODEL 215, 220 ...
5302MA
AR83.70-P-
5302MB
Remove/install combustion air blower MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
unit CODE (228) Stationary heater 5555C
Removing and installing fuel MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
metering pump heater or retrofitted stationary heater 5652M
Remove/install coolant circulation MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
pump heater or retrofitted stationary heater 5700M
MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
Remove/install burner insert
CODE (228) Stationary heater 5772C
Remove/install burner insert with MODEL 129, 163, 168, 170, 202, 203, 209, 210, AR83.70-P-
glow pin 211, 215, 219, 220, 230, 240 ... 5773A
Remove/install control unit/heat MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
exchanger unit CODE (228) Stationary heater 5935C
MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
Removing and installing check valve
heater 6015M
TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9220AA
MODEL 220
Removing and installing air collector AR83.10-P-

MODEL 215, 220
box and water collector 9998M
AR83.25-P-
Remove and install heat exchanger MODELS 215, 220 1100M
Removing and installing heater core AR83.25-P-
MODEL 215, 220
Removing and installing front
AR83.25-P-
duovalve/ coolant circulation pump MODEL 215, 220
1160M
compact unit
AR83.25-P-
Removing and installing blower motor MODEL 215, 220
1200M
Removing and installing electronic AR83.25-P-
MODEL 215, 220
blower regulator 1220M
AR83.25-P-
Removing and installing air inlet MODEL 215, 220
1401M
Removing and installing water AR83.25-P-
Models 215, 220
deflector above wiper system 1406M
leakage 219, 220, 221, 230, 240, 245, 461, 463 ... 1761P
leakage 219, 220, 221, 230, 245, 251, 461, 463 ... 1761PP
MODEL 164, 169, 171, 199, 203, 209, 211, 215,
AR83.30-P-
Repair refrigerant circuit 216, 219, 220, 221, 230, 240, 245, 251, 461,
1782A
463 ...
Removing and installing incremental
AR83.30-P-
adjustment motor electronic control MODEL 215, 220
2005M
module
Removing and installing fresh AR83.30-P-
MODEL 215, 220
air/recirculated air flap actuator motor 2010M
Removing and installing left defroster AR83.30-P-
MODEL 215, 220
MODEL 215, 220
defroster vent flap actuator motor 2040M
MODEL 215, 220
blend flap actuator motor 2050M
MODEL 215, 220
vent blend flap actuator motor 2060M
MODEL 215, 220
MODEL 215, 220
Removing and installing actuator AR83.30-P-
MODEL 215, 220
motor for activated charcoal filter flap 2090M
Removing and installing left footwell AR83.30-P-
MODEL 215, 220
Removing and installing right footwell AR83.30-P-
MODEL 215, 220
AR83.30-P-
Remove/install AC housing Models 215, 220
5200M
Correcting oil level in air conditioning
AR83.30-P-
following repair or slow refrigerant MODEL 163, 202, 208, 210, 215, 220 ...
5251E
loss
Correct oil level in air conditioning
MODEL 169, 171, 203, 209, 211, 215, 216, 219, AR83.30-P-
system in the event of repair or slow
220, 221, 230, 245 ... 5251P
refrigerant loss
Correcting oil level in air conditioning AR83.30-P-
MODEL 163, 202, 208, 210, 215, 220 ...
after replacing parts 5252E
Correct oil level in air conditioning MODEL 169, 171, 199, 203, 209, 211, 215, 216, AR83.30-P-
system after replacing parts 219, 220, 221, 230, 240, 245 ... 5252P
Correcting oil level in air conditioning
AR83.30-P-
after system suddenly loses all MODEL 163, 202, 208, 210, 215, 220 ...
5253E
refrigerant
Correct oil level in air conditioning AR83.30-P-
MODEL 199, 203, 209, 215, 220, 240
system if system is suddenly drained 5253P
MODEL 215, 220
pressure sensor 5430M
Removing and installing expansion AR83.30-P-
MODEL 215, 220
valve 5520M
AR83.30-P-
Removing and installing evaporator MODELS 215, 220
5540M
MODEL 124, 129, 140, 168, 170, 201, 202, 208, AR83.30-P-
Check evaporator for leakage
210, 215, 220, 414, 461, 463 ... 5550A
MODEL 164, 169, 171, 203, 209, 211, 215, 219, AR83.30-P-
Cleaning the evaporator
220, 221, 230, 245, 251 ... 5555T
MODEL 215, 220
AR83.30-P-
Removing and installing receiver/drier MODEL 215, 220
6520M
MODELS 215.379, 220.179 with ENGINE AR83.30-P-
275.980 6540IM
MODELS 215.373 /374 /375 /376 /378, 220 AR83.30-P-
(except, 220.179) 6540M
Removing and installing evaporator AR83.30-P-
MODEL 215, 220
MODEL 215, 220 up to 31.8.02
module 6350M
module 6350MA
AR83.40-P-
Removing and installing sun sensor MODEL 215, 220
6720M
Removing and installing multifunction MODEL 215, 220 AR83.40-P-
sensor 6730M
Removing, installing rear air MODEL 220 with CODE (582) Rear air AR83.50-P-
conditioning refrigerant shutoff valve conditioning 9000M
AR83.50-P-
Remove and install rear AC housing MODEL 220
9020M
AR83.50-P-
Remove and install rear AC housing MODELS 220.875 /878
9020MP
Removing, installing rear air AR83.50-P-
MODEL 220
conditioning blower motor 9040M
Remove/install stepper motor of center
MODEL 220 with CODE (582) Rear air AR83.50-P-
nozzle/footwell flap of rear air
conditioning 9060M
conditioning
Removing and installing rear air
conditioning pushbutton control
conditioning 9070M
module
conditioning system evaporator
conditioning 9080M
temperature sensor
conditioning system heat exchanger
conditioning 9090M
temperature sensor
Removing, installing rear air MODEL 220 with CODE (582) Rear air AR83.50-P-
conditioning evaporator conditioning 9100M
Remove and install heat exchanger for MODEL 220 with CODE (582) Rear air AR83.50-P-
rear air conditioning conditioning 9110M
Removing and installing rear blower MODEL 220 with CODE (582) Rear air AR83.60-P-
regulator conditioning 9010M
Removing and installing rear
duovalve/coolant circulation pump
conditioning 9050M
compact unit
Removing, installing stationary heater AR83.70-P-
MODEL 215, 220 ...
antenna 0002M
AR83.70-P-
Removing, installing Telestart receiver MODEL 215, 220 ...
0003M
AR83.70-P-
Removing, installing Telestart receiver MODEL 220 ...
0003MA
AR83.70-P-
Testing Telestart transmitter MODELS 215, 220 Telestart T61
0005I
MODEL 163, 168, 170, 202, 203, 208, 209, 210, AR83.70-P-
Check Telestart transmitter
211, 220, 463 ... 0005IA
Check emission level, adjust if AR83.70-P-
MODEL 203, 209, 211, 215, 220, 240 ...
necessary 1177M
Removing and installing electric AR83.70-P-
MODEL 220 with ENGINE 613.960
heater booster control module 5300M
AR83.70-P-
5302MA
AR83.70-P-
5302MB
Remove/install combustion air blower MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
unit CODE (228) Stationary heater 5555C
Removing and installing fuel metering MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
Remove/install coolant circulation MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
Remove/install burner insert
CODE (228) Stationary heater 5772C
Remove/install burner insert with glow MODEL 129, 163, 168, 170, 202, 203, 209, 210, AR83.70-P-
pin 211, 215, 219, 220, 230, 240 ... 5773A
Remove/install control unit/heat MODEL 129 as of 1.6.97, 215, 220, 240 with AR83.70-P-
exchanger unit CODE (228) Stationary heater 5935C
MODELS 215, 220 with CODE (228) Stationary AR83.70-P-
Removing and installing check valve
heater 6015M
REMOVING AND INSTALLING AIR COLLECTOR BOX AND WATER COLLECTOR - AR83.10-P-
9998M
MODEL 215, 220
Fig. 1: Identifying Air Collector Box And Water Collector Remove/Install Components (1 Of 2)
Fig. 2: Identifying Air Collector Box And Water Collector Remove/Install Components (2 Of 2)
AR82.30-P-
1 Remove wiper arms
6100M
2 Remove spreading rivets (3)
3 Pull out water deflector (2)
Disconnect connector from
4
multifunction sensor (B31x1)
5 Unscrew nuts (4)
When removing and installing air collector box
Remove air collector box and
6 and water collector (1), ensure that main air flap
water collector (1)
(5) is not damaged
REMOVE AND INSTALL HEAT EXCHANGER - AR83.25-P-1100M
MODELS 215, 220

Fig. 3: Identifying Heat Exchanger Remove/Install Components (1 Of 2)
Fig. 4: Identifying Heat Exchanger Remove/Install Components (2 Of 2)
Remove/install
Do not open cooling system unless coolant
Risk of injury to skin and eyes from temperature is below 90 °C. Open cap slowly
AS20.00-
scalding with hot coolant which and release the pressure. Do not pour coolant
Z-0001-
splashes out. Risk of poisoning from into beverage bottles.
01A
swallowing coolant. Wear protective gloves, protective clothing
and eye protection.
Do not carry out any welding work on the
Risk of explosion from welding or
closed air conditioning system or in the
soldering work on closed air
surrounding area. No smoking or open flames.
conditioning system. Risk of AS83.00-
Wear eye protection and protective gloves.
poisoning from inhaling overheated Z-0001-
Work only in well ventilated areas. Carry out
refrigerant vapors. Risk of injury 01A
repair work on the air conditioning system
from skin and eye contact with liquid
circuit only after the system has been
refrigerant.
discharged.
AH83.30-
Conduct if air conditioning system is
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-
Notes on handling refrigerant R134a All models with R134a refrigerant N-0003-
01A
Replenish extracted quantity of
compressor oil in the refrigerant circuit (fresh
oil) when filling the air conditioning system.
1 Drain air conditioning (recycle)
Installation: Evacuate air conditioning
system, fill, inspect for leaks.
Before filling the air conditioning system: ?
AR83.30-
Replace receiver/drier
P-6520M
AR83.30-
2 Remove AC housing
P-5200M
3 Unclip clamps (4)
4 Unscrew screws (2)
5 Take off cover (3)
Detach retaining clamps (5) on
6
heating water flow pipe
Remove screws (6) of heating water
7
flow pipe's bracket
Remove screws (7) of heating water
8
flow pipe's guide
Pull out heat exchanger (8) with the Clean heater housing from inside, if
9
heating water pipes necessary remove escaping coolant.
Detach socket yoke (9), remove Fit new O-rings and replace socket
10
heating water flow pipe (c) yoke.
Remove bracket screw (10) and
11 Fit new O-rings.
detach heating water flow pipe (d)
REMOVING AND INSTALLING HEATER CORE TEMPERATURE SENSOR - AR83.25-P-1110M
MODEL 215, 220
Fig. 5: Identifying Heater Core Temperature Sensor Remove/Install Components
Model AR68.20-P-
1 Remove cover on center console (2)
215 2350N
Model AR68.20-P-
220 2350M
2 Disconnect connectors (1)
Pull left heater core temperature sensor (B10/2) out of A/C
3
housing
Pull right heater core temperature sensor (B10/3) out of A/C
4
housing
REMOVING AND INSTALLING FRONT DUOVALVE/COOLANT CIRCULATION PUMP

COMPACT UNIT - AR83.25-P-1160M
MODEL 215, 220

Fig. 6: Identifying Front Duovalve/Coolant Circulation Pump Compact Unit Remove/Install Components
Open cooling system only when coolant temperature
Danger of severe burns to
is below 90 °C. Open cover slowly and release
skin and eyes from hot AS20.00-Z-
pressure. Do not fill beverage containers with
coolant spewing out. Coolant 0001-01A
coolant. Wear protective gloves, protective clothing
is toxic when swallowed
and protective goggles.
Release pressure in cooling For this purpose, turn radiator cap to catch "1"
1
system and close again
AR82.30-P-
2 Remove wiper system
6400M
Disconnect connector (5)
3
from duovalve
Disconnect connector
4 (M13x1) from coolant
circulation pump
Slide rubber mount (1) out of
5
retaining plate (2)
Attach clamps to coolant
6 Fig. 7
hoses (3)
Release hose clamps (4), pull
7
off coolant hoses
Remove heater supply unit
8
(A31)
9 Install in opposite order Installation:

After completing work correct coolant level and
check for leakage
REMOVING AND INSTALLING BLOWER MOTOR - AR83.25-P-1200M
MODEL 215, 220
Fig. 8: Identifying Blower (A32m1) Location - Model 220
Remove cover below instrument AR68.10-P-
1 Model 215
panel on right 1520N
AR68.10-P-
Model 220
1520M
2 Disconnect blower connector
4 Remove cover (2)
Disconnect connector from blower
5 regulator (3)
7 Remove blower regulator (A32n1)
Do not lay blower motor (A32m1)
9 Remove blower motor (A32m1)
down on impeller
REMOVING AND INSTALLING ELECTRONIC BLOWER REGULATOR - AR83.25-P-1220M
MODEL 215, 220
Fig. 9: Identifying Blower Regulator (A32n1) Location - Model 220
1 Remove cover below instrument panel on right Model 215 AR68.10-P-1520N
Model 220 AR68.10-P-1520M
2 Disconnect blower connector
4 Remove cover (2)
5 Disconnect connector from blower regulator (3)
7 Remove blower regulator (A32n1)
REMOVING AND INSTALLING AIR INLET - AR83.25-P-1401M

MODEL 215, 220
Fig. 10: Identifying Air Inlet Location - Model 220
1 Unclip catches (2)
2 Remove air intake (1)
REMOVING AND INSTALLING WATER DEFLECTOR ABOVE WIPER SYSTEM - AR83.25-P-

1406M
Models 215, 220
Shows model 220
Fig. 11: Identifying Water Deflector Above Wiper System Remove/Install Components - Shows Model
220
Remove/Install
Injury Hazard! Windshield wiper mechanism Always remove ignition key
AS82.30-Z-
can pinch, crush or, in extreme cases even when working on windshield
0001-01A
sever extremities. wiper mechanism
AR82.30-P-
1 Remove wiper arms
6100M
2 Remove 4 expansion rivets (1)
Pull water deflector (2) upwards out of fold
3
(arrow)
REMOVING AND INSTALLING INCREMENTAL ADJUSTMENT MOTOR ELECTRONIC

CONTROL MODULE - AR83.30-P-2005M
MODEL 215, 220
Fig. 12: Identifying Electronic Control Module And Center Console Cover - Model 220
REVISIONS
14.10.98 Synchronization of incremental adjustment motors Step 6, newly included
Remove cover from center console AR68.20-P-
1 Model 215
(5) 2350N
AR68.20-P-
Model 220
2350M
2 Disconnect connectors (2, 3 and 4) Connection and disconnection aid
Remove incremental adjustment
4 motor electronic control module
(N22/5)
Synchronize incremental adjustment STAR diagnosis, menu point "Actuation,
6 synchronizing incremental adjustment
motors
motors"
REMOVING AND INSTALLING FRESH AIR/RECIRCULATED AIR FLAP ACTUATOR MOTOR -

AR83.30-P-2010M
MODEL 215, 220
Fig. 13: Identifying Fresh Air/Recirculated Air Flap Actuator Motor (M16/21) Location - Model 220
REVISIONS
14.10.98 Synchronization of actuator motors Step 6, newly included
AR83.30-P-
1 Remove A/C housing
5200M
Connection and disconnection aid
2 Disconnect actuator motor connector (3)
4 Disconnect fresh air/recirculated air flap
actuator motor (M16/21)
STAR diagnosis, menu point
Perform synchronization of actuator
6 Actuation, synchronization of
motors
actuator motors
REMOVING AND INSTALLING LEFT DEFROSTER FLAP ACTUATOR MOTOR - AR83.30-P-

2030M
MODEL 215, 220
Fig. 14: Identifying Left Defroster Flap Actuator Motor Remove/Install Components
REVISIONS
Remove cover below instrument panel on AR68.10-P-
1 Model 215
left 1500N
AR68.10-P-
Model 220
1500M
2 Remove front left air nozzle air duct Model 215 only
Connection and disconnection
aid
5 Pull off left defroster vent flap actuator
motor (M16/13)
motors
actuator motors
REMOVING AND INSTALLING RIGHT DEFROSTER VENT FLAP ACTUATOR MOTOR -

AR83.30-P-2040M
MODEL 215, 220
Fig. 15: Identifying Right Defroster Vent Flap Actuator Motor Remove/Install Components
REVISIONS
AR68.10-P-
1 Remove glove compartment
1400M
AR68.20-P-
2 Remove cover from center console (3) Model 215
2350N
AR68.20-P-
Model 220
2350M
Connection and
disconnection aid
Pull off actuator for right defroster vent flap
5
6 Reinstall in opposite order
7 Perform synchronization of actuator motors Actuation, synchronization of
actuator motors
REMOVING AND INSTALLING LEFT CENTER BLEND FLAP ACTUATOR MOTOR - AR83.30-P-
2050M
MODEL 215, 220
Fig. 16: Identifying Left Center Blend Flap Actuator Motor Remove/Install Components
REVISIONS
Remove cover below instrument panel on AR68.10-P-
1 Model 215
left 1500N
AR68.10-P-
Model 220
1500M
2 Disconnect actuator motor connector (3) Connection and disconnection
aid
4
Pull off actuator for left center blend flap
actuator motors
REMOVING AND INSTALLING RIGHT CENTER VENT BLEND FLAP ACTUATOR MOTOR -
AR83.30-P-2060M
MODEL 215, 220
Fig. 17: Identifying Right Center Vent Blend Flap Actuator Motor Remove/Install Components
REVISIONS
AR83.30-P-
5200M
Disconnect actuator motor connectors (8), Connection and
3
unclip wiring harness disconnection aid
4 Unclip clips (4)
5 Pull off 2 clips (5)
Separate air distribution housing (1) from
6
blower housing (2)
Connection and
disconnection aid
Pull off actuator right center vent blend flap
9
actuator motors
REMOVING AND INSTALLING LEFT CENTER VENT DIVERTER FLAP ACTUATOR MOTOR -
AR83.30-P-2070M
MODEL 215, 220
Fig. 18: Identifying Left Center Vent Diverter Flap Actuator Motor Remove/Install Components
REVISIONS
AR68.10-P-
1 Remove cover below instrument panel on left Model 215
1500N
AR68.10-P-
Model 220
1500M
Connection and
disconnection aid
Pull off actuator for left center vent diverter
4
flap actuator motor (M16/17)
actuator motors
REMOVING AND INSTALLING RIGHT CENTER VENT DIVERTER FLAP ACTUATOR MOTOR -
AR83.30-P-2080M
MODEL 215, 220
Fig. 19: Identifying Right Center Vent Diverter Flap Actuator Motor Remove/Install Components
REVISIONS
AR83.30-P-
5200M
Disconnect actuator motor connectors (7), Connection and disconnection
3
unclip wiring harness aid
4 Unclip clips (4)
5 Pull off 2 clips (5)
Separate air distribution housing (1) from
6
blower housing (2)
aid
Pull off right center vent diverter flap
9
actuator motors
REMOVING AND INSTALLING ACTUATOR MOTOR FOR ACTIVATED CHARCOAL FILTER

FLAP - AR83.30-P-2090M
MODEL 215, 220
Fig. 20: Identifying Actuator Motor Remove/Install Components For Activated Charcoal Filter Flap
REVISIONS
AR68.10-P-
1.1 Remove glove compartment Only model 220 1400M
AR68.10-P-
1.2 Remove instrument panel upper section Only model 215 1020N
AR91.60-P-
2 Remove passenger airbag Only model 215 0680M
3 Unscrew screw (2)
4 Remove lever (3)
6 Remove cover (5)
aid
Remove actuator motor for activated
8
charcoal filter flap (A32m2)
actuator motors
REMOVING AND INSTALLING LEFT FOOTWELL FLAP ACTUATOR MOTOR - AR83.30-P-

2100M
MODEL 215, 220
Fig. 21: Identifying Left Footwell Flap Actuator Motor (M16/15) Location - Model 220
REVISIONS
AR68.20-P-
1 Remove cover on center console (4) Model 215
2350N
AR68.20-P-
Model 220
2350M
AR68.20-P-
2 Remove front floor covering (on left)
2050M
Disconnect actuator motor connector
3 Connection and disconnection aid
(3)
Pull off left footwell flap actuator motor
5
(M16/15)
motors
actuator motors
REMOVING AND INSTALLING RIGHT FOOTWELL FLAP ACTUATOR MOTOR - AR83.30-P-

2110M
MODEL 215, 220
Fig. 22: Identifying Right Footwell Flap Actuator Motor (M16/16) Location - Model 220
REVISIONS
Remove cover on center console AR68.20-P-
1 Model 215
(4) 2350N
AR68.20-P-
Model 220
2350M
Remove front floor covering (on AR68.20-P-
2
right) 2070M
Disconnect actuator motor
3 Connection and disconnection aid
connector (3)
Pull off right footwell flap
5
Perform synchronization of STAR diagnosis, menu point Actuation,
7
actuator motors synchronization of actuator motors
REMOVE/INSTALL AC HOUSING - AR83.30-P-5200M
Models 215, 220
Fig. 23: Identifying AC Housing Remove/Install Components (1 Of 5)


Remove/Install
Risk of injury to skin and eyes suffering Do not open cooling system unless coolant
AS20.00-
scalding from contact with hot coolant temperature is below 90 °C. Open cap
Z-0001-
spray. Risk of poisoning from slowly and release the pressure. Do not
01A
swallowing coolant. pour coolant into beverage bottles.
Wear protective gloves, protective
clothing and eye protection.
Rotate reservoir sealing cover to notch
1 Reduce pressure in cooling system
"1" and lock again.
2 Drain coolant, fill
AR20.00-
Engine 112 in model 220
P-1142HA
Engine 113 (except 113.991) in models
215, 220
Engine 137 in model 215, 220
AR20.00-
Engine 113.991 in models 215.374,
P-
220.074/174
1142RVK
Engine 275.950 in models 215.376, AR20.00-
220.176 P-1142H
Engine 613.960 in model 220.026
AR20.00-
Engine 628.960 in model 220.028/128
P-1142HB
Engine 648.960 in model 220.025/125
Never perform welding work on or near a
closed air conditioning system. No
smoking or open flames. Wear eye
conditioning system. Risk of poisoning . AS83.00-
protection and protective gloves. Work
Inhaling overheated refrigerant vapors Z-0001-
only in well ventilated areas. Carry out
may be toxic. Risk of injury. Contact 01A
with liquid refrigerant may result in
injury to the skin and eyes.
discharged.
Recycle refrigerant and note quantity of
3 Discharge air conditioning system
extracted compressor oil.
AH83.30-
All models N-0004-
damaged or leaking
01A
AH83.30-
Notes on handling refrigerant R134a All models fitted with air conditioning N-0003-
01A
AR82.30-
4 Remove wiper system (1)
P-6400M
Remove air plenum chamber and water AR83.10-
5
collector (3) P-9998M
Disconnect pressure lines at expansion
6 Plug openings (parts kit).
valve (4)
Slacken hose clamp (5) and detach
7
heater water supply hose (6)
8 Installation: Do not confuse the

Slacken hose clamps (7) and remove assignment of the heater water return
heater water return hoses (8) hoses.
9 Remove instrument panel (9) Installation: Check function before
installing the instrument panel.
AR68.10-
Model 215
P-1000N
AR68.10-
Model 220
P-1000M
Remove air ducts in rear compartment/
10
stowage compartment ventilation (11)
AR68.20-
11 Remove front left floor covering (12)
P-2050M
AR68.20-
12 Remove front right floor covering (13)
P-2070M
Remove rear compartment air ducts on
13
left/ right (14)
Remove air ducts for side outlets and left
14
footwell (16)
Remove air ducts for side outlets and
15
right footwell (17)
Unplug plug of front passenger airbag
16
squib 1 (R12/4)
Unplug connector of control unit box
17
blower motor (M2/2x1)
Unplug connector of electronic ignition
18
switch (15)
Unplug connector of stepper motor
19
electronics (20)
Temperature sensor connector Unplug
20
left heat exchanger (19)
Temperature sensor connector Unplug
21
right heat exchanger (18)
Unplug connector of evaporator
22
temperature sensor (20a)
23 Unscrew bolts from jacket tube (21)
24 Unscrew bolts from left A-pillar (22)
25 Unscrew bolts from firewall (23)
26 Unscrew nut from AC housing (24)
Unscrew bolt from left transmission
27
tunnel (25)
28 Unscrew bolts from right A-pillar (26)
Unscrew bolt (28), remove cable duct
29
(29) with wiring harness
30 Unscrew nuts from AC housing (27)
Disconnect all tie straps from transverse
31 Installation : Use new tie straps.
pipe (30)
Remove transverse pipe (30) and put on
32
the front seats
33 Remove AC housing
AR83.30-
34 Replace fluid reservoir
P-6520M
Risk of accident. Accidents may result
if the vehicle starts off unintentionally
Secure vehicle to prevent it from moving. AS00.00-
with the engine running. Risk of injury
Wear closed and snug-fitting work clothes. Z-0005-
as working around the engine during
Do not grasp hot or rotating parts. 01A
start-up or while running may result in
Correct coolant level and perform a leak
36
test
CORRECTING OIL LEVEL IN AIR CONDITIONING FOLLOWING REPAIR OR SLOW

REFRIGERANT LOSS - AR83.30-P-5251E
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
A/C compressor 7SB16
MODEL 202 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
conditioning (Automatic) A/C compressor ND6CA17, A/C compressor 7SB16
conditioning (Automatic) A/C compressor 7SB16
MODELS 215,220 A/C compressor 7SE16
Correct oil level

Carry out work quickly,
compressor oil is
hygroscopic.
When evacuating
refrigerant, the quantity of
compressor oil evacuated
must be added again to
refrigerant circuit when
refilling air conditioning
(new oil)
1 If loss of refrigerant is <
400 g (no leakage
detectable) do not add
compressor oil ?
Carry out leak-tightness refer to SI83/85
test
2 If loss of refrigerant is > *BF83.55-P-1009-01A
400 g (leakage detectable)
fill with new compressor
oil, also ?
AR83.30-P-6520E
Replace fluid reservoir Models 202, 208, 210
Model 163 AR83.30-P-6520GH
Models 215, 220 AR83.30-P-6520M
A/C COMPRESSOR
Number Designation A/C A/C A/C
compressor compressor compressor
7SB16 in ND6CA17 in 7SB16
models 140, model 202 Refrigerant
170, 202, 208, R134a in
210 model 163
BF83.55-P- Additional oil Compressor oil 3
cm 20 20 20
1009-01A capacity when Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
leakage for service 0362-00A 0362-00A 0362-00A
detected products
A/C COMPRESSOR
Number Designation A/C compressor A/C compressor
7SE16 in model 7SE16 in model
215 220
BF83.55-P- Additional oil Compressor oil cm3 20 20
1009-01A capacity when Specifications for Sheet BB00.40-P- BB00.40-P-
leakage detected service products 0362-00A 0362-00A
CORRECTING OIL LEVEL IN AIR CONDITIONING AFTER REPLACING PARTS - AR83.30-P-

5252E
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
A/C compressor 7SB16
Correct oil level

Carry out work quickly, compressor oil is
hygroscopic
When evacuating refrigerant, the quantity of
compressor oil evacuated must be added again
to refrigerant circuit when refilling air
conditioning (new oil)
Replace A/C compressor, additionally fill *BF83.55-P-
1
with new compressor oil 1008-01A
Replace condenser and additionally fill with *BF83.55-P-
2
new compressor oil 1003-01A
Replace evaporator and additionally fill with *BF83.55-P-
3
compressor oil 1004-01A
Replace fluid reservoir and additionally fill *BF83.55-P-
4
with compressor oil 1005-01A
Replace suction pipe from evaporator to A/C
*BF83.55-P-
5 compressor and additionally fill with new
1006-01A
compressor oil
Replace pressure pipe from A/C compressor
*BF83.55-P-
6 to condenser and additionally fill with new
1007-01A
compressor oil
Additional oil quantity when replacing *BF83.55-P-
7 Model 220
evaporator, rear air conditioning 1010-01A
Additional oil quantity when replacing rear air *BF83.55-P-
8 Model 220
conditioning lines 1011-01A
Turn temperature thumb wheel of
center nozzles to stop in blue range,
Switch on air conditioning and allow engine
9 or on automatic air conditioning to
to run at idle speed for approx. 4 minutes
"Lo"
Blower at max.
Air output temperature at center
10 Check function of air conditioning nozzle must not fall below + 50 C, if
necessary ? Carry out diagnosis
A/C COMPRESSOR
7SB16 in 7SB16 ND6CA17 in
models 140, Refrigerant model 202
170, 202, 208, R134a in
210 model 163
BF83.55-P- Additional oil Compressor oil cm3 20 20 20
1003-01A quantity when Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
replacing for service 0362-00A 0362-00A 0362-00A
condenser products
evaporator products
replacing fluidfor service 0362-00A 0362-00A 0362-00A
reservoir products
suction line products
pressure line products
replacing A/C for service 0362-00A 0362-00A 0362-00A
compressor products
BF83.55-P- Additional oil Compressor oil cm3 - - -
1010-01A quantity when
replacing Specifications Sheet - - -
evaporator, for service
rear air products
conditioning
BF83.55-P- Additional oil Compressor oil cm3 - - -
1011-01A quantity when
replacing rear Specifications Sheet - - -
air for service
conditioning products
lines
A/C COMPRESSOR
A/C compressor A/C compressor
Number Designation 7SE16 in model 7SE16 in model
215 220
Compressor oil cm3 3 3
BF83.55-P- Additional oil quantity
1003-01A when replacing condenser Specifications for Sheet
BB00.40-P-0362- BB00.40-P-0362-
service products 00A 00A
Compressor oil 3
cm 40 40
BF83.55-P- Additional oil capacity
1004-01A when replacing evaporator Specifications for Sheet
BB00.40-P-0362- BB00.40-P-0362-
Additional oil quantity Compressor oil 3
cm 10 10
BF83.55-P-
when replacing fluid Specifications for BB00.40-P-0362- BB00.40-P-0362-
1005-01A Sheet
reservoir service products 00A 00A
Compressor oil 3
cm 20 20
BF83.55-P- Additional oil quantity
1006-01A when replacing suction line Specifications for Sheet
BB00.40-P-0362- BB00.40-P-0362-
Additional oil quantity Compressor oil cm3 10 10
BF83.55-P-
when replacing pressure Specifications for BB00.40-P-0362- BB00.40-P-0362-
1007-01A Sheet
line service products 00A 00A
Additional oil quantity Compressor oil cm3 20 20
BF83.55-P-
when replacing A/C Specifications for BB00.40-P-0362- BB00.40-P-0362-
1008-01A Sheet
compressor service products 00A 00A
cm - 3
BF83.55-P-
when replacing evaporator, Specifications for BB00.40-P-0362- BB00.40-P-0362-
1010-01A Sheet
rear air conditioning service products 00A 00A
cm - 20
BF83.55-P-
when replacing rear air Specifications for BB00.40-P-0362- BB00.40-P-0362-
1011-01A Sheet
conditioning lines service products 00A 00A
CORRECTING OIL LEVEL IN AIR CONDITIONING AFTER SYSTEM SUDDENLY LOSES ALL
REFRIGERANT - AR83.30-P-5253E
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA A/C compressor 7SB16

Correct oil level
Carry out work quickly, compressor oil is hygroscopic
When evacuating refrigerant, the quantity of compressor oil
evacuated must be added again to refrigerant circuit when refilling
air conditioning (new oil)
Models 202, AR83.30-P-
1 Replace defective component and fluid reservoir
208, 210 6520E
AR83.30-P-
Model 163
6520GH
Model 215, AR83.30-P-
220 6520M
*BF83.55-P-
2 Additionally fill new compressor oil to specified oil capacity
1002-01A
A/C COMPRESSOR
7SB16 7SB16 in ND6CA17 in
Refrigerant models 140, model 202
R134a in 170,202,208,
model 163 210
F83.55-P- Additional oil Compressor oil 3
cm 40 40 40
1002-01A capacity after
sudden Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
emptying of for service 0362-00A 0362-00A 0362-00A
system (e.g. products
ruptured line)
A/C COMPRESSOR
215 220
BF83.55-P- Additional oil Compressor oil 3
cm 50 50
1002-01A capacity after
sudden emptying Specifications for Sheet BB00.40-P- BB00.40-P-
of system (e.g. service products 0362-00A 0362-00A
ruptured line)
REMOVING AND INSTALLING REFRIGERANT PRESSURE SENSOR - AR83.30-P-5430M
MODEL 215, 220

Fig. 28: Identifying Refrigerant Pressure Sensor Remove/Install Components
Do not perform any type of
welding work on closed air
conditioning system or in its
Explosion hazard when performing welding or vicinity. Smoking and open
brazing work on closed air conditioning. flame prohibited.
AS83.00-Z-
Poisoning hazard from inhaling overheated Wear protective goggles and
0001-01A
refrigerant vapors. Injury hazard from skin and protective gloves, work only in
eye contact with liquid refrigerant. well-ventilated rooms.
Perform repair work on air
conditioning circuit only with
system emptied.
Action to be taken in the event air conditioning AH83.30-N-
is damaged or leaks 0004-01A
Protect air conditioning circuit and components AH83.30-N-
from moisture during repair work 0005-01A
AH83.30-N-
Notes on handling R134a refrigerant
0003-01A
Add quantity of
Empty air conditioning (recycle), evacuate, compressor oil removed to
1
charge, check for leaks refrigerant circuit when charging
Disconnect connector for refrigerant pressure
2
sensor (3)
3 Unscrew refrigerant pressure sensor (B12) *BA83.30-
P-1007-01A
Close openings (parts kit)
Installation:
Replace O-ring
Moisten thread with compressor
oil
AR83.30-P-
4 Replace receiver/drier
6520M
AIR CONDITIONING
BA83.30-P-1007-01A Refrigerant pressure sensor on receiver/drier Nm 12 12
REMOVING AND INSTALLING EXPANSION VALVE - AR83.30-P-5520M
MODEL 215, 220
Fig. 29: Identifying Expansion Valve Remove/Install Components - Model 215 And 220
Explosion hazard when Do not perform any type AS83.00-Z-0001-01A
performing welding or of welding work on
brazing work on closed closed air conditioning
air conditioning. system or in its vicinity.
Poisoning hazard from Smoking and open flame
inhaling overheated prohibited. Wear
refrigerant vapors. Injury protective goggles and
hazard from skin and eye protective gloves, work
contact with liquid only in well-ventilated
refrigerant. rooms. Perform repair
work on air conditioning
circuit only with system
emptied.
Action to be taken in the AH83.30-N-0004-01A
event air conditioning is
damaged or leaks
Protect air conditioning AH83.30-N-0005-01A
circuit and components
from moisture during
repair work
Notes on handling R134a AH83.30-N-0003-01A
refrigerant
1 Empty air conditioning Add quantity of
(recycle), evacuate, compressor oil removed
charge, check for leaks to refrigerant circuit when
charging air conditioning
(new oil)
3 Unscrew nut (1) *BA83.30-P-1001-01A
4 Pull off pressure lines Plug openings
(parts kit), Replace O-
rings (4) (moisten with
compressor oil)
5 Unscrew screws (3) *BA83.30-P-1002-01A
6 Pull expansion valve (5) Plug openings
off of pressure lines (7) (parts kit), Replace O-
rings (4) (moisten with
compressor oil)
Installation: In order
to avoid canting, tighten
screws alternately
7 Replace receiver/drier AR83.30-P-6520M
AIR CONDITIONING
BA83.30-P-1001- Nut on expansion Nm 10 10
01A valve
BA83.30-P-1002- Bolt on expansion Nm 10 10
01A valve
REMOVING AND INSTALLING EVAPORATOR - AR83.30-P-5540M
MODELS 215, 220
Fig. 30: Identifying Evaporator Remove/Install Components (1 Of 4)

Risk of explosion through welding Do not carry out welding operations on
or soldering operations on closed air closed air conditioning system or around it.
conditioning system. Risk of Smoking and naked flame are forbidden.
AS83.00-Z-
poisoning through inhaling Wear protective glasses and protective
0001-01A
overheated refrigerant vapors. Risk gloves, work only in well ventilated areas.
of injury through skin and eye Only carry out repair operations on air
contact with fluid coolant conditioning circuit with system drained.
AH83.30-
Procedure with damaged or leaking
N-0004-
air conditioning system
01A
components from dampness when N-0005-
carrying out repair operations 01A
AH83.30-
N-0003-
Notes for handling refrigerant R134a
01A
When evacuating refrigerant, the
Drain air conditioning system
1 (recycling), purge, fill, check for quantity of compressor oil evacuated must be
added again to refrigerant circuit when
leaks
refilling air conditioning (new oil)
AR83.30-P-
2 Remove evaporator housing (1)
5200M
AR83.25-P-
3 Remove heat exchanger
1100M
Detach stepper motors connections
4
(4)
5 Detach 2 clamps (2)
6 Detach 4 clips (3)
Detach stepper motors connections
7
(5)
Remove air distributor, upper section
10
(8)
11 Detach evaporator core (9) Clean air distributor, lower section
Installation: Note oil top-up quantity *BF83.55-
when replacing evaporator P-1004-01A
12 Unscrew screws (10) Installation: Tighten screws alternately
to avoid jamming
*BA83.30-
P-1002-01A
13 Detach expansion valve (11) Close off openings (parts kit), replace
O-rings (4) (moisten with compressor oil)
AR83.30-P-
6520M
AIR CONDITIONING
BA83.30-P-1002-01A Screw, expansion valve Nm 10 10
A/C COMPRESSOR
215 220
3
Additional oil quantity Compressor oil cm 40 40
BF83.55-P- when replacing Specifications for BB00.40-P-0362- BB00.40-P-0362-
1004-01A evaporator service products Sheet 00A 00A
CHECK EVAPORATOR FOR LEAKAGE - AR83.30-P-5550A
MODEL 124, 129, 140, 168, 170, 201, 202, 208, 210 with CODE (580) Air conditioning (or Tempmatic for
USA)
MODEL 124, 129, 140, 201, 202, 208, 210, 215, 220 with CODE (581) Automatic air conditioning
MODEL
461.217 /219 /223 /227 /229 /238 /239 /249 /266 /267 /302 /321 /322 /323 /326 /327 /328 /329 /332 /335 /336 /33
with CODE (H02) Air conditioning
MODEL
463.200 /204 /206 /207 /208 /209 /220 /221 /224 /225 /227 /228 /230 /231 /232 /233 /240 /241 /300 /304 /307 /30
with CODE (H02) Air conditioning
MODEL 414.700 with CODE (H06) Air conditioning
Shown using model 168 as an example
Fig. 34: Identifying Test Adapter, Evaporator Intake/Pressure Connection And Sealing Ring - Shown
Using Model 168
Shown using model 463 as an example

Fig. 35: Identifying Test Adapter, Evaporator Intake/Pressure Connection And Sealing Ring - Shown
Using Model 463
Checking
Risk of explosion caused Never perform welding AS83.00-Z-0001-01A
by welding or soldering work on or near a closed
work on closed air air conditioning system.
conditioning system. Risk No smoking or open
of poisoning caused by flames. Wear safety
inhaling overheated glasses and protective
refrigerant vapors. Risk gloves. Work only in well
of injury to skin and eyes ventilated areas. Carry out
caused by contact with repair work on the air
liquid refrigerant. conditioning system
circuit only after the
system has been
discharged.
Conduct if air All models fitted with air AH83.30-N-0004-01A
conditioning system is conditioning.
damaged or leaking
Protect air conditioning All models fitted with air AH83.30-N-0005-01A
circuit and components conditioning.
from moisture when
carrying out repair work
Notes on handling All models with R134a. AH83.30-N-0003-01A
refrigerant R134a refrigerant.
1 Remove expansion valve Model 168 AR83.30-P-5520GC
Model 170 AR83.30-P-5520G
Model 202 AR83.30-P-5520E
Model 208, 210 AR83.30-P-5520F
Model 220, 215 AR83.30-P-5520M
Model 463, 461 AR83.30-P-5520GA
Model 414.700 AR83.30-L-5520VA
2 Install corresponding test Test adapter
adapter (1) in vehicle in dependent on pipe
place of expansion valve. diameter at air conditioner
housing
Test adapter Fig. 36
Adapter Fig. 37
Adapter hose Fig. 38
Use new O-rings (2, 6)
(coat with compressor oil)
to install the test adapter.
Model 129, 140, 168, *BA83.30-P-1002-01A
170, 202, 208, 210, 215,
220, 414
Model 461, 463 *BA83.30-P-1001-01C
3 Connect testing unit to
test adapter (1).
4 Check evaporator for First fill system with
leakage 20.5 bar of system
pressure, reduce system
pressure to 20 bar after
approx. 10 min. Pressure
must be maintained for at
least 4 hours.
Temperature changes
during the pressure test
can cause pressure
fluctuations, e.g. due to
weather changes,
overnight, cooling down
of engine compartment.
Consistent ambient
conditions must be strictly
ensured.
If in poor condition: ?
Remove/install evaporator
Model 168 AR83.30-P-5540GC
Model 170, 202, 208, 210 AR83.30-P-5540E
Model 215, 220 AR83.30-P-5540M
Model 463, 461 AR83.30-P-5540G
Model 414 AR83.30-L-5540VA
order
AIR CONDITIONING SYSTEM

Number Designation Model 129 Model 140 Model 168 Model 170
BA83.30-P- Bolt for Nm 8 8 8 8
1002-01A expansion
valve

BA83.30-P- Bolt for Nm 8 8 8 10
1002-01A expansion
valve

Number Designation Model 215 Model 414.700
BA83.30-P-1002- Bolt for expansion Nm 10 8
01A valve

Number Designation Model 461 Model 461.302/ Model
except model 304/331/ 463.200/204/206/207/
461.302/ 332/334/ 208/209/220/221/224/
331/332/ 342/344/ 225/227/228/230/231/
342/345 345/346 232/233/240/241/300/
303/304/307/308/320/
321/324/325/327/328/
330/331/340/341
BA83.30-P- Nut on Nm 10 10 10
1001-01C expansion valve
Fig. 36: Identifying Test Adapter (140 589 51 63 00)

Fig. 37: Identifying Adapter (463 589 01 63 00)
Fig. 38: Identifying Adapter Hose (140 589 51 63 01)
REMOVING AND INSTALLING REFRIGERANT TEMPERATURE SENSOR - AR83.30-P-5630M
MODEL 215, 220
Fig. 39: Identifying Refrigerant Temperature Sensor Remove/Install Components
Do not perform any type of welding work on
Explosion hazard when performing
closed air conditioning system or in its
welding or brazing work on closed
vicinity. Smoking and open flame prohibited.
air conditioning. Poisoning hazard AS83.00-Z-
Wear protective goggles and protective
from inhaling overheated refrigerant 0001-01A
gloves, work only in well-ventilated rooms.
vapors. Injury hazard from skin and
Perform repair work on air conditioning
eye contact with liquid refrigerant.
circuit only with system emptied.
AH83.30-
Action to be taken in the event air
N-0004-
conditioning is damaged or leaks
01A
components from moisture during N-0005-
repair work 01A
AH83.30-
Notes on handling R134a refrigerant N-0003-
01A
Empty air conditioning (recycle), Add quantity of compressor oil
1 removed to refrigerant circuit when charging
evacuate, charge, check for leaks
Disconnect connector for refrigerant
2
temperature sensor (3)
Unscrew refrigerant temperature Installation:
3 Replace O-rings
sensor (B12/1)
When connecting lines, moisten thread with
compressor oil
*BA83.30-
P-1008-01A
AR83.30-P-
6520M
AIR CONDITIONING
BA83.30-P-1008-01A Refrigerant temperature sensor on receiver/drier Nm 6 6
REMOVING AND INSTALLING RECEIVER/DRIER - AR83.30-P-6520M
MODEL 215, 220

Fig. 40: Identifying Receiver/Drier Remove/Install Components - Model 215 And 220
Risk of explosion from Do not carry out any AS83.00-Z-0001-01A
welding or brazing work welding work on the
on closed air conditioning closed air conditioning
system. Risk of system or in the
poisoning from inhaling surrounding area. No
overheated refrigerant smoking or naked flames.
vapors. Risk of injury Wear eye protection and
from skin and eye contact protective gloves. Work
with liquid refrigerant. only in well ventilated
areas. Do not carry out
repair work on the circuit
of the air conditioning
system unless the system
is drained.
Conduct if air AH83.30-N-0004-01A
conditioning system is
damaged or leaking
Protect air conditioning All models fitted with air AH83.30-N-0005-01A
circuit and components conditioning
from moisture when
carrying out repair work
Notes for handling R134a All models with R134a AH83.30-N-0003-01A
refrigerant refrigerant
1 Drain air conditioning Add extracted
(recycle) quantity of compressor oil
to the refrigerant circuit
again when filling the air
conditioning system
(fresh oil).
Installation: Drain air
conditioning system,
evacuate, fill, inspect for
leaks
compartment lining
3 Disconnect refrigerant
pressure sensor connector
(B12)
4 Unplug connector (B12/1)
at temperature sensor
5 Remove screws (3) at Plug openings
fluid reservoir (parts kit)
Installation:
Replace O-rings. When
installing lines, moisten
threads with compressor
oil
*BA83.30-P-1003-01A
6 Unscrew nuts (4)
7 Withdraw fluid reservoir
downwards (1) with strap
retainer
8 Loosen strap restrainer
(5) with retaining lugs
and pull off
9 Install in the reverse order Observe quantity of oil *BF83.55-P-1005-01A
to be added when
replacing receiver/drier
Risk of accident from Secure vehicle to prevent AS00.00-Z-0005-01A
vehicle starting off by it moving off by itself.
itself when engine Wear closed and close-
from bruises and burns if Do not grasp hot or
you hold your hand into rotating parts.
engine when it is started
or when it is running.
10 Switch on air Set center nozzle
conditioning and allow it temperature control dial
to idle for approx. 4 to limit stop in blue range,
minutes turn left and right
temperature dials on air-
conditioning control to "
Lo"
Blower to max.
11 Check air conditioning Air outlet temperature
for proper function at center nozzle should
not drop below +5 ° C, if
necessary: ? carry out
diagnosis
12 Find leaky point in air *WE58.40-Z-1002-20A
conditioning circuit

BA83.30-P-1003- Lines on Nm 10 10
01A receiver/drier
A/C COMPRESSOR
Number Designation Refrigerant Refrigerant
compressor compressor
7SE12 in Model 7SE16 in Model
215 220
BF83.55-P- Additional oil Compressor oil cm3 10 10
1005-01A filling capacity
when replacing Specifications for Sheet BB00.40-P- BB00.40-P-
receiver/drier service products 0362-00A 0362-00A
WORKSHOP EQUIPMENT
WE58.40-Z-1002-20A Air conditioning leak detector
INSTALL/REMOVE CONDENSER - AR83.30-P-6540
Install/remove condenser - AR83.30-P-6540IM
MODELS 215.379, 220.179 with ENGINE 275.980
Shown on MODEL 220

Fig. 41: Identifying Condenser Remove/Install Components - Shown On Model 220
Vehicles with Active Body Control
Fig. 42: Identifying Condenser Remove/Install Components - Vehicles With Active Body Control
Remove/Install
conditioning system. Risk of poisoning .
protection and protective gloves. Work AS83.00-Z-
Inhaling overheated refrigerant vapors
only in well ventilated areas. Carry out 0001-01A
may be toxic. Risk of injury. Contact
repair work on the air conditioning
system circuit only after the system has
been discharged.
AH83.30-
All models N-0004-
damaged or leaking
01A

components from moisture when N-0005-
All models with AC
AH83.30-
Notes on handling refrigerant R134a All models with AC N-0003-
01A
In the event of air conditioning failure
due to leaks, contamination or ice
formation, when repairing or exchanging
the refrigerant compressor, a new fluid
reservoir has to be installed
When filling the air conditioning
system, feed extracted quantity of
1 (recycling), evacuate, fill, inspect for
compressor oil back into the refrigerant
leaks
circuit (new oil).
AR20.20-P-
2 Remove radiator unit
3865IM
Unscrew nut (5) from the pressure line
3 connection or hot gas line connection at Plug openings (parts kit).
the condenser
*BA83.30-
P-1011-01A
Only vehicles with Active Body
Control (ABC), code 487a.
Unscrew bolt (6) from radiator ABC
Only vehicles with Active Body
5.1 suspension (7) and set radiator ABC
Control (ABC), code 487a.
suspension (7) aside
Observe the oil refill quantity when *BF83.55-
6 Remove condenser (1)
replacing the condenser. P-1003-01A
AR83.30-P-
6520M

BA83.30-P-1011-01A Pressure and hot gas line to condenser Nm 10 10
REFRIGERANT COMPRESSOR
compressor 7SE16 compressor 7SE16
in Model 215 in model 220
Additional oil filling Compressor oil 3
cm 30 30
BF83.55-P-
capacity when Specifications for BB00.40-P-0362- BB00.40-P-0362-
1003-01A
replacing condenser Operating Fluids Sheet 00A 00A
Install/remove condenser - AR83.30-P-6540M
MODELS 215.373 /374 /375 /376 /378, 220 (except, 220.179)
Fig. 43: Identifying Condenser Remove/Install Components - Models 215.373
Vehicles with Active Body Control
Fig. 44: Identifying Condenser Remove/Install Components - Vehicles With Active Body Control
Remove/Install
conditioning system. Risk of poisoning.
protection and protective gloves. Work AS83.00-Z-
Inhaling overheated refrigerant vapors
only in well ventilated areas. Carry out 0001-01A
may be toxic. Risk of injury. Contact
discharged.
AH83.30-
All models N-0004-
damaged or leaking
01A
components from moisture when All models with AC N-0005-
AH83.30-
Notes on handling refrigerant R134a All models with AC N-0003-
01A
When filling the air conditioning
system, feed extracted quantity of
1 (recycling), evacuate, fill, inspect for
compressor oil back into the refrigerant
leaks
circuit (new oil).
2 Remove radiator Type 215.373/376
AR20.20-P-
Type 215.374/375
3865AB
AR20.20-P-
Type 215.378
3865MC
Installation: Check hydraulic fluid
3 Loosen hydraulic oil lines (3) level of power steering and correct
hydraulic fluid level if necessary.
Unscrew nut (5) from the pressure or
4 hot gas line connection at the condenser Plug openings (parts kit).
(1)
*BA83.30-
P-1011-01A
Vehicles with Active Body Control (ABC)
code 487a
Unscrew ABC suspension bolt (6) at Vehicles with Active Body Control (ABC)
6.1
radiator (7) and set radiator (7) aside code 487a
7 Unscrew screw (4)
Observe the oil refill quantity when *BF83.55-
8 Remove condenser (1)
replacing the condenser. P-1003-01A
AR83.30-P-
9.1 Replace fluid reservoir If necessary
6520M
In the event of air conditioning failure
due to leaks, contamination or ice
formation, when repairing or exchanging
the refrigerant compressor, a new fluid
reservoir has to be installed

BA83.30-P-1011-01A Pressure and hot gas line to condenser Nm 10 10
in Model 215 in model 220
cm 30 30
BF83.55-P-
1003-01A
replacing condenser Operating Fluids Sheet 00A 00A
REMOVING AND INSTALLING EVAPORATOR TEMPERATURE SENSOR - AR83.30-P-8085M
MODEL 215, 220
Fig. 45: Identifying Evaporator Temperature Sensor (B10/6) Location - Model 220
Model AR68.10-P-
1 Remove cover on left below instrument panel
215 1500N
Model AR68.10-P-
220 1500M
Disconnect connector for evaporator temperature sensor
2
(B10/6x1)
Pull evaporator temperature sensor (B10/6) out of A/C housing
3
(1)
REMOVE/INSTALL PUSHBUTTON CONTROL MODULE - AR83.40-P-6350
Remove/install pushbutton control module - AR83.40-P-6350M
MODEL 215, 220 up to 31.8.02
Fig. 46: Identifying Pushbutton Control Module Remove/Install Components - Up To 31.8.02
Remove/Install
1 Remove cover on center console Model 215. AR68.20-P-2350N
Model 220. AR68.20-P-2350M
2 Unscrew bolts (12).
3 Remove AC pushbutton control module (N22)
Remove/install pushbutton control module - AR83.40-P-6350MA
Fig. 47: Identifying Pushbutton Control Module Remove/Install Components - As Of 1.9.02 (1 Of 2)

Fig. 48: Identifying Pushbutton Control Module Remove/Install Components - As Of 1.9.02 (2 Of 2)
Remove/Install
AR68.20-P-
1 Remove ashtray from front center console
2400M
Pull AC pushbutton control module (N22) out of Until electrical
2
instrument panel together with cover (1) connectors are accessible.
3 Disconnect electrical connectors
Unscrew mounting bolts on cover (1) from AC
4 Two M4x12 bolts.
pushbutton control module (N22)
Remove cover (1) from AC pushbutton control
5
module (N22)
7 Read diagnostic trouble code memory and erase
Connect STAR DIAGNOSIS, interrogate fault AD00.00-P-
memory 2000-04A
STAR DIAGNOSIS *WH58.30-Z-
system. 1048-13A

Number Designation
REMOVING AND INSTALLING SUN SENSOR - AR83.40-P-6720M
MODEL 215, 220

Fig. 49: Identifying Sun Sensor Remove/Install Components
2 Remove insulating mat (1)
3 Unclip cover (3)
Disconnect connector for sun
4
sensor (5)
Press clip (4) together and pull out When the sun sensor is to be replaced, the old mounting
5
sun sensor (B32) clip must be reused for installation.
REMOVING AND INSTALLING MULTIFUNCTION SENSOR - AR83.40-P-6730M
MODEL 215, 220
Fig. 50: Identifying Multifunction Sensor Remove/Install Components

2 Remove cover (2)
3 Disconnect connector on multifunction sensor (1)
4 Remove multifunction sensor (B31)
REMOVING, INSTALLING REAR AIR CONDITIONING REFRIGERANT SHUTOFF VALVE -

AR83.50-P-9000M
MODEL 220 with CODE (582) Rear air conditioning
Fig. 51: Identifying Rear Air Conditioning Refrigerant Shutoff Valve Remove/Install Components
Do not perform any type of welding work on
Explosion hazard when performing
closed air conditioning system or in its
welding or brazing work on closed
vicinity. Smoking and open flame prohibited.
air conditioning. Poisoning hazard AS83.00-Z-
Wear protective goggles and protective
from inhaling overheated refrigerant 0001-01A
gloves, work only in well-ventilated rooms.
vapors. Injury hazard from skin and
Perform repair work on air conditioning
eye contact with liquid refrigerant.
AH83.30-
N-0004-
01A
components from moisture during N-0005-
repair work 01A
AH83.30-
01A
Add quantity of compressor oil
Empty air conditioning (recycle),
1 removed to refrigerant circuit when charging
AP40.10-P-
2 Remove left front wheel
4050Z
AR88.10-P-
3 Remove left front inner fender
1300M
4 Unscrew plastic nut (1)
5 Unscrew 2 union nuts (2) Installation:
Renew O-rings
Moisten thread with compressor oil
*BA83.50-
P-1001-01A
6 Unscrew 4 plastic nuts (3)
7 Remove undercarriage paneling (4)
Carefully pull line (5) out of
grommet and disconnect rear
8
refrigerant shutoff valve connector
(Y67x1)
Remove rear refrigerant shutoff valve
9
(Y67)
AR83.30-P-
6520M
REAR AIR CONDITIONING

BA83.50-P-1001-01A Union nut for rear air conditioning shutoff valve Nm 17
REMOVE AND INSTALL REAR AC HOUSING - AR83.50-P-9020M
MODEL 220
Fig. 52: Identifying Rear AC Housing Remove/Install Components (1 Of 2)
Fig. 53: Identifying Rear AC Housing Remove/Install Components (2 Of 2)
Remove/Install
Do not carry out any welding

work on the closed air
conditioning system or in the
surrounding area. No smoking or
Risk of explosion from welding or soldering open flames.
work on closed air conditioning system. Risk Wear eye protection and AS83.00-Z-
of poisoning . Inhaling overheated refrigerant protective gloves. 0001-01A
vapors may be toxic. Risk of injury from skin Work only in well ventilated
and eye contact with liquid refrigerant. areas. Carry out repair work on the
air conditioning system circuit
only after the system has been
discharged.
Procedures if air conditioning system is AH83.30-N-
damaged or leaking 0004-01A
Protect air conditioning circuit and components AH83.30-N-
from moisture when carrying out repair work 0005-01A
AH83.30-N-
Notes on handling refrigerant R134a
0003-01A
Resupply suctioned off
Drain air conditioning (recycle), evacuate, quantity of compressor oil to
1
charge, check for leakage refrigerant circuit when filling air
conditioning system (new oil)
Do not open cooling system unless
coolant temperature is below 90 °
Risk of injury to skin and eyes suffering C. Open cap slowly and release
AS20.00-Z-
scalding from contact with hot coolant spray. the pressure. Do not pour coolant
0001-01A
Risk of poisoning from swallowing coolant. into beverage bottles.
To do this, turn radiator cap
2 Reduce pressure in cooling system
into position "1" and reseal
AR20.00-P-
3 Drain coolant, pour in
1142HA
AR91.10-P-
4 Remove front seats until 31.8.02 1000M
AR91.10-P-
as of 1.9.02 1000MB
AR83.50-P-
5 Remove rear AC control module (N22/4)
9070M
AR68.20-P-
6 Remove center console (1) Except models 220.074/ 174. 2000M
AR68.20-P-
Only models 220.074/ 174. 2000AM
7 Spit back left and right floor covering
*BA83.50-
8 Unscrew bolt (2), close heat exchanger
P-1004-01A
9 Unplug connector (3)
Plug openings (parts kit)

10 Unscrew bolt (4), detach refrigerant lines (5)
Installation:
Replace O-rings.
Moisten thread with compressor
oil.
*BA83.50-
P-1003-01A
11 Unclip and detach air ducts (7)
12 Unscrew 4 bolts (6)
13 Remove rear air conditioning module (8).
AR83.30-P-
6520M
After completing the operations
15 Install in the reverse order correct engine coolant level.
Perform leakage test.
REAR AIR CONDITIONING UNIT

220
BA83.50-P-1003- Separation point of refrigerant lines at rear air conditioning
NM 8
01A evaporator
BA83.50-P-1004- Separation point of coolant lines to rear air conditioning heat
NM 8
01A exchanger
REMOVING, INSTALLING REAR AIR CONDITIONING BLOWER MOTOR - AR83.50-P-9040M
MODEL 220
Fig. 54: Identifying Rear Air Conditioning Blower Motor Remove/Install Components (1 Of 2)
Fig. 55: Identifying Rear Air Conditioning Blower Motor Remove/Install Components (2 Of 2)
Do not perform any type of welding
Explosion hazard when performing work on closed air conditioning system
welding or brazing work on closed air or in its vicinity. Smoking and open
AS83.00-
conditioning. Poisoning hazard from flame prohibited. Wear protective
Z-0001-
inhaling overheated refrigerant vapors. goggles and protective gloves, work only
01A
Injury hazard from skin and eye contact in well-ventilated rooms.
with liquid refrigerant. Perform repair work on air conditioning
AH83.30-
N-0004-
01A
components from moisture during repair N-0005-
work 01A
AH83.30-
01A
Add quantity of compressor oil
Empty air conditioning (recycle),
1 removed to refrigerant circuit when
charging air conditioning (new oil)
AR83.50-
2 Remove rear A/C housing (1)
P-9020M
AR83.60-
3 Remove rear blower regulator (N29/2)
P-9010M
Disconnect connectors (2) from rear
4
blower motor
5 Unclip 5 clips (3)
Remove housing (4) with rear blower
6
motor
8 Disconnect housing (4)
9 Unscrew screw (6)
Do not set rear blower motor
10 Remove rear blower motor (M2/1)
down on impeller
REMOVE/INSTALL STEPPER MOTOR OF CENTER NOZZLE/FOOTWELL FLAP OF REAR AIR

CONDITIONING - AR83.50-P-9060M
Fig. 56: Identifying Stepper Motor Of Center Nozzle/Footwell Flap Of Rear Air Conditioning
Remove/Install Components
Remove/Install
Remove rear AC control module AR83.50-P-
1
(N22/4) 9070M
AR68.20-P-
Only models 220.047/ 174. AR68.20-P-
2000AM
3 Disconnect connector (2)
Detach stepper motor of center
5
nozzle/footwell flap (4)
STAR-Diagnosis, menu item Actuations,
7 Synchronize the stepper motors
Synchronization of the actuator motors.
REMOVING AND INSTALLING REAR AIR CONDITIONING PUSHBUTTON CONTROL

MODULE - AR83.50-P-9070M
Fig. 57: Identifying Rear Air Conditioning Pushbutton Control Module Remove/Install Components
Unhook rear A/C pushbutton control module
(N22/3) with rear compartment nozzle from Do not use sharp tools. Rear
1 compartment nozzle cover and center
catch lugs (1) on top toward rear with plastic
wedge console could be damaged!
Fig.
58
4
Remove rear A/C pushbutton control module
(N22/3)
Fig. 58: Identifying Installation Wedge (115 589 03 59 00)
REMOVING AND INSTALLING REAR AIR CONDITIONING SYSTEM EVAPORATOR

TEMPERATURE SENSOR - AR83.50-P-9080M
Fig. 59: Identifying Evaporator Temperature Sensor (B10/11) Location
Remove/Install
1
(N22/4) 9070M
AR68.20-P-
AR68.20-P-
Only models 220.074/ 174. 2000AM
Detach connector at rear air
3 conditioning evaporator temperature
sensor (B10/11)
Pull rear air conditioning evaporator
4 temperature sensor (B10/11) out of
the AC housing
Set left and right temperature of rear AC
Turn on air conditioning and allow
6 control and operating module to "Lo" Switch
engine to idle for about 4 minutes
blower over to the maximum setting
Air outlet temperature at the center
7 Check function of air conditioning nozzle shall not fall below + 5°C, and if
necessary ?
8 carry out diagnosis.
REMOVING AND INSTALLING REAR AIR CONDITIONING SYSTEM HEAT EXCHANGER

TEMPERATURE SENSOR - AR83.50-P-9090M
Fig. 60: Identifying Heat Exchanger Temperature Sensor Location
Remove/Install
1
(N22/4) 9070M
AR68.20-P-
AR68.20-P-
Only models 220.074/ 174. 2000AM
Pull heat exchanger temperature sensor
4 for rear air conditioning, from the AC
housing on the left (B10/9)
Pull heat exchanger temperature sensor
5 for rear air conditioning from the AC
housing on the right (B10/10)
Set left and right temperature of rear
Turn on air conditioning and idle AC control and operating module to "Lo"
7
engine for about 4 minutes Switch blower over to the maximum
setting
Air outlet temperature at the center
8 Check function of air conditioning nozzle shall not fall below + 5° C, and if
necessary ?
9 carry out diagnosis.
REMOVING, INSTALLING REAR AIR CONDITIONING EVAPORATOR - AR83.50-P-9100M
Fig. 61: Identifying Rear Air Conditioning Evaporator Remove/Install Components (1 Of 2)

Fig. 62: Identifying Rear Air Conditioning Evaporator Remove/Install Components (2 Of 2)
Do not perform any type of welding
work on closed air conditioning
Explosion hazard when performing welding system or in its vicinity. Smoking
or brazing work on closed air conditioning. and open flame prohibited.
AS83.00-Z-
Poisoning hazard from inhaling overheated Wear protective goggles and
0001-01A
refrigerant vapors. Injury hazard from skin protective gloves, work only in
and eye contact with liquid refrigerant. well-ventilated rooms. Perform
repair work on air conditioning
AH83.30-
N-0004-
01A
AH83.30-
Protect air conditioning circuit and
N-0005-
components from moisture during repair work
01A
AH83.30-
01A
Add quantity of compressor
Empty air conditioning (recycle), evacuate, oil removed to refrigerant circuit
1
charge, check for leaks when charging air conditioning
(new oil)
AR83.50-
2 Remove rear A/C housing (1)
P-9020M
4 Remove housing upper section (3)
5 Remove evaporator (4)
AR83.30-
P-6520M
REMOVE AND INSTALL HEAT EXCHANGER FOR REAR AIR CONDITIONING - AR83.50-P-
9110M
Fig. 63: Identifying Heat Exchanger Remove/Install Components For Rear Air Conditioning
Remove/Install
Risk of injury to skin and eyes
coolant temperature is below 90 °C.
suffering scalding from contact with hot AS20.00-Z-
Open cap slowly and release the pressure.
coolant spray. Risk of poisoning from 0001-01A
Do not pour coolant into beverage
swallowing coolant.
bottles.
1 Reduce pressure in cooling system To do this, turn radiator cap into
position "1" and reseal
AR20.00-P-
2 Drain coolant, pour in
1142HA
3
(N22/4) 9070M
AR68.20-P-
AR68.20-P-
Only models 220.074/ 174.
2000AM
Remove connector at rear evaporator
5
temperature sensor
6 Unclip wiring harness (2) at top part of
housing
8 Remove top part of housing (4)
Unscrew bolt (5), close and remove *BA83.50-P-
9
heat exchanger (6) 1004-01A
AR83.30-P-
6520M
After completing the operations reset
11 Install in the reverse order engine coolant level and perform leak
test.
REAR AIR CONDITIONING UNIT

220
BA83.50-P-1004- Separation point of coolant lines at rear air conditioning heat
NM 8
01A exchanger
CORRECT OIL LEVEL IN AIR CONDITIONING SYSTEM WHEN REPLACING AC

COMPRESSOR - AR83.55-P-5250E
ENGINE 104, 111, 112, 601, 604, 605 in MODEL 202 with CODE (580) Air conditioning (or Tempmatic
for USA) with CODE (581) Automatic air conditioning AC compressor ND6CA17, AC compressor 7SB16
ENGINE 111, 112, 113 in MODEL 208 with CODE (580) Air conditioning (or Tempmatic for USA) with
CODE (581) Automatic air conditioning AC compressor 7SB16
ENGINE 104, 111, 112, 602, 604, 605, 606 in MODEL 210 with CODE (580) Air conditioning (or
Tempmatic for USA) with CODE (581) Automatic air conditioning AC compressor 7SB16
ENGINE 113, 137 in MODEL 215 AC compressor 7SE16
ENGINE 112, 113, 137 in MODEL 220 AC compressor 7SE16
ENGINE 112 in MODEL 170 AC compressor 7SB16
ENGINE 113.9 in MODEL 230 with CODE (581) Automatic air conditioning AC compressor 7SEU16C
ENGINE 155 in MODEL 199 AC compressor 7SEU16C
Correct
1 Drain removed refrigerant Use suitable measuring
compressor cup.
2 Measure oil quantity
3 Drain new refrigerant Use suitable measuring
compressor cup.
4 Measure oil quantity Perform work rapidly,
since compressor oil is
hygroscopic.
5 Fill new refrigerant Fill in the same
compressor with quantity of new
compressor oil compressor oil that was
measured in the
refrigerant compressor
which has been removed
Fill in an additional 10
3
cm for the new AC
compressor. Drained oil
from the new refrigerant
compressor can be used.
Model 140, 170, 202, *BF83.55-P-1001-01A
208, 210, 215, 220, 230
Model 199 *BF83.55-P-1001-01D
Number Designation A/C Refrigerant Refrigerant
7SB16 on 7SEU16C in ND6CA17 in
models 140, model 230 model 202
170, 202, 208,
210
BF83.55-P- Refrigerant Compressor oil cm3 120 120 155
1001-01A compressor Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
filling quantity for Operating 0362-00A 0362-00A 0362-00A
Fluids
compressor compressor
215 220
BF83.55-P- Refrigerant Compressor oil cm3 120 120
1001-01A compressor Specifications for Sheet BB00.40-P- BB00.40-P-
filling quantity Operating Fluids 0362-00A 0362-00A
Number Designation Type 199
BF83.55-P-1001- Refrigerant Compressor oil cm3 170
01D compressor filling Specifications for Sheet BB00.40-P-0362-
quantity Operating Fluids 00A
REMOVE/INSTALL REFRIGERANT COMPRESSOR - AR83.55-P-5300M
ENGINE 112, 113, 137, 613 in MODEL 220
Fig. 64: Identifying Refrigerant Compressor Remove/Install Components
Remove/install
Risk of explosion from welding or Never perform welding work on or near a
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
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.
AH83.30-
N-0004-
damaged or leaking
01A
AH83.30-
Notes on handling refrigerant R134a All models with R134a refrigerant N-0003-
01A
Drain air conditioning system Add quantity of compressor oil
1 (recycling), evacuate, fill, inspect for evacuated to refrigeration circuit when
leaks charging air conditioning (new oil).
Remove lower engine compartment AR61.20-P-
2.1 Engine 112, 113 and 137
paneling 1105M
AR13.22-P-
3 Slacken poly-V-belt and remove. Engine 112, 113 in model 220
1202BA
AR13.22-P-
Engines 613.960/961
1202HB
AR20.40-P-
4.1 Remove fan shroud Engine 113, 137 only. 6800AB
Vehicles with Active Body Control AR46.30-P-
5.1 Remove power steering pump
(code 487) only. 0500N
AR46.30-P-
5.2 Loosen power steering pump Model 220 with engine 613 only. 0500B
Unscrew the 3 mounting bolts; do not
disconnect lines.
Disconnect refrigerant compressor
6
(A9x1) plug-type connector
Unscrew bolts (1), remove suction line
7 Plug openings (parts kit).
and pressure line and place to one side
Engine 112, 113, 137 *BA83.55-
Bolt, refrigerant lines to refrigerant P-1002-01A
compressor
Engine 613.960/961 *BA83.55-
Bolt, refrigerant lines to refrigerant P-1003-01C
compressor
Unscrew bolts connecting front engine Engine 112 only.
8.1
mount to front axle carrier Unscrew on both sides
Engine 112.922/944 *BA22.10-
Bolt, front engine mount to front axle P-1001-01L
carrier
AR01.10-P-
9.1 Lift engine (approx. 60 mm) Only engine 112 7500-03I
Engine 112, 113, 137 *BA83.55-
10 Unscrew bolt (2)
Bolt, refrigerant compressor to bracket P-1001-01A
Engine 613.960/961 *BA83.55-
Bolt, refrigerant compressor to timing case P-1001-01C
cover
Engine 613.960/961 *BA83.55-
Bolt, refrigerant compressor to bracket P-1002-01C
Before installing a new refrigerant
compressor, slowly allow pressure in
11 Remove refrigerant compressor (A9) refrigerant compressor to dissipate by
loosening the pressure-side connector
cover.
Replace O-rings (moisten with
compressor oil) if the AC compressor is not
to be replaced.
Correct the oil level in the refrigerant AR83.55-P-
12
compressor 5250E
If the AC compressor has been
replaced because of damage caused by an
internal fault: ?
Replace suction and pressure lines
together with sealing rings
Note oil filling quantity on replacement *BF83.55-
of the lines: ? P-1006-01A
*BF83.55-
P-1007-01A
AR83.30-P-
Replace expansion valve
5520M
AR83.30-P-
6520M

113.941/960, 137.970 in model 220 in model 220
Bolt, front engine
BA22.10-P-
mounts to front axle Nm 35 35
1001-01L
carrier
Number Designation Engine 112.922/ 944 in Engine 113.960 in
model 220 model 215
BA83.55-P- Bolt, refrigerant compressor to
Nm 20 20
1001-01A bracket
BA83.55-P- Bolt, refrigerant lines to
Nm 20 20
1002-01A refrigerant compressor
Number Designation Engine 113.941/ 960 in Engine 137.970 in
model 220 model 215, 220
BA83.55-P- Bolt, refrigerant compressor to
Nm 20 20
1001-01A bracket
BA83.55-P- Bolt, refrigerant lines to
Nm 20 20
1002-01A refrigerant compressor
Number Designation Engines 613.960/961
BA83.55-P-1001-01C Bolt of refrigerant compressor to timing case cover Nm 20
BA83.55-P-1002-01C Bolt, refrigerant compressor to bracket Nm 20
BA83.55-P-1003-01C Bolt, refrigerant lines to refrigerant compressor Nm 20
in model 215 in model 220
cm 20 20
BF83.55-P-
1006-01A
replacing suction line Operating Fluids Sheet 00A 00A
cm 10 10
BF83.55-P-
1007-01A
replacing pressure line Operating Fluids Sheet 00A 00A
REMOVING AND INSTALLING REAR BLOWER REGULATOR - AR83.60-P-9010M
Fig. 65: Identifying Blower Regulator (N29/2) Location
Remove/Install
AR83.50-P-
1 Remove rear AC control module (N22/4)
9070M
Except models AR68.20-P-
2 Remove center console (1)
220.074/ 174. 2000M
Only model 220.074/ AR68.20-P-
174. 2000AM
Remove electronic blower controller for rear air
5
conditioning (N29/2)
REMOVING AND INSTALLING REAR DUOVALVE/COOLANT CIRCULATION PUMP

COMPACT UNIT - AR83.60-P-9050M
Fig. 66: Identifying Rear Duovalve/Coolant Circulation Pump Compact Unit Remove/Install
Components
Open cooling system only when coolant temperature
Danger of severe burns to
is below 90 °C. Open cover slowly and reduce
skin and eyes from hot AS20.00-Z-
pressure. Do not fill beverage containers with
coolant spewing out. Coolant 0001-01A
is toxic when swallowed
and protective goggles.
Release pressure in cooling For this purpose, turn radiator cap to catch "1"
1
system and close again
AP40.10-P-
2 Remove right front wheel
4050Z
Remove right front inner AR88.10-P-
3
fender 1300M
4 Unscrew 2 nuts (1)
5 Remove rear auxiliary heater

supply unit (A31/1) with
bracket
6 from coolant circulation
pump
7
from duovalve
Attach clamps to heater hoses
8 Fig. 7
(2)
Loosen hose clamps (3), pull
9
off heater hoses (2)
Push rubber mount (4) for
rear auxiliary heater supply
10
unit (A31/1) out of mount
and remove
Installation: After completion of work correct
coolant level and check for leakage

ENGINE
Crank Assembly - 215 & 220 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: CRANK ASSEMBLY - AH03.00-Z-9999AZ
MODEL all
Assignment of the piston to the AH03.10-P-

ENGINE 166.940/960/990/995
cylinder bore 0001-02GF
General information on
AH03.20-P-
assigning balancing shaft to ENGINE 112
1000-01AV
engine
Assignment of pistons to AH03.10-P-
ENGINE 266.920 /940 /960 /980
cylinder bore 0001-02AK
ENGINE 134.9, 135.9 in MODEL 454.0
cylinder bore 0001-02FF
ENGINE 639.939 in MODEL 454.0
cylinder bore 0001-02FG
AH03.20-N-
Bearing diagram of crankshaft ENGINE 601.943,602.980/981 /982/983/984 /985
4351-01B
Installation notes for AH03.20-P-
ENGINE 120
crankshaft radial shaft seals 0001-01AO
AH03.20-P-
Bearing diagram for crankshaft ENGINE 266.920 /940 /960 /980
4351-01AK
AH03.20-P-
Bearing diagram of crankshaft ENGINE 640
4351-01AL
AH03.20-P-
Bearing diagram of crankshaft ENGINE 601, 602, 603 (except, 602.98)
4351-01AW
AH03.20-P-
Bearing diagram of crankshaft ENGINE 639.939 in MODEL 454.0
4351-01FG
AH03.20-P-
4351-01TK
Precision fit of crankshaft AH03.20-P-
ENGINE 266.920 /940 /960 /980
bearing cap 4351-02AK
Interference fit of crankshaft AH03.20-P-
ENGINE 640
bearing cap 4351-02AL
ENGINE 134.9, 135.9 in MODEL 454.0
bearing cap 4351-02FF
Interference fit of the AH03.20-P-
crankshaft bearing cap 4351-02FG
Precision fit of crankshaft ENGINE 271 AH03.20-P-

bearing cap 4351-02TK
ENGINE 273
bearing cap 4351-02SX
ENGINE 272
bearing cap 4351-02VA
ENGINE 611,612,613...
bearing cap 4351-02C
ENGINE 668.940 /941 /942
cylinder bore 0001-02GD
AH03.20-N-
4351-01A
AH03.20-P-
Bearing diagram of crankshaft ENGINE 166,668
4351-01GF
Interference fit of crankshaft ENGINE 111 / 601.943, AH03.20-P-
1/4
bearing cap 602.980/981 /982 /983 /984 /985, 604, 605, 606 4351-02A
ENGINE 166,668
bearing cap 4351-02GF
GENERAL INFORMATION ON ASSIGNING BALANCING SHAFT TO ENGINE - AH03.20-P-1000-

01AV
Engine 112
1. Front correctional weight

2. Rear correctional weight
3. Balancing shaft
Balancing shafts where the correctional weights have this form (refer image), can be fitted in the
engines
112.910
112.911
112.913
112.914
112.915
112.920
112.921
112.922
112.923
Fig. 1: Balancing Shaft Rear And Front Correctional Weight (1 Of 2)
4. Front correctional weight

5. Rear correctional weight
6. Balancing shaft
Balancing shafts where the correctional weights have this form (refer image), can be fitted in the
engines
112.940
112.941
112.942
112.943
112.944
112.945
112.949
Fig. 2: Balancing Shaft Rear And Front Correctional Weight (2 Of 2)
BASIC KNOWLEDGE
CONNECTING ROD GENERAL - GF03.10-P-9611-01C
Connecting rod
Forged steel connecting rod cracked.
The connecting rod is forged in one piece and has a specified fracture point (a) in the middle of the crankshaft
boss, at which it is cracked.
This ensures more accurate fit than was previously the case between connecting rod and conrod bearing cap.
Fig. 3: Identifying Connecting Rod Specified Fracture Point
GENERAL INFORMATION ON CRANKSHAFT - GF03.20-P-9611-01AA
Crankshaft
Steel-forged and supported on seven bearings, the fifth main bearing designed as a fitted bearing with shims.
Two connecting rods of the opposite cylinders in each case are assigned to each crank.
Main bearing Ø 63,940 -63,965 mm I-VII
Conrod bearing Ø 45,940 -45,965 mm 1-12
Stroke 87 mm
The tolerance subdivision for lower half of main bearings and fitted bearing shims identified with laser text on
front crankshaft journal, same as M112 and 113.
Fig. 4: Identifying Crankshaft
BELT PULLEY/VIBRATION DAMPER ARRANGEMENT - GF03.30-P-1600-01C
Engines 112, 113
Shown on engine 112
Fig. 5: Identifying Belt Pulley/Vibration Damper Arrangement
FLYWHEEL, TWO-MASS FLYWHEEL, DRIVEN PLATE ARRANGEMENT - GF03.30-P-8001-01B
Engine 112, 113
Shown on engine 112

Fig. 6: Locating Flywheel, Two-Mass Flywheel, Driven Plate Arrangement
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY - AR03.00-Z-9112AB
ENGINE 112
Piston removal and ENGINE 112, 113... AR03.10-P-7021AV

installation
Remove/install piston ENGINE 112, 113... AR03.10-P-7311BV
rings
Remove/install balancing ENGINE 112 AR03.20-P-1000A
shaft
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 112.973 in AR03.20-P-3000R
radial sealing ring MODEL 230.467
Replace rear crankshaft ENGINE 112, 113... AR03.20-P-3063B
radial sealing ring
Inspect basic position of ENGINE 112 AR03.20-P-3637AV
the balancing shaft
Remove/install crankshaft ENGINE 112 AR03.20-P-4351AV
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 retaining ENGINE 112, 113, 137, AR03.30-P-5000B
lock for crankshaft / ring 275...
gear
Remove/install flywheel / ENGINE 112, 113, 137... AR03.30-P-8001C
drive plate
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
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
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
ENGINE 113.990 in
MODEL 219.376
Replace rear crankshaft ENGINE 113.988 in AR03.20-P-3063AC
radial sealing ring MODEL 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Replace rear crankshaft ENGINE 112, 113... AR03.20-P-3063B
radial sealing ring
Replace rear crankshaft ENGINE 113.964 in AR03.20-P-3063GZ
radial seal MODEL 164.175
Replace rear crankshaft ENGINE 113.971 in AR03.20-P-3063RT
radial seal MODEL 251.075 /175
Replacing rear crankshaft ENGINE 113... AR03.20-P-3063RVK
radial seal
Replace rear crankshaft ENGINE 113.967 in AR03.20-P-3063TY
radial 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
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install belt ENGINE 112, 113... AR03.30-P-1600C
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 ENGINE 112, 113, 137, AR03.30-P-5000B
lock for crankshaft / ring 275...
gear
Removing/installing ENGINE 113.964 in AR03.30-P-5000GZ
retaining lock for MODEL 164.175 with
crankshaft / ring gear TRANSMISSION 722.901
Removing/installing the ENGINE 113.971 in AR03.30-P-5000RT
retaining lock for MODELS 251.075 /175
crankshaft / ring gear
Removing/installing the ENGINE 113.967 in AR03.30-P-5000TY
retaining lock for MODEL 219.375
crankshaft / ring gear ENGINE 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 137
AR03.10-P-
Piston removal and installation ENGINE 137.970
7021L
AR03.10-P-
Removing/installing piston rings ENGINE 137.970
7311L
Replace front crankshaft radial AR03.20-P-
ENGINE 137 in MODEL 220
seal ring 3000L
Replace rear crankshaft radial AR03.20-P-
sealing ring ENGINE 137 in MODEL 220, 215 3063L
AR03.20-P-
Remove/install crankshaft ENGINE 137.970
4351L
Measuring crankshaft and ENGINES 137.970, AR03.20-P-
remounting in bearings 275.950 /951 /953 /954 /980 /981 /982 4355L
Remove/install belt ENGINE 137 in MODEL 215, 220 ENGINE 275 in AR03.30-P-
pulley/vibration damper MODEL 215, 216, 220, 221, 230 1600L
Remove/install retaining lock for AR03.30-P-
ENGINE 112, 113, 137, 275 ...
crankshaft / ring gear 5000B
Remove/install flywheel / drive AR03.30-P-
ENGINE 112, 113, 137 ...
plate 8001C
ENGINE 275
AR03.10-P-
Piston removal and installation ENGINE 275
7021MC
Replace front crankshaft radial AR03.20-P-
ENGINE 275
sealing ring 3000MC
ENGINE 275 in MODEL 215, 216, 220, 221
seal 3063MC
sealing ring 3063R
AR03.20-P-
Remove/install crankshaft ENGINE 275 in MODEL 215, 216, 220, 221
4351MC
AR03.20-P-
Remove/install crankshaft ENGINE 275 in MODEL 230
4351R
Measuring crankshaft and ENGINES 137.970, AR03.20-P-
remounting in bearings 275.950 /951 /953 /954 /980 /981 /982 4355L
Remove/install belt ENGINE 137 in MODEL 215, 220 ENGINE 275 in AR03.30-P-
pulley/vibration damper MODEL 215, 216, 220, 221, 230 1600L
Remove/install retaining lock AR03.30-P-
ENGINE 112, 113, 137, 275 ...
for crankshaft / ring gear 5000B
Remove/install retaining lock AR03.30-P-
ENGINE 275 in MODEL 216, 221
for crankshaft / ring gear 5000SZ
Remove, install flywheel / AR03.30-P-
ENGINE 275 in MODEL 215, 216, 220, 221
drive plate 8001MC
Remove/install flywheel/driven AR03.30-P-
plate 8001R
INSTALLING AND GAUGING CONNECTING ROD BEARINGS - AR03.10-P-6111
Inspect connecting rod bolts - AR03.10-P-6111-01BV

TEST DATA FOR CONNECTING ROD BOLTS
Number Designation Engine 112 Engine
except 113.987/988/
112.951/976, 990/991/993
Engines
113.94/96/971/
980/981/982/
984/986
BE03.10-P- connecting rod Thread dia. Ø M 8x1 8x1
1001-03A bolts Shank length when new mm 47 41.7...42.3
max. mm 47.6 42,5
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. 7: Identifying Shank Length
Inspect connecting rod bolts - AR03.10-P-6111-01L
CHECK VALUES FOR CONNECTING ROD BOLTS

Number Designation Engine 137, 275, 285
Thread dia. Ø M7 x 1
When new mm 38
BE03.10-P-1001-03A Connecting rod bolts
Shank length Max. mm 38.4
Part no. -
1. Measure length (L).
If the length (L) of connecting rod bolts exceeds the maximum permissible dimension then the connecting
rod bolts must be replaced.
Fig. 8: Identifying Connecting Rod Shank Length
Tightening conrod screws - AR03.10-P-6111-02BV
CONNECTING ROD
Number Designation Engine 112,113
BA03.10-P-1001- Connecting rod bolt Stage 1 Nm 5
01E Stage 2 Nm 25
Stage 3 Angle° 90
Fig. 9: 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 connecting rod bolts using an angle wrench to step 3.
If no torquing angle wrench is available, the 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.
Fig. 10: Tightening Connecting Rod Bolts Using An Angle Wrench
Shown on engine 112
Tightening connecting rod screws - AR03.10-P-6111-02L
CONNECTING ROD
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15 15
Stage 3 Angle° 90 90
1. Coat thread and head contact surfaces of bolt with engine oil.
2. Pretighten connecting rod bolts with torque (stage 1, stage 2).
3. Tighten connecting rod bolts using an angle wrench to stage 3.
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.
Fig. 11: Identifying Connecting Rod Bolts Tightening Angle

Installing and gauging connecting rod bearings - AR03.10-P-6111-06AV
MODIFICATION NOTES
Figure revised from Value modified in BE03.20-P-1002-04E on engine 112
*BE03.20-
10.3.04 0.026...0.054 mm to except 112.951, 113.940/941/942/943/944/948/
P-1002-04E
0.022...0.067 mm 960/961/963/965/966/967/968/980/981 / 984/986
Value modified from
*BE03.20-
10.3.04 0.022...0.072 mm to Value modified in BE03.20-P-1002-04E for engine 113.992
P-1002-04E
0.022...0.067 mm
CHECK VALUES OF CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 112 Engine Engine
except 113.987/988/989 /990/991/993 113.992/995
112.951/976,
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 mm 0.026 to 0.050 0.026 to 0.050 0.026 to
1002-04E rod when new 0.050
bearing
play
CONNECTING ROD
Number Designation Engine 112 except
112.951/976, 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
01E Stage 2 Nm 25
Stage 3 Angle° 90
1. Clean the bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing
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 may be combined, yellow with
yellow and red with blue.
The sequence of the individual color combinations on the connecting rod bearing journals can be selected
at random.
3. Insert connecting rod bearing shells (7) into the connecting rod (4) and connecting rod bearing cap
The connecting rod bearing shell (7) with the oil drilling (arrow) must be installed in the connecting
rod (4) otherwise the connecting rod bearings will not be lubricated.
The anti-twist locks (8) of the connecting rod bearing shells (7) must be located in the slots (9) of the
connecting rods (4) and the connecting rod bearing caps.
Fig. 13: Locating Bearing Points Of Connecting Rod
4. Install connecting rod bearing cap with connecting rod bearing shells (7).
5. Lubricate thread and bolt head contact surface of connecting rod bolts with engine oil.
6. Screw in connecting rod bolts and tighten to step 1 .
Shown on engine 112
Fig. 14: Locating Connecting Rod Bearing Cap With Connecting Rod Bearing Shells
7. Tighten connecting rod bolts to step 2 .

8. Tighten connecting rod bolts using an angle wrench to step 3 .
specified angle in a single operation using a wrench and tommy bar.
Installing and gauging connecting rod bearings - AR03.10-P-6111-06L
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 137 Engines 275.95, Engines 275.98,
285.95 285.98
BE03.20-P- Connecting rod radial
mm 0.017...0.052 0.026...0.059 0.019...0.048
1002-04E bearing play when new
CONNECTING ROD
Number Designation Engine 137 Engines 275, 285
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15 15
Stage 3 Angle° 90 90
1. Clean bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing journals
with a chamois leather and.
Blow through oil galleries in direction of flow oil with compressed air.
Do not use any hard objects for cleaning.
2. The assignment of connecting rods to connecting rod bearing journals is indicated on the back of
connecting rod bearing shells by a colored dot.
Only the following color combinations of connecting rod bearing shells may be fitted to each other.
A. Upper connecting rod bearing shells of connecting rod in yellow, lower connecting rod bearing
shells in connecting rod bearing cap in yellow
or
B. Upper connecting rod bearing shells of connecting rod in blue, lower connecting rod bearing shells
in connecting rod bearing cap in red
or
C. Upper connecting rod bearing shells of connecting rod in red, lower connecting rod bearing shells
in connecting rod bearing cap in blue
The sequence of the individual color combinations on the connecting rod bearing journals can be
selected at random.
3. Insert connecting rod bearing shell (7) into connecting rod (4) and connecting rod bearing cap.
Connecting rod bearing shells (7) with oil holes (arrow) must be fitted in the connecting rods,
otherwise the connecting rod bearings will not be lubricated. The anti-twist locks (8) of the connecting
rod bearing shells (7) must be located in the grooves (9) in the connecting rod (4) and the connecting rod
bearing cap.
4. Wet thread and head contact surfaces of bolt with engine oil.
5. Pretighten connecting rod bolts with torque (stage 1, stage 2).
Fig. 15: Locating Connecting Rods Oil Holes
6. Tighten connecting rod bolts using an angle wrench to stage 3.
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.
Fig. 16: Identifying Connecting Rod Bolts Tightening Angle
PISTON REMOVAL AND INSTALLATION - AR03.10-P-7021
Piston removal and installation - AR03.10-P-7021AV
ENGINE 112
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Shown on engine 112

Fig. 17: Identifying Piston Position
Removing
toppling off of the lifting
platform and position the
1 Remove engine Model 463.206/ 209/ 232/ AR01.10-P-2400CC
233/ 240/ 241
Model 463.244/ 245/ 247/ AR01.10-P-2401GT
248/ 249/ 250/ 254
Model 463.243/ 246 AR01.10-P-2401MG
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-2400RVK
Model 220 without AR01.10-P-2400AB
4MATIC
Model 210 with 4MATIC AR01.10-P-2400C
Model 129, 202, 208, 210 AR01.10-P-2400CB
without 4MATIC
Model 203 without AR01.10-P-2400PV
4MATIC, 209 with engine
112
Model 209 with engine 113 AR01.10-P-2400Q
Models 211.061/065/070 AR01.10-P-2400TC
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
2.1 Remove automatic Model 463.206/ 209/ 232/ AR27.10-P-0500BD
transmission from engine 233/ 240/ 241
Model 463.243/ 244/ 245/ AR27.10-P-0500GA
246/ 247/ 248/ 249/ 250/
254
Model 230.475 AR27.10-P-0500R
Model 230.474
Model 220 without AR27.10-P-0500I
4MATIC
Models 129, 170, 202, 208, AR27.10-P-0500B
210
4MATIC, 209 with engines
112, 113
Model 211.061/065/070 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
2.2 Remove manual Models 129, 202, 210 AR26.10-P-0020A
transmission from engine Models 203, 209 with AR26.10-P-0020P
engine 112
Model 211.061 AR26.10-P-0020T
Model 208 with AR26.10-P-0020E
transmission 716.662/622
Model 170, AR26.10-P-0020D
Model 208 with
transmission 716.663
3 Remove oil pan top Model 463.206/ 209/ 232/ AR01.45-P-7500FG
section 233/ 240/ 241/ 243/ 244/
245/ 246/ 247/ 248/ 249/
250/ 254
Model 230. AR01.45-P-7500R
4MATIC
Model 210 with 4MATIC AR01.45-P-7500FA
Model 210 without AR01.45-P-7500F
4MATIC
Models 208, 202 AR01.45-P-7500FC
112, 113
Models 211.061/065/070 AR01.45-P-7500TV
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
4 Take off cylinder head Remove intake manifold
with complete wiring
harness during this step.
Model 463.206/ 209/ 232/ AR01.30-P-5800GV
233/ 240/ 241/ 243/ 244/
245/ 246/ 247/ 248/ 249/
250/ 254 Engine 112 in
model 129 and engine 113
in model 129, 202, 208, 210
Engine 112 in
Model 170, 202, 208, 210, AR01.30-P-5800B
220 and Engine 113 in
Model 220, 230.474 /475 AR01.30-P-5800BA
Model 163 AR01.30-P-5800MV
Model 203, 209 with engine AR01.30-P-5800PV
112, 113
Models 211.061/065/070
5 Remove oil pump For this step, push back
chain tensioner and take off
chain.
All except 203, 209, AR18.10-P-6020B
211.061/065/070, 220
without 4MATIC,
230.474 /475
4MATIC, 209,
211.061/065/070
Model 203 with 4MATIC, AR18.10-P-6020PW
model 220 with 4MATIC
Model 230.474/475 AR18.10-P-6020R
6 Remove connecting rod For this step, mark
bearing cap (5) conrod (4) and connecting
rod bearing cap (5) on one
side relative to each other.
7 Remove conrod (4) If pistons have been used
together with pistons (3) (3), the arrows indicating
by lifting up and out the direction of the travel
and the markings on the
pistons may no longer be
visible due to carbon
deposits. For this reason,
remove the carbon deposits
from the pistons. If the
arrows indicating direction
of travel on the pistons are
no longer recognizable,
these must be re-marked.
8 Remove circlip (1) of Do not damage piston
piston pin (2) (3). Place a clean cloth
underneath.
9 Press out piston pin (2)
Install
10 Assign piston (3) to AR03.10-P-7021-02BV
cylinder bore
11 Oil piston pin (2) and
conrod bush
12 Assemble piston (3) and Install piston (3) with
conrod (4) arrow in direction of travel.
13 Push in piston pin (2) by
hand
14 Insert circlip (1) of piston Do not damage piston
pin (2) in the groove on (3). Place a clean cloth
piston (3) underneath.
15 Oil the cleaned parts
(cylinder bore, conrod
bearing journal, conrod
bearing shells and
pistons)
16 Fit the tensioning strap Piston ring gaps must be Fig. 18
(10) and tighten offset 120°.
Tensioning strap
17 Install piston (3) with Rotate crankshaft
arrow pointing in sufficiently so that the
direction of travel connecting rod does not
touch the connecting rod
journal when the piston is
pushed into the cylinder
bore.
18 Inspect the conrod bolts Thread and shank length AR03.10-P-6111-01BV
(6) *BE03.10-P-1001-03A
19 Install the conrod The connecting rod AR03.10-P-6111-06AV
bearings and fit the bearing shell (7) with oil
conrod bearing cap (5) drilling (arrowed) must be
mounted in the connecting
rod, otherwise the piston
pin (2) is not lubricated.
The anti-twist locks (8) of
the connecting rod bearing
shells (7) must be seated in
the grooves (9) in the
conrods (4) and connecting
rod bearing caps (5).
The connecting rod and
connecting rod bearing cap
are cracked (broken)
(arrowed). They must not
be installed the wrong way
round!
20 Tighten conrod bolts (6) AR03.10-P-6111-02BV
*BA03.10-P-1001-01E
21 Rotate crankshaft To check for
unobstructed movement.
22 Install oil pump  Ensure that the oil
return shutoff valve is
correctly located.
 Clean the oil pump
strainer.
 Fill the oil pump with
engine oil before
installing, so that oil
is delivered at the
initial startup.
All except 203, 209, AR18.10-P-6020B
211.061/065/070, 220
without 4MATIC,
230.474 /475
4MATIC, 209,
211.061/065/070
model 220 with 4MATIC
Model 230.474/475 AR18.10-P-6020R
23 Fit the cylinder head Model 463.206/ 209/ 232/ AR01.30-P-5800GV
233/ 240/ 241/ 243/ 244/
245/ 246/ 247/ 248/ 249/
250/ 254
Engine 112 in model 129 AR01.30-P-5800B
and engine 113 in model
129, 202, 208, 210
Engine 112 in Model 170, AR01.30-P-5800BA
202, 208, 210, 220 and
Engine 113 in Model 220,
230.474 /475
Model 163 AR01.30-P-5800MV
Model 203, 209 with AR01.30-P-5800PV
Engine 112, 113
Models 211.061/065/070
24 Fit the oil pan top section Model 463 AR01.45-P-7500FG
Model 230.474/475 AR01.45-P-7500R
4MATIC
4MATIC
Models 208, 202 AR01.45-P-7500FC
112, 113
Models 211.061/065/070 AR01.45-P-7500TV
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
25.1 Fit the automatic Model 463.206/ 209/ 232/ AR27.10-P-0500BD
transmission 233/ 240/ 241
Model 463.243/ 244/ 245/ AR27.10-P-0500GA
246/ 247/ 248/ 249/ 250/
254
Model 230.475 AR27.10-P-0500R
Model 230.474
4MATIC
Model 210, 208, 202,170. AR27.10-P-0500B
129
112, 113
Models 211.061/065/070 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
25.2 Fit on manual Models 210,202, 129 AR26.10-P-0020A
transmission Models 203, 209 with AR26.10-P-0020P
engine 112
Model 211.061 AR26.10-P-0020T
transmission 716.662/622
Model 170, AR26.10-P-0020A
Model 208 with AR26.10-P-0020D
transmission 716.663
26 Install engine Model 463.243/ 244/ 245/ AR01.10-P-2400CC
246/ 247/ 248/ 249/250/
254
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-2400RVK
4MATIC
Model 210 without AR01.10-P-2400CB
4MATIC, 208, 202, 129
4MATIC, 209 with engine
112
Model 209 with engine 113 AR01.10-P-2400Q
Model 211.061/065/070 AR01.10-P-2400TC
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
TEST DATA FOR CONROD BOLTS

except 113.992/995
112.951/976,
engine
113.94/96/971/
980/981/982/
984/986
BE03.10-P- Conrod bolts Thread dia. Ø M 8x1 8x1
1001-03A Shank length When new mm 47 42
Max. mm 47.6 42.6
Part no. - -
CONNECTING ROD
01E Stage 2 Nm 25
Stage 3 Angle° 90
Fig. 18: Identifying Retaining Strap (000 589 04 14 00)
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

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
Repair size mm 97.250 to 97.265
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

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. 19: 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. 20: Identifying Cylinder Bore Diameter On Engines
Piston removal and installation - AR03.10-P-7021L
ENGINE 137.970
Shown on the piston of a crankshaft journal

Fig. 21: Identifying Piston Remove/Install Components - Shown On Piston Of Crankshaft Journal
(Engine 137.970)
Removing
AR01.10-P-
1 Remove engine
2400L
Detach automatic AR27.10-P-
2
transmission from engine 0500I
Take engine mounts off
3
engine support
Mount engine onto
4
assembly stand
AR01.30-P-
5 Remove cylinder head
5800L
AR01.45-P-
6 Remove oil pan
7500L
Remove oil deflector
7
plate
Mark connecting rod (2) and connecting rod bearing
cap (1) relative to each other so that parts are not mixed
up when installing.
Remove connecting rod
8 The connecting rod (2) and connecting rod bearing
bearing cap (1)
cap (1) are cracked (broken) (magnified section). They
must not be installed on wrong side since the accuracy of
fit would no longer be given.
Mark connecting rod
bearing shell and
9
connecting rod bearing
cap (1) to each other
Mark position of pistons
Do not mix up piston (4a, 4b) with each other since
10 (4a, 4b) and cylinder liner
this can lead to engine damage.
relative to each other
Observe the identification arrow on the piston crown.
On pistons which are used, the identification arrow of the
Remove connecting rod pistons may no longer be visible because of carbon
11
(2) together with pistons deposits. The carbonization must therefore be removed
from the piston. If the identification arrow is no longer
recognizable on the piston, the piston must be marked
again.
Mark connecting rod
bearing shell and Do not mix up the upper and lower connecting rod
12
connecting rod (2) to each bearing shell as this can lead to engine damage.
other
Remove circlip (5) of Use a clean shop towel as a base so that the piston is
13
piston pin (6) not damaged.
The connecting rod (2) is not marked so mark
14 Press out piston pin (6) connecting rod (2) and piston relative to each other so
that connecting rod (2) can be reinstalled in its original
installation position with piston.
Inspect connecting rods Connecting rods with blue discoloration (as a result of
15 for blue discoloration, bearing damage), with cross scores and notches must be
cross scores and notches replaced as this can lead to engine damage.
Install
Assigning a standard size AR03.10-P-
16
piston to a cylinder bore 7021-02L
Oil piston pin (6) and
17
connecting rod bush
Assemble piston (4a, 4b) Installation: When assembling ensure that broad side
18 (a) of connecting rod collar points in direction of crank
and connecting rod (2)
web in the installed condition
Push in piston pin (6) by
19
hand
Insert snap ring (5) for
Use a clean rag as a base so that the piston is not
20 gudgeon pin (6) into
damaged.
groove in piston
Lubricate cleaned
cylinder bores, connecting
21 rod journals, connecting
rod bearing shells and
pistons (4a, 4b)
Offset piston ring gaps 120°.
Fit on tensioning strap (7) When installing piston, piston ring end gap of first piston
22 for piston rings and ring (upper piston ring) points in direction of travel
tension towards the front while other end gaps are each offset by
120°.
Fig. 18
Install piston (4a, 4b) with To prevent damage during installation, turn
23 crankshaft until connecting rod (2) does not touch
arrow pointing in
direction of vehicle front connecting rod journal while inserting the respective
piston (4a, 4b).
Inspect the connecting rod AR03.10-P-
24
bolts (3) 6111-01L
Insert connecting rod In accordance with markings; do not mix up top and
bearing shell into bottom connecting rod bearing shells.
25 connecting rod (2) and The anti-twist locks of connecting rod bearing shells
connecting rod bearing must seat in grooves of connecting rods (2) and
cap (1) connecting rod bearing caps (1).
Install connecting rod Bolt connecting rod bearing cap (1) and connecting AR03.10-P-
26
bearing cap (1) rod (2) to each other with the markings (arrows) lined up. 6111-02L
The contact surfaces must be free of oil and grease *BA03.10-
and must not have any damage. P-1001-01E
27 Install oil deflector plate
AR01.45-P-
28 Installing oil pan
7500L
AR01.30-P-
29 Install cylinder head
5800L
Install engine mounts at *BA22.10-
30
engine support P-1004-01L
Mount automatic AR27.10-P-
31
transmission on engine 0500I
AR01.10-P-
32 Install engine
2400L

113.941/960, 137.970 in model 220 in model 220
Bolt, front engine
BA22.10-P-
mount to engine Nm 55 55
1004-01L
support

Number Designation Engine 137.970 in model 215
BA22.10-P-1004-01L Bolt, front engine mount to engine support Nm 55
CONNECTING ROD
Stage 1 Nm 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15
Stage 3 Angle° 90
Assign standard size piston to cylinder bore - AR03.10-P-7021-02L

Standard marking X mm 83.975 to 84.003
BE03.10-P-1001-02E Piston dia. Ø
Auxiliary stage marking mm 84.025 to 84.053
Standard marking X mm < or = 0,04
BE03.10-P-1002-02E Piston clearance
Auxiliary stage Marking mm < or = 0,04

Number Designation Engine 275, 285.950
Standard Step markings X mm 81.974 to 82.004
BE03.10-P-1003-02F Piston dia. Ø
Step marking mm -
BE03.10-P-1004-02F Piston clearance Standard mm < or = 0.04

Number Designation Engine 137.970 Engine
275.950/951/953/954,
285.950
BE01.40-P- Cylinder dia. Standard mm 84.000 to 84.015 82.000 to 82.015
1001-01G marking X
Auxiliary size mm 84.050 to 84.065 82.050 to 82.065
marking
BE01.40-P- Cylinder Wear limit in mm 0.20 0.2
1002-01G bore longitudinal
and lateral
direction
BE01.40-P- Cylinder Permissible mm 0.000...0.007 0.000...0.007
1003-01G bore deviation from
a cylindrical
shape (when
new)
Wear limit mm 0.05 0.05
BE01.40-P- Cylinder Run-out mm 0.07 0.07
1004-01G bore
BE01.40-P- Cylinder Peak-to-valley mm 0 to 0.0045 0 to 0.0045
1005-01G bore height (R3 Z )

Number Designation Engine 275.980/981/982
285.980
BE01.40-P-1001- Cylinder Standard marking X mm 82.600 to 82.615
01G dia. Auxiliary size marking mm 82.650 to 82.665
BE01.40-P-1002- Cylinder Wear limit in longitudinal and lateral
mm -
01G bore direction
Permissible deviation from a cylindrical
BE01.40-P-1003- Cylinder mm -
shape (when new)
01G bore
Wear limit mm -
BE01.40-P-1004- Cylinder
Run-out mm -
01G bore
BE01.40-P-1005- Cylinder Peak-to-valley height (R3Z ) mm -
01G bore
1. Assign piston to the cylinder bore
The cylinder bore diameter is specified in two tolerances. The two tolerances of the cylinder bore
diameters are distinguished by the letters x and
This marking is located at the bottom right on the crankcase at the mount for the engine support.
The piston diameters result from the tolerances (standard, auxiliary stage) of the cylinder bore diameters
and do not have a marking of their own. If necessary, the piston diameter can be read off on the piston
crown.
Fig. 23: Identifying Tolerances Of Cylinder Bore Diameters
No piston with a standard diameter in should be installed in a cylinder bore with
identification
 Piston with standard diameter in cylinder bore with standard diameter (marking x)
 Piston with auxiliary diameter in cylinder bore with auxiliary diameter (identification marking
Piston removal and installation - AR03.10-P-7021MC
ENGINE 275
Shown on piston for a crankshaft journal

Fig. 24: Identifying Piston Remove/Install Components - Shown On Piston Of A Crankshaft Journal
(Engine 275)
MODIFICATION NOTES
Remove, install engine 275.951/981 with front axle carrier - added Steps 1.2, 33.2
22.11.05 Remove, install engine 275.951/981 transmission - added Steps 2.1, 32.1
Remove, install engine 275.951/981 from front axle carrier - added Steps 3.1, 31.1
Removing
Removal of piston on the
left occurs (4b) analog to
removal of piston on the
right (4a)
Model 215, 220 except 220 with special protection
version, code 979, light armoring, code Z04 or top
AR01.10-P-
1.1 Remove engine protection, code Z07
2400MC
Model 220 with special protection version, code 979,
light armoring, code Z04 or top protection, code Z07
Remove engine with front AR01.10-P-
1.2 Model 216, 221
axle carrier 2500SZ
AR01.10-P-
Model 230
2500RC
AR27.10-P-
2 Remove transmission Model 216, 221
0500SZ
AR27.10-P-
Model 230 0500RC
Detach engine from front AR01.10-P-
3 Model 216, 221
axle carrier 2510SX
AR01.10-P-
Model 230
2510RX
Mount engine onto
4
assembly stand
The right or the left cylinder head must be removed AR01.30-P-
5 Remove cylinder head
depending on the piston which should be removed. 5800M
AR01.45-P-
6 Detach oil pan Model 215, 220
7500L
AR01.45-P-
Model 216, 221
7500SZ
AR01.45-P-
Model 230
7500RA
7 Remove oil deflector plate
Mark connecting rod (2) and connecting rod bearing
cap relative to each other so that, when installing, the
Remove connecting rod parts are not mixed up.
8
bearing cap (1) Connecting rod (2) and connecting rod bearing caps
are cracked. They must not be installed on the wrong
side as the accuracy of fit is no longer given.
Mark connecting rod
bearing shell and
9
cap (1) to each other
Mark piston on the right
Do not mix up the pistons, as this can lead to engine
10 (4a) and cylinder liner
relative to each other damage.
Observe the identification arrow on the piston crown.
On pistons which are used, the identification arrow of
Remove connecting rod the pistons may no longer be visible because of carbon
11 (2) with piston on the right deposits. The carbonization must therefore be removed
(4a) from the piston. If the identification arrow is no longer
recognizable on the piston, the piston must be identified
again.
Mark connecting rod
bearing shell and Do not mix up the upper and lower connecting rod
12
connecting rod (2) to each bearing shell as this can lead to engine damage.
other
Remove the circlip (5) Use a clean shop towel as a base so that the piston is
13
from the piston pin (6) not damaged.
14 Press out piston pin (6) The connecting rod (2) is not marked so mark
connecting rod (2) and piston relative to each other so
that the connecting rod (2) can be reinstalled in its
original installation position with the piston.
Inspect connecting rod (2) Connecting rods with blue discoloration as a result of
15 for blue discoloration, bearing damage, with transverse scores and notches
cross scores and notches. must be replaced as this can lead to engine damage
Install
Assigning a standard size AR03.10-P-
16
piston to a cylinder bore 7021-02L
Oil piston pin (6) and
17
connecting rod bush
Assemble right-hand side Installation: When installing, ensure that connecting
18 piston (4a) and connecting collar (broad side) (a) points in direction of crank web
rod (2) when fitted.
Push in piston pin (6) by
19
hand
Insert circlip (5) for piston
Use clean shop towels as a base so that the piston on
20 pin (6) into the groove on
the right side (4a) is not damaged.
piston on the right (4a)
Lubricate cleaned cylinder
bore, connecting rod
21 journal, connecting rod
bearing shells and piston
on the right (4a)
During installation of the piston, the piston ring end
Fit on tensioning gap of the first piston ring (upper piston ring) on the
22 strap (7) for piston rings right side (4a) points forward in the direction of travel
and tension and the remaining piston ring end gaps are each offset
by 120°.
Fig. 18
Install piston on the right On order to avoid causing damage during installation,
(4a) with marking arrow turn crankshaft until connecting rod (2) does not touch
23
pointing in direction of connecting rod journal when inserting the piston on the
front of vehicle right (4a).
Check connecting rod AR03.10-P-
24
bolts (3) 6111-01L
According to the attached markings. Do not mix up
Insert connecting rod
top and bottom connecting rod bearing shells.
bearing shell into
25 connecting rod (2) and The anti-twist locks of the connecting rod bearing
connecting rod bearing shells must be located in the slots of the connecting rods
cap (1) (2) and in the slots of the connecting rod bearing caps
(1).
Bolt connecting rod bearing cap (1) and connecting AR03.10-P-
Install connecting rod
26 rod (2) to each other with the markings (arrows) lined
bearing cap (1) 6111-02L
up.
*BA01.40-
P-1002-01I
AR01.45-P-
28 Installing oil pan Model 215, 220
7500L
AR01.45-P-
Model 216, 221
7500SZ
AR01.45-P-
Model 230
7500RA
AR01.30-P-
29 Install cylinder head
5800M
Detach engine from
30
engine assembly stand
Attach engine to front axle AR01.10-P-
31 Model 216, 221
carrier 2510SX
AR01.10-P-
Model 230
2510RX
AR27.10-P-
32 Mount transmission Model 216, 221
0500SZ
AR27.10-P-
Model 230
0500RC
AR01.10-P-
33.1 Install engine protection, code Z07 Model 220 with special protection
2400MC
protection, code Z07
Install engine with front AR01.10-P-
33.2 Model 216, 221
axle carrier 2500SZ
AR01.10-P-
Model 230
2500RC
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 137.970, 275, 285
BA01.40-P-1002-01I Bolt, oil baffle to lower crankcase section Nm 8

REMOVE/INSTALL PISTON RINGS - AR03.10-P-7311
Remove/install piston rings - AR03.10-P-7311BV
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINE 112 /945, 113.962 /982
Fig. 26: Identifying Piston Rings
Figure item,
Work instructions
etc.
Piston removal and AR03.10-P-
4
installation 7021AV
1,2,3 Piston rings
remove Fig. 27
Pliers
with the pliers.
Removal: Oil scraper ring The oil scraper ring (3) must be removed and
installed by hand.
 Measure width of compression rings (1, 2).
 Note the installation position of compression *BE03.10-P-
Compression rings rings (1,2). The inscription "Top" or the
Installation: 1003-05B
manufacturer's designation must point toward
the piston crown (5).
Measure the side
AR03.10-P-
1,2 clearance of the
7311-01V
compression rings
Measure end gap of AR03.10-P-
1,2
the compression rings 7311-02V
CHECK VALUES FOR PISTON RINGS
Number Designation Engine 112.910/ Engine Engine
911/912 112.913 112.920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
960, Engine
113.940/941/
942/943
BE03.10-P- Dimension Plain mm 83.2x1.5x3.1 89.9x1.5x3.1 89.9x1.5x3.1
1003-05B compression
ring
Taper-faced mm 83.23.53.589.91.753.5 89.9x1.75x3.5 89.9x3.5x3.5
hook scraper
ring

BE03.10-P-1003- Dimension Plain compression mm 89.91.53.1
05B ring
Taper-faced hook mm 89.91.753.5
scraper ring

Number Designation Engines Engines Engine
113.944/980/ 113.960/961/ 113.960/961/
981/982/984 962/963/964/ 992/995
965/968/971
ring
Taper-faced mm 97.01.54.0 97.0x3.5x3.5 97.0x1.75x3.5
hook scraper
ring
Measure end clearance of piston rings - AR03.10-P-7311-01V
MODIFICATION NOTES
Value in series 1001 for engine 113.967 modified Value in BE03.10-P-1001-
*BE03.10-P-
12.6.02 from 0.012...0.060 to 0.033...0.07 and from 05B for engine 113.967
1001-05B
0.010...0.030 to 0.01...0.04 modified
INSPECTION DATA FOR PISTON RINGS

Number Designation Engine Engines Engines
112.910/ 112.920/ 113.944/980/
911/912 921/922/923/ 981/982/984
940/941/942/
943/944/945/
946/947/948/
960, Engine
113.940/941/
942/943
BE03.10-P- Piston ring Groove 1 mm 0.012...0.060 0.012...0.060 0.012...0.060
1001-05B vertical
clearance Groove 2; mm 0.010...0.030 0.010...0.030 0.010...0.030

113.960/961/
962/963/964/
965/968/971
BE03.10-P- Piston ring Groove 1 mm 0.012...0.060 0.033...0.070
1001-05B vertical
clearance Groove 2 mm 0.010...0.030 0.01...0.04
Number Designation
WH58.30-Z-1004-12A Feeler gauge
1. Measure the side clearance of the compression rings between the compression ring and the mounting
groove in the piston with a feeler gauge. Replace the compression rings or the piston if necessary.
The end 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. 28: Measuring Side Clearance Of Compression Rings
Measure piston ring end clearance - AR03.10-P-7311-02V

Number Designation Engine Engines 112.920/ Engines
112.910/911/912 921/922/923/ 113.944/980/
940/941/942/ 981/982/984
943/944/945/
946/947/948/ 960,
Engine
113.940/941/942/943
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- Piston ring end Groove 1 mm 0.200...0.350 0.200...0.350
1002-05B gap Groove 2 mm 0.200...0.400 0.200...0.400

Number Designation
1. Clean cylinder wall.

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. Replace the piston rings if necessary.
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. 29: Measuring Cylinder Wall
Removing/installing piston rings - AR03.10-P-7311L
ENGINE 137.970
Fig. 30: Identifying Piston Rings Remove/Install Components

Removing/installing
AR03.10-P-
1 Remove pistons
7021L
Determine side clearance of AR03.10-P-
2
piston rings (groove 1, 2) 7311-01L
*BE03.10-P-
Piston ring vertical clearance
1001-05B
*WH58.30-Z-
1004-12A
The piston ring (groove 3) must not be removed
and installed using the pliers, but must be done by
hand.
Installation: Note installation position of the
piston rings (groove 1, 2). The emblem "Top" or
Remove piston rings (groove the name of the manufacturer must point towards
3
1, 2, 3) from piston (4) the piston crown.
Insert the hook spring (8) with the garter spring (4)
offset 180° to the ring gap of the oil scraper ring
(arrow).
Install piston rings (groove 1, 2, 3) with the piston
ring end gaps offset by 120°.
Installation: Measure ring width of piston *BE03.10-P-
rings (groove 1, 2). 1003-05B
Fig. 27
Determine end gap of piston Insert the piston ring in the unused area of the AR03.10-P-
4
rings (groove 1, 2) cylinder contact surface. 7311-02L
*BE03.10-P-
Piston ring end gap
1002-05B
*WH58.30-Z-
1004-12A

Groove 1 mm 0.012...0.060
BE03.10-P-1001-05B Piston ring vertical clearance
Groove 2 mm 0.010...0.030
Groove 1 mm 0.250...0.350
BE03.10-P-1002-05B Piston ring end gap
Groove 2 mm 0.250...0.500
Plain compression ring mm 84.0 X 1.2 X 3.1
BE03.10-P-1003-05B Dimension
Taper-faced hook scraper ring mm 84.0 X 1.5 X 3.5

Number Designation
Measure end clearance of piston rings - AR03.10-P-7311-01L

285.95 285.98
Groove
mm 0.012...0.060 0.03...0.08 0.03...0.07
BE03.10-P- Piston ring vertical 1
1001-05B clearance Groove
mm 0.010...0.030 0.015...0.055 0.03...0.07
2

Number Designation
1. Use the feeler gage to measure end clearance of compression rings between compression ring and
mounting groove in the piston; replace compression rings or piston, if necessary.
The side 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. 32: Measuring End Clearance Of Compression Rings Using Feeler Gauge
Measure piston ring end clearance - AR03.10-P-7311-02L

285.95 285.98
Groove
mm 0.250...0.350 0.200...0.400 0.20...0.35
BE03.10-P-1002- Piston ring end 1
05B gap Groove
mm 0.250...0.500 0.200...0.400 0.35...0.55
2

Number Designation
1. Clean cylinder wall.

2. Insert both compression rings, one after the other, above the running surface in the cylinder barrel and
measure end gap with a feeler gauge; replace piston rings if necessary.
The end gap of the 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. 33: Measuring Cylinder Barrel End Gap
REMOVE/INSTALL BALANCING SHAFT - AR03.20-P-1000A
ENGINE 112
Fig. 34: Identifying Balancing Shaft Remove/Install Components

Remove/Install
vehicle slipping or toppling columns of the lifting
off of the lifting platform. platform and position the
four support plates at the
1 Remove engine Model 463 AR01.10-P-2400CC
4MATIC
Model 210 without AR01.10-P-2400CB
4MATIC, 208, 202, 129
Model 211 AR01.10-P-2400TC
4MATIC, 209
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
2.1 Remove automatic Model 463 AR27.10-P-0500BD
transmission Model 220 without AR27.10-P-0500I
4MATIC
Model 210, 208, 202, 170, AR27.10-P-0500B
129
Model 211 AR27.10-P-0500T
4MATIC, 209
2.2 Remove manual Model 210, 202, 129 AR26.10-P-0020A
transmission Model 211 AR26.10-P-0020T
Model 203, 209 AR26.10-P-0020P
Model 170 AR26.10-P-0020D
3 Remove flywheel AR03.30-P-8001C
4 Remove end cover AR01.40-P-8913B
Installation: Replace AR03.20-P-3063B
rear crankshaft radial
sealing ring
5 Remove the cylinder head Air cleaner mounted on AR01.20-P-5014B
covers (15, 16) vehicle.
Air cleaner positioned at AR01.20-P-5014BV
engine side.
6 Position crankshaft to 40° Engine must not be AR05.10-P-6858V
after ignition TDC of rotated backwards.
cylinder 1
7 Take bottom part of oil pan Model 163 AR01.45-P-7555V
(18) off top part of oil pan Model 203 without AR01.45-P-7555PV
(19) 4MATIC, 209, 211.061,
065061/065
Model 463, 220 without AR01.45-P-7555VA
4MATIC, 210, 208, 202,
170, 129
8 Take top part of oil pan Model 463 AR01.45-P-7500FG
(19) off crankcase Model 220 without AR01.45-P-7500I
4MATIC
4MATIC
Model 211.061/065 AR01.45-P-7500TV
Model 208, 202 AR01.45-P-7500FC
4MATIC, 209
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
9 Take timing case cover Do not damage
(31) off crankcase cylinder head gaskets.
Model 463 AR01.40-P-8000GV
Model 220 210 without AR01.40-P-8000B
4MATIC, 208, /129
Model 203, 209, AR01.40-P-8000PV
211.061/065
Model 210 with 4MATIC AR01.40-P-8000V
10 Remove position sensor AR15.10-P-2000A
camshaft (L5/1)
11 Remove right camshaft *BA05.20-P-1001-01B
sprocket (27) Locating plate Fig. 36
Locating plate Fig. 37
Open-end wrench Fig. 38
Insertion tool Fig. 39
Torque wrench Fig. 40
Installation: ?
Inspecting timing of AR05.10-P-6858V
engine
? If necessary after
checking:
Set the basic position of AR05.20-P-6020AU
camshafts
12 Take off rear balancing Check stem and thread
weight (20) length of bolt, when
exceeding maximum
length the bolt must be
replaced, otherwise there
is risk of cracks and
fracture.
Balancing shaft can
only be removed to the
front.
Fix rear weight at Fig. 9
crankcase with a pin or
suitable drift (Ø 8.40 to
8.55 mm) for this step.
*BA03.20-P-1002-02A
13 Take off locking plate (29) *BA03.20-P-1001-02A
at front of balancing shaft
(28)
14 Pull out balancing shaft Installation: When
(28) to the front installing balancing shaft,
pay attention to
assignment of balancing
shaft to engine.
General information on AH03.20-P-1000-01AV
assigning balancing shaft
to engine
Risk of accident caused by Secure vehicle to prevent AS00.00-Z-0005-01A
vehicle starting off by itself it from moving. Wear
when engine is running. closed and snug-fitting
Risk of injury caused by work clothes. Do not grasp
contusions and burns when hot or rotating parts.
working in engine during
starting procedure
16 Run engine and inspect for
leaks
17 Inspect cooling system for Warm up the engine to
leaks operating temperature.
All except Model 170, AR20.00-P-1010HA
203, 209
Model 170, 203, 209 AR20.00-P-1010P
BALANCING SHAFT
Number Designation Motor 112
BA03.20-P-1001- Bolt of locking plate M7 x 16.5 Nm 15
02A to crankcase
BA03.20-P-1002- Bolt of balancing 1st stage Nm 20
02A weight to balancing Step 2 Angle° 90
shaft Length mm < or = 50,7
CAMSHAFT
Number Designation Engine 112 except Engine
112.951/976 112.951/ 976
BA05.20-P- Bolt of M12x45 1st stage Nm 50 50
1001-01B camshaft
sprocket Step 2 Angle° 90 90
Fig. 36: Locating Plate (112 589 00 32 00)

Fig. 37: Locating Plate (112 589 01 32 00)
Fig. 38: Identifying Open-End Wrench (112 589 00 01 00)
Fig. 39: Identifying Insertion Tool (112 589 01 03 00)
REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000

Replace front crankshaft radial sealing ring - AR03.20-P-3000BA
ENGINE 112 in MODEL 170, 202, 203, 208, 209, 210, 220
ENGINE 113 (except 113.991) in MODEL 215, 220
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.988 in MODEL 203.076/276
Shown on engine 112 in model 203
Fig. 41: Identifying Front Crankshaft Radial Sealing Ring, Belt Pulley/Vibration Damper
MODIFICATION NOTES
9.1.06 Central bolt to vibration damper *BA03.30-P-1001-01D
Remove/install
1 Remove belt pulley / Model 170.466, 203 with
vibration damper (5) engine 112
Except model 170.466, AR03.30-P-1600CA
203 with engine 112
Inspect contact
surface of hub for signs
of wear.
2 Remove crankshaft radial Press out with a
sealing ring (7) screwdriver.
Do not damage
crankshaft and mounting
bore for crankshaft radial
sealing ring (7). Use a
clean rag as a base.
Circumference and
sealing lip of crankshaft
sealing ring (7) as well as
the mating contact
surface on the vibration
damper must be free of
oil and grease.
Installation: Install AR03.20-P-3000-01B
front crankshaft radial
sealing ring (7) with the
aid of the sleeve (6).
Do not coat crankshaft
radial sealing ring (7)
with sealant.
Sleeve Fig. 43
procedure or when
as it is running
4 Check oil viscosity after
performing engine test run
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR

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
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. 44: 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. 45: 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. 46: 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. 47: Identifying Crankshaft Radial Sealing Ring To Crankpin
Replace front crankshaft radial seal ring - AR03.20-P-3000L

Fig. 48: Identifying Front Crankshaft Radial Seal Ring Remove/Install Components - Engine 137 In
Model 220
Remove/install
Align vehicle lifting platform posts
and position the four mounting plates
Hazardous due to slipping off or tilting of AS00.00-Z-
on the lifting support strongpoints as
the vehicle off the lifting platform 0010-01A
instructed by the automotive
manufacturer.
AR61.20-P-
1 Remove engine compartment paneling
1105M
Separate plug connection of AR20.40-P-
2 Remove fan shroud with suction fan (1)
suction fan. 6800AC
3 Attach guard plate for radiator / condenser
WF58.50-P-
Guard plate for radiator/condenser
0110-01A
Installation: AR13.22-P-
4 Remove poly V-belt (2) Arrest clamping device using drift or 1202L
pin (diameter 5 mm).
AR03.30-P-
5 Remove belt pulley/ vibration damper (4)
1600L
Do not damage crankshaft and
mounting hole for crankshaft radial
seal. Use a clean cloth as a base. AR03.20-P-
6 Remove crankshaft radial seal (5)
Use a screwdriver to press it out. 3000-01B
Installation: Circumference and
sealing lip of the crankshaft radial
seal as well as the mating contact
surface on the vibration damper must
be free of oil and grease.
Fig. 43
Risk of accident due to automatic starting Secure vehicle to prevent it from
off when engine is running. Injury hazard moving off by itself.
AS00.00-Z-
due to crimped connection and combustion Wear closed and close-fitting work
0005-01A
when meshing during starting procedure or clothes.
when engine is running Do not grasp hot or rotating parts.
Find the oil leak after spraying
8 Run engine and inspect for leaks the cleaned and dried surrounding
area with MB contrast spray.
*BR00.45-
Crack detector
Z-1001-03A
REPAIR MATERIALS
BR00.45-Z-1001-03A Crack detector A 000 989 03 59
Replace front crankshaft radial sealing ring - AR03.20-P-3000MC
ENGINE 275
Fig. 50: Identifying Front Crankshaft Radial Sealing Ring Remove/Install Components - Engine 275
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
AR01.10-P-
1 Remove engine cover (1) front section Engine 275.95
2405LA
AR01.10-P-
Engine 275.98
2405IM
Model 215, 220 except 215.379,
AR20.40-P-
2 Remove fan shroud 220.179
6800AC
Model 230
AR20.40-P-
Model 215.379, 220.179
6800IM
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
3 Attach guard plate for radiator / condenser
WF58.50-P-
Radiator guard plate/ condenser
0110-01A
AR13.22-P-
4 Remove poly-V belt (2) Model 215, 220, 230
1202L
AR13.20-P-
Model 216, 221
0001SZ
AR03.30-P-
5 Remove belt pulley/vibration damper (3)
1600L
Do not damage crankshaft and
mounting hole for crankshaft AR03.20-P-
6 Remove crankshaft radial sealing ring (4)
radial seal (4). Use a clean cloth as 3000-01B
a base.
Fig. 43
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
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.
engine as it is running Do not touch hot or rotating parts.
Determine oil leakage after
8 Check for leaks with engine running spraying the cleaned and dried
surrounding area with MB contrast
spray.
*BR00.45-
Crack detector
Z-1001-03A
REPAIR MATERIALS
BR00.45-Z-1001-03A Crack detector A 000 989 03 59
Replacing front crankshaft radial sealing ring - AR03.20-P-3000RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074 /174

Fig. 52: Identifying Front Crankshaft Radial Sealing Ring Remove/Install Components
Remove/install
Remove belt
AR03.30-P-
1 pulley/vibration damper
1600RVK
(3)
Do not damage crankshaft and mounting hole for
Remove crankshaft radial crankshaft radial seal (4). Use a clean cloth as a
2
sealing ring (4) base.
Press out with a screwdriver.
Installation: Install front crankshaft radial AR03.20-P-
sealing ring (4). 3000-01B
Sleeve Fig. 43
REPLACE REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3063
Replace rear crankshaft radial sealing ring - AR03.20-P-3063B

ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 220, 230.474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
Shown on engine 112
Fig. 54: Identifying Rear Crankshaft Radial Sealing Ring, End Cover, Flywheel
Remove/install
1 Remove flywheel AR03.30-P-

(3)/ driven plate 8001C
Remove end cover AR01.40-P-
2
(1). 8913B
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 replaced.
Crankshaft radial sealing ring (2) must not be pushed
Remove crankshaft
3 out when the end cover (1) is fitted.
radial seal (2)
Installation: First install the end cover (1) and then
install the crankshaft radial sealing ring (2):? AR03.20-P-
Install crankshaft radial sealing ring (2). 3063-01B
Fig. 56
Install in the reverse
4 Before installing transmission, inspect for oil leaks
order
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. 57: 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. 58: 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. 59: 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. 60: Identifying Crankshaft Rear Radial Sealing Ring
Replace rear crankshaft radial sealing ring - AR03.20-P-3063L

Fig. 61: Identifying Rear Crankshaft Radial Sealing Ring Remove/Install Components
Remove/install
Remove automatic AR27.10-P-
1
transmission 0500I
AR03.30-P-
2 Remove flywheel (3)
8001C
Fig. 63
*BA03.30-P-
1002-01D
AR01.40-P-
3 Remove end cover (1)
8913L
Fig. 9
*BA01.40-P-
1004-01C
Crankshaft radial sealing ring must not be
pushed out with a screwdriver if end cover is
Remove crankshaft radial installed
4
sealing ring (2) Installation:
First of all, install end cover and then the crankshaft
radial sealing ring ?
AR03.20-P-
Install crankshaft radial sealing ring
3063-01B
Before installing the transmission, inspect for oil
leaks

Thread not pre-tapped Nm -
BA01.40-P-1004-01C End cover screw
Thread pre-tapped Nm 8
FLYWHEEL, DRIVE PLATE, VIBRATION DAMPER, STARTER RING GEAR

137
Stage
Nm 45
BA03.30-P-1002- Bolt connecting two-mass flywheel/drive plate to 1
01D crankshaft Stage
Angle° 90
2
Fig. 63: Identifying Torx Bit Set (000 589 01 10 00)
Replace rear crankshaft radial seal - AR03.20-P-3063MC
ENGINE 275 in MODEL 215, 216, 220, 221
Fig. 64: Identifying Crankshaft Radial Seal, End Cover And Drive Plate
Remove/install
1 Model 215, 220
transmission 0500I
AR27.10-P-
Model 216, 221
0500SZ
AR03.30-P-
2 Remove drive plate (1)
8001MC
Remove the end cover AR01.40-P-
3
(2) 8913MC
The rear crankshaft radial sealing ring (3) must
only be removed once the end cover (2) has been
Remove rear crankshaft
4 taken off.
radial seal (3)
Installation: First install end cover (2) and then
install crankshaft radial sealing ring (3): ?
AR03.20-P-
Install crankshaft radial seal
3063-01B
5 Before installing transmission, inspect for oil leaks
order
Replacing rear crankshaft radial seal - AR03.20-P-3063RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074 /174
Fig. 65: Identifying Rear Crankshaft Radial Seal Remove/Install Components
Remove/install
Align vehicle between columns of the
lifting platform and position four
Risk of death caused by vehicle slipping AS00.00-Z-
support plates at the lifting platform
or toppling off the lifting platform. 0010-01A
support points specified by the vehicle
manufacturer.
AR27.10-P-
1 Remove automatic transmission Model 211 0500T
AR27.10-P-
Models 215, 220
0500I
AR27.10-P-
Model 230
0500R
AR03.30-P-
2 Remove flywheel (3) Models 211, 215, 220
8001C
AR03.30-P-
Model 230
8001RVK
Pry off end cover (1) carefully at both
marked points with a slanted
screwdriver (see arrows).
3 Remove end cover (1). Installation: The crankshaft radial
sealing ring (2) cannot be exchanged at
end cover (1). This end cover (1) is
fitted at the factory and therefore must
be replaced.
*BA01.40-
P-1004-01C
Installation: Circumference and lip
of crankshaft radial sealing ring (2) as
4 Replace front crankshaft radial seal (2) well as counter contact surface on
crankshaft must be free of oil and
grease, in order to guarantee proper
function.
Notes on application of sealant to end
cover with radial shaft seal AH01.40-P-
Pay attention to fitted sleeves when 1000-06A
pressing on end cover (1).
*BR00.45-
Sealant
Z-1013-01A
Secure vehicle to prevent it from moving
by itself.
clothes.
procedure or when working near a
running engine

Number Designation Engines 113.987/ Engines 113.940/941/
988/990/991/993 942/943/944/945/946/948/ 960/961/962/
963/964/965/ 966/967/968/ 969/971/980/
981/982/984/ 986/992/995
Thread not
End Nm - -
BA01.40-P- pretapped
cover
1004-01C
screw Thread Nm 8 10
pretapped
REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
INSPECT BASIC POSITION OF THE BALANCING SHAFT - AR03.20-P-3637AV
ENGINE 112
Fig. 66: Identifying Basic Position Of Balancing Shaft
Remove/install
vehicle slipping or toppling columns of the lifting
off of the lifting platform. platform and position the
four support plates at the
1.1 Remove automatic Models 129, 170, 202, AR27.10-P-0500B
transmission 208, 210
Model 463 up to AR27.10-P-0500BD
31.10.2000
Model 463 as of AR27.10-P-0500GA
1.11.2000
4MATIC
4MATIC, 209
Model 211 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
1.2 Remove manual Model 210, 202, 129 AR26.10-P-0020A
transmission Models 203, 209 AR26.10-P-0020P
Model 211 AR26.10-P-0020T
Model 170 AR26.10-P-0020D
1.3 Remove the Sequentronic Model 203, 208, 209 AR26.10-P-0020E
automated manual
Model 211.0 AR26.10-P-0020TA
transmission
2 Install the retaining lock AR03.30-P-5000B
(6) for the crankshaft (5)
and starter ring gear
3.1 Dismount clutch Vehicles with manual
transmission
Only unscrew or screw
in bolts by 1 to 1.5 turns at
a time
Models 129, 163, 170,
202, 208, 210 AR25.10-P-0050A
Models 203, 209, 211 AR25.10-P-0050P
*BA25.10-P-1001-01A
4 Remove flywheel Except model 211 AR03.30-P-8001C
Model 211 AR03.30-P-8001T
5 Remove cylinder head Air filter mounted on AR01.20-P-5014B
covers vehicle AR01.20-P-5014BV
Air filter mounted on
engine
6.1 Detach combination valve On engines fitted with air
(right) pump
combination valve gasket.
*BA09.20-P-1001-01D
7 Position engine to 40° after Engine must not be
ignition TDC of cylinder 1 cranked back.
Rotate engine at
crankshaft in direction of
rotation until 40° marking
on belt pulley/ vibration
damper is aligned with
marking on timing case
cover. Grooves (1) on the
camshafts must point
toward the inner V.
8 Check basic position of Place locating plates
camshafts (2) flush on the right and
left cylinder heads, and fit
into the grooves (1) of the
camshafts.
Fig. 36
Fig. 37
If this is not possible: ?
Set the basic position of
camshafts AR05.20-P-6020AU
9 Inspect basic position of The hole (3) at the rear
the balancing shaft correctional weight (4)
must align with the hole in
the crankcase. Fix hole
with a pin or suitable drift
(Ø 8.40 to 8.55 mm).
If the hole (3) at the rear
of the correctional weight
(4) is aligned with the hole
in the crankcase, then, the
pin at the crankcase (A)
and the notch in the front
correctional weight (B)
must point toward each
other.
The pin (A) and the notch
(B) can be seen through
the left timing case recess
at a depth of about 22 cm
from the cylinder head
cover separating surface.
If the markings of the
front and rear balance
shaft do not match, the
balance shaft must be
replaced:?
Remove balancing shaft AR03.20-P-1000A
Installation: When
installing balancing shaft,
pay attention to
assignment of balancing
shaft to engine.
General information on AH03.20-P-1000-01AV
assigning balancing shaft
to engine
INTAKE MANIFOLD
Number Designation Engines 112,113
01D to cylinder head
CLUTCH
Number Designation Models 129, 140, 163,
170, 202, 203, 208, 209,
210,211, 230
BA25.10-P-1001-01A Bolt of pressure plate to Nm 25
flywheel or two-mass
flywheel
Fig. 67: Identifying Locating Plate (112 589 00 32 00)
Fig. 68: Identifying Locating Plate (112 589 01 32 00)
DETERMINE CRANKSHAFT BEARING AXIAL PLAY - AR03.20-P-4291-03AV

CHECK VALUES OF CRANKSHAFT BEARING CLEARANCE
except 113.962/982
112.951/976,
Engines
113.940/941/
942/943/944/
948/960/961/
963/964/965/
966/967/968/
971/980/981/
984/986
BE03.20-P- Main bearing play radial when mm 0.026 to 0.050 0.026 to 0.050
1001-04E new
axial when mm 0.10 to 0.266 0.10 to 0.266
new
BE03.20-P- Connecting rod radial when mm 0.022 to 0.067 0.022 to 0.067
1002-04E bearing play new

113.987/988/989 /990/991/993 113.992/995
BE03.20-P- Main bearing radial when mm 0.026 to 0.050 0.026 to 0.050
1001-04E play new
axial when mm 0.10 to 0.266 0.10 to 0.266
new
BE03.20-P- Connecting rod radial when mm 0.022 to 0.067 0.022 to 0.067
Assignment of thrust washers to crankshaft M 112,113

Crankcase Fitted bearing base journal Thrust washers Axial play
of crankshaft Crankshaft
Inscription Designation Marking (mm)
No subdivision N 0 N Abbreviated 0.10-0.266
reference number
No subdivision N1 1 N1 Abbreviated 0.10-0.266
reference number
Fig. 69: Identifying Dial Indicator (001 589 32 21 00)
Fig. 70: Identifying Dial Indicator Holder (363 589 02 21 00)
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. 71: Identifying Thrust Plates Assigned To Fitted Bearing Cap
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.
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 the measured value on the dial indicator (2).
The measured value corresponds to the axial play of the crankshaft.
Fig. 72: Identifying Dial Indicator With Extension And Dial Indicator Holder
INSTALL / GAUGE THE CRANKSHAFT BEARINGS - AR03.20-P-4341
Install / gauge the crankshaft bearings - AR03.20-P-4341-01CV
MODIFICATION NOTES
Figure modified from
30 Nm and 90 < or =° Figure in BA03.20-P-1003-01D of engine 112, 113 *BA03.20-
27.2.04
to 5 Nm, 30 Nm and 90 modified P-1003-01D
< or =°
Figure changed from Value modified in BE03.20-P-1001-04E on engine 112
*BE03.20-
10.3.04 0.030...0.052 mm to except 112.951, 113.940/941/942/943/944/948/
P-1001-04E
0.026...0.050 mm 960/961/963/965/966/967/968/980/981 / 984/986
Figure changed from
Value modified in BE03.20-P-1001-04E for engine *BE03.20-
10.3.04 0.030...0.052 mm to
113.992 P-1001-04E
0.026...0.050 mm
INSPECTION DATA OF CRANKSHAFT BEARING CLEARANCE

except 113.987/988/989 /990/991/993 113.992/995
112.951/976,
Engine
113.940/941/
942/943/944/
948/960/961/
963/964/965/
966/967/968/
971/980/981/
984/986
BE03.20-P- Main radial mm 0.026...0.050 0.026...0.050 0.026...0.050
1001-04E bearing when
play new
axial mm 0.10...0.266 0.10...0.266 0.10...0.266
when
new
CRANKSHAFT BEARING CAP
BA03.20-P-1001- Bolt for M8 Stage 1 Nm 20
01D crankshaft
bearing cap Stage 2 Angle° 90
BA03.20-P-1002- Side bolt for M8 Nm 30
01D crankshaft
bearing cap
01D crankshaft Stage 2 Nm 30
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
objects for cleaning.
The top bearing shell halves (1) are assigned to the basic journal of the crankshaft by means of a
colored ring on the rear of the upper bearing shell half (1) and numbers (arrows) or center punch marks,
which are stamped into the crankcase.
Only assigned color and numerical combinations (see table) may be fitted together.
Fig. 73: Identifying Bearing Points In Crankcase
Assignment of crankshaft bearing shell top halves (crankcase) M 112,113

Diameter Main Number or chisel Color coding for Order index Main bearing play
bearing bore in punches bearing shell (mm)
crankcase
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 Color coding for Order index Main bearing play
bearing journal AM crankshaft bearing shell (mm)
journal Front
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 (7) are assigned to the basic journal of the crankshaft by
means of the first letter of the respective color.
The color coding of the lower bearing shell halves (7) is located on the rear of the lower bearing shell
halves (7).
The initial letters of the particular colors are engraved on the journal of the crankshaft.
When installing the bearing shell halves, it is important to keep to the order of the colors which is
engraved on the journal of the crankshaft!
Fig. 74: Identifying Bottom Halves Of Bearing Shells
Example: Engine 112
Arrow identifies direction of travel.
 First letter `r': A bearing shell with the color coding red must be inserted in bearing cap `1'.
 Second letter `b': A bearing shell with the color coding blue must be inserted in the bearing cap `2'.
 Third letter V: A bearing shell with the color coding purple must be inserted in the bearing cap `3'.
 Fourth letter `w': A bearing shell with the color coding white must be inserted in the bearing cap
`4'.
Fig. 75: Identifying Bearing Shell
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. 76: Inserting Bearing Shell Top Halves With Oil Drillings And Oil Grooves Into Crankcase
5. The thrust plates (8) 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 plates (8) installed must have the same designation.
Fig. 77: Identifying Thrust Plates Assigned To Bearing Caps
Assignment of thrust washers to crankshaft M 112,113

Crankcase Basic journal of the fitted Thrust washers Axial play
bearing of the crankshaft Crankshaft
Inscription Designation Marking (mm )
No subdivision N 0 N Abbreviated 0.10-0.266
reference number
No subdivision N1 1 N1 Abbreviated 0.10-0.266
reference number
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. 78: Identifying Crankshaft Into Crankcase
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. 79: Identifying Bearing Caps
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. 80: Locating Bolts Of Bearing Caps
Install / gauge the crankshaft bearings - AR03.20-P-4341-01CVA
MODIFICATION NOTES
Figure changed from Value modified in BE03.20-P-1001-04E on engine 112
*BE03.20-
10.3.04 0.030...0.052 mm to except 112.951, 113.940/941/942/943/944/948/
P-1001-04E
0.026...0.050 mm 960/961/963/965/966/967/968/980/981 / 984/986
Figure changed from
*BE03.20-
10.3.04 0.030...0.052 mm to Value modified in BE03.20-P-1001-04E for engine 113.992
P-1001-04E
0.026...0.050 mm
INSPECTION DATA OF CRANKSHAFT BEARING CLEARANCE

except 113.987/988/989 /990/991/993 113.992/995
112.951/976,
Engine
113.940/941/
942/943/944/
948/960/961/
963/964/965/
966/967/968/
971/980/981/
984/986
BE03.20-P- Main Radial mm 0.026...0.050 0.026...0.050 0.026...0.050
1001-04E bearing when new
play Axial mm 0.10...0.266 0.10...0.266 0.10...0.266
when
new

01D crankshaft
BA03.20-P-1002- Side bolt for M8 Nm 30
01D crankshaft
bearing cap
01D crankshaft Stage 2 Nm 30
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
objects for cleaning.
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.
Fig. 81: Identifying Bearing Shell Top Halves
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).
5. Mount bearing cap (6), tighten without rotation angle for measuring procedure .
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. 82: Identifying Crankshaft Into Crankcase
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), order thrust washer parts
kit repair size 1 and measure the axial play of the crankshaft without thrust washer.
For this purpose, add the axial bearing play to the thickness measured for the repair size thrust plate (8)
and subtract the measured axial play without the repair thrust plate (8) to obtain the dimension by which
the crankshafts must be ground at the contact point of the axial bearing (bearing point 3).
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 of the thrust washers (8) must point toward the crankshaft 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).
Fig. 83: Identifying Crankshaft, Bearing Caps
16. Moisten the thread and head contact surface of the bolts of the bearing caps with oil.
17. Tighten the bolts of the bearing caps 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. 84: Locating Bolts Of Bearing Caps
REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351
Remove/install crankshaft - AR03.20-P-4351AV

ENGINE 112
Fig. 85: Identifying Crankshaft, Crankshaft Bearing Shell
MODIFICATION NOTES
Figure modified from 30 Nm and 90 < or Figure in BA03.20-P-1003-01D of *BA03.20-P-
27.2.04
=° to 5 Nm, 30 Nm and 90 < or =° ENGINE 112, 113 modified 1003-01D
Removing
toppling off the lifting platform and position the
1 Remove engine Model 463 AR01.10-P-2400CC
4MATIC
Model 210 without 4- AR01.10-P-2400CB
MATIC, 208, 202, 129
Models 211.061/065 AR01.10-P-2400TC
4MATIC, 209
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
2.1 Remove automatic Model 463 AR27.10-P-0500BD
transmission from engine Model 220 without AR27.10-P-0500I
4MATIC
Models 210, 208, 202, 170, AR27.10-P-0500B
129
Models 211.061/065 AR27.10-P-0500T
4MATIC, 209
Model 163 AR27.10-P-0500GH
2.2 Remove manual Models 210,202, 129 AR26.10-P-0020A
transmission from engine Model 211.061 AR26.10-P-0020T
MODEL 203, 209 AR26.10-P-0020P
Model 170 AR26.10-P-0020D
transmission 716.6
transmission 716.6 (code
424)
3 Remove oil pan top Model 463 AR01.45-P-7500FG
section Model 220 without AR01.45-P-7500I
4MATIC
4MATIC
Models 211.061/065 AR01.45-P-7500TV
Models 208, 202 AR01.45-P-7500FC
4MATIC, 209
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
4 Remove oil pump For this step, push back
chain tensioner and take
off chain.
Models 129, 163, 170, 202, AR18.10-P-6020B
208.365/465, 210, 220
without 4MATIC, 463
4MATIC, 209,
211.061/065
220 with 4MATIC
5 Detach belt Models 129, 463, 163 AR03.30-P-1600C
pulley/vibration damper Model 170, 202, 203, AR03.30-P-1600CA
208.365/465, 209, 210,
211.061/065,220
6 Detach flywheel/driven AR03.30-P-8001C
plate
7 Take off end cover AR01.40-P-8913B
8 Take off timing case MODEL 463 AR01.40-P-8000GV
cover Models 220, 210 without AR01.40-P-8000B
4-MATIC, 208, 202, 129,
163, 170
Models 203, 209, AR01.40-P-8000PV
211.061/065
9 Remove connecting rod While turning the
bearing cap (16) crankshaft, ensure that the
connecting rods (11) do not
get jammed.
For this step, mark
connecting rod (11)and
(16) on one side relative to
each other.
10 Unscrew the crankshaft Pay attention to the bolt AR03.20-P-4351-02AV
bearing cap bolts release pattern: ? Bolt
tightening pattern for
crankshaft bearing cap(s)
11 Remove the crankshaft Before removing, mark
bearing caps (4, 10) and the crankshaft bearing caps
fitted bearing (5) (4, 10) and fitted bearing
(5). Carefully lever out
crankshaft bearing caps
(10) and (5).
12 Take crankshaft (1) out of
the crankcase
13 Take crankshaft bearing
shells (2) and thrust
washers (6) out of the
crankcase
Install
14 Insert crankshaft (1) Oil crankshaft journals
and crankshaft bearing
shells (2)
If a new crankshaft is being AR03.20-P-4341-01CV
installed
If crankshaft is being AR03.20-P-4341-
repaired 01CVA
15 Tighten the crankshaft The crankshaft bearing
bearing caps cap bolts M8X75 and
M10X90 must always be
replaced otherwise there is
a risk of cranks and
fracture. Tighten all bolts
(M10, M8) at the same
time, as specified in the
tightening diagram.
Tightening pattern AR03.20-P-4351-02AV
Bolt (7) *BA03.20-P-1001-01D
Side bolt (9) *BA03.20-P-1002-01D
Bolt (8) *BA03.20-P-1003-01D
16.1 Check axial play of If a new crankshaft is being AR03.20-P-4291-03AV
crankshaft installed
17 Inspect the connecting Test data: ? AR03.10-P-6111-01BV
rod bolts (12) Thread and shank length *BE03.10-P-1001-03A
18 Install the connecting rod The connecting rod AR03.10-P-6111-06AV
bearings and fit the bearing shell (13) with oil
connecting rod bearing drilling (arrowed) must be
cap (16) mounted in the connecting
rod (11), otherwise the
connecting rod bearings
will not be lubricated. The
anti-twist locks (14) of the
shells (13) must be located
in the grooves (15) in the
connecting rod (11) and the
(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 dimensional accuracy
would be lost.
19 Tighten connecting rod AR03.10-P-6111-02BV
bolts (12) *BA03.10-P-1001-01E
20 Rotate crankshaft To check that it turns
freely.
21 Fit on end cover Fit a new radial sealing AR01.40-P-8913B
ring. The sealing lip of the
radial sealing ring and its
mating surface must not be
oiled or greased. Pay
attention to the fitted
sleeves when pressing on
the end cover.
22 Mount the flywheel/drive AR03.30-P-8001C
plate
23 Mount the timing case Replace the O-rings and
cover radial sealing ring. The
sealing lip of the radial
sealing ring and its mating
surface must not be oiled
or greased. Pay attention to
the fitted sleeves when
pressing on the end cover.
Model 463 AR01.40-P-8000GV
Models 220, 210 without AR01.40-P-8000B
4-MATIC, 208, 202, 129,
163, 170
Models 203, 209, AR01.40-P-8000PV
211.061/065
24 Mount belt Models 129, 463, 163 AR03.30-P-1600C
pulley/vibration damper Model 170, 202, 203, AR03.30-P-1600CA
208.365/465, 209, 210,
211.061/065,220
25 Mount oil pump Ensure that the oil
return shutoff valve is
correctly located.
Clean oil pump strainer.
Fill oil pump with engine
oil before installing, so that
oil is delivered at the initial
startup.
Models 129, 163, 170, 202, AR18.10-P-6020B
208.365/465, 210, 220
without 4MATIC, 463
4MATIC, 209,
211.061/065
220 with 4MATIC
26 Fit oil pan top section Model 463 AR01.45-P-7500FG
4MATIC
4MATIC
Models 211.061/065 AR01.45-P-7500TV
Models 208, 202 AR01.45-P-7500FC
4MATIC, 209
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
27 Check engine valve AR05.10-P-6858V
timing
28.1 Fit the automatic Model 463 AR27.10-P-0500BD
transmission Model 220 without AR27.10-P-0500I
4MATIC
Models 210, 208, 202, 170, AR27.10-P-0500B
129
Models 211.061/065 AR27.10-P-0500T
4MATIC, 209
Model 163 AR27.10-P-0500GH
28.2 Fit on manual Models 129, 210, 202 AR26.10-P-0020A
transmission Model 211.061 AR26.10-P-0020T
Model 203, 209 AR26.10-P-0020P
Model 170 AR26.10-P-0020D
transmission 716.6
transmission 716.6 (code
424)
29 Install engine Model 463 AR01.10-P-2400CC
4MATIC
Model 210 without 4- AR01.10-P-2400CB
MATIC, 208, 202, 129.
Models 211.061/065 AR01.10-P-2400TC
4MATIC, 209
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA

112.951/976,
Engine
113.94/96/971/
980/981/982/
984/986
BE03.10-P- Connecting rod Thread dia. Ø M 8x1
1001-03A bolts Shank length When new mm 47
max. mm 47.6
Part no. -
CONNECTING ROD
01E Stage 2 Nm 25
Stage 3 Angle° 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
01D bearing cap bolt Stage 2 Nm 30
Stage 3 Angle° 90
Tightening diagram of crankshaft bearing caps - AR03.20-P-4351-02AV

Stage 3 Angle° 90
1. Moisten the thread and head contact surface of the bolts of the crankshaft bearing caps with oil.
2. Tighten the bolts of the crankshaft bearing caps as specified in the tightening diagram.
Pay attention to tightening torque and tightening angle of crankshaft bearing cap bolts.
Fig. 87: Identifying Bolts Of Crankshaft Bearing Caps
If no tightening angle wrench is available, tighten crankshaft bearing cap bolts further by the specified
angle at a stroke, using a socket wrench and locking handle.
3. Turn the crankshaft (to check that it moves freely).
Fig. 88: Checking Crankshaft Bearing Cap Bolts
Remove/install crankshaft - AR03.20-P-4351BV

ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 208, 209, 210, 211, 215, 220, 230
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
Fig. 89: Identifying Crankshaft, Crankshaft Bearing Cap, Thrust Washer
MODIFICATION NOTES
Figure modified from 30 Nm and 90 < or Value modified in series BA03.20-P- *BA03.20-P-
27.2.04
=° to 5 Nm, 30 Nm and 90 < or =° 1003-01D on engines 112, 113 1003-01D
Removing
1 Remove engine Model 463.206/ 209/ 232/ 233/ 240/ AR01.10-P-2400CC
241
Model 463.244/ 245/ 247/ 248/ 249/ AR01.10-P-2401GT
250/ 254
Model 463.243/ 246 AR01.10-P-2401MG
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-
2400RVK
Model 220 AR01.10-P-2400AB
Model 209 AR01.10-P-2400Q
Model 210 without 4-MATIC, 208, AR01.10-P-2400CB
202, 129
Model 211.070 AR01.10-P-2400TC
Model 163 AR01.10-P-2400CA
2 Remove automatic Model 463.206/ 209/ 232/ 233/ 240/ AR27.10-P-0500BD
transmission from 241
engine Model 463.243/ 244/ 245/ 246/ 247/ AR27.10-P-0500GA
248/ 249/ 250/ 254
Model 230.475 AR27.10-P-0500R
Model 230.474
Model 220 AR27.10-P-0500I
Model 209 AR27.10-P-0500P
Models 210, 208, 202, 129 AR27.10-P-0500B
Model 211.070 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
3 Remove oil pan top Models AR01.45-P-7500FG
section 463.209 /232 /233 /244 /245 /250 with
Engine 112.945.
Models
463.206 /240 /241 /247 /248 /249 /254
with Engine 113.962.
MODELS 463.243 /246 with
ENGINE 113.982
Model 230. AR01.45-P-7500R
Model 220 AR01.45-P-7500I
Model 210 without 4-MATIC AR01.45-P-7500F
Model 211.070 AR01.45-P-7500TV
Models 208, 202 AR01.45-P-7500FC
Model 209 AR01.45-P-7500PV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
4 Remove oil pump For this step, push back chain AR18.10-P-6020B
tensioner and take off chain.
Model 230. AR18.10-P-6020R
Models 209, 211.070 AR18.10-P-6020PV
5 Detach belt Models 129, 208, 210, 463, 163 AR03.30-P-1600C
pulley/vibration damper except 163.174
Models 163.174, 209.375 AR03.30-P-1600CA
Model 211 except 211.076 /176
Model 215 except 215.374
Model 220 except 220.074 /174
Models 211.076/176 AR03.30-P-
1600RVK
Model 215.374
Models 220.074/174
Model 230.474
6 Detach flywheel/driven AR03.30-P-8001C
plate
7 Take off end cover AR01.40-P-8913B
8 Take off timing case Model AR01.40-P-8000GV
cover 463.209 /232 /233 /244 /245 /250 with
Engine 112.945.
Model
463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982
Models 230.474 /475, 220, 210 AR01.40-P-8000B
without 4-MATIC, 208, 202, 163, 129
Models 209, 211.070 AR01.40-P-8000PV
9 Remove connecting rod While turning the crankshaft
bearing cap (16) ensure that the connecting rods (11)
do not get jammed.
To do this, mark connecting rod
(11) and connecting rod bearing cap
(16) on one side relative to each other.
10 Unscrew the crankshaft Pay attention to the bolt release AR03.20-P-4351-
bearing cap bolts pattern: ? Tightening diagram of 02BV
crankshaft bearing caps
11 Remove the crankshaft Before removing, mark the
bearing caps (4, 10) and crankshaft bearing caps (4, 10) and
fitted bearing (5) fitted bearing (5). Carefully lever out
crankshaft bearing caps (10) and (5).
12 Take crankshaft (1) out
of the crankcase
13 Take crankshaft bearing
shells with oil hole and
oil groove (crankcase)
(2) and thrust washers
(6) out of the crankcase
Installing
14 Insert crankshaft (1) Oil the crankshaft journals and
crankshaft bearing shells.
If a new crankshaft is being installed AR03.20-P-4341-
01CV
If crankshaft is being repaired AR03.20-P-4341-
01CVA
15 Tighten the crankshaft The crankshaft bearing cap bolts AR03.20-P-4351-
bearing caps M8x75 and M10x90 must always be 02BV
replaced otherwise there is a risk of
cranks and fracture.
Tighten all bolts at the same time
as specified in the tightening diagram.
Crankshaft bearing cap bolt *BA03.20-P-1001-
01D
Side crankshaft bearing cap bolt *BA03.20-P-1002-
01D
Crankshaft bearing cap bolt *BA03.20-P-1003-
01D
16 Check axial play of If a new crankshaft is being installed AR03.20-P-4291-
crankshaft 03AV
17 Inspect connecting rod Test data: ? AR03.10-P-6111-
bolts (12) Thread and shank length 01BV
*BE03.10-P-1001-
03A
18 Install connecting rod The connecting rod bearing shell AR03.10-P-6111-
bearings and fit (13) with the drilling (arrowed) must 06AV
connecting rod bearing be installed in the connecting rod
cap (16) (11), otherwise the connecting rod
bearings will not be lubricated.
The anti-twist lock (14) on the
connecting rod bearing shell (13)
must be located in the grooves (15) of
the connecting rods(11)and of the
connecting rod bearing cap (16).
connecting rod (11) and
connecting rod bearing cap (16) are
cracked They must not be installed on
the wrong side, as dimensional
accuracy would be lost.
19 Tighten connecting rod AR03.10-P-6111-
bolts (12) 02BV
*BA03.10-P-1001-
Connecting rod bolt 01E
20 Rotate crankshaft To check that it turns freely.
21 Fit on end cover Fit new radial sealing ring. The AR01.40-P-8913B
sealing lip of the radial sealing ring
and its mating surface must not be
oiled or greased. Pay attention to the
fitted sleeves when pressing on the
end cover.
22 Mount the AR03.30-P-8001C
flywheel/drive plate
23 Mount the timing case Replace O-rings and radial seal.
cover The sealing lip of the radial sealing
ring and its mating surface must not
be oiled or greased. Pay attention to
the fitted sleeves when pressing on
the end cover.
Models AR01.40-P-8000GV
463.209 /232 /233 /244 /245 /250 with
Engine 112.945.
Models
463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982
Models 220, 210 without 4-MATIC, AR01.40-P-8000B
208, 202, 163, 129,230.474/475
Models 209, 211.070 AR01.40-P-8000PV
24 Mount belt All except model 163.174, 208, AR03.30-P-1600C
pulley/vibration damper 209.375, 220.
Models 163.174, 209.375 AR03.30-P-1600CA
Model 211 except 211.076 /176
Model 220 except 220.074 /174
Models 211.076/176 AR03.30-P-
1600RVK
Model 215.374
Models 220.074/174
Model 230.474
25 Mount the oil pump Ensure oil return flow check valve
is correctly located. Clean the oil
pump strainer. Fill oil pump with
engine oil before installing, so that oil
is delivered at the initial startup.
Models 129, 163, 202, 208, 210, 220, AR18.10-P-6020B
463
Models 230. AR18.10-P-6020R
Models 209, 211.070 AR18.10-P-6020PV
26 Fit the oil pan top Models AR01.45-P-7500FG
section 463.209 /232 /233 /244 /245 /250 with
Engine 112.945.
Models
463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982
Model 230. AR01.45-P-7500R
Model 220 AR01.45-P-7500I
Model 210 without 4-MATIC AR01.45-P-7500F
Model 211.070 AR01.45-P-7500TV
Model 209 AR01.45-P-7500PV
Models 208, 202 AR01.45-P-7500FC
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
27 Check engine valve AR05.10-P-6858V
timing
28 Fit automatic Model 463.206/ 209/ 232/ 233/ 240/ AR27.10-P-0500BD
transmission 241
Model 463.243/ 244/ 245/ 246/ 247/ AR27.10-P-0500GA
248/ 249/ 250/ 254 Type 230.475
Model 230.474 AR27.10-P-0500R
Model 220 AR27.10-P-0500I
Models 210, 208, 202, 129 AR27.10-P-0500B
Model 211.070 AR27.10-P-0500T
Model 209 AR27.10-P-0500P
Model 163 AR27.10-P-0500GH
29 Install engine Models 463.206/ 209/ 232/ 233/ 240/ AR01.10-P-2400CC
241
Models 463.243/ 244/ 245/ 246/ 247/ AR01.10-P-2401GT
248/ 249/ 250/ 254
Models 463.243/ 246 AR01.10-P-2401MG
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-
2400RVK
Model 220 AR01.10-P-2400AB
Model 209 AR01.10-P-2400PV
Model 210 without 4-MATIC, 208, AR01.10-P-2400CB
202, 129
Model 211.070 AR01.10-P-2400TC
Model 163 AR01.10-P-2400CA

112.951/976,
Engine
113.94/96/971/
980/981/982/
984/986
BE03.10-P-1001- Connecting rod Thread dia. Ø M8 x 1
03A bolts Shank length When new mm 47
max. mm 47.6
Part no. -
CONNECTING ROD
112.951/976, 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
01E STAGE 2 Nm 25
STAGE 3 Angle° 90

Stage 3 Angle° 90

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. 92: Identifying Diagram Of Crankshaft Bearing Caps
Remove/install crankshaft - AR03.20-P-4351L
ENGINE 137.970
Fig. 93: Identifying Crankshaft Remove/Install Components
Removing
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
glasses. Only pour battery acid into suitable 0001-01A
injury caused by burns to skin and
and appropriately marked containers.
eyes from battery acid or when
handling damaged lead-acid batteries
Align vehicle between columns of lifting
Lethal injuries are possible if vehicle platform and position four support plates at AS00.00-Z-
slips off lifting platform lifting platform support points specified by 0010-01A
Risk of injury to skin and eyes due to Do not open cooling system unless coolant
AS20.00-Z-
scalding caused by contact with hot temperature is below 90°C.
0001-01A
coolant spray. Open cap slowly and release the pressure.
Do not pour coolant into beverage
Risk of poisoning from swallowing containers.
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
conditioning system. Risk of or open flames. Wear safety glasses and
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.
Risk of explosion caused by fuel No fire, sparks, open flames or smoking.
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.
Risk of accident due to vehicle Secure vehicle to prevent it from moving by AS00.00-Z-
starting off when engine is running. itself. 0005-01A
Risk of injury caused by contusions
Wear closed and snug-fitting work clothes.
and burns during starting procedure or
when working near a running engine
AR01.10-P-
1 Remove engine
2400L
2 Take engine mounts off engine support
Attach engine to assembly stand with
3
engine support
AR27.10-P-
4 Remove automatic transmission
0500I
AR03.30-P-
5 Remove flywheel/driven plate
8001C
AR01.40-P-
6 Remove rear end cover
8913L
AR01.40-P-
7 Remove timing case cover
8000L
AR01.45-P-
8 Remove oil pan
7500L
Remove oil pump chain from oil pump Press back chain tensioner and remove
10
drive gear oil pump chain: ?
AR18.10-P-
Remove oil pump
6020L
Unscrew bolts (7, 8, 9) and pry off
11 Pay attention to the bolt release pattern: ?
lower crankcase section (1)
Tightening pattern for crankcase bottom AR03.20-P-
section 4351-05L
Observe dowel pins when prying off. If
the lower crankcase section (1) cannot be
pried off: ?
Remove dowel pins
Threaded bolt Fig. 94
Impact extractor Fig. 95
Identify the crankshaft bearing shells
(6, without oil hole) in the lower
12 crankcase section (1) and crankshaft
bearings in the lower crankcase section
(1) relative to one another.
Mark connecting rod and connecting
13
rod bearing cap to each other
When rotating the crankshaft, ensure that
14 Remove connecting rod bearing caps
the connecting rods are not twisted.
Mark connecting rod bearing shell and
Do not mix up top and bottom
15 connecting rod bearing cap to each
connecting rod bearing shells.
other
Mark connecting rod bearing shell and Do not mix up top and bottom
16
connecting rod to each other connecting rod bearing shells.
Take crankshaft (2) out of the upper
17
crankcase section (3)
Identify crankshaft bearing shells (4,
with oil hole) in upper crankcase
18 section (3) and crankshaft bearings in
upper crankcase section (3) relative to
one another.
Install
Lubricate crankshaft bearing shells (4,
with oil hole) in upper crankcase section (3)
before installing crankshaft (2). The oil
grooves in thrust plates (thrust bearing) (5/1,
5/2) must point towards thrust collars of
19 Insert crankshaft (2)
crankshaft. The thrust washers (5/1, 5/2)
each have a retaining lug as an anti-twist
lock.
Observe crankshaft bearing shell
assignment: ?
AR03.20-P-
Assign crankshaft bearing shells
4360-01L
Oil bolts of lower crankcase section at
thread and bolt head contact surface.
20 Install lower crankcase section (1) Rotate crankshaft to check clearance.
Observe sealing compound flow and
tightening pattern: ?
Notes on applying sealant to bottom part of AH01.40-
crankcase P-1000-03A
Fig. 96
*BR00.45-
Loctite sealant 5970 Z-1013-
01A
Tightening pattern for crankcase bottom AR03.20-P-
section 4351-05L
*BA01.40-
P-1001-01I
AR03.20-P-
21 Check axial play of crankshaft
4355-02L
AR03.10-P-
22 Inspect connecting rod bolts
6111-01L
The anti-twist locks of connecting rod
bearing shells must be located in slots of
connecting rods and in connecting rod
bearing caps.
Fit connecting rod bearing and mount AR03.10-P-
23 Connecting rod and connecting rod
connecting rod bearing cap 6111-06L
bearing caps are cracked (broken) (enlarged
detail). They must not be installed on the
wrong side as the accuracy of fit would no
longer be given.
AR03.10-P-
24 Tightening connecting rod screws
6111-02L
*BA03.10-
P-1001-01E
25 Crank the crankshaft (2) To check that it turns freely.
AR01.45-P-
27 Installing oil pan
7500L
Replace the O-rings and radial sealing
ring.
The sealing lip of the radial sealing ring and AR01.40-P-
28 Install timing case cover its mating surface must not be oiled or 8000L
greased.
Pay attention to fitted sleeves when pressing
on end cover.
Replace radial seal!
The sealing lip of the radial sealing ring and
its mating surface must not be oiled or AR01.40-P-
29 Install end cover
greased. 8913L
Pay attention to the fitted sleeves when
AR03.30-P-
30 Install flywheel/driven plate
8001C
AR27.10-P-
31 Install automatic transmission
0500I
*BA22.10-
32 Attach engine mount to engine support
P-1004-01L
AR01.10-P-
33 Install engine
2400L

113.941/960, 137.970 in model 220 in model 220
Bolt, front engine
BA22.10-P-
mount to engine Nm 55 55
1004-01L
support

Number Designation Engine 137.970 in model 215
BA22.10-P-1004-01L Bolt, front engine mount to engine support Nm 55
CONNECTING ROD
Stage 1 Nm 5
Stage 3 Angle° 90
Number Designation Engine 137.970, 275,
285
Stage
Nm 40
1
1-14 M10
Stage
Angle° 90
2
Stage
Nm 12
1
15- Stage
M8 Angle° 90
28 2
Stage
BA01.40-P-1001- Bolt, crankcase bottom section to top Angle° 90
3
01I section
Stage
Nm 8
29- 1
M6
54 Stage
Angle° -
2
Stage
Nm 20
55- 1
M8
61 Stage
Angle° -
2
See picture -
Fig. 94: Identifying Threaded Pin (116 589 01 34 00)
Fig. 95: Identifying Impact Extractor (116 589 20 33 00)

Fig. 96: Identifying Sealant Gun (112 589 00 25 00)
REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
Tightening pattern for crankcase bottom section - AR03.20-P-4351-05L

285
Stage
Nm 40
1
1-14 M10
Stage Angle
90
2 °
Stage
Nm 12
1
15- Stage Angle
M8 90
28 2 °
Stage Angle
BA01.40-P-1001- Bolt, crankcase bottom section to 90
3 °
01I top part
Stage
Nm 8
29- 1
M6
54 Stage Angle
-
2 °
Stage
Nm 20
55- 1
M8
61 Stage Angle
-
2 °
See picture -
Fig. 97: Identifying Bolt Assignment
Bolt assignment
Attach bolts by hand and tighten slightly e.g. with a battery-operated screwdriver
Inner and center threaded connection:
1. Tighten bolts 1 to 14 according to tightening stage 1, starting with bolt 1.

2. Drive in dowel pins.
External threaded connection:
7. Tighten bolts 29 to 35 starting with bolt 29.

10. Tighten bolts 55 and 56, starting with bolt 55
11. Tighten bolts 57 and 61, starting with bolt 57
Remove/install crankshaft - AR03.20-P-4351MC
ENGINE 275 in MODEL 215, 216, 220, 221

Fig. 98: Identifying Crankshaft Remove/Install Components
Removing
AR01.10-P-
1.1 Remove engine protection, code Z07
2400MC
Remove engine with front AR01.10-P-
1.2 Model 216, 221
axle carrier 2500SZ
AR27.10-P-
2 Remove transmission Model 216, 221
0500SZ
Detach engine from front AR01.10-P-
3 Model 216, 221
axle carrier 2510SX
Mount engine onto
4
assembly stand
AR01.40-P-
5 Remove end cover
8913MC
AR01.40-P-
6 Remove timing case cover
8000M
AR01.45-P-
7 Remove oil pan Model 215, 220
7500L
AR01.45-P-
Model 216, 221
7500SZ
AR18.10-P-
9 Remove oil pump
6020L
Remove bolts (M10) (7),
bolts (M8) (8), bolts (M6) Loosen bolts (7, 8, 9) in reverse order of tightening
10
(9) and prise off crankcase procedure: ?
bottom section (1)
Tightening procedure for crankcase bottom section
Observe dowel pins when prying off. If lower AR03.20-P-
crankcase section (1) cannot be prised off:? 4351-05L
Remove dowel pins
Fig. 94
Fig. 95
Place match marks on
crankshaft bearing shells in
lower crankcase section
11
(without oil hole) (6) and
on crankshaft bearings in
lower crankcase section (1).
12 connecting rod and
Remove connecting rod While turning crankshaft (2) ensure that connecting
13
bearing caps rods do not get jammed.
Mark connecting rod
bearing shell and Do not mix up top and bottom connecting rod
14
connecting rod bearing cap bearing shells.
to each other
Mark connecting rod
bearing shell and Do not mix up top and bottom connecting rod
15
connecting rod to each bearing shells.
other
Take crankshaft (2) out of
16
top part of crankcase (3)
crankshaft bearing shells in
upper crankcase section
17
(with oil hole) (4) and on
crankshaft bearings in
upper crankcase section (3).
Install
Lubricate crankshaft bearing shells in upper
crankcase section (with oil hole) (4) before installing
crankshaft (2). The oil grooves in the thrust washers
(thrust bearing) (5/1) and thrust washers (thrust
bearing) (5/2) must point towards thrust collars of the
crankshaft (2). Thrust washers (thrust bearing) (5/1) and
18 Insert crankshaft (2) thrust washers (thrust bearing) (5/2) are each fitted with
a retaining lug as an anti-twist lock.
Observe crankshaft bearing shell assignment: ?
AR03.20-P-
Assign crankshaft bearing shells.
4360-01L
Lubricate bolts for the lower crankcase section (1)
Install lower crankcase
19 on thread and bolt head contact surface.
section (1)
Observe sealant flow and tightening procedure:?
Notes on application of sealant to crankcase bottom AH01.40-
section P-1000-03A
Fig. 96
*BR00.45-
Sealant Z-1013-
01A
AR03.20-P-
Tightening procedure for crankcase bottom section
4351-05L
*BA01.40-
P-1001-01I
20 Crank the crankshaft (2) To check for unobstructed movement.
Check axial play of AR03.20-P-
21
crankshaft (2) 4355-02L
Inspect Connecting rod AR03.10-P-
22
bolts 6111-01L
The anti-twist locks of connecting rod bearing shells
must be located in slots of connecting rods and of
Fit connecting rod bearing
connecting rod bearing caps. AR03.10-P-
23 and mount connecting rod
bearing cap The connecting rod and connecting rod bearing cap 6111-06L
are broken. They must not be installed on wrong side
since the accuracy of fit would no longer be given.
Tighten connecting rod AR03.10-P-
24
screws 6111-02L
*BA03.10-
P-1001-01E
25 Crank the crankshaft (2) To check for unobstructed movement.
AR18.10-P-
26 Install oil pump
6020L
*BA01.40-
P-1002-01I
AR01.45-P-
28 Installing oil pan Model 215, 220
7500L
AR01.45-P-
Model 216, 221
7500SZ
Replace the O-rings and radial sealing ring.
The sealing lip of radial sealing ring and its mating AR01.40-P-
29 Install timing case cover
surface must not be oiled or greased. Pay attention to 8000M
fitted sleeves when pressing on end cover.
Replace radial sealing ring. The sealing lip of radial
sealing ring and its mating surface must not be oiled or AR01.40-P-
30 Install end cover
greased. Pay attention to the fitted sleeves when 8913MC
Detach engine from engine
31
assembly stand
Attach engine to front axle AR01.10-P-
32 Model 216, 221
carrier 2510SX
AR27.10-P-
33 Attach transmission Model 216, 221
0500SZ
AR01.10-P-
34.1 Install engine protection, code Z07
2400MC
Install engine with front AR01.10-P-
34.2 Model 216, 221
axle carrier 2500SZ

137.970, 275,
285
BA01.40-P- Bolt, crankcase 1-14 M10 Stage 1 Nm 40
1001-01I bottom section Stage 2 Angle° 90
to top part 15-28 M8 Stage 1 Nm 12
Stage 2 Angle° 90
Stage 3 Angle° 90
29-54 M6 Stage 1 Nm 8
Stage 2 Angle° -
55-61 M8 Stage 1 Nm 20
Stage 2 Angle° -
See picture -
BA01.40-P- Bolt, oil baffle to lower crankcase section Nm 8
1002-01I
CONNECTING ROD
Stage 1 Nm 5
Stage 3 Angle° 90
Fig. 99: Identifying Threaded Stud (116 589 01 34 00)
Fig. 100: Identifying Impact Extractor (116 589 20 33 00)
Fig. 101: Identifying Squeeze Gun (112 589 00 25 00)

REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
MEASURING CRANKSHAFT AND REMOUNTING IN BEARINGS - AR03.20-P-4355L
ENGINES 137.970, 275.950 /951 /953 /954 /980 /981 /982
Fig. 102: Identifying Crankshaft With Associated Components
Removing
The oil grooves (arrows) in the
thrust washers (thrust bearing) 5th
main bearing = fitted bearing (5)
must point towards the thrust collar
of the crankshaft
AR03.20-
1 Remove the crankshaft (2) Engine 137
P-4351L
AR03.20-
Engine 275.950 /953 /980 /982
P-4351MC
AR03.20-P-
Engine 275.951/ 954/ 981
4351R
After bearing damage has occurred, remove

2 Clean engine parts any swarf which is present in the connecting
rod bores and in the crankshaft and crank case
oil galleries: ?
Clean main oil gallery
Checking
After a bearing damage has occurred: ?
Connecting rods which overheated due to
3 Inspect connecting rod bearing damage (blue discoloration), must be
replaced.
The connecting rod shank must not have any
cross scores and notches.
If there is damage to the crankshaft (2):
4 Check crankshaft (2) ?
Install new crankshaft.
AR03.20-
Mount crankshaft (2) radially in
5 P-4355-
bearings
01L
A radial mounting of the main bearings in
case of standard dimension crankshafts is
possible by assigning crankshaft bearing shells
marked in colors.
?
AR03.20-
Assign crankshaft bearing shells. P-4360-
01L
AR03.20-
6 Mount crankshaft (2) axially P-4355-
02L
Installing
AR03.20-
7 Install crankshaft (2) Engine 137
P-4351L
AR03.20-
Engine 275.950 /953 /980 /982
P-4351MC
AR03.20-P-
Engine 275.951/ 954/ 981
4351R
Mount crankshaft radially in bearings - AR03.20-P-4355-01L
TEST AND ADJUSTMENT VALUES

68.500 to
Basic bore dia. Ø mm
68.519
68.500 to
Code number 52 1st stage blue mm
BE01.40-P-1001- Crankshaft 68.506
02G bearing 68.506 to
Code number 54 2nd stage yellow mm
68.513
Code number 56 3rd stage red mm 68.513 to
68.519
17.073 to
Basic bore width at fit bearing mm
18.00
Permissible out-of-roundness and conicity of
mm 0.02
basic bore
TEST AND ADJUSTMENT VALUES

Number Designation Engine 275,
285
68.500 to
Basic bore dia. Ø mm
68.519
68.500 to
Code number 52 1st stage blue mm
68.506
68.506 to
Code number 54 2nd stage yellow mm
BE01.40-P-1001- Crankshaft 68.513
02G bearing 68.513 to
Code number 56 3rd stage red mm
68.519
19.967 to
Basic bore width at fit bearing mm
20.00
Permissible out-of-roundness and conicity of
mm 0.02
basic bore
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

137 275.950/951/95
3/954, 285.950
Replacement part
Main bearing shells standard size for additional number 52 52
BE03.20-P- upper crankcase section and (color coding blue)
1001-03E crankcase bottom section main
bearing bore dia. Ø68.5 mm Bearing shell 2.252 to
mm 2.255 to 2.262
thickness 2.257
Replacement part
BE03.20-P- upper crankcase section and (color coding yellow)
mm 2.260 to 2.267
thickness 2.262
Replacement part
BE03.20-P- upper crankcase section and (color coding red)
mm 2.265 to 2.272
thickness 2.267
Replacement part
additional number 57 57
Main bearing shells standard size for (color coding white)
BE03.20-P- bottom part of crankcase main
1004-03E bearing bore dia. Ø68.5 mm Bearing shell 2.267 to
mm 2.270 to 2.277
thickness 2.272
Replacement part
BE03.20-P- (color coding purple)
crankcase bottom section main
1005-03E
mm 2.275 to 2.282
thickness 2.277

275.980/981/982,
285.980
Replacement part
Main bearing shells standard size for additional number (color 52
BE03.20-P- upper crankcase section and crankcase coding blue)
1001-03E bottom section main bearing bore dia.
68.5 mm Bearing shell
mm 2.252 to 2.257
thickness
Replacement part
BE03.20-P- upper crankcase section and crankcase coding yellow)
mm 2.257 to 2.262
thickness
Replacement part
BE03.20-P- upper crankcase section and crankcase coding red)
mm 2.262 to 2.267
thickness
Replacement part
BE03.20-P- coding white)
crankcase bottom section main bearing
1004-03E
bore dia. 68.5 mm Bearing shell
mm 2.267 to 2.272
thickness
Replacement part
BE03.20-P- coding purple)
1005-03E
mm 2.272 to 2.277
thickness

Number Designation Engine 137 Engine 275.95, Engine 275.98,
285.95 285.98
radial when 0.028 to
mm 0.022 to 0.047 0.018 to 0.058
BE03.20-P-1001- Main bearing new 0.052
04E play
axial when mm 0.10 to 0.100 to 0.254 0.100 to 0.254
new 0.260

285.950
Stage
Nm 40
1
1-14 M10
Stage
Angle° 90
2
Stage
Nm 12
1
15- Stage
M8 Angle° 90
28 2
Stage
BA01.40-P-1001- Bolt, crankcase bottom section to Angle° 90
3
01I top part
Stage
Nm 8
29- 1
M6
54 Stage
Angle° -
2
Stage
Nm 20
55- 1
M8
61 Stage
Angle° -
2
See picture -
Fig. 103: Identifying Dial Indicator (36 001 589 53 21 00)

Number Designation
WH58.30-Z-1001-12A Quick calipers for internal measurements
WH58.30-Z-1012-12A Setting gage for micrometer
1. Mount lower crankcase section (1).

Fig. 104: Identifying Lower Crankcase Section
Measurement without bearing shells for determining thickness of bearing shell
2.1 Measure crankshaft bearing bore in direction A, B and C at two levels (out-of-roundness).
Fig. 105: Identifying Crankshaft Bearing Bore Measuring Directions
Fig. 106: Measuring Crankshaft Bearing Bore
Measurement with bearing shells for determining radial bearing clearance
2.2 Measure crankshaft bearing bore in direction A, B and C at two levels (out-of-roundness).
3.1 Measure crankshaft bearing bore, without bearing shells, in direction A, note measurement, example:
68.51 mm.
3.2 Measure crankshaft bearing bore, without bearing shells, in direction A, note measurement, example:
64 mm.
4 Dismount lower crankcase section (1).
Fig. 107: Identifying Crankshaft Bearing Bore Measuring Directions
Fig. 108: Measuring Crankshaft Bearing Bore
5 Measure crankshaft bearing journal dia. example: 63.95 mm

6.1 Determine bearing shell thickness
Example:
Bearing bore dia. 68.51 mm
Crankshaft journal dia. -63. 95 mm
4.56 mm
Radial bearing play: - 0.04 mm
Test values --> table "crankshaft bearing play". -

4.52 mm : 2
Bearing shell thickness 2.26 mm
Fig. 109: Measuring Crankshaft Bearing Journal Diameter
6.2 Determine radial bearing clearance
Example:
Bearing bore dia. 64. 00 mm
Crankshaft journal dia. -63. 95 mm
Radial bearing play: 0.05 mm
7 Assign bearing shells (only for standard dimension crankshaft)
Example:
Bearing shell thickness 2.26 mm --> chart "test values of crankshaft bearing shells"
Upper bearing shell "yellow"
Lower bearing shell "yellow"
If the thickness of the bearing shell differs, install thicker bearing shell in lower crankcase section (1).
Mount crankshaft axially - AR03.20-P-4355-02L

285.95 285.98
radial when
BE03.20-P-1001- Main bearing new mm 0.028...0.052 0.022...0.047 0.018...0.058
04E play
axial when
new mm 0.10...0.260 0.100...0.254 0.100...0.254

Number Designation
WH58.30-Z-1001-12A Quick calipers for internal measurements
WH58.30-Z-1012-12A Setting gage for micrometer
1. Note width of fitted bearing (5th main bearing) at upper crankcase section and note value.
2. Measure width of fitted bearing at crankshaft, note.
3. Determine thickness of thrust washer.
Fig. 112: Measuring Crankshaft Bearing Width
4. Insert thrust plates (5).
The oil grooves (arrows) must be pointing toward the contact surface of the crankshaft and be oiled.
Fig. 113: Locating Oil Grooves
5. Measure axial bearing play, adjust if necessary.

Fig. 114: Measuring Axial Bearing Play
ASSIGNING CRANKSHAFT BEARING SHELLS - AR03.20-P-4360-01L

Number Designation Engine 137 Engines
275.950/951/
953/954, 285.950
Replacement part
Main bearing shells standard size additional number 52 52
BE03.20-P- for upper crankcase section and Ø (color coding blue)
bearing bore dia. 68.5 mm Bearing shell
mm 2.252...2.257 2.255 to 2.262
thickness
Replacement part
BE03.20-P- for upper crankcase section and Ø (color coding yellow)
mm 2.257...2.262 2.260 to 2.267
thickness
Replacement part
BE03.20-P- for upper crankcase section and Ø (color coding red)
mm 2.262...2.267 2.265 to 2.272
thickness
Replacement part
additional number 57 57
Main bearing shells standard size
(color coding white)
BE03.20-P- for crankcase bottom section main
1004-03E bearing bore dia. Ø68.5 mm Bearing shell
mm 2.267...2.272 2.270 to 2.277
thickness
Replacement part
BE03.20-P- (color coding purple)
for crankcase bottom section main
1005-03E
bearing bore dia. Ø68.5 mm Bearing shell
mm 2.272...2.277 2.275 to 2.282
thickness

Number Designation Engines
275.980/981/982,
285.980
Replacement part
BE03.20-P- upper crankcase section and crankcase coding blue)
mm 2.252...2.257
thickness
Replacement part
BE03.20-P- upper crankcase section and crankcase coding yellow)
mm 2.257...2.262
thickness
Replacement part
BE03.20-P- upper crankcase section and crankcase coding red)
mm 2.262...2.267
thickness
Replacement part
1004-03E
mm 2.267...2.272
thickness
Replacement part
1005-03E
mm 2.272...2.277
thickness
1. Assign bearing shells to upper crankcase section
The bearing shells are marked on the side in color.
The upper crankcase section carried letters, which correspond to the sequence of the bearing shells (1, 2,
3, 4, 5, 6, 7) in the upper crankcase section. The bearing shells should be selected according to the letter
sequence (only shown in picture with "b"). Letters "g" and "r" may also be used. The following letters
require the following wheel offset code numbers of bearing shells (upper section):
b (blue) = wheel offset code number 52
g (yellow) = wheel offset code number 54
r (red) = wheel offset code number 56
Shown on engine 137
Fig. 115: Identifying Bearing Shells With Identification Marks - Shown On Engine 137
2. Assign bearing shells to lower crankcase section.
The bearing shells are marked on the side in color. Letters for assigning the bearing shells to the
bottom part of the crankcase are included on the crankshaft journal. Select the bearing shells to match the
letters.
Shown on engine 137

Fig. 116: Identifying Bearing Shells With Identification Marks - Shown On Engine 137
REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-P-1600
Remove/install belt pulley/vibration damper - AR03.30-P-1600CA
ENGINE 112.947 in MODEL 170
ENGINE 112 in MODEL 202, 208, 209, 210, 220
ENGINE 113 (except 113.991) in MODEL 215, 220
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282

ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.988 in MODEL 203.076/276
Fig. 117: Identifying Pulley/Vibration Damper, Center Bolt
MODIFICATION NOTES
9.1.06 Central bolt to vibration damper *BA03.30-P-1001-01D
Remove/install
Risk of death Align vehicle between columns of vehicle lift and position four AS00.00-Z-
caused by support plates at vehicle lift support points specified by vehicle 0010-01A
vehicle slipping manufacturer.
or toppling off
the lifting
platform.
1 Remove engine Model 163 AR61.20-P-
compartment 1105GH
paneling Model 171 AR61.20-P-
1105V
2.1 Remove front MODEL
engine cover 211.061 /065 /070 /080 /082 /083 /261 /265 /270 /280 /282 /283
2.2 Remove air filter Model 163.174 with engine 113.981
housing Model 170 with engine 112.947
Model 202, 208, 209, 210, 220 with engine 112
Model 209 with engine 113 except engine 113.987 from
24.04.04
Model 215, 220 with engine 113
Model 230.467 with engine 112.973
Model 171.473 with engine 113.989 AR09.10-P-
1150AC
Model 203.076 /276 with engine 113.988
Model 209.376 /476 with engine 113.987 as of 24.04.04
3 Remove fan Model 163 AR20.40-P-
shroud 5000GH
Model 170.465 AR20.40-P-
5000SV
Model 171.473 AR20.40-P-
6800VT
Model 211.070 /270 /083 /283 AR20.40-P-
6800TB
Model 202, 208
4 Remove poly-V Model 163.174, 202, 208, 210, 215, 220 AR13.22-P-
belt (3) 1202BA
Model 170.465 AR13.22-P-
1202SV
Model 171.473 AR13.22-P-
1202PV
Model 203.076/ 276
Model 209.361/ 365/ 375/ 376/ 461/ 465/ 475/ 476 MODEL
211.061 /065 /070 /080 /082 /083 /261 /265 /270 /280 /282 /283
Model 230.467/ 475 AR13.22-P-
1202R
5 Remove center Installation: The center bolt (2) should always be replaced.
bolt (2) Installation: Make two markings on counterholder to aid
applying tightening angle.
Use extension.
*BA03.30-
P-1001-01D
Fig. 118
Fig. 119
6 Detach belt Installation: The groove on belt pulley/ vibration damper
pulley/vibration (1) must engage in feather key of crankshaft.
damper (1) from
crankshaft
Checking
7 Check belt
pulley/vibration
damper (1) for
faults
Noises from belt AF03.30-P-
drive * Not for USA, Japan 1001AG
8 Check tread of Check for scoring and galling, if necessary, replace belt
crankshaft radial pulley/vibration damper (1).
sealing ring at
hub of belt
pulley/vibration
damper (1)
9 Replace front Only when replacing belt pulley/vibration damper (1) or in
crankshaft radial the event of a leak at crankshaft radial sealing ring.
sealing ring Except model 230.467 AR03.20-P-
3000BA
Model 230.467 AR03.20-P-
3000R
10 Install in the
reverse order
11 Check engine oil
level and
replenish oil if
necessary
Risk of accident Secure vehicle to prevent it from moving by itself. AS00.00-Z-
caused by Wear closed and snug-fitting work clothes. 0005-01A
vehicle starting Do not touch hot or rotating parts.
off by itself
when engine is
running. Risk of
injury caused by
contusions and
burns during
starting
procedure or
when working
near the engine
as it is running
12 Conduct engine
test run and
check the engine
for leaks

113.94/96 /97/98
Fig. 119: Identifying Counterholder (112 589 00 40 00)
Remove/install belt pulley/vibration damper - AR03.30-P-1600L
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Shown on engine 137

Fig. 120: Identifying Belt Pulley/Vibration Damper Remove/Install Components - Shown On Engine 137
Remove/install
Remove fan shroud Model 215, 220 except 215.379, 220.179 AR20.40-P-
1
(1) Model 230 6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
Model 216.379, 221.179 AR20.40-P-
Disconnect plug connection for the suction fan. 6800SXM
Remove poly-V belt AR13.22-P-
2 Model 215, 220, 230
(2) 1202L
AR13.20-P-
Model 216, 221
0001SZ
In order to avoid damage to starter ring gear, the center
Remove center bolt bolt (3) must not be counterheld at starter ring gear (with
3 retaining lock) for disassembly. Using a high torque,
(3)
counterhold with the counterholder on the spokes of the belt
pulley/ vibration damper (4).
For better disassembly use the extension.
WF58.50-P-
Extension for counterholder
0330-02A
Installation: Replace center bolt (3).
*BA03.30-
Engine 137 P-1001-01D
*BA03.30-
Engine 275 P-1001-01I
Fig. 119
Installation: The installation position is given by feather
Remove belt
key.
4 pulley/vibration
damper (4) Inspect running surface of hub for signs of wear; if lateral
trueness is not correct: ?
AR03.30-P-
Check belt pulley/vibration damper for lateral trueness.
1600-01B
*BE03.30-P-
Engine 137
1001-02A
*BE03.30-P-
Engine 275
1001-02C
Fig. 103
Fig. 70
5
order
BELT PULLEY/VIBRATION DAMPER
Radial runout mm -
BE03.30-P-1001-02C Permissible difference at vibration damper
Lateral trueness mm 0,3

Radial runout mm -
BE03.30-P-1001-02A Permissible difference at vibration damper
Lateral trueness mm 0.3

Stage 1 Nm 200
BA03.30-P-1001-01D Central bolt to vibration damper
Stage 2 Angle° 90

Stage 1 Nm 275
BA03.30-P-1001-01I Central bolt, belt pulley to crankshaft
Stage 2 Angle° 90

Inspecting belt pulley / vibration damper for axial and radial runout - AR03.30-P-1600-01B
BELT PULLEY / VIBRATION DAMPER

Number Designation Motor 112, Engine Engine
113.94/ 96/98 113.992 113.990/ 991
BE03.30-P- Permissible Radial runout mm 0.5 0.4 0.4
1001-02A difference at
vibration Axial runout mm 0.3 0,2 0.4
damper
BELT PULLEY / VIBRATION DAMPER

Engine 275,
Number Designation Engine 137 Engine 271 285
BE03.30-P- Permissible Radial runout mm - 0.3 -
1001-02C difference at
vibration Axial runout mm 0.3 0.3 0.3
damper

1. Bolt dial gage holder (03) onto timing case cover.

2. Insert dial gage (04) into dial gage holder (03).
3. Check axial runout .
Position tracer pin (05) of dial gage (04) at measuring point (B).
4. Rotate belt pulley/ vibration damper (62) by hand, inspect axial runout.
Fig. 126: Identifying Axial Runout
5. Inspect concentricity
Position tracer pin (05) of dial gage (04) at measuring point (A).
6. Rotate belt pulley/ vibration damper (62) by hand, inspect concentricity.
Remove/install belt pulley/vibration damper - AR03.30-P-1600RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074 /174

Fig. 127: Identifying Belt Pulley/Vibration Damper And Center Bolt
Remove/install
Align vehicle between the columns of
the lifting platform and position the
four support plates at the lifting
or toppling off of the lifting platform. 0010-01A
platform support points specified by
1 Remove front engine cover
AR20.40-P-
2 Remove fan shroud Model 211
6800TC
AR20.40-P-
Model 215, 220, 230
6800AB
AR13.21-P-
3 Remove poly-V-belt on supercharger
1202RVK
AR13.22-P-
4 Remove poly-V-belt Model 211
1202RV
AR13.22-P-
Model 215, 220, 230
1202R
Installation: The center bolt (2)
should always be replaced.
Installation: Make two markings
5 Remove the center bolt (2)
on the counterholder to aid applying
the tightening angle.
Use extension.
*BA03.30-
P-1001-01D
Torque wrench Fig. 118
Counterholder Fig. 129
Installation: The groove on the belt
Detach the belt pulley/vibration damper (1) pulley/vibration damper (1) must
6
from the crankshaft engage in the feather key of the
crankshaft.
Checking
Check for scoring and galling; if
Check the tread of the crankshaft radial
necessary: ?
7 sealing ring at the hub of the belt pulley/
Replace belt pulley/vibration damper
vibration damper (1)
(1)
When replacing the belt
pulley/vibration damper (1) or in the AR03.20-P-
8.1 Replace front crankshaft radial sealing ring
event of leaks at the crankshaft radial 3000RVK
sealing ring.
Check engine oil level and replenish oil if AR18.00-P-
10 Model 211, 230
necessary 3035-01O
AR18.00-P-
Model 215, 220
3035-01DA
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.
In the event of oil loss determine
and eliminate cause, otherwise
Conduct engine test run and check the
11 malfunctions, transmission damage,
engine for leaks
and serious environmental pollution
may occur.

Number Designation Engine 113.990/ 991/992/
993/995
Stage
Nm 200
BA03.30-P-1001- Central bolt to vibration 1
01D damper Stage Angle
90
2 °

REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT / RING GEAR - AR03.30-P-5000B
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220, 230.467
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 211.076 /276, 215, 220, 230.472 /474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 275.950 /980 in MODEL 215, 220
ENGINE 113.988 in MODEL 203.076/276
Shown on engine 112

Fig. 130: Identifying Retaining Lock For Crankshaft / Ring Gear
Remove/install
Risk of death Align vehicle between columns of vehicle lift and position four AS00.00-
caused by support plates at vehicle lift support points specified by vehicle Z-0010-
vehicle slipping manufacturer. 01A
or toppling off
the lifting
platform.
1 Remove starter Model 203.065 /265 /764
Model 210.074/274
Model 215.373
Model 220.073/163/173
Model 202, 208.474 with engine 113
Model 463 with engine 112.945 AR15.30-
P-
7100GW
Model 463 with engine 113.962/ 982 AR15.30-
P-
7100GV
Model 129 AR15.30-
P-7100CS
Model 211 except 211.076 /276
Model 163 with engine 112, 113 AR15.30-
P-
7100GH
Model 170 with engine 112.947 /960 AR15.30-
P-
7100GA
Model 171.473 AR15.30-
P-7100VT
Model 202.026 /086 with engine 112.910 AR15.30-
P-7100ED
Model 203.061 /261 with engine 112.912 AR15.30-
P-7100P
Model AR15.30-
210.061 /062 /063 /065 /081 /082 /261 /262 /263 /265 /281 /282 /663 P-7100FF
with ENGINE 112
Model 210.070 /270 /083 /283 with engine 113
Model 215.378 AR15.30-
P-7100N
Model 215, 220, 230 with engine 275 AR15.30-
P-7100H
Model 215.375 with engine 113 AR15.30-
P-7100I
Model 220.070/ 075/170/175/ 875 with engine 113
Model 220.063 /065 /067 /165 /167 with engine 112
Model 203.081 /084 /281 /284, 220.087 /187 with engine 112 AR15.30-
P-
7100PW
Model 220.083 /084 /183 /184 with engine 113
Model 211.076 /276 with engine 113 AR15.30-
P-7100R
Model 215.374 with engine 113
Model 220.074 /174 with engine 113
Model 230 with engine 112, 113
2 Insert retaining Slide retaining lock (1) into starter opening and allow to latch in
lock (1) ring gear; if required crank engine at crankshaft in direction of
rotation.
Retaining lock for engine 112, 113, 137 Fig. 131
Retaining lock for engine 275 Fig. 132
3 Install in the
reverse order
Fig. 131: Identifying Retaining Lock (112 589 03 40 00)
Fig. 132: Identifying Retaining Lock (285 589 02 40 00)
REMOVE/INSTALL FLYWHEEL / DRIVE PLATE - AR03.30-P-8001
Remove/install flywheel / drive plate - AR03.30-P-8001C
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 211.076/276, 215, 220, 230.474/475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 112.917 in MODEL 211.080/280

ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
Shown on Engine 112 with manual transmission
Fig. 133: Identifying Flywheel / Drive Plate, Straight Pin, Crank Shaft
Remove/install
Risk of death caused by
platform and position the four support plates AS00.00-Z-
vehicle slipping or toppling
below the lifting platform support points specified 0010-01A
off of the lifting platform.
by the vehicle manufacturer.
AR27.10-P-
Model 129, 170, 202, 208, 210
0500B
AR27.10-P-
Model 463
0500BD
AR27.10-P-
Model 463
0500GA
AR27.10-P-
Model 230.474 /475
0500R
Model 215, 220 without 4MATIC with engine AR27.10-P-
112, 113 0500I
Remove automatic Model 220, 211 with 4MATIC with engine 112, AR27.10-P-
1.1
transmission 113 0500IW
AR27.10-P-
0500I
Model 203 without 4MATIC, 209 with engine AR27.10-P-
112, 113 0500P
AR27.10-P-
Model 203 with 4MATIC
0500PW
AR27.10-P-
Model 211 without 4MATIC with engine 112, 113
0500T
AR27.10-P-
0500GH
AR26.10-P-
Model 210, 202, 129 with engine 112
0020A
AR26.10-P-
0020P
1.2 Remove manual transmission
AR26.10-P-
Model 211 with engine 112
0020T
AR26.10-P-
Model 170
0020D
AR26.10-P-
Remove Sequentronic Model 203, 208, 209.3 with engine 112
0020E
1.3 automated manual
transmission (AMT) AR26.10-P-
Model 211.0 with engine 112
0020TA
Install the retaining lock (6)
AR03.30-P-
2 for the crankshaft (5) and
5000B
starter ring gear
Vehicles with manual transmission
Only unscrew or screw in bolts by 1 to 1.5
turns at a time
AR25.10-P-
Models 129, 163, 170, 202, 208, 210
3.1 Dismount clutch 0050A
AR25.10-P-
Model 203, 209, 211
0050P
Bolt of pressure plate to flywheel or two-mass *BA25.10-P-
flywheel 1001-01A
Installation: Replace bolts, because if they are
used again, the connection may loosen and the
Unscrew bolts (3) of bolts may shear off.
4
flywheel or of drive plate
Torx bolts of two-mass flywheel/driven plate *BA03.30-P-
at crankshaft 1002-01D
5 Remove washer (2)
Remove flywheel with starter Installation: The cylinder pin (4) determines
6
ring gear (1) and drive plate the installation position.
Flywheel, two-mass GF03.30-P-
Engine 112, 113
flywheel, drive plate, location 8001-01B
If a new flywheel or drive plate is installed,
perform initialization in the ME control unit with
STAR DIAGNOSIS in the menu item "Control
8 Carry out initialization
unit adaptation".
*WH58.30-Z-
STAR DIAGNOSIS diagnosis system
1048-13A

BA03.30-P-1002- Torx bolts of two- Stage 1 Nm 45
01D mass flywheel/drive Stage 2 Angle° 90
plate at crankshaft

Engine
Engine 113.990/
113.94/96/ 991/992/
Number Designation 97/98 993/995 Engine 137
BA03.30-P- Torx bolts of Stage 1 Nm 45 45 45
1002-01D two-mass
flywheel/drive
plate at Stage 2 Angle° 90 90 90
crankshaft
CLUTCH
Number Designation Model 129, 140, Model 461,463
163, 170, 202, 203,
208, 209, 210,211,
230
BA25.10-P-1001- Bolt of pressure Nm 25 25
01A plate to flywheel or
two-mass flywheel

Number Designation
Remove, install flywheel / drive plate - AR03.30-P-8001MC
ENGINE 275 in MODEL 215, 216, 220, 221

Fig. 134: Identifying Flywheel/Drive Plate Remove/Install Components
Remove/install
1 Model 215, 220
transmission 0500I
AR27.10-P-
Model 216, 221
0500SZ
AR03.30-P-
2 Install retaining lock Model 215, 220
5000B
AR03.30-P-
Model 216, 221
5000SZ
Installation: replace bolts (2), as if they are used
Remove bolts (2) from
3 again, the connection may not be tight or the bolts may
drive plate (1)
shear off.
*BA03.30-P-
1003-01I
4 Remove washer (3)
Remove drive plate (1) Installation: The cylindrical pin (arrow) determines
5
with starter ring gear the installation position.
6
order
If a new drive plate (1) is installed, perform
7 Carry out initialization initialization in the ME control unit with STAR
Diagnosis in the menu point "Control unit adaptation".
*WH58.30-Z-
1048-13A

285
Stage
Nm 45
BA03.30-P-1003- Bolt, flywheel or two-mass flywheel / driven plate to 1
01I crankshaft Stage Angle
90
2 °

Number Designation

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-10
rod 01D
Check values ENGINE 137.970 BE03
for connecting P-10
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-10
02E
Check values ENGINE 271, 275, 285... BE03
for pistons P-10
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-10
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-10
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 CONNECTING ROD/PISTONS - BE03.10-P-1000
Inspection data of connecting rod - BE03.10-P-1000-01D
Engines 112, 113, 155
MODIFICATION NOTES
9.3.04 Value modified from Value in series 1001 modified on
153.950...153.050 mm to engine 112.910/911/920/921/922/923
153.950...154.050 mm
55.600...55.965 mm to engine 112.910/911/920/921/922/923
55.600...55.614 mm
9.3.04 Value modified from Value in series 1008 with engine
55.600...55.965 mm to 112.940/941/942/943/944/945/948,
55.600...55.614 mm 113.940/941/942/943/960/961/962/963
changed
55.600...55.619 mm to engine 113.987/988
55.600...55.614 mm
55.600...55.619 mm to engine 113.990/991
55.600...55.614 mm
7.4.04 Value changed from 7 g to Value in series 1004 modified on
14 g engine 112
7.4.04 Value changed from 4 g to Value in series 1004 modified on
12 g engine 113
INSPECTION DATA FOR CONNECTING ROD

112.910/911/920/921/922/923 112.940/941/942/943/944/945/948,
113.940/941/942/943/960/961/962/963
BE03.10-P- Distance from mm 153.950...154.050 148.450...148.550
1001-01D center of
conrod
bearing bore
to conrod
bush bore (L)
BE03.10-P- Width of mm 19.948...20.000 19.948...20.000
1002-01D conrod at
conrod
bearing bore
(B)
BE03.10-P- Width of mm 19.948...20.000 19.948...20.000
1003-01D conrod at
conrod bush
bore (b)
BE03.10-P- Permissible g 14 14
1004-01D difference in
weight of
complete
conrod within
an engine
BE03.10-P- Conrod bush mm 22.007...22.013 22.007...22.013
1005-01D inner ø (d)
BE03.10-P- Conrod bush mm 24.500...24.521 24.500...24.521
1006-01D basic bore
(d1)
BE03.10-P- Peak-to- µm 5 5
1007-01D valley height
(R z ) of
conrod bush
on inside
BE03.10-P- Conrod mm 55.600...55.614 55.600...55.614
1008-01D bearing basic
bore diameter
BE03.10-P- Conrod mm 51.940...51.965 51.940...51.965
1009-01D bearing
journal
diameter
crankshaft
INSPECTION DATA OF CONNECTING ROD

Number Designation Engines Engines Engine 155
113.987/988/989 113.990/991
BE03.10-P- Distance from mm 146.450...146.550 145.750...145.850 -
1001-01D center of conrod
bearing bore to
conrod bush bore
(L)
BE03.10-P- Width of conrod mm 19.948...20.000 19.948...20.000 -
1002-01D at conrod
bearing bore (B)
BE03.10-P- Width of conrod mm 19.948...20.000 19.948...20.000 -
1003-01D at conrod bush
bore (b)
BE03.10-P- Permissible g 14 12 -
1004-01D difference in
weight of
complete conrod
within an engine
BE03.10-P- Conrod bush mm 22.007...22.013 22.007...22.013 -
1005-01D inner ø (d)
BE03.10-P- Conrod bush mm 24.500...24.521 24.500...24.521 -
1006-01D basic bore (d1)
BE03.10-P- Peak-to-valley µm 5 5 -
1007-01D height (R z ) of
conrod bush on
inside
BE03.10-P- Conrod bearing mm 51.600...51.614 51.600...51.614 -
1008-01D basic bore
diameter
BE03.10-P- Conrod bearing mm 47.940...47.965 47.940...47.965 -
1009-01D journal diameter
crankshaft
Check values for connecting rod - BE03.10-P-1000-01E
Engine 137
CHECK VALUES FOR CONNECTING ROD

137.970
BE03.10-P- Distance from center of connecting rod bearing bore to connecting
mm 144.45...144.55
1001-01E rod bush bore (L)
BE03.10-P-
Width of connecting rod at connecting rod bearing bore (B) mm 18.548...18.600
1002-01E
BE03.10-P-
Width of connecting rod at connecting rod bush bore (b) mm 16.900...17.100
1003-01E
BE03.10-P- Permissible twist of connecting rod bearing bore to connecting rod
mm 0.1
1004-01E bush bore over a length of 100 mm
BE03.10-P- Permissible variation of axial parallelism of connecting rod bearing
mm 0.045
1005-01E bore to connecting rod bush bore over a length of 100 mm
BE03.10-P-
connecting rod bearing shell basic bore (D1) mm 49.600...49.614
1006-01E
BE03.10-P-
connecting rod bush inner dia. (d) mm 19.007...19.013
1007-01E
BE03.10-P-
connecting rod bush basic bore (d1) mm 21.500...21.521
1008-01E
BE03.10-P-
Piston pin play in connecting rod bush mm 0.007...0.013
1009-01E
BE03.10-P- Peak-to-valley height (RZ ) of connecting rod bush µM 5
1010-01E
BE03.10-P-
Permissible out-of-roundness and conicity of basic bore mm 0.02
1011-01E
BE03.10-P-
Connecting rod bush outside dia. mm 21.545...21585
1012-01E
BE03.10-P-
connecting rod bolt thread dia. M 7X1
1013-01E
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

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
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 values for pistons - BE03.10-P-1000-02E
Engine 137
MODIFICATION NOTES
17.7.02 Text "Identification X" deleted Text in series 1001 in column 1 deleted
Text "Identification Text in series 1001 in column 2 deleted
Text "Identification X" deleted Text in series 2002 in column 1 deleted
Text "Identification Text in series 2002 in column 2 deleted
TEST VALUES FOR PISTONS

Standard mm 83,975...84,003
BE03.10-P-1001-02E Piston Ø
Auxiliary stage mm 84,025...84,053
Standard mm < or = 0,04
BE03.10-P-1002-02E Piston clearance
Auxiliary stage mm < or = 0,04
Check values for pistons - BE03.10-P-1000-02F
Engine 271, 275, 285
MODIFICATION NOTES
21.10.05 Piston ø Engine 275, 285
8.11.05 Piston projects or stands Engine 271
back

271.921/940/941/944/946/948/950/952/955/956 271.942/943 275.950/951/953
285.950
BE03.10- Piston projects or mm 0.055/...-0.255 0.080/...- -
P-1001- stands back 0.280
02F
BE03.10- Piston Groove 1 mm < or = 0.08 < or = 0.08 -
P-1002- ring Groove 2 mm < or = 0.05 < or = 0.055 -
02F vertical Groove mm < or = 0.18 < or = 0.18 -
clearance 3
BE03.10- Piston ø Standard mm 81.946 to 81.964 81.944 to 81.970 to 82.008
P-1003- step 81.962
02F markings
X
Step mm 81.996 to 82.014 - 82.020 to 82.058
marking
BE03.10- Piston Standard mm - - < or = 0.04
P-1004- clearance
02F

275.980/981/982,
285.980
BE03.10-P-1001- Piston projects or stands back mm -
02F
BE03.10-P-1002- Piston ring vertical Groove 1 mm -
02F clearance Groove 2 mm -
Groove 3 mm -
BE03.10-P-1003- Piston ø Standard step mm 82.563 to 82.575
02F markings X
Step marking mm 82.613 to 82.625
BE03.10-P-1004- Piston clearance Standard mm 0.015
02F
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
clearance Groove 2 mm 0.015...0.05 0.015...0.05 0.01...0.04
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
clearance Groove 2 mm 0.01...0.04 0.015...0.045 0.015...0.050
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
TEST VALUES OF CRANKSHAFT MAIN BEARING SHELLS - BE03.20-P-1000

Inspection data of crankshaft bearing cap bolts - BE03.20-P-1000-01C
Engine 137, 275, 285
INSPECTION DATA OF CRANKSHAFT BEARING CAP BOLTS

Number Designation Engine 137, 275, 285
Thread diameter M 10
BE03.20-P-1001-01C Crankshaft bearing cap bolts Length (L) when new mm 117,7...118,3
max. length (L) mm 119
Thread diameter M8
BE03.20-P-1002-01C Crankshaft bearing cap bolts Length (L) when new mm 111,7...112,3
max. length (L) mm 113,5
Test values of crankshaft main bearing shells - BE03.20-P-1000-03E
ENGINE 137, 275, 285
TEST VALUES OF CRANKSHAFT MAIN BEARING SHELLS

275.950/951/
953/954, 285.950
Replacement part
BE03.20-P- for top part of crankcase and (color coding blue)
1001-03E bottom part of crankcase main
mm 2.252...2.257 2.255...2.262
thickness
Replacement part
BE03.20-P- for top part of crankcase and (color coding yellow)
mm 2.257...2.262 2.260...2.267
thickness
Replacement part
BE03.20-P- for top part of crankcase and (color coding red)
mm 2.262...2.267 2.265...2.272
thickness
Replacement part
BE03.20-P-
for bottom part of crankcase main (color coding white)
1004-03E
mm 2.267...2.272 2.270...2.277
thickness
Replacement part
BE03.20-P- additional number 58 58
1005-03E Main bearing shells standard size (color coding purple)
for bottom part of crankcase main
mm 2.272...2.277 2.275...2.282
thickness
TEST VALUES OF CRANKSHAFT MAIN BEARING SHELLS

275.980/981/982,
285.980
Replacement part
Main bearing shells standard size for top additional number (color 52
BE03.20-P- part of crankcase and bottom part of coding blue)
1001-03E crankcase main bearing bore dia. 68.5
mm Bearing shell
mm 2.252...2.257
thickness
Replacement part
BE03.20-P- part of crankcase and bottom part of coding yellow)
mm Bearing shell
mm 2.257...2.262
thickness
Replacement part
BE03.20-P- part of crankcase and bottom part of coding red)
mm Bearing shell
mm 2.262...2.267
thickness
Replacement part
bottom part of crankcase main bearing
1004-03E
mm 2.267...2.272
thickness
Replacement part
bottom part of crankcase main bearing
1005-03E
mm 2.272...2.277
thickness
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

Belt pulley/vibration damper - BE03.30-P-1000-02A
Engine 111, 112, 113, 137, 155

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

BE03.30-P-1001- Permissible difference Radial runout mm -
02A at vibration damper Axial runout mm -
Belt pulley/vibration damper - BE03.30-P-1000-02C
Engine 271, 275, 285

BE03.30-P-1001- Permissible Radial runout mm 0,3 -
02C deviation at
vibration damper Axial runout mm 0,3 0,3
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-1000-01E
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
BA03.10-P-1001- Connecting rod Stage 1 Nm 5 5
01E bolt Stage 2 Nm 15 20
Stage 3 Angle ° 90 90
CONNECTING ROD
BA03.10-P-1001- Connecting rod Stage 1 Nm 5 5
01E bolt Stage 2 Nm 25 15
Stage 3 Angle ° 90 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

Stage 3 Angle° 90
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

113.94/96/97/98
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, driven plate, vibration damper, starter ring gear - BA03.30-P-1000-01I
ENGINE 271, 275, 285

Number Designation Engine 271 Engines 275,
285
BA03.30-P-1001- Central bolt of belt pulley to 1st stage Nm 200 275
01I crankshaft 2nd stage Angle ° 90 90
BA03.30-P-1002- Bolt of retaining lock to oil pan Nm 10 -
01I
BA03.30-P-1003- Bolt for flywheel or two-mass 1st stage Nm 45 45
01I flywheel / driven plate to
crankshaft 2nd stage Angle ° 90 90
ACCESSORIES & BODY CAB
Throttle Control, Speed Control Systems - 215 & 220 Chassis
BASIC KNOWLEDGE
ACCELERATOR PEDAL SENSOR, COMPONENT DESCRIPTION - GF30.20-P-2010SM
ENGINE 113.986 in MODEL 215, 220
View of accelerator pedal module
Fig. 1: Identifying Accelerator Pedal Sensor And Kickdown Simulator - Engine 113.988
Task
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical
voltage corresponding to the accelerator pedal position.
The kickdown simulator is not an electrical component. It is designed to make it easier for the driver to
sense with his foot the point at which the accelerator pedal is fully depressed (full load position).
On models 215 and 220, up to MJ 02, the kick-down switch is fitted instead of the kick-down simulator
(S16/6).
Design (internal circuit)

Fig. 2: Identifying Accelerator Pedal Sensor Design (Internal Circuit)
Function
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.
Information on the accelerator pedal position is sent as two voltages at pin 4 (at around 0.2 to 2.25 V) and at pin
5 (at around 0.4 to 4.5 V) to the ME control unit (N3/10).
The accelerator pedal sensor is supplied with 5 V voltage through pin 1 by the ME control unit.
Pin 3 and 6 are ground connections.
The accelerator pedal sensor can only be replaced completely with an accelerator pedal module!
COMPONENT DESCRIPTION OF THROTTLE VALVE ACTUATOR - GF30.20-P-2020SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 3: Identifying Throttle Valve Actuator - Engine 113.988
The throttle valve is located at the rear at the variable intake manifold.
Task
The throttle valve actuator controls the functions:
 Idling speed
 Driving mode, corresponding with the accelerator pedal position and load
 Cruise control mode
 Emergency electronic accelerator pedal
Design
Fig. 4: Throttle Valve Actuator Design

Function
Fig. 5: Identifying Throttle Valve Actuator Circuit Diagram
The actuator motor in the throttle valve adjusts the opening angle of the throttle valve continuously from around
0 to 90°, according to the preset from the ME control unit (N3/10).
Both actual value potentiometers advise the current position of the throttle valve to the ME control unit.
In de-energized status (e.g. limp-home) the opening angle of the throttle valve (from 10 to 12°) is determined by
the spring capsule.
When the throttle valve actuator is connected to the vehicle for the first time, the motor electronics
control unit carries out an adaptation of the actuator (learning the lower and upper mechanical end stop of the
throttle valve) on its own.
CC [TPM] SWITCH, COMPONENT DESCRIPTION - GF30.20-P-2100SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 6: Identifying CC Switch
The CC push-button switch is located at the top left at the steering column module.
Task
The CC push-button switch s witches the cruise control functions and the variable speed limitation (except )
on or off.
Body
Fig. 7: Locating Components For CC [TPM] Switch - Engine 113.988
Function
When the cruise control switch is operated, two switching contacts are always activated simultaneously. The
actual input takes place by closing one of the switch contacts (storing the speed). The control contact must close
simultaneously so that the input is accepted. S40/4 N80 The switching signals are detected by the steering
column module and transmitted to the CAN databus.
ELECTRONIC ACCELERATOR, LOCATION/DESIGN/FUNCTION - GF30.20-P-3010E
ENGINE 104.941 /943 /944 /991 /994 as of 1/8/96

ENGINE 104.995
with CODE (494a) USA version
with CODE (807) Model year 1997
with CODE (498) as of Model year 97 Japanese version
ENGINE 111.943 /947 /951 /952 /955 /956 /957 /958 /973 /982 /983,
111.944/975 as of 1.8.96,
111.946 as of 1.6.98,
111.921/942 as of 1.9.98
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
202.020/080 as of 1.9.98
ENGINE 111.974
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 137.970
Fig. 8: Identifying Electronic Accelerator Function
The function of the electronic accelerator pedal EFP in the ME control unit determines the opening angle of the
throttle valve over the actuator EFP/TPM/LLR (other designation: throttle valve actuator).
Further functions are:
 Idle speed control [ISC]

 Variable speed limiter
 30 km/hour limit
 Reduce/increase the engine torque for ASR/ESP operation
 short performance limitation, for example for a higher coolant temperature
 Safety concept
 Actuate indicator lamp EPC (up to 5/96)
 Storing faults
 Data exchanger via CAN
The opening angle of the throttle valve will only be determined by the accelerator pedal specification when no
limiting functions are active.
The accelerator pedal position is detected by the set value potentiometer (B37r1) or Hall sensor in the pedal
value sensor (B37) and information is released to the ME control unit (N3/10). In this way, the ME-SFI control
unit determines the position of the throttle valve and actuates the throttle valve motor (M16/1 m1).
The actual value potentiometer in the actuator (M16/1r1) signals the throttle valve position back to the ME-SFI
control unit.
The second potentiometer in the actuator (M16/1 r2) and the second signal from the pedal value sensor
(potentiometer or Hall sensor) supplies a reference value for the plausibility check. In addition, the system
switches over to the second potentiometer or the Hall sensor if the first potentiometer or Hall sensor fails
(emergency mode).
Adaptive accelerator pedal (model 203, 209, 211, 215, 220, 230):
The engine 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 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 motorway then the
accelerator pedal must be pressed down unusually hard to obtain a higher acceleration level.
Kickdown switch (S16/6)
The kickdown switch was no longer used from 9/01. Recognition of full load is now achieved over the signal
from the pedal value sensor. The pressure point on the accelerator pedal before achieving the full load position
remains.
GF07.61-P-
except M111 EVO
Motor electronics control unit, location/task/ 5000F
design/function GF07.61-P-
M111 EVO
5000GS
Electronic accelerator/cruise control/idle speed GF30.22-P-
except M111 EVO
control actuator location/task/design/function 4010F
Throttle valve actuator, location/task/design/ GF30.22-P-
M111 EVO
function 4101GS
Pedal value sensor, location/task/design/ GF30.20-P-
function 4011L
GF30.22-P-
Except engine 120 and engine 111 EVO
0003E
ME-SFI idle speed control function
GF30.22-P-
M111 EVO
0003GS
Electronic power control indicator lamp, Engine 119, 120 in Model 129, 140 up GF30.20-P-
location/task/design/function to 5/96 4012L
Electronic accelerator pedal emergency running GF30.20-P-
Engine 104, 111, 112, 113, 119, 137
mode function 4026E
Model 129, 140 with Engine 104,
GF30.20-P-
30 km/h limit, function 119.98, 120.98
4027F
except
GF30.30-P-
With cruise control
0001F
Engine 104 (except HFM sequential
Cruise control (CC) function multiport fuel injection/ignition system),
119.98, 120.98
With cruise control GF30.30-P-
Engine 111, 112, 113, 137 0001FA
Additional cruise control function except GF30.30-P-
Variable speed limiter, function
3001A
Model 220, 215 with code 219a up to GF30.30-P-
6/00 0002K
Model 203, 209, 211, 230 with code
Distronic (DTR), function
219a GF30.30-P-
Model 215, 220 with code 219a as of 0002KA
7/00
Pedal value sensor characteristic curve when GF30.20-P-
reversing function 4013E
with code 471 a
GF42.40-P-
ASR V control unit location/task/design/function Model 129, 140, 202 as of 6/94, 170,
4500A
208, 210
with code 472a
Model 129 with Engine 104, 119, 120 GF42.45-P-
Model 140 4500A
with code 472a
Model 163 up to 8/02, 168, 215 GF42.45-P-
Model 220 (except 220.08/18) Model 4500B
ESP control unit location/task/function 202, 208 with engine 112, 113
Model 210 with engine 111, 112, 113
with code 472a
Model 170 with Engine 111, 112 GF42.45-P-
Model 202, 208 with Engine 111 4500C
Model 203
GF42.45-P-
Model 211, 230
4500SL
ME-SFI ELECTRONIC ACCELERATOR, FUNCTION - GF30.20-P-3012
ME-SFI electronic accelerator, function - GF30.20-P-3012AM
ENGINE 113.990 in MODELS 211, 219

Fig. 9: Identifying ME-SFI Electronic Accelerator Function
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.
The position of the accelerator pedal and the 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 control unit. The
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 in the throttle valve actuator in line with the driver input and
the operating conditions. An actual value potentiometer in the throttle valve actuator reports the current position
of the throttle valve to the motor electronics control unit.
A second actual value potentiometer in the throttle valve actuator and a second Hall sensor in the accelerator
pedal sensor supply a reference value for a plausibility check by the ME control unit.
Any detected faults are stored in the fault memory and can be read out and deleted using STAR DIAGNOSIS.
Additional functions of the electronic accelerator pedal:
 Idle speed control

 Cruise control (CC [TPM])
 Torque reduction
 Emergency running
 Data transfer over CAN
Input signals for the electronic accelerator pedal:
 Accelerator pedal position

 Brake actuation (via the ESP control unit)
 Cruise control operation (via the steering column module or the ESP control unit)
 Reduction of the engine torque (from ESP control unit)
 Drive position (via the ETC [EGS] control unit)
ME-SFI control unit, location/task/design/ function GF07.61-P-5000AM

Accelerator pedal sensor, location/task/design/function GF30.20-P-4010HA
Throttle valve actuator, location/task/design/function GF30.22-P-4101AM
Cruise control pushbutton switch, location/task/design/function GF30.30-P-3100AM
Stop light switch, location/task/design/function GF42.10-P-4000AM
ME-SFI electronic accelerator, function - GF30.20-P-3012M

Fig. 10: Identifying ME-SFI Electronic Accelerator Function
The function of the electronic accelerator (EA) in the ME-SFI [ME] control unit determines the opening angle
of the throttle valve in line with the accelerator pedal input.
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. This 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 (sliding contact 1) (M16/6r3) in the throttle valve actuator reports the current
position of the throttle valve to the ME-SFI [ME] control unit.
The actual value potentiometer (sliding contact 1) (M16/6r4) in the throttle valve actuator and the second signal
from the pedal value sensor supply a reference value for a plausibility check.
Furthermore it is switched over to the additional sensors, if the first signal fails (emergency mode).
Further functions are:

 Tempomat (cruise control)/Distronic
 Variable Speed Limiter
 Requests of momentary interface, such as:
 Reducing or increasing the engine torque for ESP operation
 Load limitation at too high coolant temperature
 Load limitation at too high boost pressure
 Reducing engine torque during gearshift operation
 Reducing engine torque at maximum speed
 Fault storage
 Data transfer via CAN
The input signals for the EA function are:
 Accelerator pedal sensor

 Brake light signal (CAN message "Driver brakes") from ESP control unit
 Pressure sensor downstream of throttle valve actuator (B28/7)
 Cruise control/Distronic requests
 Torque request from ESP control unit
 Driving stages from ETC control unit
If the brake pedal is operated, this always means idle speed input.
Adaptive accelerator pedal
The ME-SFI [ME] control unit recognizes how the accelerator pedal is being actuated and switches between
characteristic curves. After a pedal travel of about 50% about 80% of the engine load is released for a sporty
driver and about 10% 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.
ME-SFI [ME] control unit, location/task/design/function GF07.61-P-5000M

Accelerator pedal sensor, location/task/design/function GF30.20-P-4010M
Throttle valve actuator, location/task/design/function GF30.22-P-4101M
Pressure sensor downstream of throttle valve actuator, location/task/function GF07.04-P-5049M
Crankshaft position sensor, location/task/design/function GF07.04-P-4116M
ME-SFI electronic accelerator, function - GF30.20-P-3012SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 11: ME-SFI Electronic Accelerator Function Diagram - Engine 113.988
The electronic accelerator function is integrated and controlled in the motor electronics control unit (N3/10)
depending upon the driver input and the operating condition, the opening angle of the throttle valve.
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 (M16/6).
The opening angle of the throttle valve is changed by the actuator motor in the throttle valve actuator in
accordance with the driver input and the operating conditions.
An actual value potentiometer in the throttle valve actuator reports the current position of the throttle valve to
the motor electronics control unit.
A second actual value potentiometer in the throttle valve actuator and a second Hall sensor in the accelerator
pedal sensor supply a reference value for the plausibility check.
Any detected errors are stored in the diagnostic trouble code memory and can be read out and deleted using
STAR DIAGNOSIS.
Additional functions of the electronic accelerator pedal are:

 Cruise control (CC)
 Torque reduction
 Data transfer over CAN
Input signals for electronic accelerator pedal:
 Accelerator pedal sensor

 Stop lamp switch (S9/1) from ESP and BAS control unit (ESP, PML and BAS) (N47-5)
 Cruise control switch (S40/4) from the steering column module (N80)
 Reduction data (torque) from ESP and BAS control unit (ESP, PML and BAS)
 Driving stages from the ETC [EGS] control unit (N15/3)
Throttle valve damping function
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.
The damping function of the throttle valve is integrated in the motor electronics control unit.
Following input signals are processed:
 Change in the speed of the accelerator pedal position.

 Engine speed
 Coolant temperature
 Throttle valve position
 Vehicle speed
Characteristic during reversing (drive position "R")
A modified characteristic curve of the electronic accelerator should optimize the driving comfort and the safety
while reversing.
The reversing action is indicated by the ETC [EGS] control unit to the motor electronics control unit via the
CAN databus. The motor electronics control unit then utilizes a modified characteristic curve to regulate the
throttle valve actuator.
Hereby, the throttle valve is opened slowly and the opening angle is limited to maximum 60 %.
Crankshaft position sensor L5 GF07.04-P-6010SM

component description
Coolant temperature B11/4 GF07.04-P-6040SM
sensor component
description
ME-SFI [ME] control unit N3/10 GF07.61-P-6000SM
Accelerator pedal sensor, B37 GF30.20-P-2010SM
Component description of M16/6 GF30.20-P-2020SM
CC [TPM] switch, S40/4 GF30.20-P-2100SM
Stop lamp switch S9/1 GF42.10-P-2010SM
ACCELERATOR PEDAL SENSOR, LOCATION/TASK/DESIGN/FUNCTION - GF30.20-P-4010
Accelerator pedal sensor, location/task/design/function - GF30.20-P-4010HA
ENGINES 113.990 /991 /992 /993 /995
Shown on the accelerator pedal module
Fig. 12: Identifying Accelerator Pedal Sensor And Kickdown Simulator
Accelerator pedal GF30.20-P-

Models 211, 219
sensor location 4010-01T
GF30.20-P-
Models 215, 220, 230, 463
4010-01R
The accelerator pedal sensor detects the accelerator pedal position
Accelerator pedal
and sends an appropriate voltage signal to the ME control unit
sensor task
(N3/10).
sensor design 4010-02HA
sensor function 4010-03HA
Accelerator pedal sensor design - GF30.20-P-4010-02HA
Fig. 13: Identifying Accelerator Pedal Module With Kickdown Simulator Components
Shown on the accelerator pedal module
The kickdown simulator (a) 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 by a complete accelerator pedal module!
Accelerator pedal sensor function - GF30.20-P-4010-03HA
Internal shift mechanism

Fig. 14: Identifying Internal Circuitry Of Pedal Value Sensor
The accelerator pedal sensor (B37) converts the mechanical operation input by the accelerator pedal (foot
actuation) into an electrical voltage corresponding to the accelerator pedal position.
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. Information on the
accelerator pedal position is transmitted in the form of two signal voltages (0.20 to 2.25 V and 0.40 to 4.50 V)
to the ME control unit (N3/10).
Accelerator pedal sensor, location/task/design/function - GF30.20-P-4010M

Fig. 15: Identifying Accelerator Pedal Sensor
Accelerator pedal sensor The accelerator pedal sensor is located at the top of the
location accelerator pedal module.
Accelerator pedal sensor Detects the accelerator pedal position and passes on the
task information to the engine control unit
Accelerator pedal sensor GF30.20-P-
design 4010-02M
Accelerator pedal sensor GF30.20-P-
function 4010-03M
Accelerator pedal sensor design - GF30.20-P-4010-02M
View of accelerator pedal module
Fig. 16: Identifying Accelerator Pedal Sensor And Kickdown Simulator

Fig. 17: Identifying Accelerator Pedal Module With Kickdown Simulator Components
Replace accelerator pedal module always complete!
Accelerator pedal sensor function - GF30.20-P-4010-03M
Illustrated is the internal shift in the accelerator pedal sensor (Hall principle)
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical
voltage corresponding to the accelerator pedal position.
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.
Via Pin 1 the accelerator pedal sensor is supplied by the ME control unit with 5 V voltage. 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.
The ranges of signal 1 are defined in percentage of the supply voltage (approx. 5 V) as follows:
 up to 4 % the signal through the short circuit to ground or through the line interruption is too small
 4 to 9.4 % idle speed range
 9.4 to 81 % partial-load range
 81 to 96 % full-load range
 over 96 % the signal through the short circuit to positive is too great.
In case of error on signal 1, it is switched over to signal 2 and the emergency mode is activated.
Kickdown detection via accelerator pedal sensor is performed, if the signals 1 and 2 remain in the full-load
range for a definite time.
If the brake pedal is operated, only the idle speed values from the accelerator pedal sensor are accepted. If
required, the engine control unit generates the substitute values. The signals from the accelerator pedal sensor
are rejected until then.
PEDAL VALUE SENSOR, LOCATION/TASK/DESIGN/FUNCTION - GF30.20-P-4011L
ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
ENGINE 104.995
with CODE (494a) USA-Ausfuhrung
with CODE (498) as of Model Year 97 Japan-Ausfuhrung
ENGINE 111.921 /942 as of 1.9.98,
111.946 as of 1.6.98,
111.944/975 as of 1.8.96,
111.943 /947 /951 /952 /955 /956 /957 /958 /973 /974 /982 /983
ENGINE 111.945
in MODEL 202.020 /080 as of 1.9.98,
208.335/435 as of 1.6.98
with CODE (494a) USA-Ausfuhrung
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982 /983
ENGINE 137.970
ENGINE 166.940 /960 /990 /995
ENGINE 604.910/915 as of 1.2.98
ENGINE 604.912/917 as of 1.4.98
ENGINE 611.961/960/962
ENGINE 612.961/962/963
ENGINE 613.960/961
ENGINE 628.960 /963
ENGINE 668.940 /941 /942
Shown on model 203, 215, 220

Fig. 19: Identifying Accelerator Pedal Sensor - Shown On Model 203, 215, 220
GF30.20-P-
Model 129
4011-01D
GF30.20-P-
Model 140
4011-01A
GF30.20-P-
Model 163
4011-01GH
GF30.20-P-
Model 168
4011-01GC
GF30.20-P-
Model 170
4011-01G
GF30.20-P-
Pedal value sensor position Model 202, 208
4011-01E
GF30.20-P-
Model 203, 209
4011-01P
GF30.20-P-
Model 210
4011-01F
GF30.20-P-
Model 211
4011-01T
GF30.20-P-
Model 215, 220
4011-01M
GF30.20-P-
Model 230
4011-01R
Detects the accelerator pedal position and passes on the
Pedal value sensor task
information to the engine control unit
Located in engine compartment with two rotary GF30.20-P-
potentiometers 4011-02A
GF30.20-P-
Located in engine compartment with two Hall elements
Pedal value sensor design 4011-02B
Model 203, 209, 211, 215, 220, 230 and
GF30.20-P-
Model 170 with Engine 111 EVO and 112: Location at
4011-02C
accelerator pedal module
The accelerator pedal sensor (B37) converts the mechanical
Pedal value sensor function actuation determined by the accelerator pedal into an
electrical signal according to the accelerator pedal position.
Pedal value sensor
GF30.20-P-
characteristic curve when
4013E
reversing function
Pedal value sensor position - GF30.20-P-4011-01M
Fig. 20: Identifying Accelerator Pedal Sensor - Shown On Model 203, 215, 220
Pedal value sensor design - GF30.20-P-4011-02A
with two rotary potentiometers
Fig. 21: Identifying Pedal Value Sensor Design - With Two Rotary Potentiometers
The pedal value sensor consists of two synchronous rotary potentiometers. The voltage for the two
potentiometers is supplied to connection 1 and 6 with 5V and to connection 2 and 3 with 2.5 V. A restoring
spring is integrated in the pedal value sensor.
Pedal value sensor design - GF30.20-P-4011-02B

with two Hall elements
Fig. 22: Identifying Pedal Value Sensor (With Hall Principle)
Illustration shows internal circuitry of pedal value sensor B37 (with Hall principle)
The pedal value sensor based on the Hall principle consists of two Hall elements, 2 magnets, electronics and a
restoring spring. The magnets are moved by means of the linkage or cable attached to the pedal value sensor
and thus alter the direction of the magnetic field relative to the fixed Hall elements. This produces a change in
the voltage.
The pedal value sensor is supplied with 5V only at pin 1. Pin 2 is not connected internally. The information
regarding the accelerator pedal position is passed to the engine control module by means of two voltages (pin 4:
approx. 0 to 2.25V and pin 5: approx. 0 to 4.5V). The pedal value sensor with potentiometer can be replaced
with the pedal value sensor based on the Hall principle (but not vice versa).
Pedal value sensor design - GF30.20-P-4011-02C

Fig. 24: Identifying Accelerator Pedal Module With Kickdown Switch (Up To 7/02) Components
Illustration shows accelerator pedal module with kickdown switch (S16/6).
Was only installed until about 7/02. One then used the accelerator pedal module with kick-down simulator (a).
Fig. 25: Identifying Accelerator Pedal Module With Kickdown Simulator (From 7/02) Components
Illustration shows accelerator pedal module with kickdown simulator (a).
Replace accelerator pedal module always complete!
Illustration shows internal circuitry of pedal value sensor B37 (Hall principle)
Fig. 26: Identifying Internal Circuitry Of Pedal Value Sensor (Hall Principle)
The sensor on the accelerator pedal which works according to the Hall principle is integrated into the pedal
lever axis. It consists of a shaft with 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 by the engine control unit with 5 V. The information regarding the
accelerator pedal position is passed on to the engine control unit by means of two voltages (pin 4: approx. 0 to
2.25 V and pin 5: approx. 0 to 4.5V).
The kick-down switch (S16/6) was no longer used from 7/02. Full load recognition takes place now over the
signal from the accelerator pedal sensor. The pressure point on the accelerator pedal is simulated before
achieving the full load position.
PEDAL VALUE SENSOR CHARACTERISTIC CURVE WHEN REVERSING FUNCTION - GF30.20-

P-4013
Pedal value sensor characteristic curve when reversing function - GF30.20-P-4013AM

Fig. 27: Identifying Pedal Value Sensor Characteristic Curve When Reversing Function
A modified characteristic curve of the electronic accelerator (EFP) optimizes ride comfort and safety while
reversing.
The reversing action (drive position "R") is indicated by the ETC [EGS] control unit to the motor electronics
control unit via the CAN data bus. The ME control unit then uses an altered characteristic to regulate the throttle
valve actuator.
Here the throttle valve is opened slowly and the opening angle is limited to maximum 60%.
ME-SFI control unit, location/task/design/function GF07.61-P-5000AM

Pedal value sensor characteristic curve when reversing function - GF30.20-P-4013E
ENGINE 104.943 /944 /991 /994 as of 1.8.96
ENGINE 104.995
ENGINE 104.941 as of 1.8.96
ENGINE 111.921 /942 as of 1.9.98,

111.946 as of 1.6.98,
111.944/975 as of 1.8.96,
111.943 /947 /951 /952 /955 /956 /957 /958 /973 /974 /982 /983
ENGINE 111.945
in MODEL 202.020 /080 as of 1.9.98,
208.335/435 as of 1.6.98
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE 137.970
Fig. 28: Identifying Pedal Value Sensor Function Diagram
Task
Optimizing driving comfort and safety when reversing.
Design/function
The pedal value sensor characteristic curve is changed if reverse travel is recognized by the ME control unit.
The throttle valve opens more slowly. The entire opening angle in this case is approx. 50%.
Reversing is detected:
 if a manual transmission fitted, the ME control unit is connected parallel to the reversing light switch.
 if an automatic transmission is fitted, the information is supplied over the CAN by the ETC control unit.
GF07.61-P-
other than engine 111 EVO
Engine 111 EVO
5000GS
GF30.20-P-
Pedal value sensor, location/task/design/ function
4011L
Engine 111 EVO
function 4101GS
Information on selector lever position
P/N and gear engaged in the case of GF27.19-P-
ETC control unit, location/task
automatic transmission. 4012G
Transmission 722.6
Pedal value sensor characteristic curve for reversing function - GF30.20-P-4013M

Fig. 29: Identifying Pedal Value Sensor Characteristic Curve For Reversing Function
This function has the task of optimization of ride comfort and safety when reversing.
If the ME-SFI control unit detects reversing via 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%.
ME-SFI control unit, GF07.61-P-

location/task/design/function 5000M
Accelerator pedal sensor, GF30.20-P-
Throttle valve actuator, GF30.22-P-
Selector lever position information P/N and
GF27.19-P-
ETC control unit, location/task drive position engaged.
4012G
Transmission 722.6
ELECTRONIC ACCELERATOR PEDAL EMERGENCY RUNNING MODE, FUNCTION - GF30.20-

P-4026
Electronic accelerator pedal emergency running mode, function - GF30.20-P-4026AM

Fig. 30: Identifying Electronic Accelerator Pedal Emergency Running Mode And Function
The task of the electronic accelerator emergency mode consists in ensuring that the car can be continued to be
driven safely even in case of any 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. The throttle valve opening is limited to
about 60 % of the maximum opening. In addition, the speed at the 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. If both potentiometers
are faulty, the throttle valve is brought to the emergency mode position of approx. 10° opening angle by the
spring capsule.
Emergency mode in the event of failure of the throttle valve actuator
The throttle valve actuator is switched in denergized status and the throttle valve is brought to the emergency
mode position of approx. 10° opening angle by the spring capsule.
Engine speed control with throttle valve in emergency mode position
In the idle speed range, engine speed is controlled to about 1200 rpm by shutting off and switching on the
cylinders on the 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 throttle valve
emergency mode position.
Input signals for deactivating and switching on the cylinder (injection valve shutoff) are:
 Engine speed
 Brake detection (via the ESP control unit)
 Drive position (via the ETC [EGS] control unit)
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.
Fuel injection valve, location/task/design/function GF07.03-P-5004KE

Crankshaft position sensor, location/task/design/function GF07.04-P-4116AM
Stop lamp switch. location/task/function GF42.10-P-4000AM
Electronic accelerator pedal emergency running mode function - GF30.20-P-4026E
ENGINE 104.941 /943 /944 /991 /994 as of 1/8/96
ENGINE 104.995
ENGINE 111.921 /942 as of 1.9.98,
111.946 as of 1.6.98,
111.944/975 as of 1.8.96,
111.943 /947 /951 /952 /955 /956 /957 /958 /973 /982 /983
ENGINE 111.945
in MODEL 202.020 /080 as of 1.9.98,
208.335/435 as of 1.6.98
ENGINE 111.974
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 137.970
Task
To allow safe further driving depending on the fault which has arisen in the electronic accelerator pedal system.
Pedal value sensor emergency mode
If the sensor in the pedal value sensor (B37) fails, the system will switch over to the second sensor. The throttle
valve opening is limited to approx. 60%. There is also dynamic limitation of the throttle valve's opening speed
where the throttle valve opening is delayed (the indicator lamp EPC does not light up).
If the plausibility check delivers a negative result or both sensors are defect only the idling speed will be
regulated (the indicator lamp EPC lights up).
Actuator for the throttle valve - emergency running, electrical
If a potentiometer in the actuator for the throttle valve breaks down the system switches-over to the second
intact potentiometer. The air flow mass serves as a second parameter for comparative purposes. Following a
plausibility check, the throttle valve opening is limited to approx. 60% in line with engine speed and load (EPC
indicator lamp does not come on).
If the plausibility check is negative or if both potentiometers are faulty, the throttle valve adopts a mechanical
emergency running position which is fixed by the spring capsule in the actuator (EPC indicator lamp comes on).
Actuator for the throttle valve - emergency running, mechanical emergency running stop
If the actuator motor is defect or there are other faults present the power supply to the actuator will be shut off.
The throttle valve then lies on the mechanical stop (spring box) so the throttle valve opening remains at a
constant 10-12°. At no engine load (idling) engine speed is regulated to about 900 rpm by shutting off or
activating the cylinders at the fuel side.
When driving, engine speed is controlled, in line with the engine load, by switching the cylinders off and on at
the fuel side. The maximum engine speed is about 1800 rpm. which is limited by the mechanical stop (the
indicator lamp EPC lights up).
Safety fuel shutoff
If a mechanical fault exists in the actuator, the safety fuel shutoff is activated.
Here the fuel injection valves are shut off for engine speeds < 1400 rpm and actuated again at speeds < 1200
rpm (the indicator lamp EPC lights up).
If the faults described above exist, read out the fault memory. The indicator lamp EPC is only installed on types
129, 140 from about 4/95 to 6/96.
GF30.20-P-
4011L
Electronic accelerator/cruise control/idle speed control GF30.22-P-
actuator location/task/design/function 4010F
GF30.22-P-
Throttle valve actuator, location/task/design/ function Engine 111 EVO
4101GS
Electronic power control indicator lamp, Engine 119.98, 120.98 in GF30.20-P-
location/task/design/function Model 129, 140 up to 5/96 4012L
GF07.61-P-
Engine 111 EVO
5000GS
Electronic accelerator pedal emergency running mode, function - GF30.20-P-4026M

Illustrated model 215, 220, 230, 240
Fig. 31: Identifying Electronic Accelerator Pedal Emergency Running Mode And Function
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 pressure
sensor downstream of throttle valve actuator serves 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 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 (B37) and the throttle valve actuator are stored in the fault
memory and can be read out and deleted with STAR DIAGNOSIS.
Emergency mode is recognizable on a clearly surging engine running.
GF07.61-P-
ME-SFI control unit, location/task/design/function
5000M
GF07.03-P-
Fuel injection valve, location/task/design/function
5004M
Crankshaft position sensor, GF07.04-P-
Pressure sensor downstream of throttle valve GF07.04-P-
actuator, location/task/function 5049M
Selector lever position information
GF27.19-P-
ETC control unit, location/task P/N and drive position engaged.
4012G
Transmission 722.6
Electronic accelerator pedal emergency running mode, function - GF30.20-P-4026SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 32: Electronic Accelerator Pedal Emergency Running Mode Function Diagram - Engine 113.988
The task of the emergency mode consists in ensuring that the car can be continued to be driven safely even in
case of any faults in the electronic accelerator system.
Accelerator pedal sensor, emergency mode (B37)
If one Hall sensor fails, the system switches over to the second Hall sensor. The throttle valve opening is limited
to about 60 % of the maximum opening. In addition, the speed at the 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 if the actuator potentiometer fails (throttle valve)
If one potentiometer fails, the system switches over to the second, intact potentiometer. If both potentiometers
fail, the throttle valve is then moved by the restoring spring in the actuator to mechanical emergency running
position (M16/6 approx. 10° opening angle).
M16/610
Emergency mode if the actuator or the actuator motor (throttle valve) is faulty
In both cases, the actuator is switched in de-energized status and the throttle valve is moved into the mechanical
emergency running position by the return spring (approx. 10° opening angle).
In the idle speed range, engine speed is controlled to about 1200 rpm by shutting off and switching on the
cylinders on the fuel side.
In drive operation, the engine speed is controlled according to the load of the engine through fuel side cylinder
cut-out and cut-in up to approx. 1800/rpm. The maximum engine speed is given by the mechanical stop.
Input signals for switching the cylinders on and off (injection valve shutoff) are:
 Speed of crankshaft position sensor (L5)

 Brake detection from ESP and BAS control unit (ESP, PML and BAS) (N47-5)
 Driving stages from the ETC [EGS] control unit (N15/3)
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.
Fuel injection valves, Y62 GF07.03-P-6010SM

Crankshaft position sensor L5 GF07.04-P-6010SM
ME-SFI [ME] control unit N3/10 GF07.61-P-6000SM
Accelerator pedal sensor, B37 GF30.20-P-2010SM
Component description of M16/6 GF30.20-P-2020SM
Stop lamp switch S9/1 GF42.10-P-2010SM
ME-SFI IDLE SPEED CONTROL, FUNCTION - GF30.22-P-0003
ME-SFI idle speed control, function - GF30.22-P-0003AM

Fig. 33: Identifying ME-SFI Idle Speed Control Function
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 a 20° crank angle and
advanced by as much as a 20° crank angle.
The ME control unit controls the idle speed in the warm-up phase and at different engine loads (e.g. drive
position engaged, refrigerant compressor activated) according to the input signals.
Warm-up phase (heating speed)
In order to bring the catalytic converter more rapidly to its operating temperature, the engine speed is raised
from 1100 to 1300 rpm:
 at coolant temperatures < 40°C,

 after each starting procedure,
 during idling
for approximately 20 seconds.
After this time elapsed, the idle speed is increased at a coolant temperature < 70°C depending on the
temperature for about 50 seconds by about 50 to 100 rpm.
Automatic transmission
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 ETC control unit via
the CAN data bus to the ME control unit.
AC compressor
Before connecting the AC compressor, the AAC control and operating unit sends a signal via the CAN data bus
to the ME control unit to prevent a fall in the rpm at idle speed while connecting the AC compressor. The ME
control unit upsizes subsequently the opening angle of the throttle valve.
Adjusting the ignition angle enables a faster response than adjusting the throttle valve.
The idle speed can be influenced with the STAR DIAGNOSIS.

Coolant temperature sensor, location/task/design/function GF07.04-P-5026AM
Ignition coils, location/task/design/function GF15.10-P-3102AM
ME-SFI idle speed control function - GF30.22-P-0003E
ENGINE 104.941 /943 /944 /991 /994 as of 1/8/96
ENGINE 104.995
ENGINE 111.921 /942 as of 1.9.98,
111.943,
111.944 as of 1.8.96,
111.946 as of 1.6.98,
111.947/973,
111.975 as of 1.8.96
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
202.020/080 as of 1.9.98
ENGINE 111.974
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 137.970
Fig. 34: Identifying ME-SFI Idle Speed Control Function Diagram

Task
Controlling idle speed in the case of
 different engine loads, e.g. power steering turned to full lock, engaging drive mode, switching on AC
compressor
 different mixture, e.g. from activated charcoal canister if purging activated (depending on activated
charcoal charge)
Function
The actuator EFP/TPM/LLR (additional designation: throttle valve actuator) regulates the idling speed by
changing the throttle valve position. It is actuated by the ME-SFI control unit.
The ME-SFI control unit actuates the throttle valve motor (M16/1 m1) in line with the input signals received at
the ME-SFI control unit (N3/10).
Heating speed of the catalytic converter
In order to warm up the catalytic converter more rapidly to operating temperature, engine speed is increased in
the idle speed range to 1100 up to 1500 rpm for about 20 seconds after each starting procedure at coolant
temperatures of < 40 °C. When a Drive position is engaged, engine speed is immediately controlled to a lower
value.
Automatic transmission
the vehicle. The information "Drive position engaged/not engaged" is transmitted by the ETC control unit
(N15/3) over the CAN databus to the ME-SFI control unit.
Ignition angle
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 from the calculated specified value.
The control in the idle speed range by altering the ignition angle reacts more rapidly than altering the position of
the throttle valve.
The idling speed can be influenced with HHT or the STAR DIAGNOSIS.
AC compressor
In order to avoid engine speed dropping in the idle speed range when the AC compressor is engaged, the AC
push-button control unit (N19) or automatic air conditioning push-button control unit (N22) supplies a signal to
the ME-SFI control unit (as of approx. 6/96 over CAN) and the opening cross-section of the throttle valve is
enlarged.
When the air conditioning unit is switched on and the external temperature exceeds 35° C the idling speed on
vehicles delivered from 6/00 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 cancelled 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.
If the control unit SBC reports an undervoltage to the engine control unit over CAN the idling speed for the
driving mode selected is increased to about 750 rpm.
Motor electronics control unit, location/task/ GF07.61-P-

design/function 5000F
GF15.12-P-
ME-SFI ignition system function
0001F
GF15.15-P-
ECI ignition system function Engine 137
3000L
GF30.20-P-
4011L
GF07.04-P-
Engine 119, 120
5026F
Coolant temperature sensor, location/task/ GF07.04-P-
Engine 104, 111
design/function 5026G
GF07.04-P-
Engine 112, 113, 137
5026A
Intake air temperature sensor, location/task/ GF07.04-P-
Engine 104, 111, 119, 120 in Model 129, GF07.61-P-
140, 170, 202, 208, 210 3004F
Engine 112, 113, 137 (except in Model GF07.61-P-
203, 209, 211) 3004A
ME fuel supply function Engine 112.91/94/95 203
Engine 112.91/94/95, 113.96 in Model
GF07.61-P-
211
3004P
Engine 112.912/955, 113.968 in Model
209
Crankshaft position sensor, location/task/ GF07.04-P-
GF30.20-P-
Engine 120.98
Electronic accelerator pedal emergency running 4026F
mode function GF30.20-P-
Engine 104, 111, 112, 113, 119, 137
4026E
GF07.61-P-
ME-SFI TWC heating-up function
3032F
Information on selector lever position
P/N and gear engaged in the case of GF27.19-P-
automatic transmission. 4012G
Transmission 722.6
GF29.10-P-
Clutch pedal switch, location/task/function with MT
2100F
Model 211, 230: Request for increased GF42.46-P-
SBC control unit, location/task/function
idle speed 4500SL
ME-SFI idle speed control, function - GF30.22-P-0003M

Fig. 35: Identifying ME-SFI Idle Speed Control Function
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 20° crank angle.
The ME-SFI control unit actuates the throttle valve motor in line with the input signals received at the ME-SFI
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,
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)

the vehicle. The information "Drive position engaged/not engaged" is transmitted by the transmission control
unit via the CAN databus to the ME-SFI control unit.
AC compressor
To avoid engine speed dropping in the idle speed range when the refrigerant compressor is engaged, the
automatic air conditioning control and operating unit supplies a signal to the ME-SFI control unit which adapts
(increases) the idle speed accordingly.
When the air conditioning unit is switched on and the external temperature exceeds 35°C the idling speed on
vehicles delivered from 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 cancelled 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. The SBC control unit stores the fault. If the SBC control unit
(model 230, 240) detects undervoltage, an increased idle speed is requested via a CAN message.
The idle speed can be influenced with the STAR DIAGNOSIS. If the connectors of the pressure sensors
downstream of the air filter (B28/4 or B28/5) are interchanged with the pressure sensor upstream of throttle
valve actuator (B28/6), the engine switches off after starting.

GF15.12-P-
ME-SFI ignition system, function
0001M
GF15.15-P-
ECI ignition system, function
3000M
Coolant temperature sensor, GF07.04-P-
Crankshaft position sensor, GF07.04-P-
Selector lever position information P/N and
GF27.19-P-
ETC control unit, location/task driving position engaged.
4012G
Transmission 722.6
GF42.46-P-
SBC control unit, location/task/function Model 230
4500SL
GF42.46-P-
Model 240
4500MB
ELECTRONIC ACCELERATOR/CRUISE CONTROL/IDLE SPEED CONTROL ACTUATOR

LOCATION/TASK/DESIGN/FUNCTION - GF30.22-P-4010F
ENGINE 104.941 /943 /944 /991 /994 as of 1/8/96
ENGINE 104.995
ENGINE 111.921 /942 as of 1.9.98,
111.943,
111.944 as of 1.8.96,
111.946 as of 1.6.98,
111.947/973,
111.975 as of 1.8.96
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
202.020/080 as of 1.9.98
ENGINE 111.974
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE 137.970
Fig. 36: Identifying Electronic Accelerator/Cruise Control/Idle Speed Control Actuator Function
GF30.22-P-
Engine 104
4010-01D
GF30.22-P-
Engine 111
4010-01G
GF30.22-P-
Electronic accelerator/cruise Engine 112, 113
4010-01A
control/idle speed control actuator
position GF30.22-P-
Engine 119
4010-01E
GF30.22-P-
Engine 120
4010-01F
GF30.22-P-
Engine 137
4010-01L
Determining the opening angle of the throttle valve

Electronic accelerator/cruise in accordance with the operating condition:
task  Controlling idle speed under different engine
loads (power steering turned to full lock, AC
compressor engaged)
 Driving, in accordance with accelerator pedal
position.
Electronic accelerator/cruise
GF30.22-P-
4010-02F
task
Electronic accelerator/cruise
GF30.22-P-
4010-03F
function
Electronic accelerator/cruise control/idle speed control actuator position - GF30.22-P-4010-01A
Fig. 37: Identifying Throttle Valve Actuator
Electronic accelerator/cruise control/idle speed control actuator position - GF30.22-P-4010-01L
Engine 137
Electronic accelerator/cruise control/idle speed control actuator design - GF30.22-P-4010-02F
Illustration shows actuator M16/4 (further designations: M16/1, M16/3, M16/6 throttle valve actuator)
Fig. 39: Identifying Electronic Accelerator/Cruise Control/Idle Speed Control Actuator Components
Each actuator contains two actual value potentiometers for detecting the position of the throttle valve. The
second potentiometer is used as a reference value to the plausibility check. In addition, the system switches over
to the second potentiometer if the first potentiometer fails.
Electronic accelerator/cruise control/idle speed control actuator function - GF30.22-P-4010-03F
Illustration shows actuator M16/4
Fig. 40: Identifying Electronic Accelerator/Cruise Control/Idle Speed Control Actuator Components
Function
The actual value potentiometers for the throttle valve inform the ME control unit about the position of the
throttle valve (idling up to full load) in order to recognize the various loading conditions.
A. Ignition "Off"
In the de-energized state the throttle valve position is determined by the spring capsule (3).
B. Ignition "On"
When the ignition is switched on, the actuator motor in the EA/CC/ISC actuator is operated by the ME
control unit and the return spring is checked. The throttle valve adopts a position which then depends on
the coolant temperature.
C. Idle speed
The actuator motor controls the engine speed in the idle speed range by opening the throttle valve further,
depending on coolant temperature and engine load (increased mixture), or closing it further (reduced
mixture).
In this case, the throttle valve may be closed further by the actuator motor by overcoming the force of the
spring capsule (mechanical end stop).
If the actuator is de-energized, the throttle valve is resting against the spring capsule. As a result the
throttle valve opening is constantly approx. 10 to 12 °. The engine speed for the no load condition is
about 1800 rpm.
D. Driving mode
The actuating motor when driving (partial/full load) regulates the throttle valve according to the various
loading conditions or according to the input signals from the front pedal value sensor (B37) according to
the position of the accelerator pedal.
E. Throttle valve damping
A damping function for the throttle valve is integrated in the ME control unit. In case of a sudden release of the
accelerator, the throttle valve in the idle speed range is closed with delay.
When first connecting to terminal 30 the ME control unit independently undertakes adaptation of the actuator
(learn the lower mechanical limit stop and full-load position of the throttle valve).
THROTTLE VALVE DAMPING FUNCTION - GF30.22-P-4020
Throttle valve damping function - GF30.22-P-4020AM

Fig. 41: Identifying Throttle Valve Damping Function
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.
The performance map for the throttle valve damping function is integrated in the ME control unit.
Following input signals are processed:
 Change in the speed of the accelerator pedal position.

 Engine speed
 Vehicle speed

Coolant temperature sensor, location/task/design/function GF07.04-P-5026AM
Throttle valve damping function - GF30.22-P-4020F

ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
ENGINE 104.995 with CODE (494a) USA version with CODE (807) Model year 1997 with CODE (808)
Model year 1998 with CODE (498) as of Model Year 97 Japanese version
ENGINE 111.921 /942 as of 1.9.98, 111.946 as of 1.6.98, 111.944 /975 as of 1.8.96,

111.943 /947 /951 /952 /955 /956 /957 /958 /973 /982 /983
ENGINE 111.945 in MODEL 202.020 /080 as of 1.9.98, 208.335 /435 as of 1.6.98
ENGINE 111.974 with CODE (494a) USA version with CODE (807) Model year 1997 with CODE (808)
Model year 1998
ENGINE 112.910 /911 /920 /921 /922 /923 /940 /941 /942 /943 /944 /947
ENGINE 113.940 /941 /942 /943 /960 /961
ENGINE 119.980 /981 /982 /985
ENGINE 120.982 /983
ENGINE 137.970
Task
Closing the throttle valve only with a time lag in the idle speed range if the accelerator is released suddenly.
Design/function
A damping function for the throttle valve is integrated in the ME-SFI control module.
The following information is processed:
 Engine speed
 Vehicle speed
THROTTLE VALVE ACTUATOR - LOCATION/TASK/DESIGN/FUNCTION - GF30.22-P-4101
Throttle valve actuator - location/task/design/function - GF30.22-P-4101AM
ENGINE 113.990 /991 /992 /993 /995

Throttle valve actuator - GF30.22-P-4101-

position 01AM
The following functions are regulated by the throttle valve
actuator:
Throttle valve actuator -  Idling speed regulation

task  Driving mode, corresponding with the accelerator
pedal position and load
design 03HA
function 02HA
Throttle valve actuator position - GF30.22-P-4101-01AM
The throttle valve actuator is located at the rear at the compressor inlet.
Throttle valve actuator, function - GF30.22-P-4101-02HA

Fig. 44: Identifying Throttle Valve Actuator With Circuit Diagram
The actuator motor in the throttle valve actuator adjusts the opening angle of the throttle valve continuously
from approx. 0 to 90° according to the presets from the ME control unit (N3/10).
Hereby, both the actual value potentiometers indicate the current position of the throttle valve to the ME control
unit.
In de-energized status (e.g limp-home), the opening angle of the throttle valve (from 10 to 12°) is determined by
the spring capsule.
When the throttle valve actuator is connected to the vehicle for the first time, the ME control unit carries out an
adaptation of the actuator (learning the lower and upper mechanical end stop of the throttle valve) on its own.
A throttle flap actuator with a larger cross section will be installed starting 03/2006.
Throttle valve actuator design - GF30.22-P-4101-03HA

Throttle valve actuator, location/task/design/function - GF30.22-P-4101M

Throttle valve GF30.22-P-

actuator position 4101-01M
Function rules:
 Idling speed
Throttle valve  Drive mode, according to accelerator pedal position, load
actuator, task and requests of momentary interface
 Emergency mode of electronic accelerator.
actuator design 4101-03M
actuator, function 4101-02M
Throttle valve actuator position - GF30.22-P-4101-01M
Fig. 47: Identifying Throttle Valve Actuator Components
Throttle valve actuator, function - GF30.22-P-4101-02M

Fig. 49: Identifying Throttle Valve Actuator With Circuit Diagram
The actuator motor (M16/6m1) in the throttle valve actuator (M16/6) adjusts the throttle valve (1) continuously
from about 0 to 90° according to specifications from motor electronics 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. The
power is limited to 6 A after approx. 30 seconds for output stage protection. The actual value of potentiometers
(M16/6r3, M16/6r4) inform the motor electronics control unit about the position of throttle valve. The signals of
both actual value potentiometer are opposed.
A. Ignition "Off"
In the voltage-free condition the throttle valve position is determined by the spring capsule (2) (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
control unit.
The throttle valve adopts a position which depends on the coolant temperature.
C. Idling speed
Depending upon the coolant temperature and engine load, the actuator motor changes the rpm in the
idling 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 de-energized, the throttle valve is set by the spring capsule to an about 8 up to 10°
opening angle.
This in the idling speed range results in an engine speed of around 1800 rpm
For first time connection of the throttle valve actuator to circuit 30 or 87, the ME control unit carries out
the following actions automatically within approx. 60 seconds:
 Determining the emergency running position

 Determining the lower mechanical stop
 Adaptation of the 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 with STAR DIAGNOSIS, if the throttle valve actuator or the
motor electronics control unit was replaced, otherwise engine surges can occur.
Throttle valve actuator design - GF30.22-P-4101-03M
CRUISE CONTROL (CC) FUNCTION - GF30.30-P-0001
Cruise control (CC) function - GF30.30-P-0001FA
ENGINE 112.923 /943, 113.961, 120.983 in MODEL 129
ENGINE 112.942 /970, 113.942 /965 in MODEL 163
ENGINE 111.943 /946 /958 /973 /983, 112.947 in MODEL 170
ENGINE 111.921 /944 /945 as of 1.8.99,
111.952/956/974,
111.975 as of 1.8.99,
112.910/920,113.944
in MODEL 202
ENGINE 111.951 /955, 112.912 /916 /946 /953 in MODEL 203
ENGINE 111.945/975#2,
111.945 /975 #0 as of 1.8.99,

111.956/982, 112.940, 113.943
in MODEL 208
ENGINE 111.957, 112.911 /914/921 /941, 113.940/980,
111.942/947 as of 1.8.99
in MODEL 210
ENGINE 112.922 /944 /972 /975, 113.941 /948 /960 /966, 137.970 in MODEL 220
ENGINE 113.960, 137.970 in MODEL 215
ENGINE 112.973, 113.963 in MODEL 230
ENGINE 112.913 /917 /949 /954, 113.967 /969 in MODEL 211
ENGINE 112.912 /955, 113.968 in MODEL 209
Shown on engine 111 EURO3/4 B37
Fig. 51: Identifying Cruise Control Function - Shown On Engine 111 Euro3/4
Task
Maintaining the preselected vehicle speed constant irrespective of the engine load, without operation of the
accelerator pedal.
Function
The cruise control function is integrated in the engine control unit. It can be activated from > 40 km/h with the
cruise control 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:
 pushing the cruise control push-button switch (S40) or variable cruise control push-button switch (S40/4)
into the "OFF" position
 Operating the service brake
 Moving selector lever into position "N"
 Control intervention function of traction system
Vehicles with column sleeve module (MRM)
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.
Vehicles with EZS control unit without column sleeve module (MRM)
The signals from the push-button switch for the cruise control are detected by the control unit EIS and
transmitted to the CAN data bus.
Vehicles without EZS control unit
The signals from the cruise control switch are transmitted directly to the engine control unit.
Vehicles with manual transmission (MT)
Cruise control remains active during gear change, in other words the cruise control is not switched off when the
clutch is operated.
Traction systems control unit
Transmits the vehicle speed signal via CAN to the ME control unit.
GF07.61-P-
Engine 111 EVO
5000GS
Cruise control switch, location/task/design/ GF30.30-P-
function with cruise control or Distronic 3100F
Variable cruise control switch, location/task/ with cruise control or Distronic except GF30.30-P-
design/function 3101A
Engine 111 EVO
function 4101GS
GF42.10-P-
Stop lamp switch, location/task/function
4000A
GF29.10-P-
Clutch pedal switch, location/task/function with MT
2100F
3001A
Transmits information about the selector
lever position P/N and the driving mode GF27.19-P-
selected via CAN. 4012G
Transmission 722.6
Cruise control (CC) function - GF30.30-P-0001M

Fig. 52: Identifying Cruise Control Function
The cruise control function must maintain the preselected speed constant irrespective of the load condition,
without the accelerator pedal being operated.
The cruise control function can be activated at speeds above 40 km/h with the cruise control switch. Using the
input signals and the position of the cruise control switch, the engine control unit actuates the throttle valve
actuator for the cruise control function.
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"
 Control intervention function of the traction system.
The signals from the cruise control switch are detected by the steering column module and transmitted via the
CAN data bus to the engine control unit.
The speed signal is transmitted by the ESP control unit via the CAN to the engine control unit.

Cruise control switch, GF30.30-P-
With cruise control or Distronic
Variable cruise control switch, location/task/ With cruise control or Distronic except GF30.30-P-
design/function 3101M

3001M
Selector lever position information P/N
GF27.19-P-
ETC control unit, location/task and drive position engaged.
4012G
Transmission 722.6
DISTRONIC (DTR), FUNCTION - GF30.30-P-0002
Distronic (DTR), function - GF30.30-P-0002K
ENGINE 112.922 /944, 113.941 /960 /986, 137.970, 613.960 in MODEL 220 up to 30.6.00 with CODE
(219a) Distronic (DTR)
ENGINE 113.960 /986, 137.970 in MODEL 215 up to 30.6.00 with CODE (219a) Distronic (DTR)
Fig. 53: Identifying Distronic (DTR) Function
Tasks
 Maintaining the selected vehicle speed (cruise control function) and, in addition, controlling the distance
to a vehicle ahead
 Variable speed limiter (VSL)
 Controlling driver information in the instrument cluster and warning signal (distance warning)
Design
The Distronic consists of the following components:
 Distronic control module

 Distronic radar sensor
 Distronic switch block with distance potentiometer and distance warning function switch
 Variable cruise control switch
 Displays in instrument cluster and warning signal
 CAN databus
Function
The cruise control can rarely be used in dense traffic. The driver either has to constantly adapt the selected
speed or switch off the cruise control.
The Distronic detects the traffic situation ahead of the vehicle by means of the radar sensor located behind the
radiator grille.
If the driver's own vehicle approaches another vehicle traveling at a slower speed, the speed of the driver's
vehicle is reduced. The Distronic (DTR) control unit calculates the distance required and can activate the
following over the CAN:
 Increase/reduction in engine specified speed (through ESP control module)

 Braking (ESP control module)
 Shifting gears (ETC control module)
The Distronic can be used from a speed of about 40 km/h up to 160 km/h.
If no vehicle is driving ahead, the Distronic behaves in the same way as the cruise control.
The Distronic is a convenience system and not a safety system. The driver has to apply the brakes himself if the
traffic situation so demands.
The system has a diagnostic capability.
If a vehicle suddenly appears ahead (e.g. as a result of changing lanes), the Distronic attempts to control. For
safety reasons, however, the braking action is limited to approx. 2 m/s2 (equals approx. 20 % of maximum
braking power). If more braking power is required, the driver is warned by means of a double warning signal
(accept signal).
A further audible signal (off signal) signals if the vehicle speed leaves the range of approx. 40 km/h up to 160
km/h.
The driver is able to influence the distance to the vehicle ahead with the distance potentiometer (S46/8r1). The
setting range equals about 1 to 2 s the time distance to the vehicle ahead.
If the Distronic is switched off, the calculation of the distance continues to remain active. The display in the
instrument cluster and the warning signal inform the driver if the distance in insufficient. The audible and visual
distance warning function can be switched on with the distance warning function switch (S46/8s1).
On AMG models the Distronic is switched off at a speed of more than 260 km/h and a brief warning signal
sounds. Consequently, no warning is given if the distance drops below the specified distance. The Distronic
cannot be activated again until vehicle speed is less than 260 km/h.
The variable speed limiter (VSL) is integrated in the Distronic system. It is possible to switch between the
functions by pressing the variable cruise control switch.
The variable speed limiter is enlarged as follows:
 Range of use from 10 km/h up to maximum vehicle speed
Further technical data of Distronic:
 Distance measuring range of radar: 0 to 150 m

 Number of radar beams: 3
 relative vehicle speed measuring range for vehicles ahead: -50 up to +200 km/h
GF30.30-P-0002-
Distronic (DTR) input/output signals
02K
GF30.30-P-0002-
Distronic (DTR) display and operating information except
01K
GF30.30-P-0002-
01KU
Distronic radar sensor position/task/design/function GF30.30-P-3103K
DTR control module position/task/design/function GF30.30-P-3104K
Distance potentiometer
Distronic switch block position/task/design/function Distance warning function GF30.30-P-3105K
switch
Variable cruise control switch
except GF30.30-P-3101A
Cruise control switch position/task/design/function GF30.30-P-3100F
Variable speed limiter function Gasoline engines GF30.30-P-3001A
Diesel engines GF30.30-P-3001I
Distronic (DTR) display and operating information - GF30.30-P-0002-01KU

Model 215, 220
Operation if the Distronic is over the pushbutton switch for the cruise control system (S40)
Operation of switch position 1:
The Distronic is switched on with the speed of the vehicle at that moment. Multiple individual actuations cause
the desired speed to be raised up to maximum of 110 mph in 5 mph steps.
Vehicle can accelerate up to the selected desired speed.
Operation from switch position 2:
The Distronic is switched on with the speed of the vehicle at that moment. Multiple individual actuations cause
the desired speed to be lowered in 5 mph steps.
The vehicle slows down to the preset speed.
Actuation of (1) and (2) additionally store the indicated speed.
If the Distronic is switched off, the speed stored in the memory can be retrieved. The distance control is thus
activated. Multiple individual actuations cause the desired speed to be raised up to maximum of 110 mph in 1
mph steps.
The Distronic is switched off.
The speed last selected remains stored.
Fig. 54: Identifying Cruise Control System Pushbutton Switch Positions
Displays in the instrument cluster
If the Distronic if activated for example at 50 mph, only one or segments on the tachometer light up in the area
of the stored speed of 50 mph in order to show the driver the indicated speed.
The set speed appears in the display for about 5 s and a symbol of the own vehicle on the right-hand edge.
The set specified distance is shown with the bar graph. This is dependent on the speed at which the vehicle is
driven.
Fig. 55: Identifying Instrument Cluster Display - Vehicle Speed (MPH)
If the Distronic detects a vehicle ahead driving at a lower speed, further segments between the desired speed
(e.g. 40 km/h) and the speed of the vehicle ahead (e.g. 30 km/h) light up. At the same time the system reduces
the speed of the own vehicle until the speed of the vehicle ahead is reached. The vehicle ahead is shown on the
display while this is happening.
Fig. 56: Identifying Instrument Cluster Display - Vehicle Speed (DTR)
Distronic (DTR) input and output signals - GF30.30-P-0002-02K

Fig. 57: Distronic Input And Output Signals
The Distronic control unit receives all the information it requires for its calculations over the CAN data bus.
The Distronic uses the engine torque and braking torque interface in the ESP control unit. All requests are first
collected in the ESP control unit so that there are no conflicts with engine and brake interventions between the
Distronic and ESP systems. The interventions are then executed according to their importance.
CAN input signals to the Information

Distronic control unit (N63/1)
from
 Left front, right front, left rear and right rear wheel speeds
 Reduction or increase of the engine nominal torque
 Distronic shutoff (if message is erroneous)
ESP, SPS and BAS control unit
(N4747-5)  Set braking torque
 Distronic brake intervention active
 Emergency braking (all 4 wheels regulated)
 ESP brake intervention active
 Driver braking
 Stop lamp switch
 Vehicle code
 Adjusted engine torque for traction control
 Engine speed
ME-SFI control unit (N3/10)  Minimum and maximum engine torque, engine drag torque
 Distronic switched on
 Cylinder shutoff
 Inertia fuel shutoff
 Actual gear
 Target gear
ETC control unit (N15/3  Kick-down
 Transmission code
 ETC in limp-home mode
 Country code
 Distronic (DTR) distance warning function OFF or ON (from
EIS control unit (N73) upper control panel control unit over interior compartment CAN)
 Distronic (DTR) distance potentiometer specification (from
upper control panel control unit over interior compartment CAN)
 mph instead of km/hour (variable speed limitation)
Instrument cluster (A1)
 Winter tire maximum speed
 Pushbutton switch for the cruise control system : "OF"
 Pushbutton switch for the cruise control system : "SET
MEMORY"
 Pushbutton switch for the cruise control system : "SET
ACCELERATION"
Steering column module (N80)  Pushbutton switch for the cruise control system : "SET DELAY"
 Operation of variable speed limiter, except for
 Cruise control switch implausible
 Steering angle (from 0 to 720°)
 Steering angle sign (right/left)
 Steering angle sensor defective
CAN output signals from the Distronic control Information

unit (N63/1) to
 Stop lamp suppression for minimal braking

 Distronic braking
 Distronic defective or OK
 Increase in specified engine torque
 Decrease of specified engine torque
ESP, SPS and BAS control unit (N4747-5)  Distronic active
 Variable speed limiter (VSL) active, except
for
 Distronic distance warning lamp
 Distronic warning tone
 Recognized stationary objects (e.g. a
stationary vehicle)
 Switch display to Distronic display
 Distronic switched on (no vehicle ahead)
Instrument cluster (A1)  Speedometer flashing
 Switch Distronic segment display on
 Vehicle detected ahead
 Distronic switched on (proximity control
active)
 "LIMIT" in display, except
 Distronic error
 Shift curve offset
 Suppression of dynamic full load position
ETC control unit (N15/3)
 Maintain gear position
 Active downshift required
The following data is used to detect objects:
Vehicle data:
 Wheel speeds
 Steering angle
 Yaw rate
 Own speed.
Radar data:
 Distance to object
 Relative speed of object
 Angle of object
 Radar beam assignment
 Strength of reflected radar beams.
Distronic (DTR), function - GF30.30-P-0002KA
ENGINES 112, 113, 137, 275, 613, 628 in MODEL 220 as of 1.7.00 up to 31.5.04 with CODE (219a)
Distronic (DTR)
ENGINES 113, 137, 275 in MODEL 215 as of 1.7.00 up to 31.5.04 with CODE (219a) Distronic (DTR)
ENGINES 112, 113, 275 in MODEL 230 up to 31.5.04 with CODE (219a) Distronic (DTR)
ENGINES 112, 113, 271, 646, 647, 648 in MODEL 211 up to 31.5.04 with CODE (219a) Distronic (DTR)
ENGINES 112, 113, 271, 612 in MODEL 209 up to 31.5.04 with CODE (219a) Distronic (DTR)
ENGINE 285 in MODEL 240 with CODE (219a) Distronic (DTR)
Shows model 220
Tasks
 Maintaining the selected vehicle speed (cruise control function) and also regulating the distance to a
vehicle ahead
 Variable speed limiter (VSL), except
 controlling driver information in the instrument cluster and warning signal (distance warning).
Design
The Distronic consists of the following components:
 Distronic control unit

 Distronic radar sensor
 Variable cruise control switch Cruise control switch
 Displays in instrument cluster and warning signal
 CAN databus.
Function
The cruise control can rarely be used in dense traffic. The driver must either constantly adjust the selected speed
or switch off the cruise control.
The Distronic detects the traffic situation ahead of the vehicle by means of the radar sensor located behind the
radiator grille. If the driver's own vehicle approaches another vehicle traveling at a slower speed, the speed of
the driver's vehicle is reduced. The Distronic (DTR) control unit calculates the distance required and can
activate the following over the CAN:
 Increase/reduction in the specified engine speed (through ESP control unit)

 Braking (ESP control unit)
 Shifting gears (ETC control unit).
The Distronic can be used from a speed of approx. 30 km/h to 180 km/h or 20 to 110 mph ( 25 to 110 mph).
If no vehicle is driving ahead, the Distronic behaves in the same way as the cruise control.
The Distronic is a convenience system and not a safety system. The driver must himself brake when
corresponding traffic situations arise.
The system has a diagnostic capability.
If a vehicle suddenly appears ahead (e.g. as a result of changing lanes), the Distronic attempts to take control.
The braking action is, however, limited to approx. 2 meters/s2 (equals approx. 20% of maximum braking
power) for safety reasons. If more braking power is required, the driver is warned by means of an intermittent
signal (accept signal).
A further audible signal (off signal) sounds if the vehicle speed drops below approx. 30 km/hour ( 25 mph).
If the speed set with the cruise control lever is exceeded by depressing the accelerator pedal, the distance
measurement of the Distronic continues to remain active even above 180 km/hour ( 110 mph). The Distronic
again controls the vehicle to the speed last set after the accelerator pedal is released.
The driver is able to influence the distance to the vehicle ahead with the distance potentiometer. The setting
range equals about 1 to 2 seconds the time distance to the vehicle ahead.
If the Distronic is switched off, the calculation of the distance continues to remain active.
The display in the instrument cluster and the intermittent signal inform the driver if the distance to the vehicle
ahead is extremely close or if there is a major difference in speed to the vehicle ahead.
Visual indication (red distance warning lamp in the instrument cluster remains on) is also given if the time
distance to the vehicle ahead is less than 0.8 seconds over a time period of more than 3 seconds (except ).
on AMG models the Distronic is switched off at a speed of more than 260 km/hour (160 mph) and a brief
warning signal sounds. Consequently, no warning is given if the distance drops below the specified distance.
The Distronic cannot be activated again until vehicle speed is less than 260 km/hour.
The variable speed limiter (VSL) is integrated in the Distronic system (except ). It is possible to switch
between the functions by pressing the variable cruise control switch (S40/4).
The variable speed limiter is extended as follows in vehicles with Distronic:
 When traveling downhill, the brakes are applied to prevent the vehicle exceeding the set speed.
 Range of use from 10 km/hour up to the maximum vehicle speed.
Further technical data of Distronic:
 Distance measurement range of the radar: 0 to 150 meters

 number of radar beams: 3
 relative speed measurement range for vehicles ahead: -50 to +200 km/hour.
GF30.30-P-0002-
Distronic (DTR) input and output signals Models 215, 220
02K
Models 209, 211, 230, 240 GF30.30-P-0002-02T
Distronic (DTR) display and operating GF30.30-P-0002-
Models 220, 215 except
information 01K
GF30.30-P-0002-
Models 220, 215 01KU
Model 230 GF30.30-P-0002-01R
Models 209, 211, 240 GF30.30-P-0002-01T
Distronic radar sensor, Models 209, 211, 215, 220, 230,
GF30.30-P-3103K
location/task/design/function 240
Models 209, 211, 215, 220, 230,
DTR control unit, location/task/design/function 240 GF30.30-P-3104K
Distronic switch block,
Distance warning function GF30.30-P-3105K
switch
Distronic (DTR) - function - GF30.30-P-0002KB
ENGINES 112, 113, 271, 612 in MODEL 209 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINES 112, 113, 271, 272, 646, 647, 648 in MODEL 211 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINES 112, 113, 137, 275, 613, 628 in MODEL 220 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINES 113, 137, 275 in MODEL 215 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINES 112, 113, 275 in MODEL 230 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINES 113, 272 in MODEL 219 with CODE (219) Distronic (DTR)

The Distronic (DTR) must maintain the selected speed (cruise control function) and also regulate the distance to
the vehicle immediately ahead.
The Distronic is a convenience system and not a safety system. The driver must himself brake when
corresponding traffic situations arise.
The following component are required for the Distronic:
 DTR control unit (radar sensor and control unit for destination assessment)
 Cruise control pushbutton switch variable or cruise control pushbutton switch (switching On and
Off, setting speeds)
 Instrument cluster (display and warning tone)
 Traction systems control unit
 ME-SFI control unit or CDI control unit
 EGS control unit, add-on control unit control unit or VSG control unit
 SBC control unit
 Multifunction steering wheel (select Distronic display).
The Distronic uses the engine torque and braking torque interface in the traction systems control unit. Thus
there are no conflicts with engine and brake interventions between the Distronic and ESP systems, all requests
are first collected in the ESP control unit. The interventions are then executed according to their importance.
Conditions for functioning of the Distronic are:
 Engine running
 Electronic Stability Program not switched off
 Speed is in the controlled range (that is 30 to 180 km/hour, AMG-vehicles 30 to 260 km/hour, up to
model year 2004: from 25 to 110 mph, from model year 2005: from 20 to 110 mph)
 Parking brake not operated
 selector lever position D or AG or drive mode for ASG
 for SBC: the function DTR is only released under 60 km/hour if the function Sensotronic Brake Control
Stop is disabled
 no fault or warning message is being shown in the instrument cluster.
The Distronic switches off if
 the driver brakes

 selector lever position N is engaged while driving
 Switch over takes place in the function VGA (except ) by pressing on the Cruise control press
button switch (light emitting diode LIM in Cruise control pushbutton switch)
 ESP regulates.
The Distronic recognizes the traffic situation in front of its own vehicle using the radar sensor and the control
unit for destination assessment and creates the conditions to be able to react to changing traffic conditions by
braking, accelerating and shifting gear. The driver is also warned about an inadequate distance to the next
vehicle ahead optically and acoustically.
The Distronic (DTR) regulates and maintains the desired speed for a free lane like a conventional cruise control.
If, however, one's own vehicle gets too close to the vehicle ahead then the speed is reduced by braking, shifting
down and reducing the engine torque and the vehicle ahead is followed with an appropriate clearance between
them. The distance is dependent on the setting of the DTR distance potentiometer (N72r1).
If the traffic situation allows the speed to be increased since the vehicle immediately ahead accelerated or left
the lane, the Distronic (DTR) regulates the speed again to the set speed. Here the acceleration is limited to a
maximum of 1 m/second2 .
Interventions by the brake system are limited to a maximum deceleration on comfort and safety grounds to
about 20% of the maximum possible braking power. Driving situations which require more than a 20% braking
power are indicated to the driver optically (red warning lamp in the Instrument cluster) and acoustically using
an intermittent tone.
This takeover tone requests to the driver that he observe the traffic situation and takes action himself. The
takeover tone is automatically emitted when there is danger and cannot be switched off.
If the speed falls below 30 km/hour, the Distronic switches off. A signal tone sounds and a message appears in
the multifunction display for about 5 seconds "DTR OFF".
If the speed increases above 180 km/hour (AMG: 260 km/hour) then the Distronic switches off the distance
regulation system The message "DTR passive" appears in the multifunction display. The Distronic regulates
again to the last set speed after enabling the accelerator pedal and the distance regulation system is active again.
Nominal distance for Distronic
The distance potentiometer on the Distronic is used to set the nominal distance to the vehicle immediately
ahead. The adjustment range lies between a time interval of 1 to 2 seconds to the vehicle immediately ahead
which represents 0.28 to 0,56 times the speedometer reading in meters.
The distance set is indicated in the multifunction display.

Fig. 60: Identifying DTR Distance Potentiometer And DTR Switch
Distance warning
The driver can activate a separate distance warning function quite independently of the Distronic using the DTR
switch (LED in switch ON, the loudspeaker also appears in the multifunction display). The distance warning
warns the driver in the speed range 30 km/hour up to the maximum speed (max. 250 km/hour) about moving or
stationary obstacles in his lane. The warning also occurs optically (red warning lamp in the instrument cluster)
and acoustically by an intermittent tone. The distance warning is triggered if deceleration of one's own vehicle
in excess of 6 m/s 2 is needed to avoid a collision.
The driver is also shown as an additional function if he remains for longer than 300 meters at a distance of less
than a 0.9 second time distance
The red warning lamp lights up until an adequate distance is achieved again. There is no acoustic information
emitted in this case.
Variable speed limiter (except )
The variable speed limiter is extended as follows in vehicles with Distronic:
 the brakes are applied to prevent the vehicle exceeding the set speed.

Fig. 61: Identifying Multifunction Display Functions And DTR Warning And Indicator Lamp
Shows model 211
Fig. 62: Identifying Cruise Control Switch Functions - Shows Model 211
Operating the Distronic
Operation takes place using the CC [TPM] switch. The yellow light emitting diode in the CC [TPM] switch
must be off; switch between Speedtronic and Distronic by actuating switch position 5 if this not the case.
The system is operated with the CC [TPM] switch (S40).
GF30.30-P-0002-
Distronic (DTR) input and output signals
02R
DTR control unit - location/task/function GF30.30-P-3115K
Distronic switch block -
Distance warning function GF30.30-P-3105K
switch
Distronic (DTR) input and output signals - GF30.30-P-0002-02R

Fig. 63: Distronic Input And Output Signals
Shown in model 211
CAN participant Information

The Distronic uses the engine torque and braking torque interface in the
traction systems control unit. Thus the traction systems control unit has
ESP, SPS and BAS control
access to the total data flow. Required braking interventions are undertaken
unit (N47N47-5)
by a vehicle without Sensotronic Brake Control directly by the traction
systems control unit.
CAN messages from ESP, SPS and BAS control unit (N47-5):
 Left front, right front, left rear and right rear wheel speeds
 Steering angle sign (right/left).
CAN messages to the ESP control unit (N47-5):

 Distronic error
 Target evaluation (distance to it, relative speed, angle, radar lobe
orientation and strength of the reflected radar beams).
DTR control unit (A89A89) Data output takes place over two different interfaces:
a. for models 209, 215, 220
b. for models 211, 219, 230.
Any possibility of confusing the two is excluded through having different

connectors on the DTR control unit (A89).
 Braking torque (reduction or increase).
SBC control unit (A7/3n1)

CAN messages arriving at the ESP, SPS and BAS control unit (N47-5):
 Driver braking
 Left front, right front, left rear and right rear wheel speeds.
CAN messages from the lower control panel control unit (N72) over CAN-
B:
 DTR switch OFF or ON (proximity warning function)

 Specification from the DTR distance potentiometer.
Central gateway control unit
(N93N93)
CAN messages arriving at the ESP, SPS and BAS control unit (N47-5)
over CAN-C:
 DTR switch OFF or ON (proximity warning function)

 Specification from the DTR distance potentiometer.
 Pushbutton switch for the cruise control system : "OF"

Steering column module  Pushbutton switch for the cruise control system : "SET MEMORY"
(N80N80)  Pushbutton switch for the cruise control system : "SET
ACCELERATION"
 Pushbutton switch for the cruise control system : "SET DELAY"
 a Operation of variable speed limiter, except
Cruise control pushbutton switch implausible
 Steering angle sign (right/left)
 Steering angle sensor defective.
 mph instead of km/hour (variable speed limitation)

 Winter tire maximum speed.
 Distronic distance warning lamp

 Distronic warning tone
Instrument cluster (A1A1)  Recognition of a stationary object (e.g. stationary vehicle)
 Switch display to Distronic display
 Distronic switched on (no vehicle ahead)
 Speedometers
 Switch Distronic segment display on
 Vehicle detected ahead
 Distronic switched on (proximity control active)
"LIMIT" in display, except
 Distronic error.
 Actual gear
 Target gear
 Kick-down
 Transmission code
 Transmission emergency running mode.
Transmission control unit
 Shift curve offset

 Suppression of dynamic full load position
 Maintain gear position
 Active downshift required.
 Vehicle code
 Adjusted engine torque for traction control
 Engine speed
 Minimum and maximum engine torque, engine drag torque
 Kickdown recognition
Engine control unit
 Deceleration fuel shutoff.
 Reduction or increase of the engine nominal torque.

Rear SAM control unit with CAN messages from ESP, SPS and BAS control unit (N47-5):
fuse and relay module
(N10/2) and trailer  Actuate stop lamp
connection unit control unit
 Stop lamp suppression for minimal braking.
(N28/1)
DISTRONIC (DTR) FUNCTION DESCRIPTION CONTENTS - GF30.30-P-0999Z
ENGINE 112, 113, 137, 275, 613, 628 in MODEL 220 with CODE (219) Distronic (DTR)
ENGINE 113, 137, 275 in MODEL 215 with CODE (219) Distronic (DTR)
ENGINE 112, 113, 271, 272, 646, 647, 648 in MODEL 211 with CODE (219) Distronic (DTR)
ENGINE 112, 113, 271, 612 in MODEL 209 with CODE (219) Distronic (DTR)
ENGINE 285 in MODEL 240 with CODE (219) Distronic (DTR)
ENGINE 113, 272 in MODEL 219 with CODE (219) Distronic (DTR)
Models 215, 220 up to GF30.30-P-

Distronic (DTR), function
6/00 0002K
Models 215, 220 as of 7/00 GF30.30-P-
up to 5/04 0002KA
Models 209, 211, 230 up
to 5/04
Model 240
Models 209, 211, 215, 220,
GF30.30-P-
230 as of 6/04
0002KB
Model 219
Distronic (DTR) input and output signals Models 215, 220 up to GF30.30-P-0002-
5/04 02K
Models 209, 211, 230 up
GF30.30-P-0002-
to 5/04
02T
Model 240
Models 209, 211, 215, 220,
GF30.30-P-0002-
230 as of 6/04
02R
Model 219
Models 220, 215 except GF30.30-P-0002-
Distronic (DTR) display and operating information
01K
GF30.30-P-0002-
Models 220, 215 01KU
GF30.30-P-0002-
Model 230
01R
GF30.30-P-0002-
Models 209, 211, 219, 240
01T
Distronic (DTR) overview of system components, GF30.30-P-
location/task/design/function 9999Z
CRUISE CONTROL SWITCH, LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-3100
Cruise control pushbutton switch, location/task/design/function - GF30.30-P-3100AM
ENGINES 113.990 /991 /992 /993 /995
Fig. 64: Identifying Cruise Control Pushbutton Switch Functions
Cruise control switch The cruise control

location pushbutton switch is
located at the upper left on
the steering column.
Cruise control switch task The CC pushbutton switch
switches the cruise control
functions, Distronic (with
Distronic) and variable
speed limitation (except
) on and off.
Cruise control switch The cruise control
design pushbutton switch is a
pushbutton switch with a
number of switching
contacts.
Cruise control switch When the cruise control
function pushbutton 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 switching signals are
detected by the steering
column module (N80a)
and transmitted to the
CAN data bus.
Cruise control switch, location/task/design/function - GF30.30-P-3100F
ENGINE 104 (except 104.98),
111.946 up to 31.5.98,
111.943,
111.973 up to 31.5.97,
111.920,
111.921 up to 31.8.98,
111.941,
111.942 up to 31.8.98,
111.944 up to 31.5.98,
111.945 up to 31.8.98, 111.974,
111.947/970, 112.942 up to 31.5.98,

119, 120 up to 31.5.97,
668.940/941,611.960/961
with CODE (440a) Cruise control
with CODE (443a) Cruise control and electrically adjustable steering column (codes 400 and 441)
with CODE (446) Cruise control, electrically adjustable steering column and airbag (440, 441 and 442)
ENGINE 104, 111, 112, 113, 119, 120, 137, 613.960, 628.960 (except, 112.96, 113.99) with CODE (494a)
USA version
Fig. 65: Identifying Cruise Control Switch
Cruise control
switch Left top behind the steering wheel.
location
 Setting of cruise control and Distronic.
Cruise control
switch task  With 30 km/h limitation: Switch on and off 30 km/h limitation when below 30
km/h.
Cruise control
Push-button switch with several switching contacts.
switch design
When the cruise control push-button switch is operated, two switching contacts are
Cruise control
always activated simultaneously. The actual input takes place by closing one of the
switch
switching contacts (e.g. storing the speed). The safety contact must close simultaneously
function
so that the input is accepted.
Cruise control pushbutton switch, location/task/design/function - GF30.30-P-3100M
ENGINE 275.950 in MODEL 215, 220 with CODE (494) USA version with CODE (498) Japan version
ENGINE 275.951 in MODEL 230 with CODE (494) USA version with CODE (498) Japan version
Fig. 66: Identifying Cruise Control Switch
Cruise control switch Left top behind the

location steering wheel.
Cruise control switch task Setting of cruise control
and Distronic.
Cruise control switch Pushbutton switch with
design several switching contacts.
Cruise control switch When the cruise control
function pushbutton switch is
operated, two switching
contacts are always
activated simultaneously.
The actual input takes
place by closing one of the
switch contacts (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
data bus.
DISTRONIC RADAR SENSOR, LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-3103K

ENGINES 285 in MODEL 240 with CODE (219a) Distronic (DTR)
Fig. 67: Identifying DTR Radar Sensor
Example
Fig. 68: Identifying Distronic Radar Sensor Function
Distronic
GF30.30-P-
radar sensor Models 209, 211, 215, 220, 230
3103-01K
position
GF30.30-P-
MODEL 240
3103-01M
Distronic
radar sensor,Transmitting radar signals and receiving the radar signals reflected by
task obstacles.
Distronic The radar sensor is installed in an aluminum housing. The voltage supply
radar sensor,comes from the Distronic control unit. The analog preprocessed sensor data
design is transmitted to the control unit via a coaxial connector.
Three transmission/reception beams each have a detection angle of 3°. The
Radar sensor
distances and the relative speeds to the target objects ahead are detected
Distronic
from the received signals on the basis of the signal propagation times. The
function
range is as much 150 m.
Distronic radar sensor position - GF30.30-P-3103-01K
Shows model 220
Fig. 69: Identifying DTR Radar Sensor - Shows Model 220
DTR CONTROL UNIT, LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-3104K
ENGINE 285 in MODEL 240 with CODE (219a) Distronic (DTR)

Fig. 70: Identifying DTR Control Unit With Connectors
DTR control unit, Under the floor/step plate, GF30.30-P-3104-01K

location always mounted on the
passenger side (left-hand
and right-hand drive
vehicles).
Task of the DTR control Uses the data from the
unit radar sensor and the other
input signal over CAN to
detect vehicles ahead and
determine the necessary
control interventions
(reduce/increase engine
torque, braking, gear
changes). Controls
displays and the warning
signal.
Design of the DTR Ventilated metal housing
control unit with two 8-pin connectors
and one coaxial connector
for the RF cable from the
radar sensor. Voltage
supply secured from
terminal 87.
Function of the DTR The analog radar sensor
control unit data is filtered and
digitized. The speed,
distance, angle and lane of
detected objects are
determined and compared
with the speed of the
driver's own vehicle. This
is how a vehicle ahead is
detected.
DTR control unit, location - GF30.30-P-3104-01K
Shows model 220
Fig. 71: Identifying DTR Control Unit - Shows Model 220
Models 209, 215, 220, 230, 240: Located in the front passenger footwell under the step plate at the front.
Shown in model 211
Fig. 72: Identifying DTR Control Unit - In Model 211
Mount under the front passenger seat on the floor panel.
DISTRONIC SWITCH BLOCK - LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-3105K
Shown on models 211, 219
Fig. 73: Identifying Distronic Switch Block - Shown On Models 211, 219
Distronic
GF30.30-P-
switch block Model 220, 215
3105-01K
position
GF30.30-P-
Model 230
3105-01R
GF30.30-P-
Models 209, 211, 219
3105-01T
GF30.30-P-
Model 240
3105-01M
Distronic - task Distance potentiometer: influences the distance to the
vehicle ahead.
Switch block Switch for distance warning function:
Switches the separate distance warning function on and off for a switched
off Distronic (warning tone and loudspeaker symbol).
Distronic
The Distronic switch block consists of the distance potentiometer and the
switch block
distance warning function switch.
design
Upper control panel control unit (models 215, 220) or lower control panel
Distronic
control unit (models 209, 211, 219, 230, 240) detect the switch and
switch block
potentiometer position and transfer them onto the CAN interior
function
compartment.
Distronic switch block position - GF30.30-P-3105-01K
Models 215, 220

Fig. 74: Identifying Distronic Switch Blocks
The switch block can only be replaced complete as one unit. S46/8r1 and S46/8s1 soldered to the switch block
S46/8.
DTR CONTROL UNIT, LOCATION / TASK / FUNCTION - GF30.30-P-3115K
ENGINE 112, 113, 271, 612 in MODEL 209 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINE 112, 113, 271, 272, 646, 647, 648 in MODEL 211 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINE 112, 113, 137, 275, 613, 628 in MODEL 220 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINE 113, 137, 275 in MODEL 215 as of 1.6.04 with CODE (219) Distronic (DTR)
ENGINE 112, 113, 275 in MODEL 230 as of 1.6.04 with CODE (219) Distronic (DTR)
Fig. 75: Identifying DTR Control Unit
Location of
DTR control The DTR control unit is located in the middle behind the radiator grille.
unit
To send out radar signals, receive reflected radar signals and thereby
Task of the recognize vehicles immediately ahead. Determine the required interventions
DTR control over the CAN (reduce/increase engine torque, braking, shifting gear).
unit Controls displays and the warning signal.
Function of
GF30.30-P-
DTR control
3115-01K
unit
DTR control unit - function - GF30.30-P-3115-01K
Fig. 76: Identifying DTR Control Unit Function
Do not mix up DTR control unit of the models 209, 215, 220 and the models 211, 219, 230. Observe the
different connector!
The DTR control unit (A89) transmits radar signals and receives reflected waves from obstacles. The distances
are determined based on the signal travel time of the received signals and the relative speeds to the target
objects are determined based on the Doppler shift.
The angle of the object is also determined based on the radar lobe orientation and strength of the reflected radar
beams.
The system is a three-beam radar with 3 electronically switchable transmission/reception lobes (opening angle
for each of 3.4°). The transmission and reception channels operate sequentially. The detection range is about
150 meters.
The following vehicle data is transmitted over CAN-C to the DTR control unit to detect objects:
 Rotational speeds of all wheels to determine the yaw rate when cornering and the vehicle speed
 Steering angle and direction.
The DTR control unit (A89) transmits the information over the distance and the relative speed of the detected
objects over the databus engine on the traction systems control unit, which performs the evaluation and decides
whether to reduce/increase the engine torque or whether braking or a gear shift is required.
The DTR control unit (A89) receives its voltage supply on Pin 1 (terminal 87) and Pin 6 (ground). All input and
output signals are exchanged over the CAN-C (databus engine). Output of data takes place
 for the models 209, 215, 220
 for the models 211, 219, 230
over two different interfaces. Any confusion between them is excluded based on different connectors on the
DTR control unit (A89).
The function of the DTR control unit (A89) and communication over CAN-C is monitored and recognized
errors are stored. Read out fault memory with STAR DIAGNOSIS.
Recognition and classification of target objects is only guaranteed if the DTR control unit (A89) is aligned in
the horizontal and vertical direction to the vehicle-longitudinal axis.
Shown on model 230
Fig. 77: Identifying Cover - Shown On Model 230
The radar transparent covering in the radiator grille optimizes the transmission and reception characteristics of
the radar sensor. External influences from outside (for example through metallic material in front of the sensor)
are suppressed.
KICKDOWN SWITCH LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-4000A
ENGINE 112, 113, 119, 120 in MODEL 129
ENGINE 104, 119, 120 in MODEL 140

ENGINE 111,112 (except, 112.96) in MODEL 170
ENGINE 111,112, 113 in MODEL 202
ENGINE 112,113,137 (except, 113.99) in MODEL 220
ENGINE 113,137 (except 113.99) in MODEL 215
Fig. 78: Identifying Kickdown Switch
Kickdown
in footwell behind accelerator pedal
switch position
Identify kickdown position of accelerator pedal, in order to influence
Kickdown
transmission control, cruise control, variable speed limiter and
switch task
Distronic.
Up to approx. 6/02 designed as an electrical switch (S16/6). As of
Kickdown GF30.20-P-
approx. 7/02 (without engine 166) the electrical switch is replaced by
switch design 4011-02C
the Kickdown simulator (spring).
Engine 111, 112, 113, 119, 120, 137 up to approx 6/02 and Engine 166:
on closed contact the ground is switched to the engine control unit
Kickdown
As of approx. 7/02 (without Engine 166): Kickdown recognition is
switch function
performed via the signal of the accelerator pedal sensor.
DISTRONIC (DTR) OVERVIEW OF SYSTEM COMPONENTS -

LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-9999Z
Models 209, 211, 215, 220, 230 to

Distronic radar sensor - GF30.30-P-
5/04
location/task/design/function 3103K
Model 240
Models 209, 211, 215, 220, 230 to
DTR control unit - GF30.30-P-
5/04
Model 240
Models 209, 211, 219, 215, 220, 230
as of 6/04 GF30.30-P-
DTR control unit - location/task/function
(Control unit and radar sensor 3115K
integrated)
Distronic switch block - GF30.30-P-
GF30.30-P-
Distronic (DTR) function description contents
0999Z
SAFETY PRECAUTIONS
SAFETY INFORMATION: THROTTLE CONTROL, CRUISE CONTROL SYSTEM - AS30.00-Z-
9999ZZ
MODEL all
Risk of injury to skin and eyes from laser beams MODEL all AS30.30-Z-0001-01A
RISK OF INJURY - 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.
Safety instructions/precautions
 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.
TROUBLE DIAGNOSIS
ENGINE IN LIMP-HOME MODE AND ENGINE DIAGNOSIS INDICATOR LAMP IS ON AND/OR
FAULTS CODE P2032, P202E, P208E OR P208F IS STORED IN MOTOR ELECTRONICS
CONTROL UNIT - AF30.20-P-2102A
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 113.990 in MODEL 211.076 /276
ENGINE 113.991 in MODEL 215.374, 220.074 /174
OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text Time Acc. no. Code
P 541011 Perform a quick 004 WU - -
test, MODEL 170,
203, 211.076/276,
215.374,
220.074/174, 230
MY 02, 230.474
as of MY 03
P 071488 Replace throttle 009 WU - -
valve actuator
(after inspection),
MODEL 170,
203, 230 MY 02
P 611105 Remove/install 002 WU - -
bottom engine
compartment
paneling, MODEL
170, 203
bottom center part
of engine
compartment
paneling, MODEL
215.374,
220.074/174, 230
MY 02, 230.474
as of MY 03
actuator for
compressor,
replace if
necessary,
MODEL 215.374,
220.074/174,
230.474 as of MY
03
ground cable at
on-board
electrical system
battery (when
separating
electrical
connectors)
MODEL
211.076/276
bottom front part
of engine
compartment
paneling, MODEL
211.076/276
actuator for
compressor,
replace if
necessary,
MODEL
211.076/276

59 029 74 Connection problems with 1. Remove/install/replace AR07.61-P-1401SVK
the plug socket throttle valve.
connecting the engine
wiring harness with the
throttle valve/recirculated
air flap.
2 Remove/install/replace
recirculated air flap.
Engine is in limp- Model 211, 215, 220 AR09.50-P-8843T
home mode and engine Model 230 except model
diagnosis indicator lamp year 2002, code 802
is on. Faults that may be
stored in the motor
electronics control unit
 Throttle valve
actuator M16/6
(P2032, P202E).
 Recirculated air flap
actuator M16/7
(P208E, P208F)
line is crossed.
If there is a fault at
only one actuator (throttle
valve or recirculated air flap)
both of the actuators must be
replaced on ENGINE 113
with recirculated air flap.
Before installing,
the pins of the connector on
the engine wiring harness,
throttle valve and
recirculated air flap must be
applied with contact fluid A
008 989 55 71 (supplied with
the throttle valve actuator).

A 112 141 03 25 Throttle valve actuator, valid for 1
ENGINE 112.960/961
ENGINE 113.992 with CODE
(802)
ENGINE 113.990/991 and 113.992
except CODE (802)
A 113 141 07 25 Recirculated air flap actuator, valid 1
for ENGINE 113.990/991 and
113.992 except CODE (802)
DTC IN MULTIFUNCTION DISPLAY - AF30.30-P-2000A
MODEL 220 with CODE (219) Distronic (DTR)
MODIFICATION NOTES
30.8.99 Supersedes STIP 30.30-003 dated 18.8.99
Damage Cause Remedy

code
1 Remove/install/replace N63/1
54 601 52 Control unit N63/1
control unit
In individual cases, "DTR internal error" may be
After reading the DTC,
displayed on the multifunction display. This display can
do NOT erase DTC memory.
occur for a short time. FC C 1000 stored in DTC memory.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: THROTTLE CONTROL, CRUISE
CONTROL SYSTEM - AR30.00-Z-9112AB
ENGINE 112
Adjusting throttle control ENGINE 112, 113... AR30.10-P-1010BA

Adjusting throttle control ENGINE 111, 112, 602... AR30.10-P-1010C
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

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 accelerator ENGINE 113, 271, 272... AR30.12-P-1321V
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

ENGINE 137
Remove, install electronic accelerator actuator ENGINE 137.970 in MODELS AR30.20-P-

with flap connection 215.378, 220.178 /878 1262L

CONTROL SYSTEM - AR30.00-Z-9215AA
MODEL 215
AR30.12-P-
Remove/install accelerator pedal MODEL 220, 215, 230
1321I
Remove/install electronic accelerator MODEL 129, 163, 170, 171, 202, 203, 208, AR30.20-P-
actuator with flap connection 209, 210, 215, 220, 230, 463 ... 1262A
Check / adjust the sensor setting of MODEL 164, 209, 211, 215, 216, 219, 220, AR30.30-P-
Distronic (DTR) 221, 230, 240, 251 ... 1000R

CONTROL SYSTEM - AR30.00-Z-9220AA
MODEL 220
AR30.12-P-
Remove/install accelerator pedal MODEL 220, 215, 230
1321I
Remove/install electronic accelerator MODEL 129, 163, 170, 171, 202, 203, 208, AR30.20-P-
actuator with flap connection 209, 210, 215, 220, 230, 463 ... 1262A
Check / adjust the sensor setting of MODEL 164, 209, 211, 215, 216, 219, 220, AR30.30-P-
Distronic (DTR) 221, 230, 240, 251 ... 1000R

ENGINE 275
Removing/installing the electronic accelerator ENGINE 275 in MODEL 215, 216, 220, AR30.20-P-
actuator with flap connection 221, 230 ENGINE 285 in MODEL 240 1262H
REMOVE/INSTALL ACCELERATOR PEDAL - AR30.12-P-1321I
MODEL 220, 215, 230

Fig. 79: Identifying Accelerator Pedal Remove/Install Components
Remove/Install
Remove key from Vehicles with Code (889) Keyless Go: Switch
1 electronic ignition switch off engine, remove Keyless-Go cards from the vehicle
(EIS) and store outside of transmitter range
Remove front cover below AR68.10-P-
2 Model 215
instrument panel on left 1500N
AR68.10-P-
Model 220
1500M
AR68.10-P-
Model 230
1500R
Unscrew nut (arrow)
3 attaching accelerator pedal
(33)
Accelerator pedal must not be disassembled
Take out accelerator pedal otherwise it will be damaged.
4
(33) Installation: Accelerator pedal must be
inserted with front guide lug (arrow) in firewall.
Unplug connector of pedal
5
value sensor (B37)
Unplug connector of
6.1 Vehicles with kickdown switch (S16/6)
kickdown switch (S16/6)
REMOVE/INSTALL ELECTRONIC ACCELERATOR ACTUATOR WITH FLAP CONNECTION -

AR30.20-P-1262
Remove/install electronic accelerator actuator with flap connection - AR30.20-P-1262A
MODEL 129, 163, 170, 171, 202, 203, 208, 209, 210, 215, 220, 230, 463 (except, 215.376 /378 /379,
220.176 /876 /178 /878 /179, 230.476 /477 /479)
Mass air flow sensor removed
Shown on engine 112 in model 210
Fig. 80: Identifying Electronic Accelerator Actuator With Flap Connection
Remove/install
Detach crankcase vent line (1/2) from intake
1
manifold (19)
2 Disconnect electrical connector (arrow) Pull catch backwards.
Remove bolts (8/1) and throttle valve actuator Installation: Replace O-ring
3
(M16/6) (8/2).
Removing/installing the electronic accelerator actuator with flap connection - AR30.20-P-1262H
ENGINE 275 in MODEL 215, 216, 220, 221, 230

Fig. 81: Identifying Electrical Connector And Bolts
Remove/install
Remove charge air duct to charge air AR09.50-P-
1
cooler 8680H
Detach electrical connector (2) and
2 remove line from retaining clamp
(arrow)
Installation: Observe installation
Remove bolts (1) and throttle valve
3 position of the retaining clamp (arrow);
actuator (M16/6)
replace seal.
*BA30.20-P-
1002-01C
ELECTRONIC ACCELERATOR PEDAL ACTUATOR

BA30.20-P-1002-01C Bolt, throttle valve actuator to intake manifold Nm 10 10
Remove, install electronic accelerator actuator with flap connection - AR30.20-P-1262L
ENGINE 137.970 in MODELS 215.378, 220.178 /878

Fig. 82: Identifying Electronic Accelerator Actuator Remove/Install Components With Flap Connection
AR09.10-P-
1 Remove air cleaner
1050L
AR07.07-P-
2 Remove hot film mass air flow sensor
1453L
Unplug connector (arrow) of electrical connection Place electric
3
of electronic accelerator (M16/6) cable to the side.
4 Detach crankcase ventilation line (1/2)
*BA30.20-P-
5 Unscrew bolts (8/1)
1001-01B
6 Detach crankcase ventilation line (1/3)
7 Take out electronic accelerator actuator (M16/6)
gasket (8/2).
ELECTRONIC ACCELERATOR PEDAL ACTUATOR

BA30.20-P-1001-01B Bolt of electronic accelerator to inlet connection Nm 8
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. 83: Identifying Distronic Sensors - Shown On Model 230 With Arched Radar Sensor
Fig. 84: Identifying Distronic Sensor Adjustment - Shown On Model 230
shown on model 230
Vehicle with an arched radar sensor

Fig. 85: Checking Distronic Sensor Setting For Vehicle With Arched Radar Sensor
Vehicle with a radar sensor that is not arched (flat)
Fig. 86: Checking Distronic Sensor Setting For Vehicle With Radar Sensor
Fig. 87: Identifying Reticule Center
Measuring, adjusting
Never look directly into the laser beam. Do
not attempt to suppress natural reflex of
Risk of injury to skin and eyes from eyelids. AS30.30-Z-
laser beams Avoid direct skin contact with the laser 0001-01A
beam. If damage to the eye is suspected,
consult an eye specialist immediately.
Conduct quick test with STAR *WH58.30-
1
DIAGNOSIS Z-1048-13A
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
Risk of injury caused by fingers
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.
AR88.40-P-
2 Open engine hood Model 164
1000GZ
AR88.40-P-
Model 209
1000Q
AR88.40-P-
Model 211
1000T
AR88.40-P-
Model 219
1000TX
Model 215, 220 AR88.40-P-
Model 216, 221 1000M
AR88.40-P-
Model 230
1000R
Model 240 except 240.179 AR88.40-P-
Model 240.179 1000H
AR88.40-P-
Model 251
1000RT
Model 164 AR88.40-P-
3.1 Remove radiator trim
Model 216 4001GZ
AR88.40-P-
Model 219
4001TX
AR88.40-P-
Model 230
4001R
AR88.40-P-
Model 251
4001RT
3.2 Remove bumper
Model 240.179 2000H
Only conduct visual test on mechanical
damages..
Check if:
 DTR radar sensor (A89b1, B29) is

damaged or dirty
 Connectors (9) are loose
Check DTR radar sensor (A89b1, On the DTR radar sensor

4 (A89b1) only one connector is
B29)
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.
The front wheels must be aligned
Align front wheels to the geometric
5 to the geometric driving axle. Measure
driving axle
chassis if necessary.
Remove front measuring heads from
6
the quick tensioning holders
Fit the measuring rods (1) onto the
7 quick tensioning holders in place of
measuring heads
Attach the spacer ring (8) to the DTR Only for vehicles with non-arched
8
radar sensor (A89b1) (flat) DTR radar sensor (A89b1).
*WH58.30-
Z-1053-12A
Observe operating instructions of

headlamp adjustment testing unit (2).
Align headlamp adjustment testing Headlamp adjustment testing unit
unit (2) to vehicle and carry out height (2) must stand on even surface, parallel to
9
adjustment to position of DTR radar contact patch.
sensor (A89b1, B29) Set headlamp range adjustment at
headlamp adjustment testing unit (2) to "0".
*WE58.40-
Headlamp adjustment testing unit
Z-1006-19A
In order to secure the optical adjusting
device (5) from falling down, hang up
fastening strap (4) at vehicle.
Fit optical adjusting device (5) with
distance pins (5b) onto DTR radar In order to guarantee a secure
sensor (A89b1, B29) and firmly seating of optical adjusting device (5) on
10
DTR radar sensor (A89b1, B29), vaseline
suction using the hand vacuum
should be applied to the rubber lip of
pump (6)
suction bell and the hand vacuum
pump (6) should be evacuated from 600 to
700 mbar.
*WE58.40-
DISTRONIC adjusting device
Z-1004-19A
Hand vacuum pump Fig. 88
For alignment look into overhead
mirror (2/1). Align headlamp adjustment
testing unit (2) by rotating (arrow) around
Align headlamp adjustment testing
11 the vertical axis, in such a way, that the
unit (2) to vehicle
right and the left sounding rods (1) overlap
with mirror reticule (2/1a) in the overhead
mirror (2/1).
On vehicles with Keyless Go Code
889: press the Keyless Go start and stop
pushbutton once without depressing the
brake pedal - the laser in the optical
Connect optical adjusting device (5) to
12 adjusting device (5) is activated.
cigarette lighter
On vehicles without Keyless Go:
turn ignition key to position "1" - the laser
in the optical adjusting device (5) is
activated.
Connect STAR DIAGNOSIS and Only for vehicles with AIRmatic,
13 code 489 or with Active Body Control
starting off automatic calibration level
(ABC), code 487.
Read off point of impact of laser beam Point of impact and graticule
14
in headlight adjustment testing unit (2) center (7) must match.
In case of a correction, ensure that
Adjust horizontal adjustment of DTR the adjustment screw (3a) is turned
radar sensor (A89b1, B29), for this counterclockwise by one piece first
step bring point of impact to height of(eliminate threaded play).
reticule center (7) by twisting The adjusting bolt (3b) is only to
15 adjusting bolt (3a) at DTR radar be twisted in the case that the range of
sensor (A89b1, B29) in the headlamp adjustment of adjusting bolts (3a, 3c),
adjustment testing unit (2) would not be adequate for a correction.
For vertical alignment of optical
adjusting device (5), observe bubble level
Set vertical adjustment of DTR radar
(5a). In case of a correction, ensure that
sensor (A89b1, B29); for this step
adjustment screw (3c) is turned
point of impact must overlap with the
counterclockwise by one piece first
16 reticule center (7) in the headlamp
(eliminate threaded play).
adjustment testing unit (2) through
twisting of the adjusting bolt (3a) at The adjusting bolt (3b) is only to
the DTR radar sensor (A89b1, B29) be twisted in the case, that range of
adjustment of the adjusting bolts (3a, 3c),
would not be adequate for a correction.
Remove vaseline from the DTR
17 Remove optical adjusting device (5)
radar sensor (A89b1, B29).
Only for vehicles with non-arched
(flat) DTR radar sensor (A89b1).
Remove the spacer ring (8) of the
18 The spacer ring (8) must be removed to
DTR radar sensor (A89b1)
ensure that DTR radar sensor (A89b1)
functions correctly.
Reset the learning values with STAR
19
DIAGNOSIS
20.1 Install radiator trim
Model 216 4001GZ
AR88.40-P-
Model 219
4001TX
AR88.40-P-
Model 230
4001R
AR88.40-P-
Model 251
4001RT
20.2 Install bumper
Model 240.179 2000H
AR88.40-P-
21 Close engine hood Model 164
1000GZ
AR88.40-P-
Model 209
1000Q
AR88.40-P-
Model 211
1000T
AR88.40-P-
Model 219
1000TX
Model 215, 220 AR88.40-P-
Model 216, 221 1000M
AR88.40-P-
Model 230 1000R
Model 240.179 1000H
AR88.40-P-
Model 251
1000RT
Fig. 88: Identifying Hand Vacuum Pump (001 589 73 21 00)

Number Designation
WH58.30-Z-1053- Spacer ring and compressed air connection, Company Polytec GmbH D-76337
12A Waldbronn
WH58.30-Z-1048-
STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
13A
WORKSHOP EQUIPMENT
WE58.40-Z-1004-19A DISTRONIC adjusting device
WE58.40-Z-1006-19A Headlamp adjustment testing unit
MAINTENANCE
LUBRICATE JOINTS OF ENGINE CONTROL SYSTEM, CHECK JOINTS FOR FREEDOM OF
MOVEMENT AND PROPER SEATING - AP30.10-P-3022ZA
ENGINE 111, 104, 112, 113, 119, 120, 602, 604, 605, 606 (except, 112.942 /970, 113.942 /965 /981)
ENGINE 611.961, 612.961, 613.961 in MODEL 210
Illustration shows engine 104

Fig. 89: Identifying Joints Of Engine Control System
Remove/install
1.1 Remove air cleaner Engines 111, 120, 604,
605, 606
Engine 111 AR09.10-P-1050G
Engine 120 AR09.10-P-1050F
Engine 604, 605.910/912,
606.912
Engine 605.911, 606.910 ra09006051051x
2 Oil joint areas of throttle
control, inspect for ease
of operation and wear
Viscosity classes of Sheet 224.1 BB00.40-P-0224-01A
engine oils (car engines)
Engine 602, 604, 605, AP30.10-P-3022-01AB
606, 611, 612.961,
613.961
Engine 104, 111, 112 AP30.10-P-3022-01CB
(except 112.942/970), 113
(except 113.942/965/981),
119, 120
Oil joint areas of throttle control, inspect for ease of operation and wear - AP30.10-P-3022-01CB
Engine 111 with HFM-SFI

Fig. 90: Identifying Joint Areas Of Throttle Control (Engine 111 With HFM-SFI)
Engine 104, 111, 112, 113, 119, 120 with ME-SFI fuel injection system
Fig. 91: Identifying Joint Areas Of Throttle Control (Engine 104, 111, 112, 113, 119, 120 With ME-SFI
Fuel Injection System)
TIGHTENING TORQUES: PASSENGER CARS: THROTTLE CONTROL, CRUISE CONTROL
SYSTEM - BA30.00-Z-9999AZ
MODEL all
Electronic accelerator ENGINE 112, 113, 119, BA30.20-P-1000-01A
actuator 120...
Electronic accelerator ENGINE BA30.20-P-1000-01B
actuator 111.951/955/958/983, 137
Electronic accelerator ENGINE 271, 275, 285 BA30.20-P-1000-01C
actuator
Accelerator pedal sensor MODEL 215, 220, 230, BA30.20-P-1000-02A
240
Accelerator pedal MODEL BA30.20-P-1000-03A
171.442/454/456/473
Accelerator pedal MODEL 169, 245 BA30.20-P-1000-03B
Accelerator pedal MODEL 219, 221 BA30.20-P-1000-03C
Idle speed control (ISC) ENGINE BA30.22-P-1000-01A
166.940/960/990 /995 in
MODEL 168 ENGINE
166.961/991 in MODEL
414
Idle speed control (ISC) ENGINE BA30.22-P-1000-01C
266.920/940/960/980 in
MODEL 169.0/3
ACCELERATOR AND COMPONENTS - BA30.20-P-1000
Electronic accelerator actuator - BA30.20-P-1000-01A
Engines 112, 113, 119, 120
ELECTRONIC ACCELERATOR THROTTLE ACTUATOR

Number Designation Engine 112, Engine Engine 119,
113.940/941/942/943/ 113.987/988/989 120
944/948/960/961/962/
963/965/966/967/968/
980/981/982/984/986/
992
BA30.20-P- Bolt, electronic Nm 9 10 25
1001-01A accelerator
throttle actuator
to intake
manifold
Accelerator pedal sensor - BA30.20-P-1000-02A
Engines 215, 220, 230, 240
ACCELERATOR PEDAL SENSOR

Number Designation Models 215, 220, 230, 240
BA30.20-P-1001-02A Nut for accelerator pedal sensor on firewall Nm 8
Detachable Body Components - 215 & 220 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: DETACHABLE BODY COMPONENTS, EXTERIOR
FLAPS - AH88.00-Z-9999AZ
MODEL all
General information on MODEL 124, 129, 140, AH88.00-P-1000-01A

repair to detachable 168, 202, 208, 210, 414
plastic components
General notes on filling MODEL 450.418 AH88.00-P-1000-02CR
detachable body
components
Notes on electric trunk lid MODEL 129, 202, 203, AH88.50-P-0001-01A
emergency release 208, 210, 215, 220 ...
General notes on repair MODEL 171.4 AH88.50-P-0002-01V
work to tubular frame
NOTES ON ELECTRIC TRUNK LID EMERGENCY RELEASE - AH88.50-P-0001-01A
Models 129, 202, 203, 208, 210, 215, 220
General
The trunk lid can be opened with a button in the trunk.
The following functions are used:
 CL open (SN1)
 Open trunk lid (HD-AS or S2)
When the button is actuated the two signals are switched one after another with time delay.
Firs the CL opens, then the trunk lid lock is actuated.
Button illumination:
 Color green.
 Flashing frequency approx. 1 Hz
 Switching on by opening trunk
 Switch-on duration after closing trunk approx. 60 min.
 The battery must be connected and charged (operating voltage range for emergency trunk release:
9V to 15.5V)
CAUTION: When the battery is removed/disconnected (e.g.: when vehicle is shut

down temporarily) remove striker eye from trunk lid lock for safety
reasons.
The function "Lock trunk lid separately" (90° position for trunk lid lock) is no longer present after the trunk lid
emergency release is installed
Function check
 Open trunk lid (the button illumination should flash)

 Close trunk lid lock, if required pull tappet switch (trunk lid remains open)
 Actuate trunk lid inner button when CL is closed:
 CL opens
 Trunk lid lock actuation with CL open:
 Trunk lid lock actuation
If lock is blocked actuation is repeated twice (after approx. 10 s and approx. 20 s)
BASIC KNOWLEDGE
ELECTRICAL EXTERIOR MIRROR ADJUSTMENT (EAS) FUNCTION - GF88.79-P-0008S
MODELS 215, 220
Fig. 1: Electrically Adjustable Outside Rearview Mirrors Block Diagram - Shown On LHS Vehicle
Block diagram
Electrically adjustable outside rearview mirrors
Shown on LHS vehicle
Function requirements:
 no overvoltage/undervoltage
 Term.15R or 15 ON
The left and right exterior mirrors are electrically adjustable and heated. The mirror housings are electrically
retractable (garage position) . The mirrors can be automatically moved to stored positions via the memory
function . In addition, the mirror glass of the exterior mirror on the driver's side can be electrochromatically
dimmed (special equipment).
All switches for controlling the exterior mirrors are integrated into the switch train for exterior mirror
adjustment with fold in/out function (S50/1) on the front left door control module (N69/1)
(RHS vehicle: Front right door control module (N69/2) ) integrated. The mirror selector switch is used to
select which of the two exterior mirrors is to be adjusted.
The mirror adjustment switches can be used to horizontally and vertically adjust the mirror glass of the relevant
exterior mirror. Two further switches can be used to move the exterior mirror housings into the garage position
or driving position.
The mirror heating is automatically controlled.
Up to 31.05.01
the fold in exterior mirror switch (S50/1s4) or the fold out exterior mirror switch (S50/1s5) must be
actuated until the mirror housings are in the desired position.
As of 01.06.01
the fold in exterior mirror switch (S50/1s4) or the fold out exterior mirror switch (S50/1s5) merely have to
be touched, and the mirror housings will automatically move to the selected position.
GF88.79-P-
Left/right heated outside rearview mirror, function
2000S
GF88.79-P-
Adjust left/right exterior mirror function
2001S
GF88.79-P-
Fold in left/right exterior mirror function
2002S
Automatically dim exterior mirror on driver's side 220.063 and 220.065 with GF88.79-P-
function code 249b only 2003S
Front driver's side door control module, GF72.29-P-
location/purpose/design/function 4105S
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF ELECTRIC EXTERIOR REARVIEW

MIRROR ADJUSTMENT (EMA) - GF88.79-P-0998SZ
MODEL 215, 220
Electric exterior rearview mirror adjustment (EMA), GF88.79-P-

function 0008S
GF68.49-P-
Automatic dimming interior rearview mirror, function
0003S
220.063 only with code GF91.29-P-
Calling stored positions, function
275a 2011S
GF88.79-P-
Heating left/right exterior rearview mirrors, function
2000S
GF88.79-P-
Adjusting left/right exterior rearview mirrors, function
2001S
GF88.79-P-
Folding in/out left/right exterior rearview mirrors, function
2002S
Automatic dimming feature for exterior rearview mirror on 220.063 and 220.065 only GF88.79-P-
driver's side, function with code 249b 2003S
Storing exterior rearview mirror position, function
275a 2004S
Calling stored exterior rearview mirror position, function
275a 2005S
Parking position for exterior rearview mirror on passenger 220.063 only with code GF88.79-P-
side, function 275a 2006S
Storing parking position for exterior rearview mirror, 220.063 only with code GF88.79-P-
function 275a 3004S
Exterior rearview mirror position measurement, function
275a 4000S
Interior rearview mirror unit, GF68.49-P-
Exterior rearview mirror adjustment motor, GF88.79-P-
Exterior rearview mirror adjustment switch, GF88.79-P-
HEATING LEFT/RIGHT EXTERIOR REARVIEW MIRRORS, FUNCTION - GF88.79-P-2000S
MODEL 215, 220

Fig. 2: Identifying Heated Left/Right Exterior Rearview Mirrors, Function Diagram

 C.61 ON
Function
The left mirror heater (M21/1r1) in the left electrically adjustable and heated exterior rearview mirror
(M21/1) and the right mirror heater (M21/1r1) in the right electrically adjustable and heated exterior rearview
mirror (M21/2) consist of a heater resistor connected in series with a PTC resistor. The heater resistor is located
on the rear of the mirror glass to which it is permanently bonded. The power supply and regulated switching on
and switching off of the heater resistors is accomplished by the left front door control module (N69/1)/right
front door control module (N69/2) . The mirror heater is controlled in relation to the outside air temperature
(CAN message from the left front SAM control module (N10/6)) and the dew point (CAN message from
automatic A/C pushbutton control module (N22)).
Left front door control module, location/purpose/design/function GF72.29-P-4105S

Right front door control module, location/purpose/design/function GF72.29-P-4106S
Left signal-acquisition and actuation module, location/purpose/design/function GF54.21-P-4101S
Right signal-acquisition and actuation module, location/purpose/design/function GF54.21-P-4102S
ADJUST LEFT/RIGHT EXTERIOR MIRROR FUNCTION - GF88.79-P-2001S

MODELS 215, 220
Adjust left/right exterior mirror (Shown on LHS vehicle)
Fig. 3: Identifying Adjustable Left/Right Exterior Mirror Function Diagram - Shown On LHS Vehicle
Function
The left and right exterior mirrors can be electrically adjusted via the switches in the switch train for exterior
mirror adjustment with fold in/out function (S50/1) in the front left door control module (N69/1) (RHS
vehicle: Front right door control module (N69/2)) . The following settings are possible:
 Horizontal mirror glass adjustment

 Vertical mirror glass adjustment
 Mirror housing folding-in (garage position) and folding-out (driving position)
The adjustments are carried out by the motors in the left electrically adjustable and heated exterior mirror
(M21/1) and the right electrically adjustable and heated exterior mirror (M21/2) . The motors are actuated
via the front left door control module (N69/1) and the front right door control module (N69/2).
The memory function (special equipment) can be used to call up stored mirror settings.
Setting the parking position of the exterior mirror on the front passenger's side enables the driver to check the
distance of the relevant rear wheel from the edge of the curb when reversing into a parking space.
Up to 31.05.01
As of 01.06.01
be touched, and the mirror housings are automatically moved to the desired position.
GF88.79-P-
Fold in left/right exterior mirror function
2002S
220.063 with code 275a GF91.29-P-
Memory switch function
only 0001S
220.063 with code 275a GF88.79-P-
Store exterior mirror position function
only 2004S
220.063 with code 275a GF88.79-P-
Call up stored exterior mirror positions function
only 2005S
Front passenger's side exterior mirror parking position 220.063 with code 275a GF88.79-P-
function only 2006S
Front left door control module GF72.29-P-
position/task/structure/function 4105S
Front right door control module GF72.29-P-
Exterior mirror adjustment motor GF88.79-P-
Exterior mirror adjustment switch GF88.79-P-
FOLD IN LEFT/RIGHT EXTERIOR MIRROR FUNCTION - GF88.79-P-2002S
MODELS 215, 220
Fold in left/right exterior mirror (Shown on LHS vehicle)

Fig. 4: Identifying Left/Right Exterior Mirror Function Diagram - Folding
Function
The left and right exterior mirror housings can be electrically folded in and out. Via the switches in the switch
train for exterior mirror adjustment with fold in/out function (S50/1) in the front left door control module
(N69/1) (RHS vehicle: Front right door control module (N69/2) ), the left/right exterior mirror housing can
be moved to the garage position (mirror housings folded in) or the driving position (mirror housings folded out).
The switch statuses of the switches for folding the exterior mirror in (S50/1s4) and the switches for folding
the exterior mirror out (S50/1s5) are read in by the front left door control module (N69/1) (RHS vehicle:
Front right door control module (N69/2) ) inserted and placed onto the CAN as a message for the door
control module on the front passenger's side.
The front left door control module (N69/1) and the front right door control module (N69/2) then actuate the
motor for folding the mirror in (M21/1m3) and the motor for folding the mirror in (M21/2m3) in the left
and right exterior mirror housings.
Up to 31.05.01
As of 01.06.01
be touched, and the mirror housings are automatically moved to the desired position.
Front left door control module position/task/structure/function GF72.29-P-4105S

Front right door control module position/task/structure/function GF72.29-P-4106S
Exterior mirror adjustment switch position/task/structure/function GF88.79-P-4101S
Exterior mirror adjustment motor position/task/structure/function GF88.79-P-4100S
AUTOMATIC DIMMING FEATURE FOR EXTERIOR REARVIEW MIRROR ON DRIVER'S SIDE,

FUNCTION - GF88.79-P-2003S
MODEL 220.063 /065 with CODE (249b) Automatic dimming interior and exterior (driver-side)
rearview mirrors
MODEL 215, 220 / (except, 220.063 /065)
Fig. 5: Identifying Automatic Dimming Feature For Exterior Rearview Mirror On Driver Side, Function
Diagram
Driver-side exterior rearview mirror automatic dimming feature

 15R or c.15 ON
Function
The mirror glass in the exterior rearview mirror on the driver's side can be dimmed electro-chromatically. For
this purpose a layer of electrolytic gel is located in the mirror glass between the reflector and cover glass. When
a voltage is supplied to this gel it changes its permeability to light.
The light reaching the surface of the mirror is reflected to a greater or lesser extent depending on the magnitude
of the control voltage. The control voltage is regulated by the interior rearview mirror unit (A67) (master)
and the overhead control panel control module (N70) . Two discrete leads are connected to the left front
door control module (N69/1) for this purpose (vehicles with right-hand steering: right front door control
module ((N69/2)).
Regulation is accomplished depending on the ambient light and the light reaching the mirror. These two
variables are measured by the ambient light sensor (A67h2) in the interior rearview mirror housing (rear) and
the automatic dimming interior rearview mirror sensor (A67h1) in the mirror glass in the interior rearview
mirror unit.
If one of the interior lights is switched on or the CAN message "Reverse gear engaged" is received from the
electronic ignition/starter switch control module (N73) , the exterior rearview mirror as well as interior
rearview mirror become brighter.
Interior rearview mirror unit, location/purpose/design/function GF68.49-P-2100S

Overhead control panel control module, location/purpose/design/function GF82.20-P-4101S
STORING EXTERIOR REARVIEW MIRROR POSITION, FUNCTION - GF88.79-P-2004S
MODEL 220 (except 220.063) with CODE (275a) Memory package (driver's seat, steering column,
rearview mirrors)
MODEL 215, 220.063

 15R or c.15 ON
Function
Two positions for the left electrically adjustable and heated exterior rearview mirror (M21/1) and right
electrically adjustable and heated rearview mirror (M21/2) can be stored per ignition/starter key.
The interior rearview mirror position, steering column position and driver's seat position are stored
simultaneously with the exterior rearview mirror position.
The positions for the left/right exterior rearview mirrors are stored in the left front door control module
(N69/1)/right front door control module (N69/2).
To store the momentary exterior rearview mirror positions press the memory switch (N69/1s9) in the left front
door control module (N69/1) and then the memory position 1 switch (N69/1s6) or memory position 2 switch
(N69/1s7) within 3 s. The door control module (N69/1, N69/2) checks whether the values from the position
measurement for the left/right exterior rearview mirror are valid. If so the values are stored in the door control
module in relation to the key.
If no positions are stored for the ignition/starter key used, the current rearview mirror positions are stored under
the key number when the key is removed.
Calling stored exterior rearview mirror position, function GF88.79-P-2005S

Memory circuit, function GF91.29-P-0001S
Calling stored positions, function GF91.29-P-2011S
Exterior rearview mirror position measurement, function GF88.79-P-4000S
Front seat adjustment switch group, with memory, location/purpose GF91.29-P-2106S
Overhead control panel control module, location/purpose/design/function GF82.20-P-4101S
Left signal-acquisition and actuation module, location/purpose/design/function GF54.21-P-4101S
CALLING STORED EXTERIOR REARVIEW MIRROR POSITION, FUNCTION - GF88.79-P-2005S
MODEL 220 with CODE (275a) Memory package (driver's seat, steering column, mirrors)
MODEL 215, 220 (except, 220.063)

 15R or c.15 ON
 Driver's door open
 None of the buttons for manual seat, rearview mirror or steering column adjustment are actuated.
Function
The stored positions for the left electrically adjustable and heated exterior rearview mirror (M21/1) and
right electrically adjustable and heated exterior rearview mirror (M21/2) can be called by pressing the
memory position 1 switch (N69/1s6) or memory position 2 switch (N69/1s7) in the left front door control
module (N69/1) . (On vehicles with right-hand steering the stored positions can be called by pressing the
corresponding switches on the right front door control module (N69/2)).
As long as the button is pressed the motors in the left electrically adjustable and heated exterior rearview
mirror (M21/1) and right electrically adjustable and heated exterior rearview mirror (M21/2) are actuated
by the left front door control module (N69/1)/ right front door control module (N69/2) until the position
measurement feature recognizes that the stored position has been reached.
Memory function
The steering column, driver's seat and interior rearview mirror also move to the associated, stored positions
when the stored exterior rearview positions are called.
Storing exterior rearview mirror position, function GF88.79-P-2004S

Calling stored positions, function GF91.29-P-2011S
Memory circuit, function GF91.29-P-0001S
Exterior rearview mirror adjustment motor, location/purpose/design/function GF88.79-P-4100S
PARKING POSITION FOR EXTERIOR REARVIEW MIRROR ON PASSENGER SIDE, FUNCTION

- GF88.79-P-2006S
MODEL 215, 220 (except, 220.063)
MODEL 220.063 with CODE (275a) Memory package (driver's seat, steering column, mirrors)
Fig. 6: Identifying Parking Position For Exterior Rearview Mirror On Passenger Side, Function Diagram
Moving the exterior rearview mirror on the passenger side to the parking position when reverse gear is
engaged (illustrated on vehicle with left-hand engaged" control module steering)

 C.15 ON
 Reverse gear engaged
 Exterior mirror changeover left/right switch (S50/1s3) in passenger-side rearview mirror position
 Position measurement supplying valid values
Purpose of parking position
After the exterior rearview mirror on the passenger side has moved to the parking position the driver can
observe the distance between the associated rear wheel and edge of the curb in the mirror when backing up to
park the car.
Function
The right front door control module (N69/2) (vehicles with right-hand steering: left front door control module
(N69/1)) receives the CAN message "Reverse gear engaged", causing the exterior rearview mirror on the
passenger side to be moved to the parking position stored for ignition/starter key in use.
One parking position can be stored in the right front door control module (N69/2) (vehicles with right-hand
steering: left front door control module (N69/1)) per ignition/starter key.
Termination of function
The exterior rearview mirror is automatically moved back to the original position when:
 The transmission is shifted to a forward gear, after expiration of a time of approx. 10 s or

 the vehicle speed increases to about 10 km/h or
 the exterior mirror changeover left/right switch (S50/1s3) in the exterior mirror adjustment switch
with mirror fold-in/out feature (S50/1) on the left front door control module (N69/1) (vehicles with
right-hand steering : right front door control module (N69/2)) has been actuated.
The mirror is also moved back to the original position even when it was adjusted manually in the parking
position with the adjustment switch.
Storing parking position for exterior rearview mirror, function GF88.79-P-3004S

Exterior rearview mirror adjustment switch, location/purpose/design/function GF88.79-P-4101S
EXTERIOR REARVIEW MIRROR ADJUSTMENT SWITCH, LOCATION - GF88.79-P-3001-01S
Model 215, Model 220
The switches for adjusting the exterior rearview mirrors are located in a separate assembly in the exterior
mirror adjustment switch with mirror fold-in/out (S50/1) on the left front door control module (N69/1)
(vehicles with right-hand steering : right front door control module (N69/2)).
Left front door control module (N69/1) (left-hand steering)
Fig. 7: Identifying Exterior Rearview Mirror Adjustment Switch

STORING PARKING POSITION FOR EXTERIOR REARVIEW MIRROR, FUNCTION - GF88.79-P-
3004S
MODEL 215, 220 (except, 220.063)
 15R or c.15 ON
 Vehicle speed v=0 km/h
Function
The parking position for the exterior mirror on the passenger side can be stored in relation to the key with the
left front door control module (N69/1) (vehicles with right-hand steering: right front door control module
(N69/2)). For this purpose it is first necessary to adjust the rearview mirror to the desired parking position
manually with the mirror adjustment switches in the exterior mirror adjustment switch group with mirror
fold-in/out feature (S50/1) . Then press the memory switch (N69/1s9) (vehicles with right-hand steering:
(N69/2s9)), and within 3 seconds the bottom half of the rocker switch of the exterior mirror adjustment
up/down switch (S50/1s1).
When this combination of buttons is pressed the left front door control module (N69/1) transmits the CAN
message "Store parking position" to the right front door control module (N69/2) (vehicles with right-hand
steering: vice versa. The momentary exterior rearview mirror position is then stored as the parking position.

Exterior rearview mirror adjustment switch, location/purpose/design/function GF88.79-P-4101S
EXTERIOR REARVIEW MIRROR POSITION MEASUREMENT, FUNCTION - GF88.79-P-4000S
MODEL 215, 220 (except, 220.063)
Function
A potentiometer for measuring the position is located on each of the shafts for the vertical mirror adjustment
motors (up/down) (M21/1m1)/(M21/2m1) and horizontal mirror adjustment motors (in/out) (M21/1m2)/
(M21/2m2) in the left and right exterior mirrors.
The voltage measured at the center potentiometer cap depends on the associated mirror glass position. It is read
in by the left front door control module (N69/1)/right front door control module (N69/2) where it is
evaluated for measurement of the position.
Exterior rearview mirror adjustment motor, location/purpose/design/function GF88.79-P-4100S
EXTERIOR REARVIEW MIRROR ADJUSTMENT MOTOR,

MODEL 215, 220
Exterior rearview
GF88.79-P-
mirror adjustment
4100-01S
motor, location
Exterior rearview
GF88.79-P-
mirror adjustment
4100-03S
motor, purpose
The motors are DC motors. Two potentiometers each are located on the
Exterior rearview motor shafts (M21/1m1)/(M21/2m1) and (M21/1m2)/(M21/2m2) for
mirror adjustment position recognition. The motors for outside rearview mirror (with fold-
motor, design in/out feature) (M21/1m3)/(M21/2m3) are not equipped with a position
recognition feature.
Exterior rearview The motors turn to the left or right depending on the polarity of the
mirror adjustment actuating voltage. Actuation is accomplished by the left front door
motor, function control module (N69/1)/right front door control module (N69/2).
Exterior rearview mirror adjustment motor, location - GF88.79-P-4100-01S
The motors for adjusting the mirror glass and housing are located in the left electrically adjustable and heated
exterior rearview mirror (M21/1)/right electrically adjustable and heated exterior rearview mirror
(M21/2).
Fig. 8: Identifying Left/Right Electrically Adjustable And Heated Outside Rearview Mirror
Exterior rearview mirror adjustment motor, purpose - GF88.79-P-4100-03S
Purpose
The left exterior rearview mirror glass can be adjusted vertically and horizontally with the vertical mirror
adjustment motor (up/down) (M21/1m1) and horizontal mirror adjustment motor (in/out) (M21/1m2) in
the left electrically adjustable and heated exterior rearview mirror (M21/1).
The right exterior rearview mirror glass can be adjusted vertically and horizontally with the vertical mirror
adjustment motor (up/down) (M21/2m1) and horizontal mirror adjustment motor (in/out) (M21/2m2) in
the right electrically adjustable and heated exterior rearview mirror (M21/2).
The housing of the left/right exterior rearview mirror can be folded in (garage position) and out (driving
position) with the mirror fold-in motors (M21/1m3)/(M21/2m3).
EXTERIOR REARVIEW MIRROR ADJUSTMENT SWITCH,

MODEL 215, 220
Exterior rearview
GF88.79-P-
mirror adjustment
3001-01S
switch, location
Exterior rearview
GF88.79-P-
mirror adjustment
4101-02S
switch, purpose
All switches for adjusting the exterior rearview mirrors are located
Exterior rearview
in the exterior rearview mirror switch group with fold-in/out
mirror adjustment
feature (S50/1) . This switch group is connected to the door control
switch, design
module on the driver's side by a discrete wiring harness.
Exterior rearview The switching status of the switches for adjustment of the exterior
mirror adjustment rearview mirrors is read in by the door control module on the driver's
switch, function side evaluated and transferred to the CAN bus as a message.
Exterior rearview mirror adjustment switch, purpose - GF88.79-P-4101-02S
Purpose
The left and right exterior rearview mirror glass can be adjusted in the vertical and horizontal directions with the
exterior mirror up/down adjustment switch (S50/1s1) and exterior mirror in/out adjustment switch
(S50/1s2) . The switch can be set to the exterior rearview mirror to be adjusted with the left exterior rearview
mirror selection switch (S50/1s3) and right exterior rearview mirror selection switch (S50/1s6) . The left
and right exterior rearview mirror housings can be folded in/out with the exterior mirror fold-in switch
(S50/1s4)/exterior mirror fold-out switch (S50/1s5).
TROUBLE DIAGNOSIS
WIND NOISE FROM OUTSIDE MIRROR ON LEFT AND/OR RIGHT FRONT DOOR - AF88.70-P-
1100BG
MODEL 215
Damage Cause Remedy

code
1 Pull roof frame seal upwards.
External roof frame sealing lip (1) The external roof frame sealing lip (1) should not
72 301 51
gets pinched when closing the door. contact the mirror triangle cover (2) when closing the
door.
Fig. 9: Identifying Roof Frame Sealing Lip And Mirror Triangle
WIND NOISE IN THE AREA OF THE ROOF FRAME SEAL - AF88.85-P-1000AG
MODEL 215
Damage Cause Remedy

code
Incorrectly adjusted side
windows may damage the 1 Inspect roof frame seal for damage, replace if
72 048
roof frame seal or cause wind necessary. Refer to: ?
noises.
Remove/install seal section at roof frame
The new roof frame seal must be at least quality
AR88.85-
status 13 (labeling on rear of roof frame seal)
P-2000N
Roof frame seals must always be replaced in
pairs (left and right).
2 Close the door and move the side window (2)
into top end stop position.
3 Check the penetration depth of the side window
(2) into the roof frame seal (1).
Use a wax pencil or the like to trace the
position of the lower edge of the roof frame
sealing lip along its entire length across the side
window.
The penetration depth (a) should be 5...7 mm
over the entire length. If the penetration depth is
not within this range?
AR72.10-
Adjust front door crank window
P-1950N
4 Close rear side window (3) completely
5 Check the penetration depth of the rear side
window (3) into the roof frame seal (1).
Use a wax pencil or the like to trace the
position of the lower edge of the roof frame
sealing lip along its entire length across the rear
side window.
The penetration depth (a) should be 6...8 mm
over the entire length. If the penetration depth is
not within this range?
AR67.30-
Adjusting rear side windows
P-4200N
6 Check transitions and gap from crank window in
driver's door to rear side window, adjust if
necessary
For this purpose remove molding from rear
fender. Correct inclination above rear adjustment Fig. 11
screw with .
7 Check short stroke position of rear side windows
(3).
Dimension (c) between the lower edge of the
roof frame sealing lip (1) and the upper edge of the
rear side window (inner window) must not exceed
4 mm.
In the event of deviations, adjust the rear
control unit settings using Star Diagnosis.
Enter via "Control unit adjustment of rear control
unit RCU 215"
Fig. 10: Identifying Roof Frame Seal With Different Dimensions
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - AR88.00-Z-9215AA
MODEL 215
Removing and installing front AR88.10-P-

MODEL 215
fender 1000N
Removing and installing inner AR88.10-P-
MODEL 220, 215
fender in front fender 1300M
AR88.20-P-
Remove/install front bumper MODEL 215, 220 ...
2000M
AR88.20-P-
Remove/install rear bumper MODEL 215 ...
2200N
Removing and installing rear MODEL 215 AR88.20-P-

bumper 2200NA
Remove/install spare wheel AR88.30-P-
MODEL 220, 215
recess 1000M
Opening engine hood, moving to AR88.40-P-
MODEL 220, 215
upright position, closing 1000M
AR88.40-P-
Remove/install engine hood MODELS 220, 215
3000M
AR88.40-P-
Adjust engine hood MODEL 220, 215
3020M
Adjust engine hood lock, safety AR88.40-P-
MODEL 215, 220 ...
hook 3030M
Remove/install engine hood AR88.40-P-
MODELS 220, 215
hinge 3060M
Remove/install control cable for AR88.40-P-
MODEL 215, 220 Rear engine hood control cable
engine hood 3100M
MODEL 215, 220 Front engine hood control cable
engine hood 3100MA
Remove/install engine hood AR88.40-P-
MODEL 215
catch 3200N
Removing, disassembling,
AR88.40-P-
assembling and installing MODEL 215
4000N
radiator cowl
AR88.40-P-
Remove/install Mercedes star MODEL 163, 203.7, 215, 230.4
4050R
AR88.50-P-
Remove/install trunk lid MODELS 215, 220
5000M
Remove/install and adjust trunk AR88.50-P-
MODEL 220, 215
lid lock and locking eye 5020M
MODEL 202.01 /02 /03 /12 /13 /07 /08 /09 /18 /19, 203, AR88.50-P-
Install model plate on trunk lid
208.4, 209, 210.2, 215, 230.4 5050A
Removing and installing trunk
MODEL 215, 220 with CODE (881b) Trunk lid remote AR88.50-P-
lid opening angle detection
control (RTL) 5065N
sensor
MODEL 215, 220 with CODE (881b) Trunk lid remote AR88.50-P-
hydraulic pump for trunk lid
control (RTL) 5070N
remote control
Removing and installing trunk MODEL 215, 220 with CODE (881b) Trunk lid remote AR88.50-P-
lid remote control button control (RTL) 5075N
Remove/install trunk lid AR88.50-P-
MODEL 215, 220 ...
telescopic spring 5115M
Remove/install hinge lever for AR88.50-P-
MODEL 215, 220 ...
trunk lid 5120M
Remove/install hinge lever for AR88.50-P-
MODEL 215, 220 ...
trunk lid 5120MA
Remove/install hinge lever with MODEL 215, 220 with CODE (881b) Remote trunk AR88.50-P-
remote trunk closing closing (RTC) 5125N
AR88.50-P-
Adjust trunk lid MODEL 220, 215
5200M
MODEL 215
complete exterior mirror 9000N
AR88.70-P-
Remove/install mirror glass MODEL 220, 215
9020M
Remove/install outside rearview AR88.70-P-
MODEL 220, 215
mirror cover 9040M
Removing and installing mirror AR88.70-P-
MODEL 220, 215
adjustment drive motor 9060M
Removing and installing mirror AR88.70-P-
MODEL 215
triangle trim 9080N
Remove/install gasket on outside AR88.70-P-
MODEL 215, 220
mirror 9090M
Removing and installing side AR88.80-P-
MODEL 215
member trim 6000N
Removing and installing outside AR88.80-P-
MODEL 208.3 /4, 215
paneling on A-pillar 8500K
Removing and installing sealing AR88.85-P-
MODEL 215
channel at roof frame 2000N
TESTING AND REPAIR WORK: PASSENGER CARS: DETACHABLE BODY COMPONENTS,

EXTERIOR FLAPS - AR88.00-Z-9220AA
MODEL 220
AR88.10-P-
Remove/install front fender MODEL 220
1000M
Removing and installing inner fender in front AR88.10-P-
MODEL 220, 215
fender 1300M
AR88.20-P-
Remove/install front bumper MODEL 215, 220 ...
2000M
AR88.20-P-
Disassemble/assemble front bumper MODEL 220.875 /878
2050M
AR88.20-P-
Disassemble/assemble rear bumper MODEL 220.875 /878
2100M
AR88.20-P-
Removing and installing rear bumper MODEL 220
2200M
AR88.20-P-
Remove/install rear bumper MODEL 220 ...
2200MA
AR88.20-P-
Removing and installing rear bumper MODELS 220.875 /878
2200MP
AR88.30-P-
Remove/install spare wheel recess MODEL 220, 215
1000M
Opening engine hood, moving to upright AR88.40-P-
MODEL 220, 215
position, closing 1000M
AR88.40-P-
Remove/install engine hood MODELS 220, 215
3000M
AR88.40-P-
Adjust engine hood MODEL 220, 215
3020M
AR88.40-P-
Adjust engine hood lock, safety hook MODEL 215, 220 ...
3030M
AR88.40-P-
Remove/install engine hood hinge MODELS 220, 215
3060M
MODEL 215, 220 Rear engine hood AR88.40-P-
Remove/install control cable for engine hood
control cable 3100M
MODEL 215, 220 Front engine hood AR88.40-P-
Remove/install control cable for engine hood
control cable 3100MA
AR88.40-P-
Remove/install engine hood catch MODEL 220
3200M
Removing radiator cover, disassembling and AR88.40-P-
MODEL 220
assembling, installing 4000M
MODEL 202, 203.0 /2, 208.3 /4, 210, AR88.40-P-
Remove/install Mercedes star
220, 211.0 /2 /6 4050E
AR88.50-P-
Remove/install trunk lid MODELS 215, 220
5000M
Remove/install and adjust trunk lid lock and AR88.50-P-
MODEL 220, 215
locking eye 5020M
AR88.50-P-
Installing model designation on trunk lid MODEL 220
5050M
MODEL 220 as of 1.9.02 with CODE AR88.50-P-
Remove/install trunk lid lock cylinder
(802) Model year 2002 5061M
Removing and installing trunk lid opening MODEL 215, 220 with CODE (881b) AR88.50-P-
angle detection sensor Trunk lid remote control (RTL) 5065N
Removing and installing hydraulic pump for MODEL 215, 220 with CODE (881b) AR88.50-P-
trunk lid remote control Trunk lid remote control (RTL) 5070N
Removing and installing trunk lid remote MODEL 215, 220 with CODE (881b) AR88.50-P-
control button Trunk lid remote control (RTL) 5075N
AR88.50-P-
Remove/install trunk lid telescopic spring MODEL 215, 220 ...
5115M
AR88.50-P-
Remove/install hinge lever for trunk lid MODEL 215, 220 ...
5120M
AR88.50-P-
Remove/install hinge lever for trunk lid MODEL 215, 220 ...
5120MA
Remove/install hinge lever with remote trunk MODEL 215, 220 with CODE (881b) AR88.50-P-
closing Remote trunk closing (RTC) 5125N
AR88.50-P-
Adjust trunk lid MODEL 220, 215
5200M
AR88.70-P-
Remove/install complete outside mirror MODEL 220
9000M
AR88.70-P-
Remove/install mirror glass MODEL 220, 215
9020M
AR88.70-P-
Remove/install outside rearview mirror cover MODEL 220, 215
9040M
Removing and installing mirror adjustment AR88.70-P-
MODEL 220, 215
drive motor 9060M
AR88.70-P-
Remove/install gasket on outside mirror MODEL 215, 220
9090M
Removing and installing rear door protective AR88.80-P-
MODEL 220
strip 1030M
AR88.80-P-
Remove/install longitudinal member paneling MODEL 220.875 /878
6000M
Removing and installing front door protective AR88.80-P-
MODEL 220
strip 6600M
AR88.80-P-
Removing and installing molding on A-pillar MODEL 220
8500M
Removing and installing sealing section at AR88.85-P-
MODEL 220
roof frame 2000M
REMOVE/INSTALL FRONT FENDER - AR88.10-P-1000
Remove/install front fender - AR88.10-P-1000M
MODEL 220
Fig. 12: Identifying Front Fender Remove/Install Components - Model 220 (1 Of 2)
Remove/install
AR88.40-P-
1 Open engine hood, position vertically
1000M
Completely remove inner fender in AR88.10-P-
2
front fender 1300M
3 Remove screw (6)
Pivot retaining bracket (7) to center of
4 vehicle, pull toward rear and remove
retaining bracket (7)
5 Unclip cover (2) Door completely open
6 Remove spreading rivet
Press off cover (3) and press
7 Fig. 14
downward until nuts (4) are accessible Do not damage cover
9 Remove fender (1)
Installation: Observe correct position in
10 Install in the reverse order relation to driver's door and engine hood,
inner fender seal should make contact
Removing and installing front fender - AR88.10-P-1000N
MODEL 215
Open engine hood and move to AR88.40-P-
1
upright position 1000M
AR88.80-P-
2 Remove A-pillar paneling 8500K
4 Unscrew screw (5)
Remove inner fender in front AR88.10-P-
5
fender 1300M
6 Unscrew screw (6)
Pivot retaining bracket (7) to
7 center of vehicle, pull backward
and remove
Remove foam rubber insert (8)
8
and unscrew screws (9)
Press off rocker panel (3) and
9 press downward until nuts (4) Fig. 14
are accessible First remove spreading rivet downward
10 Unscrew nuts (4)
Unhook front fender (1) from
11 mount (11) at front on bumper
(10) and remove
Installation: Ensure that driver's door and
12 Install in opposite order engine hood are correctly positioned, seal should
make contact with inner fender
REMOVING AND INSTALLING INNER FENDER IN FRONT FENDER - AR88.10-P-1300M
MODEL 220, 215

Fig. 19: Identifying Remove/Install Components Of Inner Fender In Front Fender
1 Remove front wheel
AP40.10-P-
4050Z
2 Unscrew screws (3) and (4)
3 Unscrew nuts (2)
Remove inner fender (1a) and Installation: Pay attention to proper
4
(1b) seating
REMOVE/INSTALL FRONT BUMPER - AR88.20-P-2000M
MODEL 215.373 /374 /375 /376 /378 /379
MODEL 220.025 /026 /028 /063 /065 /070 /073 /075 /125 /128 /165 /170 /173 /175 /176 /178 /179 /875 /878
Model 220
Fig. 20: Identifying Front Bumper Remove/Install Components - Model 220 (1 Of 2)
Model 220
Fig. 21: Identifying Front Bumper Remove/Install Components - Model 220 (2 Of 2)
Model 215
Fig. 22: Identifying Cover, Expansion Rivets And Bolt - Model 215
Remove/Install
Align vehicle between the columns of the
Risk of death cased by vehicle
hydraulic hoist and position the four support plates AS00.00-Z-
below the hoist support points specified by the 0010-01A
lifting platform.
Expose antenna line (11) for Electrical plug socket in left fuse box.
1
TV antenna Installation: Install new tie straps.
Remove bottom engine Engine 112, 113, 137, 275 AR61.20-P-
2.1
compartment paneling Only remove front part 1105M
Remove bottom part of noise Engine 613, 628, 648 AR94.30-P-
3.1
encapsulation Only remove front part 5300M
Pull outside temperature
4 display temperature sensor
(B14) out of bumper
Unlock and separate front
5 bumper PTS connector To unlock, pivot lock flap in direction of arrow.
(X26/27)
Remove fender liner from front AR88.10-P-
6 Remove only front section of fender liner.
fender 1300M
7 Unscrew bolt (6)
Pivot retaining bracket (7)
8 toward center of vehicle, pull
out to rear and remove
Remove expansion rivets (9)
9.1 Model 215
and cover (8)
10.1 Remove bolt (10) Model 215
11 Unscrew bolt (2)
12 Unclip air inlet grate (4) Do not damage paint.
13 Unscrew nuts (3).
Remove bumper (1) toward Installation: Ensure that retainer tabs on rear
14
front bumper (1) are pushed behind bracket (5)
See installation instructions for accessories: ?
15.1 Modify AMG bumper
Model 215
Retrofit AMG trims AZ88.00-P-
Model 220 0001K
AZ88.00-P-
Retrofit AMG trims
0001F
REMOVE/INSTALL REAR BUMPER - AR88.20-P-2200
Removing and installing rear bumper - AR88.20-P-2200M
MODEL 220
Fig. 23: Identifying Rear Bumper Remove/Install Components - Model 220 (1 Of 2)

Removing
Remove luggage compartment AR68.30-P-
1 Rear wall trim panel can remain in vehicle.
trim panels 4600M
Separate plug connection of
2
parktronic system (X35/28)
3 Take out screws (12)
4 Unscrew nuts (14)
Remove cover (4) and unscrew Ensure that the inner nuts do not drop into the
6 cavity in the rear center assembly when they are
nuts (5)
taken off.
Pull the side ends at the bumper down slightly
Take off bumper (1) complete
N for this step and run out the hooks (13) to the
with bumper carrier (2)
outside. Have a second person assist you.
Unscrew bolts (6) and take
8 bumper carrier (2) off the
bumper (1)
Installing
Insert bumper carrier (2) into
9 bumper (1) and screw in bolts Fit on existing M-AMG bumper.
(6)
AZ88.00-P-
Retrofit M-AMG trim parts
0001F
Fit aligning wedges (3) onto
10
stud bolts at bumper carrier (2)
Install bumper (1) complete
When inserting, ensure that the bracket (7) on
11 with bumper carrier (2) and
the left and right are pushed into the guides (8).
aligning wedges (3)
Ensure that the inner nuts do not drop into the
cavity in the rear center assembly when inserting.
12 Screw on nuts (5) Tighten the nuts (5) only sufficiently to still be
able to alter the position of the aligning wedges
(3).
Alter position of aligning wedges (3) with
Alter position of bumper (1) in
13 aligning pin (3a) until the edge at the bumper (10)
longitudinal direction
is aligned with the edge at the rear fender (9).
Tighten nuts (5) and install *BA88.20-P-
14
covers (4) 1002-01A
15 Screw in bolts (11)
16 Screw on nuts (14)
Ensure the hooks (13) are correctly located at
the inner edge at the rear fender.
Fit together plug connection of
18
parktronic system (X35/28)
Install luggage compartment AR68.30-P-
19
trim panels 4600M
BUMPER
BA88.20-P-1002-01A Nut of rear bumper to rear center assembly Nm 50
Remove/install rear bumper - AR88.20-P-2200MA
MODEL 220 with CODE (550) Trailer hitch except CODE (772) AMG styling package - front spoiler,
side skirts and rear apron trailer hitch with removable ball neck
side skirts and rear apron mechanically pivoting trailer hitch
Fig. 25: Identifying Rear Bumper Remove/Install Components (1 Of 2)
Fig. 26: Identifying Rear Bumper Remove/Install Components (2 Of 2)
Remove
1 Remove trunk lining Rear wall paneling can remain in vehicle.
Model 220.0/1. AR68.30-P-
4600M
AR68.30-P-
Model 220.8.
4600MP
Disconnect emergency call system Only on TELE AID emergency call
2.1 (TELEAID) replacement antenna system (D2B) (code 347) or with TELE
connector (X23/17) AID (code 855).
Disconnect PTS connector, rear Only on Parktronic system (PTS) (code
3.1
bumper (X35/28) 220a).
4 Unscrew bolts (10). On left and right.
5 Remove nuts (8). On left and right.
6 Unscrew bolt (15) On left and right.
Remove covers (7) and loosen nuts
7 On left and right.
(6) 2 to 3 turns
Slightly pull bumper ends downward and
Completely remove bumper (1) with
8 move catch hooks (14) toward outside. Have
bumper carrier (2)
second person help.
Unscrew bolts (3) and remove
9
bumper bracket (2) from bumper (1)
Install
Fit bumper bracket (2) in bumper *BA31.11-P-
10 Bolt, bumper to bumper reinforcement 1004-01A
(1) and screw in bolts (3)
Slightly pull bumper ends downward and
Install bumper (1), slide mount (1a)
11 hook in catch hooks (14). Have second
on left and right into guides (11)
person help.
Adjust bumper (1) in longitudinal Slide bumper (1) onto collar bolts (5)
12 until edge of bumper (13) is flush with edge
direction
of rear fender
The height of the bumper (1) can be
13 Adjust height of bumper (1)
adjusted by turning the collar bolt (5)
14 Tighten nuts (6) and fit covers (7) On left and right.
Nut, bumper reinforcement to trailer *BA31.11-P-
hitch. 1005-01A
15 Screw on nuts (8) On left and right.
16 Screw in bolts (10) On left and right.
Ensure that catch hooks (14) are seated
17 Screw in bolt (15) properly at inner edge on rear fender (12)
On left and right.
Insert emergency call system Only on TELE AID emergency call
Connect PTS connector, rear Only on Parktronic system (PTS) (code
19.1
bumper (X35/28) 220a).
AR68.30-P-
20 Install trunk lining Model 220.0/1.
4600M
AR68.30-P-
Model 220.8.
4600MP
TRAILER HITCH MECHANICAL SYSTEM

BA31.11-P-1004-01A Bolt, bumper to bumper reinforcement Nm 8
BA31.11-P-1005-01A Nut, bumper reinforcement to trailer hitch Nm 8
Remove/install rear bumper - AR88.20-P-2200N
side skirts and rear apron trailer hitch with removable ball neck
side skirts and rear apron mechanically pivoting trailer hitch

Remove
Model 215.3.
AR68.30-P-
1 Remove trunk lining Rear wall paneling can remain in 4600M
vehicle.
Disconnect emergency call system Only on TELE AID emergency call
Disconnect PTS connector, rear Only on Parktronic system (PTS) (code
3.1
bumper (X35/28) 220a).
4 Unscrew bolts (5). On left and right.
Push fender liner (7) to the side and
unscrew bolts (6)
6 Unscrew nut (14) On left and right.
Remove covers (15) and loosen nuts
(9) 2 to 3 turns
8 Remove bumper (1)
9
bumper bracket (2) from bumper (1)
Install
Fit bumper bracket (2) in bumper (1) *BA31.11-P-
10 Bolt, bumper to bumper reinforcement
and screw in bolts (3) 1004-01A
Install bumper (1), slide mount (1a)
11
on left and right into guides (8)
Slide bumper (1) onto collar bolts (10)
Adjust bumper (1) in longitudinal
12 until edge of bumper (13) is flush with
direction
edge of rear fender
13 Adjust height of bumper (1) The height of the bumper can be
adjusted by turning the collar bolt (10)
Tighten nuts (9) and install covers
(15)
Nut, bumper reinforcement to trailer *BA31.11-P-
hitch. 1005-01A
15 Screw on nut (14) On left and right.
16 Screw in bolts (5) On left and right.
Screw in bolts (6) and install fender
liner (7)
Connect rear bumper PTS connector Only on Parktronic system (PTS) (code
18.1
(X35/28) 220a).
Connect emergency call system Only on TELE AID emergency call
AR68.30-P-
20 Install trunk linings Model 215.3.
4600M
TRAILER HITCH MECHANICAL SYSTEM

BA31.11-P-1004-01A Bolt, bumper to bumper reinforcement Nm 8
BA31.11-P-1005-01A Nut, bumper reinforcement to trailer hitch Nm 8
Removing and installing rear bumper - AR88.20-P-2200NA
MODEL 215
Removing
AR68.30-P-
1 Remove trunk lining Rear wall paneling can remain in vehicle. 4600M
Disconnect PTS connector, rear
2 Code 220a.
bumper (X35/28)
Disconnect emergency call
3 system (TELEAID) backup Code 347 Code 220a.
antenna connector (X23/11)
Remove covers (9) over inner
4
nuts (4) and remove nuts (4)
5 Unscrew bolts (5)
6 Unscrew nuts (14)
Push fender liner (7) to the side
7
and unscrew bolts (6)
8 Remove bumper (1)
9 bumper bracket (2) from bumper
(1)
Installing
See installation instructions for
10 Modify M-AMG bumper
accessories: ?
AZ88.00-P-
Retrofit M-AMG trim
0001K
Fit bumper bracket (2) in bumper
11
(1) and screw in bolts (10)
Fit adjusting wedge (3) on
12 threaded studs on bumper
bracket (2)
Install bumper (1), push bracket
13 (11) into guides (8) on left and
right
Screw on nuts (4), (do not
14
tighten)
Move adjusting wedge (3) with adjusting pin
Adjust bumper (1) in
15 (3a) until edge at bumper (13) is in alignment
longitudinal direction
with the edge at the rear fender (12).
Tighten nuts (4) and fit covers *BA88.20-P-
16
(9) 1002-01A
18 Screw on nuts (14)
Screw in bolts (6) and install
19
fender liner (7)
Connect PTS connector, rear
20 Code 220a.
bumper (X35/28)
Connect emergency call system
21 (TELEAID) backup antenna Code 347.
connector (X23/11)
AR68.30-P-
22 Install trunk lining
4600M
BUMPER
BA88.20-P-1002-01A Nut, rear bumper to rear end center assembly Nm 50 50
REMOVE/INSTALL SPARE WHEEL RECESS - AR88.30-P-1000M
MODEL 220, 215
Fig. 32: Identifying Spare Wheel Recess Remove/Install Components (1 Of 2)

Fig. 33: Identifying Spare Wheel Recess Remove/Install Components (2 Of 2)
Fig. 34: Identifying Holes With Distance For Hole - Model 215
MODIFICATION NOTES
8.2.01 Procedure adapted to new repair product *BR00.45-Z-1055-02A
Remove
Remove luggage compartment trim AR68.30-P-
1
panels 4600M
Take spare wheel out of spare wheel
2
recess (1)
3 Remove screws (2) at shields (3)
Unscrew nuts (10) and suspend
4 Model 215
pressure reservoir (11) at the side
Remove screw (12) and take off cover
5
(13)
Take rubber plugs (8) and (9) out of
6
spare wheel recess (1)
Cut open spare wheel recess (1)
vertically all round with multicutter When doing this, leave an edge of *WH58.30-Z-
7
(4) and cutting blade and lift spare approx. 35 mm 1003-20A
wheel recess (1) up and out Avoid damaging paint
Fig. 35
Cut through adhesive bead all round
*WH58.30-Z-
8 with multicutter (4) and cutting blade
1003-20A
and remove remaining edge
Fig. 35
Not more than 2 mm must remain.

Cut glue residues on body flange off Remove loose glue (residues not
9 Fig. 35
with cutting blade completely cut off). Repair paint damages
on body flange not covered by glue with
primer pin
Install
Mark holes A, B, C, D, E and F at Model 215.375. Pay attention to
10
spare wheel recess (1) distances a, b, c, d, e and f
Model 215.375. The holes must be
Drill holes A, B, C, D, E and F with ø positioned vertically on the surface to be
11
8mm in spare wheel recess (1) drilled to enable the mounting clips (16) to
be reliably attached
Attach insulation mats (14) and (15)
12 from below at the spare wheel (1) with Model 215.375
the mounting clips (16)
AR67.10-P-
13 Prepare glue cartridge
1000-07P
*BR00.45-Z-
Repair kit
1049-02A
Clean adhesive flange at new spare
*BR00.45-Z-
14 wheel recess (1) with cleaning cloth
1049-02A
from cleaning set and dry with drying
cloth included in cleaning set.
Shake plastic primer thoroughly and Maximum width 20 mm
*BR00.45-Z-
15 apply in the glued area to the spare Allow primer to air-dry for at least 10 1049-02A
wheel recess. minutes.
Height of adhesive bead approx. 13 mm.
Run nozzle along contact surface of
Install spare wheel recess within 10 *WH58.30-Z-
16 spare wheel recess (1) and press out
minutes before adhesive force of glue 1002-20A
adhesive material evenly
starts to decrease
When doing this, guide pin (5) must be
Insert spare wheel (1), center and inserted into the hole (6) in body floor.
17 press on all round by light blows with Curing time is approx. 1 hour calculated
plastic hammer (7) from the time the spare wheel recess is
inserted.
Insert rubber plugs (8) and (9) into
18
spare wheel recess (1)
Insert pressure reservoir (11) and
19 Model 215
screw on nuts (10)
20 Fit on cover (13) and insert screw (12)
21 Insert screws (2) at shields (3)
Place spare wheel into spare wheel
22
recess (1)
AR68.30-P-
23 Install trunk paneling
4600M
Fig. 35: Identifying Cutting Blade, Straight, Blade Length 35 mm (202 589 17 63 00)

Number Designation
WH58.30-Z-1002-20A Electric cartridge gun
WH58.30-Z-1003-20A Multicutter
REPAIR MATERIALS
BR00.45-Z-1049-02A Repair kit A 168 670 00 93
OPENING ENGINE HOOD, MOVING TO UPRIGHT POSITION, CLOSING - AR88.40-P-1000M
MODEL 220, 215
Fig. 36: Opening Engine Hood, Moving To Upright Position, Closing - Illustrated On Model 220
Do not touch parts under high

voltage. People with electronic AS15.10-
Contact with components under high voltage can
implants (e.g. heart pacemakers) Z-0001-
pose lethal hazard
should not perform work on 01A
ignition system.
Opening
The handle (2) pops out of the
Pull lever (1) in driver's footwell to release engine
1 radiator grille, if necessary lift
hood
engine hood slightly
Pull handle (2) out of radiator grille to stop and
2 Do not lift handle
open engine hood
Moving to upright position
Press locking lever (3) on right engine hood hinge
in direction of arrow and press engine hood
3 upward lightly so that locking lever does not
catch. Repeat procedure on left engine hood hinge
and move engine hood to upright position
Closing
Press locking lever (3) on left engine hood hinge
4 in direction of arrow and close engine hood until
locking lever (3) engages
After closing engine hood
Close engine hood. For this purpose place hands
5 check locking function by pulling
on edge of engine hood only
engine hood up with a jerk
REMOVE/INSTALL ENGINE HOOD - AR88.40-P-3000M
MODELS 220, 215
Fig. 37: Identifying Engine Hood Remove/Install Components - Shown On Model 220
Shown on model 220
Remove/Install
When engine hood is replaced seal seams
See Paintwork Manual
Installation before painting
AR88.40-P-
1 Position engine hood upright (1)
1000M
2 Position protective fender covers
Remove expansion rivets (3) and fold up and
3
unhook sound deadening mat (2).
4 Unscrew bolts (4) on left and right
5 Unlock clamps (arrow) and remove cover (5)
AR83.40-P-
6 Remove sun sensor (B32)
6720M
Unplug washer nozzle heater connectors, 2-
7
pin (X88/11).
Unclip wiring harness from engine hood (1)
8
with clamps (10)
Mark installation position of engine hood (1)
9
on engine hood hinges
Lift retainer (7) with screwdriver and unhook Have 2nd person
10
gas-operated strut (8) secure engine hood
*BA88.40-P-
11 Unscrew bolts (9) from engine hood
1001-01D
Avoid damaging paint
Remove engine hood with help of 2nd person Installation: Observe
12 gaps
and put down on suitable surface
Sizes of gaps at hoods,
doors and covers
AR60.00-P-
Model 220
0700-01M
If fit is not precise: ? 0700-01N
AR88.40-P-
Adjust engine hood
3020M
TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS
Number Designation Model 215 Model 220.0/1
Dimension
Engine hood to fender mm 4.5 (±1) 4.5 (±)
"A"
Engine hood to Dimension
mm --
headlamp "R"
BE60.00-P- Size of Engine hood and Dimension
mm - -
1001-01A gap radiator grille "O"
Dimension
mm - -
Radiator grille to "N"
headlamp AR60.00-P- AR60.00-P-0700-
Fig. see
0700-01N 01M
Number Designation Model 220.875/878
Dimension
Engine hood to fender mm (4.5 (±1)
"A"
BE60.00-P-1001- Size of Dimension
Engine hood to headlamp mm -
01A gap "R"
Engine hood and radiator Dimension
mm -
grille "O"
Dimension
mm -
"N"
Radiator grille to headlamp
AR60.00-P-0700-
Fig. see
01MP
ENGINE HOOD
BA88.40-P-1001-01D Bolt for engine hood hinge on engine hood Nm 8 8
ADJUST ENGINE HOOD - AR88.40-P-3020M
MODEL 220, 215
Fig. 38: Identifying Engine Hood With Adjusting Nut And Bolts
Fig. 39: Identifying Hinge, Bolts And Stop Buffers
Adjust
1 Remove spiral spring (10)
Remove engine hood catch upper
2
section (3)
Position engine hood (1) on stop
3
buffer (8, 9)
Adjust height of stop buffer (8, 9); stop buffer
(8) can additionally be adjusted in the transverse
Check engine hood fit (1) to front direction
4 fender and adjust stop buffer (89) if
The engine hood (1) should not distort to side
necessary
with stop buffer (8)
Gap dimensions on hoods, doors and lids
AR60.00-P-
Model 220
0700-01M
AR60.00-P-
Model 215
0700-01N
Loosen bolts (7) on engine hood
5 Fig. 40
hinge and adjust engine hood (6) Gap dimensions on hoods, doors and lids
AR60.00-P-
Model 220
0700-01M
AR60.00-P-
Model 215
0700-01N
*BA88.40-P-
6 Tighten bolts (7) Engine hood hinge on engine hood 1001-01D
*BA88.40-P-
Hood hinge to body 1002-01D
Install engine hood catch upper *BA88.40-P-
7
section (3) 1003-01D
Adjust height of bracket (5) on The closed engine hood (1) should only be
8 engine hood catch upper section (3) tensioned slightly in the area of the engine hood Fig. 40
with adjustment nut (4) catch upper section (3)
AR60.00-P-
Model 220
0700-01M
AR60.00-P-
Model 215
0700-01N
9 Install spiral spring (10)
Check whether engine hood catch Engine hood (1) should fall automatically into
10 catches properly by closing engine the engine hood catch from a height of 100 - 130
hood and pulling upward with a jerk. mm (measured above fender tip) and lock.
Release engine hood and ensure that
At least 9 mm of the red arrow on the release
11 safety hook catches on radiator cross
lever should be visible.
member
mm 4.5 (±1) 4.5 (±1)
fender "A"
mm --
headlamp "R"
BE60.00-P- Gap Engine hood and Dimension
mm - -
1001-01A dimension radiator grille "O"
Dimension
mm - -
headlamp AR60.00-P- AR60.00-P-
Fig., see
0700-01N 0700-01M
Dimension
Engine hood to fender mm 4.5 (±1)
"A"
Dimension
"R"
BE60.00-P-1001- Gap Engine hood and radiator Dimension
mm -
01A dimension grille "O"
Dimension
mm -
"N"
AR60.00-P-0700-
Fig., see
01M
ENGINE HOOD
BA88.40-P-1001-01D Bolt, engine hood hinge to engine hood Nm 8 8
BA88.40-P-1002-01D Bolt, engine hood hinge to body Nm 8 8
BA88.40-P-1003-01D Bolt, upper section of engine hood catch Nm 8 8
Special tools
Fig. 40: Identifying Feeler Gauge (129 589 03 21 00)
ADJUST ENGINE HOOD LOCK, SAFETY HOOK - AR88.40-P-3030M
MODEL 215.373 /374 /375 /376 /378 /379
MODEL
220.025 /026 /028 /063 /065 /067 /070 /073 /074 /075 /083 /084 /087 /125 /126 /128 /163 /165 /167 /170 /173 /17
Shown on MODEL 220
Fig. 41: Identifying Safety Hook, Control Hook, Rotary Tumbler And Release Lever - Shown On Model
220
MODIFICATION NOTES
16.10.02 Safety information added AS00.00-Z-0011-01A
Risk of injury to fingers

being jammed or pinched AS00.00-
When moving components, ensure that no body parts or
when Remove/install or Z-0011-
limbs are within the operating range of moving parts.
aligning hoods, doors, trunk 01A
lid/tailgate or sliding roof.
Do not grease or oil locking Replace closing systems which are difficult to move,
defective or have been greased subsequently, do not
system
attempt to free up, repair or degrease.
1 Open engine hood
An idle path of min. 3 mm should be present between
Check engine hood cables
nipple (1) of engine hood cable and release lever (2) on
for easy motion and ensure
2 engine hood lock.
that they can be pushed
back completely. If the engine hood cable is not easy to move or
damaged by kinked points: ?
AR88.40-
Replace engine hood cable.
P-3100M
3 Close engine hood
Check gaps between engine
4 Refer to: ?
hood and fender, correct
AR88.40-
Adjust engine hood.
P-3020M
5 Open engine hood
Completely press rotary
6 tumbler (3) of both engine
hood locks down.
Press rotary tumbler (3) down and lock. A gap should
not be present between the rotary tumbler (3) and the
contact surface of the lock pawl (arrow). In the closed
Check engine hood catch position, it should be possible to press the rotary tumbler
7 (3) down further. Here, the gap between the rotary
for proper function
tumbler (3) and the contact surface of the lock pawl
(arrow) should not exceed 1.5 mm. Replace engine hood
lock in the event of malfunction:
?
AR88.40-
Model 215
P-3200N
AR88.40-
Model 220
P-3200M
Press control hook (4) to
8
right to arresting point of
safety hook (5). Safety hook (5) should remain in its initial position.
The control hook (4) should move back to its initial
9 Release control hook (4).
position under the force of the spring alone.
Actuate safety hook (5) by Safety hook (5) should completely pivot back to its
10 pulling handle in radiator initial position with easy motion.
paneling a number of times. If safety hook (5) does not operate properly, replace.
Smoothly position engine
11 hood on upper frame cross Safety hook (5) must engage by itself.
member.
12 Close engine hood
REMOVE/INSTALL ENGINE HOOD HINGE - AR88.40-P-3060M
MODELS 220, 215
Fig. 42: Identifying Engine Hood Hinge Remove/Install Components
Remove/Install
1.1 Remove engine hood Only when replacing both engine hood hinges
Move engine hood to upright AR88.40-P-
1.2
position 1000M
Position protective fender
2
covers
Mark installation position of
3 engine hood (7) on engine hood
hinges
Remove gas pressure strut (4) Have 2nd person secure engine hood
4
by lifting retainers (5) When replacing gas-operated strut: ?
OS00.00-P-
Dispose of old gas-operated strut
1001-01A
Mark installation position of
5 engine hood hinge (1) on
wheelhouse paneling
Engine hood hinge on engine hood *BA88.40-P-
6 Unscrew bolt (2)
Have 2nd person secure engine hood 1001-01D
Hood hinge to body
On model 215 first loosen bolts (6) for better
removal of engine hood hinge (1) The engine
Unscrew bolts (3) and remove *BA88.40-P-
7 hood hinge (1) can then be removed in direction
engine hood hinge (1) 1002-01D
of arrow
Installation: Observe gaps Sizes of gaps at
hoods, doors and covers
AR60.00-P-
Model 220
0700-01M
If fit is not precise: ? 0700-01N
AR88.40-P-
Adjust engine hood
3020M
Dimension
Engine hood to fender mm 4.5 (±1) 4.5 (±1)
"A"
mm --
headlamp "R"
BE60.00-P- Size of Engine hood and Dimension
mm - -
1001-01A gap radiator grille "O"
Dimension
mm - -
Fig. see
0700-01N 01M
Dimension
Engine hood to fender mm 4.5 (± 1)
"A"
Dimension
"R"
Engine hood and radiator Dimension
mm -
grille "O"
BE60.00-P-1001- Size of Dimension
mm -
01A gap "N"
AR60.00-P-0700-
Fig. see
01MP
ENGINE HOOD
BA88.40-P-1001-01D Bolt for engine hood hinge on engine hood Nm 8 8
BA88.40-P-1002-01D Screw for engine hood hinge on body Nm 8 8
REMOVE/INSTALL CONTROL CABLE FOR ENGINE HOOD - AR88.40-P-3100
Remove/install control cable for engine hood - AR88.40-P-3100M
MODEL 215, 220 Rear engine hood control cable
Fig. 43: Identifying Rear Engine Hood Control Cable Remove/Install Components - Shown On Model
220
Shown on model 220
Remove/Install
Open engine hood and raise to vertical AR88.40-P-

1 position 1000M
Remove left front SAM control unit AR54.21-P-
2 Do not disconnect connectors.
with fuse and relay box 1260I
Unscrew bolts (2) from lever (3) and Installation: Pay attention to correct
3
remove lever (3) installation position.
Unhook rear engine hood control cable
4
(1) from lever (3)
5 Unclip cover (4)
Unhook coupling (6) from front end,
6 fold open and unhook rear engine hood Do not twist coupling (6)
control cable (1) from coupling (6).
Expose rear engine hood control cable Installation: Ensure that rear engine
7
(1) in engine compartment hood control cable (1) is routed properly.
Installation: Ensure that grommet (5)
Pull out rear engine hood control cable is seated properly on bulkhead. Grommet
8
(1) (5) is accessible through left fuse box
(F1).
After installing, check engine hood lock
10
and safety hook for proper function
Remove/install control cable for engine hood - AR88.40-P-3100MA
MODEL 215, 220 Front engine hood control cable
Shown on model 220
Fig. 44: Identifying Engine Hood Control Cable Remove/Install Components - Shown On Model 220
Remove/Install
Open engine hood and raise to vertical AR88.40-P-
1
position 1000M
Model 215.
AR88.40-P-
2 Remove engine hood lock Left engine hood lock (2) and right 3200N
engine hood lock (3)
Model 220.
AR88.40-P-
Left engine hood lock (2) and right 3200M
engine hood lock (3)
Unhook coupling (6) from front end,
3 fold open and unhook rear engine hood Do not twist coupling (6)
control cable (1) from coupling (6).
Installation: First route engine hood
Unhook front engine hood control cable control cable to right engine hood lock (3)
4
(5) from upper frame cross member (4) and tightly below upper frame cross
member (4)
Unhook front engine hood control cable Installation: The individual engine
5 (5) from front end and remove with hood control cables of the front engine
coupling (6) hood control cable (5) should run parallel
After installing, check left (2) and right
7 (3) engine hood lock and safety hook
for proper function
REMOVE/INSTALL ENGINE HOOD CATCH - AR88.40-P-3200
Remove/install engine hood catch - AR88.40-P-3200M
MODEL 220
Fig. 45: Identifying Engine Hood Catch Remove/Install Components - Model 220
Remove
AR88.40-P-
1 Open engine hood
1000M
Unscrew bolts (2) on engine hood catch (1)
2
and radiator cross member (3)
3 Unclip engine hood cable (4)
Unhook engine hood cable (4) from engine
4 hood catch (1) and remove engine hood catch
(1) upward
5 Unscrew bolts (5) and remove safety hooks (6)
Install
Insert safety hooks (6) into engine hood and *BA88.40-P-
6
screw in bolts (5) 1005-01D
Do not lubricate engine hood
Insert engine hood catch (1) into radiator cross
7 catch (1): Coated with
member (3)
lubricating paint!
Hook engine hood cable (4) into engine hood
8
catch (1)
Clip engine hood cable (4) into radiator cross Ensure that engine hood cable
9
member (3) is routed properly.
Screw in bolts (2) and tighten engine hook *BA88.40-P-
10
catch (1) 1004-01D
Check whether engine hood catch (1) catches
11 properly by closing engine hood and pulling
upward with a jerk.
Unlock engine hood and check arrest of safety
12
hook (6) on radiator crossmember (3)
AR88.40-P-
1000M
14 Check engine hood fit Observe gaps
Gap dimensions on hoods, doors AR60.00-P-
and lids. If fit is not precise: ? 0700-01M
AR88.40-P-
Adjust engine hood
3020M
Number Designation Model 220.0/1 Model
220.875/878
mm 4.5 (±1) 4.5 (±1)
fender "A"
mm --
headlamp "R"
BE60.00-P- Gap Engine hood and Dimension
mm - -
1001-01A dimension radiator grille "O"
Dimension
mm - -
Fig., see
0700-01M 01M
ENGINE HOOD
BA88.40-P-1004-01D Bolt on engine hood catch Nm 8
BA88.40-P-1005-01D Bolt on safety hook Nm 8
Remove/install engine hood catch - AR88.40-P-3200N
MODEL 215
Fig. 46: Identifying Engine Hood Catch Remove/Install Components - Model 215
Remove
1 Open engine hood
Unscrew bolts (2) on engine hood catch (1)
2
and radiator crossmember (3)
3 Unclip engine hood cable (4)
Unhook engine hood cable (4) from engine Unclip ATA engine hood switch
4 hood catch (1) and remove engine hood (S62) from right engine hood catch
catch (1) upward (arrows)
5 Remove safety hook (6)
6 Remove engine hood upper section (8)
Install
Put down engine hood lightly, *BA88.40-P-

7 Install safety hook (6) in engine hood
safety hook (6) must arrest 1005-01D
automatically
Insert engine hood catch (1) into radiator
Allowance X from nipple (8) to
8 crossmember (3) and hook engine hood
lock pawl (10) min. 3 mm
cable (4) into engine hood catch (1)
Clip engine hood cable (4) into radiator Ensure that engine hood cable is
9
crossmember (3) routed properly.
Screw in bolts (2) and tighten engine hook *BA88.40-P-
10
catch (1) 1004-01D
11 Install engine hood upper section (8) *BA88.40-P-
1003-01D
Close engine hood catches (1)
Check whether engine hood catch (1) manually and unlock from release
12 catches properly by closing engine hood lever in passenger compartment
and pulling upward with a jerk. Engine hood catches (1) should
unlock in sequence
Unlock engine hood and check arrest of
13 safety hook (6) on radiator crossmember
(3)
14 Check engine hood fit Observe gaps
Gap dimensions on hoods, doors and
AR60.00-P-
lids. If
0700-01N
fit is not precise: ?
AR88.40-P-
Adjust engine hood
3020M
Dimension
Engine hood to fender mm 4.5 (±1)
"A"
Dimension
"R"
BE60.00-P-1001- Gap Engine hood to radiator Dimension
mm -
01A dimension grille "O"
Dimension
mm -
"N"
Radiator grill to headlamp
AR60.00-P-0700-
Fig., see
01N
ENGINE HOOD
BA88.40-P-1003-01D Bolt on engine hood catch upper section Nm 8
BA88.40-P-1004-01D Bolt on engine hood catch Nm 8
BA88.40-P-1005-01D Bolt on safety hook Nm 8
REMOVING RADIATOR COVER, DISASSEMBLING AND ASSEMBLING, INSTALLING -

AR88.40-P-4000
Removing radiator cover, disassembling and assembling, installing - AR88.40-P-4000M
MODEL 220
Fig. 47: Identifying Radiator Grill Panelling, Cowl And Engine Hood
Remove
AR88.40-P-
1 Open engine hood (1)
1000M
2 Unscrew screws (2) (4 each)
Remove radiator cowl (5) and
Avoid damaging chrome on molding (4) and
3 lay down on suitable
paint on engine hood (1)
subsurface
Install
Thereby install handle for retaining hook (3) in
radiator cowl (4).
Install radiator cowl (5) in
4 Avoid damaging chrome on molding (4) and
engine hood (1) from front
paint on engine hood (1), check handle and retaining
hook for proper function
Screw in screws (2) and
5
tighten
Check engine hood lock and retaining hook for AR88.40-P-
6 Close engine hood (1)
proper function 1000M
Removing, disassembling, assembling and installing radiator cowl - AR88.40-P-4000N
MODEL 215
Fig. 48: Identifying Radiator Cowl Remove/Install Components (1 Of 2)
Fig. 49: Identifying Radiator Cowl Remove/Install Components (2 Of 2)
Installation: Check locking function of engine

1 Open engine hood (3)
hood lock and retaining hook.
Pivot radiator cowl (1) slightly
Installation: Install handle for retaining hook (5) in
3 downward (arrows) and pull out of
radiator cowl (1) and check for proper function.
eyes (4) toward front
Disassembly, assembly
4 Unlock trim strips (6) and remove To unlock move trim strips slightly toward outside.
Unclip insert (7) together with Press collar on radiator cowl (arrow) back on left
5 and right with screwdriver and remove insert upward
Mercedes star from radiator cowl (1)
together with Mercedes star
6 Remove Mercedes star from insert (7) Lift clips (8a).
REMOVE/INSTALL MERCEDES STAR - AR88.40-P-4050
Remove/install Mercedes star - AR88.40-P-4050E
MODEL 202, 203.0 /2, 208.3 /4, 210, 220, 211.0 /2 /6
Shown on model 202
Fig. 50: Identifying Mercedes Star Components - Model 202, 203.0 /2, 208.3 /4, 210, 220, 211.0 /2 /6
Remove
1 Open engine hood Model 202 AR88.40-P-1000E
Model 203 AR88.40-P-1000P
Model 208.3/4, 210 AR88.40-P-1000F
Model 211 AR88.40-P-1000T
Model 220 AR88.40-P-1000M
2 Turn spring bracket (2) Fig. 51
90° to left with assembly
tool
3 Remove Mercedes star Carefully remove
(1) upward from engine Mercedes star (1). Danger
hood of damaging paint.
Install
4 Insert Mercedes star (1) Carefully install
from above into engine Mercedes star (1). Danger
hood of damaging paint.
5 Turn spring bracket (2) Note correct
90° to right with installation positions.
mounting tool
Fig. 51
6 Close engine hood Model 202 AR88.40-P-1000E
Model 203 AR88.40-P-1000P
Model 208.3/4, 210 AR88.40-P-1000F
Model 211 AR88.40-P-1000T
Model 220 AR88.40-P-1000M
Remove/install Mercedes star - AR88.40-P-4050R
MODEL 163, 203.7, 215, 230.4
Shown on model 230
Fig. 52: Identifying Mercedes Star And Grommet
Remove/install
Protect engine hood around Mercedes star (1)

Unclip Mercedes star (1) upward from
1 with adhesive tape to avoid damaging paint. Fig.
engine hood with long wedge.
53
2 Remove grommets (2) Check grommets (2), replace if necessary.
Fig. 53: Identifying Long Wedge (115 589 03 59 00)
REMOVE/INSTALL TRUNK LID - AR88.50-P-5000M
MODELS 215, 220
Fig. 54: Identifying Trunk Lid Remove/Install Components - Shown On Model 220
Shown on model 220

Fig. 55: Identifying Wiring Harness Roller, CL Line And Socket
Remove
1 Open trunk lid (1)
Unlock bracket (7) and take hazard warning
2
triangle out of bracket
Lift retaining clamp (7a), slide bracket (7) to left
3
(arrow) and remove bracket (7).
4 Unclip cover above trunk lid lock
5 Unscrew bolts (9) and remove cover (8) Torx bit set Fig. 56
Unclip inner trunk lid paneling (2) from trunk
6
lid (1)
7.1 Disconnect electrical connectors on trunk lid (1) Model 215.
8.1 Disconnect CL line (12) from separation point Model 215.
9.1 Unhook bracket (3) upward from trunk lid (1) Model 215.
Unclip wiring harness (10) from trunk lid (1)
10.1 Model 215.
and pull out
Model 220.0 /1. AR68.30-P-
11.1 Remove paneling in trunk
Only right side paneling. 4600M
Model 220.8. AR68.30-P-
Only right side paneling. 4600MP
Disconnect electrical connectors from wiring
12.1 Model 220.
harness roller (11)
13.1 Disconnect CL line (12) Model 220.
Model 220.
Pull out socket (13) toward front and remove
14.1 Remove wiring harness roller
wiring harness roller (11) from side wall
(11) together with trunk lid (1).
Mark installation location of trunk lid (1) on
15
hinge levers (6).
16 Unscrew bolts (5) from hinge levers (6)
17 Loosen bolts (4) from hinge levers (6) Unscrew three turns.
Lift trunk lid (1) out of hinge levers (6) upward
18 with aid of second person and lay down on
suitable subsurface
Before painting trunk lid (1) perform seam Only when installing new
19.1 sealing and after installing, preserve with cavity trunk lid (1). See Paintwork
wax Manual
Install
Only when installing new
20.1 Screw bolts (4) into trunk lid (1) five turns
trunk lid (1).
Install trunk lid (1) in hinge levers (6) with aid
21
of second person.
22 Screw bolts (4) and (5) into hinge levers (6)
23 Check trunk lid fit Observe gap dimensions
Gaps on hoods, doors and lids *BE60.00-P-
If fit is not precise: ? 1003-01A
AR88.50-P-
Adjust trunk lid.
5200M
*BA88.50-P-
24 Tighten bolts (4) and (5) Bolt, hinge lever to trunk lid 1009-01A
25 Install in the reverse order Steps 14.1 up to 1.
Trunk lid to top of rear Dimension
mm 4.0 (± 0.5) 4.0 (± 0.5)
fender "F"
Trunk lid to bottom of Dimension
mm --
rear fender "M"
Dimension
Trunk lid to rear fender mm 4.0 (± 0.5) 4.0 (± 0.5)
"F"
BE60.00-P- Size of Dimension
Trunk lid to taillamp mm 4.0 (± 1.2) 4.4 (± 0.5)
1003-01A gap "M"
Dimension
Trunk lid to bumper mm - -
"V"
Dimension
mm - -
"U"
Rear fender to taillamp
AR60.00-P- AR60.00-P-
Fig. see
0700-01N 0700-01M
Trunk lid to top of rear fender Dimension "F" mm 4.0 (± 0.5)
Trunk lid to bottom of rear Dimension
mm -
fender "M"
Trunk lid to rear fender Dimension "F" mm 4.0 (± 0.5)
Dimension
Trunk lid to taillamp mm 4.4 (± 0.5)
BE60.00-P-1003- Size of "M"
01A gap Dimension
Trunk lid to bumper mm -
"V"
Dimension
mm -
"U"
AR60.00-P-0700-
Fig. see
01MP
TRUNK LID
BA88.50-P-1009-01A Bolt, hinge lever to trunk lid Nm 9 9
Remove, install line roller for trunk lid - AR88.50-P-5000-03M
Fig. 57: Identifying Pulling Hook (140 589 02 33 00)
1. Pull out expanding anchors (13) with puller hook

2. Unclip line roller (11) all the way around
3. Remove line roller (11) from rear shelf
4. Remove wiring harnesses and disconnect connectors
5. Install in the reverse sequence.
Fig. 58: Identifying Line Roller And Expanding Anchors
REMOVE/INSTALL AND ADJUST TRUNK LID LOCK AND LOCKING EYE - AR88.50-P-5020M
MODEL 220, 215
Shown on model 220
Fig. 59: Identifying Trunk Lid Lock And Locking Eye Remove/Install Components - Shown On Model
220
Shown on model 220

220
Shown on model 220
220
MODIFICATION NOTES
15.6.04 90° trunk lid handle position, dropped Operation step 13.1, 14.1
Remove/install
Remove hazard warning triangle (8) and
1
take off bracket (5)
2 Detach bolts (22) and remove cover (7).
Remove inner trunk lid paneling (6) from
3
trunk lid (11)
Press release rod (14) off of trunk lid lock
4
(1) (arrow)
On vehicles without code (884) Trunk
Unscrew bolts (3) and remove trunk lid lid auxiliary lock
5.1
lock (1) Installation: Tighten bolts (3) after
adjustment
Remove trunk lid lock (1) with trunk lid On vehicles with code (884) Trunk lid AR88.50-P-
5.2
auxiliary lock auxiliary lock 5020-01N
Remove pneumatic line (16) from trunk
6
lid lock (1)
AR68.30-P-
7 Remove panel on rear center piece Model 215.3, 220.0/1
4600M
AR68.30-P-
Model 220.8
4600MP
Unscrew bolts (4) and remove locking Installation: Tighten bolts (4) after
8
eye (2) from rear center section adjustment
9 Unscrew nuts (10) and remove cover (9)
Press release rod (14) on ball head (17)
10
off of lever of trunk lid handle (13)
Unscrew bolts (12) and remove trunk lid *BA88.50-P-
11
handle (13) from trunk lid (11) 1006-01A
Disconnect electrical connector (15) and
12
remove trunk lid handle (13)
Remove stop for selector drum on new Only when replacing trunk lid handle
13.1
trunk lid handle (13) (13).
Model 215 up to vehicle identification AR88.50-P-
end no. 043783 5060-01N
Model 220 up to production date AR88.50-P-
4.11.03 5060-01M
Model 215 as of vehicle identification BT88.50-P-
90° trunk lid handle position, dropped
end no. 043784 1000-01N
Model 220 as of production date BT88.50-P-
5.11.03 1000-01M
Only when replacing trunk lid handle
(13) on model 215 up to vehicle
Transfer trunk lid contact switch on trunk
14.1 identification end no. 043783 or
lid handle (13)
model 220 up to production date
4.11.03
Transfer lock cylinder on trunk lid handle Only when replacing trunk lid handle
15.1
(13) (13).
Adjust
Screw bolts (3) into trunk lid lock (1) and
17
center in trunk lid cutout (11).
*BA88.50-P-
18 Tighten screws (3)
1002-01A
Align locking eye (2) in center in relation
19
to trunk lid lock (1)
Adjust height of locking (2) so that edges
20 of trunk lid (11) and rear fender are flush
and trunk lid can be closed easily (11).
21 Tighten bolts (4) *BA88.50-P-
1004-01A
Insert mechanical key (19) into trunk lid
22 handle (13) and turn to stop to left as
illustrated
Turn release rod (14) until there is no To adjust release rod (14), loosen
23
play between lever (20) and stop (21) nut (18)
Check trunk lid fit (11) in relation to rear AR88.50-P-
24
fenders, adjust if necessary 5200M
When trunk lid (11) is open, lock
trunk lid lock (1) with screwdriver and
25 Check closing system for proper function
unlock by actuating trunk lid handle
(13)
TRUNK LID
BA88.50-P-1002-01A Bolt on trunk lid lock Nm 9 9
BA88.50-P-1004-01A Bolt to locking eye Nm 9 9
BA88.50-P-1006-01A Bolt for latch section on trunk lid Nm 9 9
Remove/install trunk lid lock with trunk lid auxiliary lock - AR88.50-P-5020-01N
Fig. 62: Identifying Remove/Install Components For Trunk Lid Lock With Trunk Lid Auxiliary Lock
Removal:
1. Disconnect electrical connectors (8, 11) from trunk lid lock (1)
2. Remove CL line (7) from trunk lid lock (1)
3. Unscrew bolts (3) and remove trunk lid lock (1) with central shift rod (2)
4. Unscrew bolts (4) and remove auxiliary locks (6) with shift rods (5)
5. Unscrew bolts (10) and remove left and right locking eye (9) from rear center section
Installation
6. Align left and right locking eye (9) in center of recesses on rear center section and tighten with bolts (10)
Fig. 63: Identifying Locking Eye And Bolt

Fig. 64: Identifying Remove/Install Components For Trunk Lid Lock With Trunk Lid Auxiliary
Lock
7. Insert left and right auxiliary lock (6) with shift rod (5) in outer recesses on trunk lid, align in center and
tighten with bolts (4)
8. Insert trunk lid lock (1) with central shift rod (2) into center recess on trunk lid and connect to shift rods
(5) of auxiliary locks (6)
Ensure that shift rods (5) engage correctly in central shift rod (2)
9. Align trunk lid lock (1) in center of recess in trunk lid and tighten bolts (3)
10. Connect pneumatic line (7) with trunk lid lock (1)
11. Connect electrical connectors (8, 11) to trunk lid lock (1)
INSTALL MODEL PLATE ON TRUNK LID - AR88.50-P-5050
Install model plate on trunk lid - AR88.50-P-5050A
MODEL 202.01 /02 /03 /12 /13 /07 /08 /09 /18 /19, 203, 208.4, 209, 210.2, 215, 230.4
Show on model 202.194

Fig. 65: Identifying Outside Edge And Contour - Show On Model 202.194
Fig. 66: Identifying Outside Edge And Contour - Shown On Model 202.133
Shown on Model 203.0

Shown on model 209

Fig. 71: Identifying Outside Edge And Contour - Shown On Model 209
Shown on model 215
Shown on model 230
Fig. 75: Identifying Model Plate, Adhesive Tape And Carrier Foil
Install model plate

1 Check position of
model plate (1) on
carrier foil (3), correct
if necessary.
2 Mask model To fasten individual
designation (1) with letters and numbers of model
adhesive tape (2). plate (1).
3 Clean trunk lid in area The adhesive surface
of model plate (1) must be absolutely free of
adhesive surface. dust and grease. Otherwise
sufficient adhesion of model
plate (1) is not ensured.
Cleaner *BR00.45-Z-1025-04A
4 Heat trunk lid in area Heat adhesive surface to
of adhesive surface of approx. 40 °C.
model plate (1).
Heat gun *WH58.30-Z-1004-20A
5 Install corresponding On model 203.7, 215,
template on trunk lid 230.4: Fasten template with
or rear-end door and adhesive tape.
align on outer edge
(A) as well as on
contour (B).
Model 202.01/02/03/12/13
Fig. 77
Fig. 78
Model 202.07/08/09/18/19
Fig. 76
Model 203.0
Fig. 79
Model 203.2
Fig. 80
Model 203.7
Fig. 81
Model 208.4
Fig. 82
Model 209
Fig. 83
Model 210.2
Fig. 84
Model 215
Fig. 85
Model 230.4
Fig. 86
6 Remove carrier foil The individual letters and
(3). numbers of the model plate
(1) should remain attached.
7 Align model plate (1) If markings are present
on template and press on the template, align model
on. plate (1) according to
lettering.
Model 202.01/02/03/12/13
Fig. 77
Fig. 78
Model 202.07/08/09/18/19
Fig. 76
Model 203.0
Fig. 79
Model 203.2
Fig. 80
Model 203.7
Fig. 81
Model 208.4
Fig. 82
Model 209
Fig. 83
Model 210.2
Fig. 84
Model 215
Fig. 85
Model 230.4
Fig. 86
8 Remove adhesive tape
(2).
Fig. 76: Identifying Templates (202 589 20 23 00)
Fig. 78: Identifying Template (202 589 23 23 00)

Fig. 83: Identifying Set Of Gluing Templates (209 589 02 23 00)

Fig. 86: Identifying Template (230 589 05 23 00)

Number Designation
WH58.30-Z-1004-20A Hot-air gun
REPAIR MATERIALS
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Installing model designation on trunk lid - AR88.50-P-5050M
MODEL 220
Fig. 87: Identifying Model Designation On Trunk Lid
Installation of model designation

Clean trunk lid in area of model designation and heat up to
1
approx. 40 °C with heat radiator
Position model designation mount (3) in die (2) for template Use correct template for
2
(4) model designation
Fig.
3 Position model designation (1) in mount (3) on template (4)
88
4 Position template (4) on trunk lid (arrows) and hold in place
Press model designation (1) onto trunk lid by pressing down
5
die (2)
6 Remove template (4)
REMOVE STOP FOR SELECTOR DRUM ON TRUNK LID HANDLE - AR88.50-P-5060
Remove stop for selector drum on trunk lid handle - AR88.50-P-5060-01M
1. Break stop (3) out on trunk lid handle (1) with suitable tool until selector drum (2) can be moved to the
90° position with the mechanical key.
Carefully break out stop (3). Danger of damaging trunk lid handle (1).
Fig. 89: Identifying Trunk Lid Handle, Stop And Selector Drum
Remove stop for selector drum from trunk lid handle - AR88.50-P-5060-01N
1. Unclip trunk lid handle cover (4) from trunk lid handle (1)
Fig. 90: Identifying Trunk Lid Handle And Handle Cover
2. Break stop (arrow) out of trunk lid handle housing (1) with suitable tool until cam (2) does not hit against
housing and the selector drum (3) can be moved to the 90° position with mechanical key.
Carefully break out stop (arrow). Danger of damaging trunk lid handle (1).
The figure at the side shows the window broken out of the trunk lid handle cover for better illustration.
Fig. 91: Identifying Cam, Selector Drum And Trunk Lid Handle
3. Clip trunk lid handle cover (4) into trunk lid handle (1)
Fig. 92: Identifying Trunk Lid Handle And Handle Cover
REMOVE/INSTALL TRUNK LID LOCK CYLINDER - AR88.50-P-5061M
MODEL 220 as of 1.9.02 with CODE (802) Model year 2002
Shown with trunk lid handle removed

Fig. 93: Identifying Trunk Lid Lock Cylinder Remove/Install Components - Shown With Trunk Lid
Handle Removed
Remove/Install
1 Remove paneling from trunk lid
Insert emergency key (1) from transmit key (A8/3) into
2
lock cylinder (2)
Unlock with screwdriver through hole in lock cylinder For this purpose, turn emergency
3
(2) and pull lock cylinder (2) out of trunk lid handle (3) key (1) counterclockwise.
REMOVING AND INSTALLING TRUNK LID OPENING ANGLE DETECTION SENSOR - AR88.50-
P-5065N
MODEL 215, 220 with CODE (881b) Trunk lid remote control (RTL)
Shown on model 220

Fig. 94: Identifying Trunk Lid Opening Angle Detection Sensor - Shown On Model 220
1 Withdraw ignition key
Right side AR68.30-P-
2 Remove paneling in trunk
only 4600M
Disconnect electric connector on sensor for trunk lid
3
opening angle detection (B24/16)
Carefully pry out sensor for trunk lid opening angle
5
detection (B24/16)
Refer to: ?
7 Perform synchronization STAR
DIAGNOSIS
REMOVING AND INSTALLING HYDRAULIC PUMP FOR TRUNK LID REMOTE CONTROL -
AR88.50-P-5070N
Shown on model 215

Fig. 95: Identifying Hydraulic Pump - Shown On Model 215
Shown on model 220
Fig. 96: Identifying Hydraulic Pump - Shown On Model 220
AR68.30-P-
2 Remove paneling in trunk Right side only 4600M
AR54.10-P-
3 Remove battery Only model 215 0005I
4.1 Remove cover in battery frame Only model 215
4.2 Remove hydraulic pump protective cap Only model 220
5 Unclip hydraulic cylinder
Disconnect electric connector on hydraulic
6
pump (M51)
Remove hydraulic pump (M51) from Installation: Replace cable
7
protective cap strap
REMOVING AND INSTALLING TRUNK LID REMOTE CONTROL BUTTON - AR88.50-P-5075N

Shown on model 215
Fig. 97: Identifying Cover And Trunk Lid Remote Control Button - Shown On Model 215
2 Remove cover (1)
3 Disconnect connector from trunk lid remote control button (S62/26)
4 Unclip trunk lid remote control button (S62/26) from rear of cover (1) and remove
REMOVE/INSTALL TRUNK LID TELESCOPIC SPRING - AR88.50-P-5115M
MODEL 215.### ## as of 038084 as of 1.6.03 except CODE (881) Remote trunk closing (RTC)
MODEL 220.### ## as of 330750 as of 31.10.02 except CODE (881) Remote trunk closing (RTC)
Shown on model 220

Fig. 98: Identifying Trunk Lid Telescopic Spring Remove/Install Components - Shown On Model 220
Remove
2 Remove cover (1)
Pivot trunk lid (9) slightly
3 Until stop buffer (7) is accessible.
downward
4 Unclip stop buffer (7) Always unclip stop buffers (7) from left
and right hinge lever
Carefully open trunk lid (9) up to Telescopic spring (2) is now free of
5
mechanical end stop tension
Unlock retaining spring (6) on ball
6
socket head (4)
7 Insert trunk lid support (9) Support. Fig. 99
Remove ball socket head (4) from
8 hinge lever and unhook telescopic
spring (2) at bottom
Install
Hook telescopic spring (2) in at
Before installing new part unlock retaining
9 bottom and press ball socket head
spring (6) of ball socket head (4)
(4) onto hinge lever
Arrest retaining spring (6) of ball Ensure that retaining spring (6) of ball
10
socket head (4) socket head (4) is arrested correctly.
11 Remove trunk lid support (9) Support. Fig. 99
Pivot trunk lid (9) slightly
12 downward
Clip stop buffer (7) into left and If the stop buffer (7) is not seated tightly,
13
right hinge lever replace.
14 Install cover (1)
15 Close trunk lid (9)
Check
The trunk lid must open completely and
Check whether trunk lid opens
16 should not swing back more than max. 4 cm
correctly.
after reaching the end position. ?
AR88.50-P-
Adjust telescopic spring tension on trunk lid
5200-05M
Fig. 99: Identifying Support (170 589 04 63 00)
REMOVE/INSTALL HINGE LEVER FOR TRUNK LID - AR88.50-P-5120
Remove/install hinge lever for trunk lid - AR88.50-P-5120M
MODEL 215.### ## up to 038083 up to 31.5.03 except CODE (881b) Remote trunk closing (RTC)
MODEL 220.### ## up to 330749 up to 30.10.02 except CODE (881b) Remote trunk closing (RTC)
Fig. 100: Identifying Hinge Lever Remove/Install Components For Trunk Lid
Remove
Pivot trunk lid (6) downward to
3
pretension trunk lid spring (3)
Bracket for trunk lid spring.
When the bracket (5) is installed, the
Position bracket (5) on trunk lid spring trunk lid (6) should no longer be pressed
4 Fig. 104
(3) downward, otherwise the coils on the trunk
lid spring (3) outside the bracket (5) are
permanently deformed.
Open trunk lid (6), unhook trunk lid
5
spring (3) and remove
AR88.50-P-
6 Remove trunk lid (6)
5000M
Unscrew bolts (4) and remove hinge
7
lever (1)
Install
Insert hinge lever (1) and screw in *BA88.50-
8 Bolt at trunk lid hinge on side wall
bolts (4) P-1001-01A
AR88.50-P-
9 Install trunk lid (6)
5000M
Tension trunk lid spring (3) with
AR88.50-P-
10.1 tensioning device and install bracket Only when using new springs. 5120-01M
(5) on trunk lid spring (3)
Hook trunk lid spring (3) with bracket Trunk lid spring bracket.
(5) installed when trunk lid (6) is open Do not press trunk lid (6) too far
11 and press trunk lid (6) downward until downward, otherwise the coils of the trunk Fig. 104
bracket (5) can be removed from trunk lid spring (3) outside the bracket (5) can
lid spring (3) deform permanently.
12 Install cover (2)
Check trunk lid (6) fit in relation to Gap dimensions on hoods, doors and lids *BE60.00-P-
13
rear fenders If fit is not precise: ? 1003-01A
AR88.50-P-
Adjust trunk lid.
5200M
Trunk lid to top of Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
rear fender "F"
Trunk lid to bottom Dimension
mm --
of rear fender "M"
Trunk lid to rear Dimension
mm 4.0 (±0.5) 4.0 (± 0.5)
fender "F"
BE60.00-P- Gap Dimension
1003-01A dimension "M"
Dimension
"V"
Dimension
mm - -
Rear fender to "U"
taillamp AR60.00-P- AR60.00-P-
Fig., see
0700-01N 0700-01M
Trunk lid to top of rear
Dimension "F" mm 4.0 (±0.5)
fender
mm -
fender "M"
Trunk lid to rear fender Dimension "F" mm 4.0 (± 0.5)
Dimension
BE60.00-P-1003- Gap Trunk lid to taillamp mm 4.4 (± 0.5)
"M"
01A dimension
Dimension
"V"
Dimension
mm -
"U"
AR60.00-P-0700-
Fig., see
01M
TRUNK LID
BA88.50-P-1001-01A Bolt at trunk lid hinge to side wall Nm 9 9
Fig. 101: Identifying Bracket For Trunk Lid Spring (220 589 02 63 00)
Fig. 102: Identifying Tensioner For Trunk Lid Spring (220 589 03 31 00)
Fig. 103: Identifying Support (170 589 04 63 00)
Tensioning trunk lid spring - AR88.50-P-5120-01M

Fig. 104: Identifying Trunk Lid Spring Holder (220 589 02 63 00)
Fig. 105: Identifying Trunk Lid Spring Tensioner (220 589 03 31 00)
1. Clamp tensioner (2) into vise and hook trunk lid spring (1) into eyes on tensioner (2).
2. Tension trunk lid spring (1) with lever against stop and position holder (3) centered on trunk lid spring
(1).
Fig. 106: Identifying Trunk Lid Spring, Tensioner And Holder
Remove/install hinge lever for trunk lid - AR88.50-P-5120MA
MODEL 215.### ## as of 038084 as of 1.6.03 except CODE (881b) Remote trunk locking (RTL)
MODEL 220.### ## as of 330750 as of 31.10.02 except CODE (881b) Remote trunk locking (RTL)
Shown on MODEL 220

Fig. 107: Identifying Hinge Lever Remove/Install Components For Trunk Lid - Shown On Model 220
Remove
1 Remove trunk lid telescopic spring AR88.50-P-5115M
2 Remove trunk lid AR88.50-P-5000M
3
hinge lever (3)
Install
Only model 215, when using new
Unclip plug (8) from new hinge hinge lever (3).
4.1
lever (3) The plug (8) is replaced with the stop
buffer (7)
Insert hinge lever (3) and screw in *BA88.50-P-1001-
5 Bolt at trunk lid hinge on side wall
bolts (10) 01A
6 Install trunk lid AR88.50-P-5000M
7 Install trunk lid telescopic spring AR88.50-P-5115M
TRUNK LID
REMOVE/INSTALL HINGE LEVER WITH REMOTE TRUNK CLOSING - AR88.50-P-5125N
MODEL 215, 220 with CODE (881b) Remote trunk closing (RTC)
Shown on model 220

Fig. 108: Identifying Remove/Install Components For Hinge Lever With Remote Trunk Closing - Shown
On Model 220 (1 Of 2)
Fig. 109: Identifying Remove/Install Components For Hinge Lever With Remote Trunk Closing - Shown
On Model 220 (1 Of 2)
Fig. 110: Identifying Right Hinge Bracket, Hydraulic Cylinder And Lever
Remove/Install
1 Open trunk lid
Remove Models 215.3,
463.244 /245 /247 /248 /249 /250 /254 /309 /322 /323 /332 /333. AR68.30-
2 coverings in
P-4600M
trunk Only right side paneling
Model 220.8 AR68.30-
Only right side paneling P-4600MP
AR88.50-
3 Remove trunk lid Separate electric and pneumatic connection on retractor and
remove retractor. P-5000M
Unclip left and
4 right gas-
operated strut (2)
Unscrew bolts
5 (3) and left hinge
lever (4)
Unhook
hydraulic
6
cylinder (9) from
lever (10)
Unscrew nuts (6) Fasten drive in position with nut To facilitate removal of right
7 and right hinge hinge lever (5), press lever (10) slightly to side together with
lever (5) assembly lever
Unclip stop
8 protection caps
(7)
9.1 Unscrew stop (8) Model 220 only
Install in the
10
reverse order
Check for trunk
11 lid fit in relation Observe gap dimensions
to rear fenders
*BE60.00-
P-1003-
If fit is not precise: ?
01A
AR88.50-
Adjust trunk lid
P-5200M
Repair bolts (3)
and nuts (6) with
12
paint in visible
area
mm 4.0 (± 0.5) 4.0 (± 0.5)
rear fender "F"
mm --
of rear fender "M"
mm 4.0 (± 0.5) 4.0 (± 1.5)
fender "F"
Dimension
BE60.00-P- Gap "M"
1003-01A dimension Dimension
"V"
Dimension
mm - -
Rear fender to "U"
Fig., see
0700-01N 0700-01M
Trunk lid to top of rear Dimension
mm 4.0 (± 0.5)
fender "F"
mm -
fender "M"
Dimension
Trunk lid to rear fender mm 4.0 (±0.5)
"F"
BE60.00-P-1003- Gap Dimension
Trunk lid to taillamp mm 4.4 (± 0.5)
01A dimension "M"
Dimension
"V"
Dimension
mm -
"U"
AR60.00-P-0700-
Fig., see
01M
ADJUST TRUNK LID - AR88.50-P-5200M
MODEL 220, 215

Fig. 111: Identifying Trunk Lid, Hinge Bracket, Stop And Bolts
Fig. 112: Identifying Bolts, Striker Eye And Trunk Lid Lock
Adjust in longitudinal direction

1 Slacken bolts (5) at striker eye (6)
Loosen bolts (3) on left and right Adjust trunk lid (1) so that rear edge of trunk lid
2 hinge levers (2) and adjust trunk lid (1) is flush with rear fenders and rear center
(1) in longitudinal direction section.
*BE60.00-P-
1003-01A
Feeler gage Fig. 40
For larger range of adjustment
loosen bolts (9) on the left and right
*BE60.00-P-
3 hinge lever (2) and adjust hinge Gap dimensions on hoods, doors and lids
1003-01A
lever (2) in the longitudinal
direction.
Feeler gage Fig. 40
Adjust trunk lid lock (8) and striker AR88.50-P-
4
eye (6) 5020M
*BA88.50-P-
5 Tighten bolts (9) on hinge lever (2) Trunk lid hinge on side wall 1001-01A
*BA88.50-P-
6 Tighten bolts (3) on hinge lever (2) Hinge lever on trunk lid 1009-01A
Adjust height
Loosen bolts (9) from hinge lever Adjust hinge lever (2) until the outer edges of
7 the trunk lid (1) are flush with the rear fenders in
(2) and adjust height of trunk lid (1)
the front area
Adjust trunk lid lock (8) and striker AR88.50-P-
8
eye (6) 5020M
Screw in stop (4) and coat contact surfaces on
left and right stop (4) with chalk. Unscrew stop (4)
until the chalk makes a mark on the contact surface
9 Adjust stop (4) on the rear center section when the trunk lid (1) is
closed.
Do not slam the trunk lid (1), push into lock by
hand.
*BE60.00-P-
1003-01A
Feeler gage Fig. 40
*BA88.50-P-
10 Tighten bolts (9) on hinge lever (2) Trunk lid hinge on side wall 1001-01A
*BA88.50-P-
11 Tighten bolts (3) on hinge lever (2) Hinge lever on trunk lid 1009-01A
Adjust spring tension
The trunk lid (1) should open up to the end
Open trunk lid (1) with remote trunk
12 position.
release.
When not opened completely: ?
AR88.50-P-
Model 215 up to VIN 038083 up to 31.5.03
5200-04M
Model 220 up to VIN 330749 up to 30.10.02
Hang trunk lid spring around hinge lever
AR88.50-P-
Model 215 as of VIN 038084 as of 1.6.03
5200-05M
Model 220 as of VIN 330750 as of 31.10.02
Adjust tension on telescopic spring.
mm 4.0 (± 0.5) 4.0 (± 0.5)
rear fender "F"
mm --
of rear fender "M"
mm 4.0 (± 0.5) 4.0 (±0.5)
fender "F"
Dimension
"M"
BE60.00-P- Gap Dimension
1003-01A dimension "V"
Dimension
mm - -
Rear fender to "U"
Fig., see
0700-01N 0700-01M
Dimension "F" mm 4.0 (± 0.5)
fender
mm -
fender "M"
Trunk lid to rear fender Dimension "F" mm 4.0 (±0.5)
Dimension
BE60.00-P-1003- Gap Trunk lid to taillamp mm 4.4 (± 0.5)
"M"
01A dimension
Dimension
"V"
Dimension
mm -
"U"
AR60.00-P-0700-
Fig., see
01M
TRUNK LID
BA88.50-P-1009-01A Bolt, hinge bracket to trunk lid Nm 9 9
Special tools

Hang trunk lid spring around hinge lever - AR88.50-P-5200-04M
Fig. 114: Identifying Mount For Trunk Lid Spring (220 589 02 63 00)
1. Open trunk lid and remove cover (3). Slightly pivot trunk lid downward to pretension trunk lid spring (1).
Fig. 115: Identifying Trunk Lid Spring, Hinge Lever And Cover
2. Install mount (4) on trunk lid spring (1)
Do not push trunk lid too far down otherwise the windings on the trunk lid spring located outside the
mount (5) could be permanently deformed
3. Completely open trunk lid and unhook trunk lid spring (1) from hook (A) on hinge lever (2) and hang into
hinge lever hook (B, 2).
4. Slightly push trunk lid down until mount (4) can be removed from trunk lid spring (1).
Fig. 116: Identifying Trunk Lid Spring, Hinge Lever And Lever Hook
Adjust telescopic spring tension of trunk lid - AR88.50-P-5200-05M
Do not twist telescopic springs (2) when removed Always twist both telescopic springs (2) uniformly For
correct adjustment of the telescopic springs (2) the trunk lid should include all detachable body components
such as warning triangle, license plate, etc.
1. Turn telescopic spring (2) in direction of arrow (A) to reduce tension

2. Turn telescopic spring (2) in direction of arrow (B) to increase tension
The trunk lid must open completely and should not swing back more than max. 4 cm after reaching the end
position.
Fig. 117: Direction For Turning Telescopic Spring

REMOVE/INSTALL COMPLETE OUTSIDE MIRROR - AR88.70-P-9000
Remove/install complete outside mirror - AR88.70-P-9000M
MODEL 220
Shown on model 220 as of VIN: 316717
Fig. 118: Identifying Outside Mirror Screw And Bolts - Shown On Model 220 As Of VIN 316717
Shown on model 220 up to VIN: 316716
Fig. 119: Identifying Door Control Unit, Control Unit Cover And Mounting Wedge - Shown On Model
220 Up To VIN 316716
Shown on model 220 As of VIN: 316717

Fig. 120: Identifying Outside Mirrors, Connectors, Sheet Metal Flap And Cord - Shown On Model 220
As Of VIN: 316717
Remove/Install
Remove paneling on outside AR88.70-
1
mirror P-9040M
Fold outside mirror (6) toward
2 Fold down manually
front and unscrew bolt (7)
Fold outside mirror (6) toward
3 Fold down electrically
rear and unscrew bolt (8)
Press door control unit cover
4 (2) off of door lining (4) with The mount was modified with model refinement
as of VIN: 316716
mounting wedge (5)
Model 220
AR72.10-
except light armoring, code Z04
P-1000M
except maximum protection, code Z07
Model 220.174/175/176/178 AR72.10-
with light armoring, code Z04 P-1000MC
Model 220.174/175/176/178 AR72.10-
with maximum protection, code Z07 P-1000MB
Fig. 14
Only outside mirrors with EC dimming (2
Disconnect connector (9) from
connectors) are delivered as replacement parts On
left front door control unit
5 vehicles without EC dimming fasten connector (9)
(N69/1) or right front door
not required to wiring harness (tie strap or insulating
tape).
Bend sheet metal cap (10) To achieve more space for lines and connectors
6
toward inside (9)
Fig. 14
Fasten cord (11) to connectors
7 With friction tape
(9)
Pull outside mirror (6) out of Pull out electrical lines for outside mirror without
8
door with electrical lines damaging them.
Remove cord (11) from
9
connectors
10 Remove outside mirror (6)
Fig. 121: Identifying Mounting Wedge (110 589 03 59 00)
Removing and installing complete exterior mirror - AR88.70-P-9000N
MODEL 215
Fig. 122: Identifying Outside Rearview Mirror And Screws

Fig. 123: Identifying Front Left Door Control Module, Control Module Cover, Locking Rail With
Ventilation Grill
1 Unscrew screw (15) from ventilation grill (12) and remove ventilation grill (12)
Press locking rail from door control module cover (14) toward rear in direction of
2
arrow and unlock door control module cover (13)
Disconnect connectors for outside rearview mirror defroster and connector for outside
3
rearview mirror adjustment on door control module (N69/1, N69/2)
4 Pivot outside rearview mirror (1) downward until screws (2) are accessible
Fig.
56
6 Remove outside rearview mirror (1)
8 Check for proper function
REMOVE/INSTALL MIRROR GLASS - AR88.70-P-9020M
MODEL 220, 215

Fig. 125: Identifying Mirror Glass Remove/Install Components - Shown On Model 220 Up To VIN
316716
Fig. 126: Identifying Mirror Lens, Retaining Spring And Connector - Shown On Model 220 As Of VIN
316717
Remove/Install
Remove covering on outside AR88.70-P-
1.1 Model 220 up to VIN: 316716
rearview mirror 9040M
2 Unhook retaining spring (2)
Model 220 up to VIN: 316716
Do not break off clip (6).
Press clip (6) in direction of arrow
3.1 and remove mirror glass (1) from Installation: First hook in mirror glass (1)
drive at bottom with retaining lugs (5) into retaining
pockets (arrows) on drive.
Observe support springs (4).
Remove mirror glass (1) from
3.2 Model 220 as of VIN: 316717
drive
4 Disconnect coupling (3)
REMOVE/INSTALL OUTSIDE REARVIEW MIRROR COVER - AR88.70-P-9040M
MODEL 220, 215
Fig. 127: Identifying Outside Rearview Mirror Cover Remove/Install Components - Shown On Model
220 Up To VIN 316716

Fig. 128: Identifying Outside Rearview Mirror Cover Remove/Install Components - Shown On Model
220 As Of VIN 316717
Remove
AR88.70-P-
1.1 Remove mirror glass Model 220 as of VIN: 316717
9020M
Model 220 up to VIN: 316716
2.1 Release bottom catch spring (2)
Do not damage paintwork.
Model 220 as of VIN: 316717
2.2 Release top catch spring (7)
Avoid damaging paint.
3 Remove paneling (1)
Install
Move bottom catch spring (2) to initial
4.1 Model 220 up to VIN: 316716
position
Check position of connector for turn signal Model 220 up to VIN: 316716
on outside rearview mirror (5) and turn signal If the connectors are not in the
5.1
connectors in outside rearview mirror correct position, damage can occur
covering (6) when the covering (1) is installed.
Ensure that the covering (1) is
arrested in the end position by the
bottom catch spring (2) or top catch
spring (7).
6 Push on paneling (1) Model 220 up to VIN: 316716
Ensure that the turn signal
connector is connected properly to the
outside rearview mirror (5).
REMOVING AND INSTALLING MIRROR ADJUSTMENT DRIVE MOTOR - AR88.70-P-9060M
MODEL 220, 215
Fig. 129: Identifying Mirror Adjustment Motor, Screws And Connector
1 Remove cover on outside rearview mirror AR88.70-P-9040M
2 Remove mirror glass AR88.70-P-9020M
4 Remove mirror adjustment motor (1)
REMOVING AND INSTALLING MIRROR TRIANGLE TRIM - AR88.70-P-9080N
MODEL 215
Fig. 130: Identifying Mirror Triangle Trim Remove/Install Components
Completely remove outside rearview AR88.70-P-
1
mirror 9000N
Press covering (6) off with assembly
2 Fig. 14
wedge (7)
Unscrew screws (5) from front door (4) Installation: Ensure that the seal (2)
3 and remove covering from mirror and sealing washers (3) are seated
triangle (1) properly.
REMOVE/INSTALL GASKET ON OUTSIDE MIRROR - AR88.70-P-9090M
MODEL 215, 220

Fig. 132: Identifying Outside Mirror Gasket Remove/Install Components
Remove
Completely remove left electrically adjustable
and heated outside mirror (M21/1) or right AR88.70-
1 Model 215
electrically adjustable and heated outside P-9000N
mirror (M21/2)
AR88.70-
Model 220
P-9000M
Note correct installation
2 Remove vapor barrier (3)
positions.
Lay new gasket (2) over old gasket (1) of left
electrically adjustable and heated outside
3
mirror (M21/1) or right electrically adjustable
and heated outside mirror (M21/2)
Mark cutout (A) for new gasket (2) on old
4
gasket (1)
5 Remove new gasket (2)
Increase cutout transferred to old gasket (1) by Dimension X should be min. 5
6
dimension X and mark cutting line (B) mm.
Cut off gasket (1) off along cutting line (B) and
7
remove outer part from old gasket (1)
Cut elevations off of remaining piece (4) The remaining piece (4) should
remaining on left electrically adjustable and not have elevations, otherwise the
8 heated outside mirror (M21/1) or right remaining piece (4) and new gasket
electrically adjustable and heated outside (2) will not seal properly with one
mirror (M21/2) on old gasket (1) another.
Install
Install new gasket (2) on left electrically
adjustable and heated outside mirror (M21/1)
9
or right electrically adjustable and heated
outside mirror (M21/2)
10 Insert vapor barrier (3)
Completely install left electrically adjustable
and heated outside mirror (M21/1) or right AR88.70-
11 Model 215
electrically adjustable and heated outside P-9000N
mirror (M21/2)
AR88.70-
Model 220
P-9000M
REMOVING AND INSTALLING REAR DOOR PROTECTIVE STRIP - AR88.80-P-1030M
MODEL 220
Fig. 133: Identifying Rear Door Protective Strip And Nut
1 Unscrew nut (3)
Lift protective strip (1) at rear end and pull toward rear out of Do not damage
2
retaining clips paint
REMOVING AND INSTALLING SIDE MEMBER TRIM - AR88.80-P-6000N
MODEL 215
Fig. 134: Identifying Side Member Trim Remove/Install Components (1 Of 2)
Fig. 135: Identifying Side Member Trim Remove/Install Components (2 Of 2)
1 Remove covers (8) and (9)
2 Remove edge guard (10) in entry area
Fig.
3 Lift entry cover (11) with assembly wedge Installation: Replace 14
damaged mounting clips
5 Unscrew screws (6) and (7)
Unscrew screws (3) and press rocker panel (1) off with Fig.
6
assembly wedge downward at front and rear (arrows) 14
Remove seal (2) and unclip rocker panel (2) from Installation : Hook rocker
7
longitudinal member panel (1) into clamps (5)
REMOVING AND INSTALLING FRONT DOOR PROTECTIVE STRIP - AR88.80-P-6600M
MODEL 220
Fig. 137: Identifying Front Door Protective Strip And Nut
1 Unscrew nut (3)
Lift protective strip (1) at rear end and pull toward rear out of Do not damage
2
retaining clips paint
REMOVING AND INSTALLING OUTSIDE PANELING/MOLDING ON A-PILLAR - AR88.80-P-8500
Removing and installing outside paneling on A-pillar - AR88.80-P-8500K
MODEL 208.3 /4, 215
Illustrated on model 208.3
Fig. 138: Identifying Outside Paneling Remove/Install Components On A-Pillar - Illustrated On Model
208.3 (1 Of 2)
Fig. 139: Identifying Outside Paneling Remove/Install Components On A-Pillar - Illustrated On Model
208.3 (2 Of 2)
Removal
1 Fold back wiper arm Only model 208
2 Lift rubber channel (2) in
lower area
3 Unscrew screw (3)
4 Release slide (4) upward
(arrows)
5 Pull off paneling (1), lift
at bottom and remove
from holders (7) at top
(arrows)
6 Put down paneling (1)
Installation
7 Check rubber channel (2), Replace damaged
slider (4) and clips (8) on parts
paneling (1) and position
slider (4) to removal
position
8 Check sheet metal clip Replace damaged
nut (5), clips 6) and parts
holder (7) on A-pillar
9 Move paneling (1) into
upper holder (7) with
mount, then press
paneling (1) onto clips (6)
and (8)
10 Lift rubber channel (2) in
lower area and pull slider
(4) down (to lock)
11 screw (3) into sheet metal
clip nut (5)
12 Press knob (arrow) on
rubber channel (2) into
oblong hole in slider (4)
(arrow)
13 Align rubber channel (2)

Removing and installing molding on A-pillar - AR88.80-P-8500M
MODEL 220
Fig. 141: Identifying A-Pillar Molding Remove/Install Components
Press sealing channel (2) with mounting lugs out of Do not damage sealing
1
molding (1) channel
Fig.
53
2 Pull sealing channel (3) out of molding (1)
3 Unscrew screws (4) from molding (1)
Fig.
4 Press molding (1) off of A-pillar
53

REMOVING AND INSTALLING SEALING SECTION AT ROOF FRAME - AR88.85-P-2000
Removing and installing sealing section at roof frame - AR88.85-P-2000M
MODEL 220
Fig. 143: Identifying Sealing Channel
Pull sealing channel (1) out of Check sealing channel and replace
1
retaining rails on A-pillar according to condition
Pull sealing channel (1) out of If the sealing channel (1) is to be reused,
2 retaining rail on roof frame above ensure that the sealing channel (1) is not
front and rear doors damaged
Installation: First align sealing channel
3 Install in opposite order (1) at corners of roof frame and then press
into retaining rails.
*BR00.45-Z-
Use lubricating fluid 1010-06A
REPAIR MATERIALS
Removing and installing sealing channel at roof frame - AR88.85-P-2000N
MODEL 215
Fig. 144: Identifying Sealing Channel At Roof Frame
Removal
Pull out sealing
1 First remove sealing channel (1) in area of A-pillar.
channel (1)
Installation
Use lubricant to press in sealing channel (1)
Insert sealing channel (1) in area of C-pillar first.
Install sealing *BR00.45-Z-
2 The sealing channel (1) must be positioned with its cutout
channel (1) 1010-06A
which is not flock-coated so that the front window stay runs
into this cutout when closing.
REPAIR MATERIALS
MAINTENANCE
INSPECT ENGINE HOOD LOCK AND SAFETY HOOK - AP88.40-P-8851M
MODEL 215.373 /374 /375 /376 /378 /379
MODEL
220.025 /026 /028 /063 /065 /067 /070 /073 /074 /075 /083 /084 /087 /125 /126 /128 /163 /165 /167 /170 /173 /17
Shown on model 220

Fig. 145: Identifying Safety Hook, Coil Spring And Striker
Check
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 the operating
0011-01A
hoods, doors, trunk lid/ rear-end door range of moving parts.
or sliding roof.
Do not oil or grease the closing system.
Replace closing systems which are difficult to
move, defective or have been greased
subsequently, do not attempt to free up, repair
or degrease.
Do not actuate handle of safety hook and
do not change its position
1 Unlock engine hood If the engine hood does not raise or the
handle of the safety hook (1) is not visible,
replace safety hook (1), coil spring (2) and
striker (3).
Open engine hood about 150 mm Measured between tip of fender and tip of
2
(dimension a) engine hood
Engine hood should lock automatically
Allow hood to freely fall into locks when falling freely from this height. The
3
from this height safety hook handle (1) should not extend
beyond the radiator paneling after locking
Insert your hand from the front into the

4 Check if engine hood is locked.
radiator cowl (arrows) and pull with a firm
jerk to check if the engine hood is locked
properly. It should not be possible to open the
engine hood.
5 Unlock engine hood
Insert your hand from the front into the
radiator cowl (arrows) and pull with a firm
jerk to check whether the safety hook (1)
Check safety hook (1) for proper
6 functions properly
function
Do not actuate handle of safety hook (1) and
do not change its position. The engine hood
should not open
Adjust engine hood lock and safety In event of malfunctions of engine hood
7.1
hook (1) lock or safety hook (1).
AR88.40-
Adjust engine hood lock, safety hook
P-3030M

RETROFITTING PENNANT HOLDER - AN88.10-P-0001M
MODEL 220
Fig. 146: Exploded View Of Pennant Holder

Fig. 147: Identifying Dimensions (A-C)
Fig. 148: Identifying Reinforcement Plate, Ring, Panel And Mounts

Fig. 149: Identifying Pennant Rod And Pennant Mount
Removal
1 Remove headlamp
AR82.10-P-
4730M
Installation
Mask area of hole on front fender with adhesive
2
tape
Mark hole c on adhesive tape and drill with 44 mm Hold fender so that it
3 dia. bit cannot be deformed when
Dimension a = 98 mm, b = 32 mm (see figure) drilling.
4 Deburr hole and apply corrosion protection agent
Install M6 clip nut (2) in hole on reinforcement
5
panel (15) of body (see arrows)
Use mount (3) as template
Position mount (3) and tighten provisionally with
6 for bottom hole for pop rivet
screws (14) at top as well as on the M6 clip nut (2)
nut (4)
Drill hole for pop rivet nut in bottom mount (3) Treat hole with corrosion
7
(see arrow) protection agent
8 Remove mount (3) and press rivet nut (4) into hole
Install mount (3) and loosely tighten with screws
9
(14, 3 each)
Loosely fasten mount (5) with reinforcement ring Hook of reinforcement ring
10 (7) should be seated in the
(7) and rubber ring (8) to mount (3) (16 screws)
hole at top of mount (5)
Install pennant mount (11) into hole (dia. 44 mm)
Narrow recess on pennant
from outside on fender with washer (9) and tighten
11 mount (11) should point
to mount (5) with nuts (10, 3 each) and
toward front of vehicle.
reinforcement plate (6).
12 Grease pennant mount
Tighten mount (3) on reinforcement plate (15)
13
without tension with three screws.
Tighten mount (5) on mount (3) without tension
14
with screws (16)
Align pennant mount (11) and tighten with nuts *BA88.10-P-
15
(10, 3 each) 1001-01B
Insert cover (12) into
Insert pennant rod (1) into pennant mount (11) and
16 pennant mount (11) when
catch
pennant rod (1) is removed
Tighten pennant mounts (13) with screws (17),
17
washers (18) and nuts (19)
18 Install headlamp
AR82.10-P-
4730M
FENDER
BA88.10-P-1001-01B Nut for pennant mount Nm 5

A 220 810 01 81 Parts kit for pennant holder, left 1
A 220 810 00 81 Parts kit for pennant holder, right 1
A 220 810 00 84 Pennant rod 2
RETROFIT TRUNK LID ADDITIONAL LOCK - AN88.50-P-0001
Retrofit trunk lid additional lock - AN88.50-P-0001M
MODEL 220
Fig. 150: Identifying Trunk Lid Additional Lock With Associated Components
Remove
Remove only trunk lid lock Trunk lid
1 Remove trunk lid lock (1)
lock and door handle recess are eliminated
AR88.50-P-
5020M
Remove paneling from rear center
2 Part eliminated
section
AR68.30-P-
4600M
Install
Remove trunk lid lock (1) with Position trunk lid lock on bottom edge of
3
central shift rod (1a) recess in trunk lid
AR88.50-P-
5020M
*BA88.50-P-
Bolt on trunk lid lock 1002-01A
*BA88.50-P-
Bolt to striker eye 1004-01A
*BA88.50-P-
Bolt, locking lug to trunk lid 1006-01A
AN88.50-P-
4 Retrofit trunk lid additional lock
0001-01M
AN88.50-P-
5 Cut out trunk lid paneling
0001-02M
Install paneling on rear center
6 New part
section
AR68.50-P-
4600M
7 Reassemble trunk lid
Fasten door handle recess with two bolts
8 Install door handle recess (6)
and then clip in pins (6a)
Screw in rubber buffers until resistance
9 Install rubber buffers (7)
can be felt (stop in third coil)
Adjust
Adjust height of striker (2) for trunk
lid additional locks (3) so that they
10
close together with the trunk lid lock
(1)
Check
Check for trunk lid fit in relation to Observe dimension gaps
11
rear fenders If fit is not precise: ?
AR88.50-P-
Adjust trunk lid
5200M
Check closing system for proper
12
function
1. Pushbutton lock opened with When the trunk lid is open, unlock locked
mechanical key (key in vertical trunk lid locks by actuating the pushbutton
position) lock or the remote trunk lid release
When the trunk lid is open none of the
2. Pushbutton lock closed with
closed trunk lid locks should unlock when
mechanical key (key in horizontal
the pushbutton lock or the remote lid trunk
position)
release is actuated
220.875/878
mm 4.0 (± 0 .5) 4.0 (±0 .5)
rear fender "F"
mm --
of rear fender "M"
mm 4.0 (± 0 .5) 4.4 (± 0 .5)
BE60.00-P- Gap fender "F"
Trunk lid to taillamp mm 4.0 (±0 .5) 4.4 (±0 .5)
"M"
Dimension
"V"
Dimension
mm - -
Rear fender to "U"
Fig., see
0700-01M 0700-01M
TRUNK LID
BA88.50-P-1002-01A Bolt on trunk lid lock Nm 9
BA88.50-P-1004-01A Bolt to striker eye Nm 9
BA88.50-P-1006-01A Bolt, locking lug to trunk lid Nm 9

Group 69 Cargo space edge cover 1
Group 75 Trunk lid lock (according to equipment) 1
Group 75 Trunk lid additional lock with individual parts 2
Group 75 Door handle recess 1
Installing trunk lid auxiliary lock - AN88.50-P-0001-01M
Model 220
1. Lock trunk lid lock (1).

2. Press shift rod (5) into center shift rod (1a) of trunk lid lock (1).
3. Press shift rod (5) into auxiliary lock (3) (see magnified section).
4. Insert auxiliary lock (3) into recess and fasten with two screws (3a).
Position auxiliary lock on bottom edge of recess and center (see arrow).
Fig. 151: Identifying Trunk Lid Lock With Associated Components

5. Check recess in locking bracket (2) for correct dimensions according to figure, if necessary remachine
symmetrically around center axis.
6. Press in clip nuts, insert locking bracket (2) into recess of rear center section and fasten with two screws
(2a).
Align locking bracket (2) against screws (2a) upward and center (see arrow).
Fig. 152: Identifying Locking Bracket And Screws
Cutting out trunk lid paneling - AN88.50-P-0001-02M
Model 220
1. Mark center point for hole (2) as shown in figure.

2. Drill 12 mm dia. hole (2) on both sides of trunk lid paneling (1).
3. Cut out left and right trunk lid paneling (1) as shown in figure.
Fig. 153: Positions For Cutting Out Trunk Lid Paneling
Retrofit trunk lid auxiliary lock - AN88.50-P-0001N
MODEL 215
Fig. 154: Identifying Trunk Lid Auxiliary Lock With Associated Components
Remove
Remove only trunk lid lock
1 Remove trunk lid lock (1) Trunk lid lock and door handle
recess are eliminated
AR88.50-P-
5020M
2 Remove paneling from rear center section Part eliminated.
AR68.30-P-
4600M
Install
Install trunk lid lock (1) with central shift rod Position trunk lid lock on
3
(1a) bottom edge of recess in trunk lid
AR88.50-P-
5020M
*BA88.50-P-
Bolt on trunk lid lock 1002-01A
*BA88.50-P-
Bolt on striker eye 1004-01A
*BA88.50-P-
Bolt for locking lug on trunk lid 1006-01A
4 Retrofit trunk lid auxiliary lock
AR88.50-P-
5020-01N
5 Install paneling on rear center section New part
AR68.30-P-
4600M
6 Reassemble trunk lid
7 Fasten door handle recess (5) with bolts (5a)
Adjust
Adjust height of striker (3) for the trunk lid
auxiliary locks (3) so that edges of trunk lid
8
(2) and the fender are flush and the trunk lid
can be closed easily.
Check
Check for trunk lid fit in relation to rear Observe gaps
9
fenders If fit is not precise: ?
AR88.50-P-
Adjust trunk lid
5200M
When the trunk lid is open,
unlock locked trunk lid locks by
10 Check closing system for proper function
actuating the pushbutton or the
remote trunk release
When modifying the package, subsequently
enter code or designation of corresponding
11
special equipment on vehicle data card and
FDOK
Dimension "F" mm 4.0 (± 0.5)
fender
mm -
fender "M"
Trunk lid to rear fender Dimension "F" mm 4.0 (± 0 .5)
Dimension
BE60.00-P-1003- Gap Trunk lid to taillamp mm 4.0 (± 1 .2)
"M"
01A dimension
Dimension
"V"
Dimension
mm -
"U"
AR60.00-P-0700-
Fig., see
01N
TRUNK LID
BA88.50-P-1002-01A Bolt on trunk lid lock Nm 9
BA88.50-P-1004-01A Bolt to striker eye Nm 9
BA88.50-P-1006-01A Bolt, locking lug to trunk lid Nm 9

Group 69 Cargo space edge cover 1
Group 75 Trunk lid lock (according to equipment) 1
Group 75 Trunk lid auxiliary lock with individual parts 2
Group 75 Door handle recess 1
RETROFITTING REMOTE TRUNK LID CLOSING - AN88.50-P-0002
Retrofitting remote trunk lid closing - AN88.50-P-0002M
MODEL 220.0## 1# as of 097777 up to 31.8.02
Except AMG vehicles
MODEL 220.1## 1# as of 097777 up to 31.8.02
except AMG vehicles

Fig. 155: Identifying Remote Trunk Locking Buttons, PSE Control Unit And RTL Hydraulic Pump
Fig. 156: Identifying Gas-Operated Strut, Stop Protection Cap And Hinge Bracket
Remove
Risk of explosion caused by explosive No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns smoking. Wear protective gloves, acid-
caused by swallowing battery electrolyte. resistant clothing and safety glasses. AS54.10-Z-
Risk of injury caused by burns to skin and Pour battery electrolyte only into 0001-01A
eyes from battery acid or when handling suitable and appropriately marked
damaged lead-acid batteries containers.
AR54.10-P-
0003I
Notes on battery All models AH54.10-P-
0001-01A
Ventilation hose (4) must be routed
2 Remove ventilation hose (4) from battery. differently after installing RTL
hydraulic pump (M51).
The right side wall paneling is
eliminated and should be replaced with
3 Remove coverings in trunk
a new panel with trunk lid remote
locking
AR68.30-P-
4600M
Check line roller all the way
4 Remove line roller for trunk lid around, remove wiring harnesses and
disconnect connectors.
Puller hook. Fig. 57
AR88.50-P-
5000-03M
5 Remove trunk lid
AR88.50-P-
5000M
Paint trunk lid only in area of hinge
Pain trunk lid and new hinge lever to lever mount.
6
match color of car. Do not paint splines of right hinge
lever.
The cover is eliminated and should
7 Remove trunk lid lock cover be replaced with a new one with trunk
lid remote locking
The trunk lid lock is eliminated and
8 Remove trunk lid lock and striker eye should be replaced with a new one
with trunk lid remote locking
AR88.50-P-
5020M
The hinge lever and springs are
9 Remove hinge lever for trunk lid eliminated and should be replaced with
new ones with trunk lid remote locking
AR88.50-P-
5120M
The covers (1) are eliminated and
10 Remove left and right cover (1) should be replaced with a new ones
with trunk lid remote locking
11 Remove left and right stop (8)
12 Remove taillamp Right.
AR82.10-P-
4905M
AN88.50-P-
Only right thread plate (no longer 0002-01N
13 Remove threaded plate
required)
14 Remove pneumatic system equipment Do not disconnect pneumatic lines
AR80.20-P-
2700M
With keyless go, code (889).
15.1 Remove Keyless Go control unit
Do not disconnect electrical leads.
AR80.35-P-
0001M
Model 220.0/ 220.1 with code
(224c) electrically adjustable
16 Remove rear seat backrest individual rear seats, with seat
ventilation, seat heater and memory
package or model 220.875/ 878 only
right individual rear seat
Model 220.0/220.1 with code (223b)
AR91.12-P-
electrically adjustable individual rear
1620M
seat.
Model 220.0/220.1 except code (223b)
seat except code (224c) electrically AR91.12-P-
adjustable individual rear seats, with 1620MA
seat ventilation, seat heater and
memory package.
Model 220.0/220.1 with code (224c)
electrically adjustable individual rear AR91.12-P-
seats, with seat ventilation, seat heater 1620MB
and memory package.
Remove rear SAM control unit with fuse
17 Do not disconnect electrical leads.
and relay box
AR54.21-P-
1259I
The switch group is eliminated and
Remove front door power window switch
18 should be replaced with a new one
group
with remote trunk locking.
AR72.29-P-
0110M
Install
Install front door power window switch Install new switch group with
19
group switch for remote trunk locking
AR72.29-P-
0110M
20 Install left and right stop (8)
21 Install left and right cover (1) Use covers (1) with trunk remote
closing.
Retrofit hinge and drive for trunk lid Install new hinge lever (2, 3) and AN88.50-P-
22 drive element with remote trunk
remote control 0002-03N
locking
AN88.50-P-
23 Retrofit opening angle recognition sensor
0002-04M
AN88.50-P-
24 Retrofit hydraulic pump and work cylinder
0002-05M
Retrofitting trunk lid remote control wiring AN88.50-P-
25
harness 0002-02N
Fuse assignment of rear fuse and relay GF54.15-P-
box 1256-01IH
26 Install the PSE control unit
AR80.20-P-
2700M
Install rear SAM control module with fuse
27
and relay box
AR54.21-P-
1259I
Model 220.0/220.1 with code
(224c) electrically adjustable
individual rear seats, with seat
28 Install rear seat backrest
ventilation, seat heater and memory
package or model 220.875/ 878 only
right individual rear seat
Model 220.0/220.1 with code (223b)
AR91.12-P-
1620M
seat.
Model 220.0/ 220.1 except code (223b)
seat except code (224c) electrically AR91.12-P-
adjustable individual rear seats, with 1620MA
seat ventilation, seat heater and
memory package.
Model 220.0/ 220.1 with code (224c)
electrically adjustable individual rear AR91.12-P-
seats, with seat ventilation, seat heater 1620MB
and memory package.
29.1 Install keyless go control unit With keyless go, code (889).
AR80.35-P-
0001M
The gas pressure struts (6) are
different for the left and right side.
30
The difference can be recognized
Clip gas pressure struts (6) into left and from the final digit in the part number.
right hinge Part number with final digit "2" is for
the right side. Part number with final
digit "1" is for the left side
31 Clip in stop protection caps (7)
Connect RTL button (S62/26) with
32 connector tied back and clip into new
cover
Use new cover with remote trunk
locking Reassemble trunk lid.
33 Install trunk lid
Repair bolts with paint in visible
area
AR88.50-P-
5000M
Install trunk lid lock and striker eye and Use new trunk lid lock with remote
34
adjust trunk locking
AR88.50-P-
5020M
35 Install taillamp Right.
AR82.10-P-
4905M
36 Install line roller for trunk lid
AR88.50-P-
5000-03M
Install new right side wall paneling
37 Install paneling in trunk
with trunk lid locking.
AR68.30-P-
4600M
38 Reconnect ground lead to battery
AR54.10-P-
0003I
In function group "Synchronize"
Perform control unit adaptation (PSE) and
Open trunk lid (synchronization at
39 synchronization for trunk lid remote
control system with STAR DIAGNOSIS top), press switch in trunk lid, trunk
closes (synchronization at bottom).
*WH58.30-
STAR DIAGNOSIS diagnosis system.
Z-1048-13A
40 Test for proper operation
Add special equipment to the vehicle data
41 Trunk lid locking code (881b).
card and to the online vehicle data card

Number Designation

KG Designation Quantity
54 Relay, RTL wiring harness, adapter
69 Cap
75 Hinge lever, cover with RTL, gas pressure strut, stop, drive, trunk lid lock with RTL
80 Hydraulic pump, protective cap
82 Switch block, RTL lock, rotation angle sensor
Remove threaded plate - AN88.50-P-0002-01N
1. Unscrew screw (1) and remove threaded plate

2. Carefully pry out sheet metal disc (2) with screwdriver.
Mask surrounding area with masking tape to prevent damage.
3. Remove sealant from cutout.

4. Seal threaded hole (3) on right side with sealant water-tight.
Fig. 158: Prying Sheet Metal Disc Using Screwdriver
5. Seal second threaded hole (4) on left side with sealant water-tight.
Fig. 159: Identifying Second Threaded Hole
Retrofitting trunk lid remote control wiring harness - AN88.50-P-0002-02N
Model 215, 220
1. Insert brown fuse holder (2) with 25 ampere fuse in plug location 25 on fuse carrier on rear SAM control
unit (N10/8).
Fig. 160: Identifying Brown Fuse Holder And Rear SAM Control Unit
2. Remove black, 32-pin connector (3) from rear SAM control module (N10/8) and open.
3. Install gray/blue lead (4) for remote trunk locking wiring harness in chamber 5 of black, 32pin connector
(3)
4. Close black, 32-pin connector (3) and connect to rear SAM control module (N10/8).
Fig. 161: Identifying Gray/Blue Lead, 32-Pin Connector And Rear SAM Control Module
5. Route wiring harness (20) from passenger compartment to lead passage for rear wall in trunk along
present leads and fasten with cable strap.
Fig. 162: Identifying Wiring Harness
6. Route lead (long tie-out) to PSE control unit (combined) (A37)and fasten above tank reservoir.
Fig. 163: Identifying PSE Control Unit Harness Route
7. Connect black, 6-pin connector and black, 6-pin connector to PSE/RTL hydraulic unit connector
(X18/34).
8. Disconnect 6-pin and 10-pin connector from PSE control module (combined) (A37).
9. Open 6-pin connector for PSE control module (combined) (A37) and install leads as follows:
Chamber 3 - rose/black (rs/sw)
Chamber 6 - rose/blue (rs/bl)
10. Close 6-pin connector and connect to PSE control module (combined) (A37)
Fig. 164: Identifying PSE Control Module And PSE/RTL Hydraulic Unit Connector
11. Open 10-pin connector for PSE control module (combined) (A37) and install leads as follows:
Chamber 1 - brown (br)
Chamber 5 - brown/green (br/gn)
Chamber 7 - red/green (rt/gn)
12. Close 10-pin connector and connect to PSE control module (combined) (A37)
13. Install blue/gray lead in chamber 2 of trunk lid separation point (X8/4).
Fig. 165: Identifying Trunk Lid Separation Point
14. Screw ground lead to ground (right taillamp in trunk) (W7/1).

15. Insert black, 2-pin connector in trunk lid remote locking hydraulic pump.
16. Insert black, 3-pin connector in trunk lid opening angle recognition sensor
Fig. 166: Identifying Ground Lead
17. Clip relay holder (11) into mounting plate (10) with trunk lid open relay (K69/1) and trunk lid closed
relay (K69/2).
18. Completely fasten wiring harness with cable strap.
Mask sharp edges in area of leads with felt.
Fig. 167: Identifying Relay Holder, Mounting Plate With Trunk Lid Open And Close Relay
Retrofit hinge and drive for trunk lid remote control - AN88.50-P-0002-03N
Model 215, 220
1. Install left hinge lever (5) and fasten with screws (6).
2. Repair bolts (6) with paint in visible area.
Fig. 168: Identifying Left Hinge Lever And Screws
3.1 Model 215

 Move in drive element from bottom
3.2 Model 220

 Move in drive element through taillamp opening
4 Insert right hinge lever (7) in drive element with splines and fasten with nuts (8).
5 Repair nuts (8) with paint in visible area
Fig. 169: Identifying Right Hinge Lever And Nuts
6 Screw on drive element (9) at bottom to mounting plate (10) from rear.
Fig. 170: Locating Screw On Drive Element
Retrofit opening angle recognition sensor - AN88.50-P-0002-04M
1. Fasten trunk lid opening angle recognition sensor (B24/16) to side panel with two bolts (1)
2. Clip sensor rod (9) into right hinge lever (pin)
When installing trunk lid remote locking wiring harness connect black, 3-pin connector to trunk lid
opening angle recognition sensor (B24/16).
Fig. 171: Identifying Opening Angle Recognition Sensor, Sensor Rod And Bolts
Retrofit hydraulic pump and work cylinder - AN88.50-P-0002-05M
1. Insert RTL hydraulic pump (M51) into foam rubber bottom section (8) and insert between battery and
wheelhouse
2. Clip work cylinder (5) into lever (11) and bolts (see arrow)
3. Route hydraulic lines (12) along present reinforcement lines and fasten with cable strap.
Mask sharp edges in area of hydraulic lines (12) with felt.
Fig. 172: Identifying RTL Hydraulic Pump, Work Cylinder And Hydraulic Lines
4. Install upper foam rubber section (13) above RTL hydraulic pump (M51).
5. Route ventilation hose (4) as shown in figure and install on battery and in rubber grommet (10) (see
magnified section)
Retrofit remote trunk lid closing - AN88.50-P-0002N
MODEL 215.375 /378 as of 1.6.00 up to 31.8.02

Fig. 173: Identifying Remote Trunk Lid Associated Components (1 Of 2)
Fig. 174: Identifying Remote Trunk Lid Associated Components (2 Of 2)
Remove
1 Remove battery
AR54.10-P-
0005I
Except 2 to 11.
2 Remove trunk lid Separate electric and pneumatic
connection on retractor and remove
retractor.
AR88.50-P-
5000M
The cover is a part which can be
3 Remove trunk lid lock cover
eliminated.
4 Remove hinge lever for trunk lid The hinge levers are parts which can be
eliminated
AR88.50-P-
5120M
Remove right and lever covers (16) in
5
trunk
6 Remove coverings in trunk
AR68.30-P-
4600M
AN88.50-P-
7 Removing threaded plate
0002-01N
It is not required to loosen the
8 Remove pneumatic system equipment
pneumatic lines.
AR80.20-P-
2700M
It is not required to loosen the lines.
9.1 Remove Keyless Go antenna.
with CODE (889) Keyless Go.
AR82.62-P-
8000MD
10.1 Remove Keyless Go control module
It is not required to loosen the lines. AR80.35-P-
with CODE (889) Keyless Go. 0001M
11 Remove rear seat cushion
AR91.12-P-
1020N
12 Remove rear backrest
13 Remove side wall paneling Only right side.
AR68.30-P-
1450N
Remove rear SAM control module with
14 It is not required to loosen the lines.
fuse and relay box
AR54.21-P-
1259I
Remove switch module of power Driver power window switch group
15
window switch (S20/1) is a part which can be eliminated.
AR72.29-P-
0120N
Install
Use new switch group of driver power
Install switch module of power window
16 window switch (S20/1) with open and
switch
close trunk lid switch (S20/1s6).
AR72.29-P-
0120N
Retrofit hinge lever and drive for remote AN88.50-P-
17
trunk lid closing 0002-03N
Install trunk lid opening angle detection
18
sensor
with CODE (881b) remote trunk lid AR88.50-P-
closing (RTC). 5065N
Insert protective cap (13) below battery
19
frame
Place RTC hydraulic pump (M51) in
20
protective cap
Route the hydraulic lines between
Install working cylinder (14) into drive fender and reinforcement.
21
element together with lines. Mask sharp edges in area of lines with
felt.
Retrofitting trunk lid remote control AN88.50-P-
22
wiring harness 0002-02N
Fuse assignment of rear fuse and relay GF54.15-P-
box with combination functions. 1256-01IH
23 Install the PSE control module
AR80.20-P-
2700M
Install rear SAM control module with
24
fuse and relay box
AR54.21-P-
1259I
25 Install side wall trim
AR68.30-P-
1450N
26 Install rear seat backrest
27 Install rear seat cushion
AR91.12-P-
1020N
28.1 Install keyless go control module
AR80.35-P-
0001M
29.1 Install Keyless Go right antenna
AR82.62-P-
8000MD
Clip cover for hydraulic pump into
30
battery frame
31 Install right and left cover (16) in trunk
Clip in gas pressure struts (17) on left
32
and right hinges
33 Clip in stop protection caps (18)
34 Clip in caps (19)
35 Install trunk lid Use new cover with RTC.
AR88.50-P-
5000M
Connect RTC [HDFS] button (S62/26)
36 with plug tied back and clip into new
cover
37 Install battery
AR54.10-P-
0005I
38 Coat screws with paint in visible area
Inspect
Perform control module adaptation In function group "Synchronize" Open
(PSE) and synchronization for trunk lid trunk lid (synchronization at top), press
39
remote control system with STAR switch in trunk lid, trunk closes
DIAGNOSIS (synchronization at bottom).
When modifying the scope of equipment
enter code and designation of Remote trunk lid closing (RTC) code
41
corresponding special equipment on 881b.
vehicle data card and FDOK

KG Designation Quantity
54 Relay, HFS wiring harness, adapter, vent hose
69 Cap
75 Hinge lever, cover with RTC, gas-operated strut, stop, drive
80 Hydraulic pump, protective cap
82 Switch block, RTC switch, turning angle sensor

RETROFIT AMG PANELING PARTS - AZ88.00-P-0001
Retrofit AMG paneling parts - AZ88.00-P-0001F

MODEL 220
The paneling parts supplied with the accessories and spare parts are primed
and must be painted in the same color as the vehicle before being installed.
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.
220.025 /026/ 028/ 063/ 065/ 067/ 070/ 075/ 083/ 084/ 087/ 125/ 126/ 128/ OF88.00-
Body kit,
165/ 167/ 170/ 175/ 176/ 178/ 186/ 184/ 187. P-1000-
certificate
* For Germany only 01AB
Remove
Remove
1 front
bumper
Model AR88.20-
220.026 /028 /063 /065 /070 /073 /075 /128 /165 /170 /173 /175 /178. P-2000M
Remove
2 rear
bumper
AR88.20-
P-2200M
Install
Convert Except code (803) Model year 2003. AZ88.00-
3 front P-0001-
Model refinement vehicles up to model year 2003.
bumper 02E
AZ88.00-
With code (803) Model year 2003.
P-0001-
Model refinement vehicles as of model year 2003.
02EF
Convert AZ88.00-
4 side P-0001-
paneling 04F
Convert AZ88.00-
5 rear P-0001-
bumper 03E
Install
6 front
bumper
Model AR88.20-
220.026 /028 /063 /065 /070 /073 /075 /128 /165 /170 /173 /175 /178. P-2000M
Install
7 rear
bumper
AR88.20-
P-2200M
Front bumper (with SRA) complete: Up to model refinement without code
B6 603 6050 1
803
B6 603 6053 Complete set of side paneling W220 (220.0) 1
B6 603 6054 Complete set of side paneling V220 (220.1) 1
B6 603 6051 Complete rear bumper all W/V 220 (220.0/1) except M58 and S55 AMG 1
B6 603 6052 Complete rear bumper M58 and S55 AMG 1
B6 603 6620 Complete front bumper (with SRA): As of model refinement, code 803 1
Up to model refinement without code 803
A220 885 05
ECE covering (order according to national version) 1
81
A220 885 06
Switzerland covering (order according to national version) 1
81
A220 885 07
Italy covering (order according to national version) 1
81
A220 885 08
USA covering (order according to national version) 1
81
A220 885 09
Japan covering (order according to national version) 1
81
As of model refinement with code 803
A220 885 17
ECE covering (order according to national version) 1
81
A220 885 18
Switzerland covering (order according to national version) 1
81
A220 885 19
Italy covering (order according to national version) 1
81
A220 885 20
Japan covering (order according to national version) 1
81
A220 885 21
USA covering (order according to national version) 1
81
B6 603 66 Complete rear bumper S 55 AMG compressor (220.074/174) and vehicles
1
21 with rear muffler accessories
Converting front bumper - AZ88.00-P-0001-02E
Except model year 2003 code 803.
Preparation
1. Remove standard bumper

2. Remove inner section (1).
3. Remove impact damper (2).
4. Remove seals (3).
5. Remove Parktronic wiring harness (4).
6. Remove molding strips (5).
7. Remove windshield washer system round cover plate (6).
8. Remove towing bracket cover (7).
9. Remove license plate cover (8), grill (13).
Fig. 175: Exploded View Of Bumper
Assembly
10. Glue foil (9) to dust cover.

11. Install windshield washer system round cover plate (6).
12. Secure towing bracket cover (7) with cable strap.
13. Install protective molding (5), license plate cover (8).
14. Install Parktronic wiring harness (4).
15. Install impact damper (2), seals (3), inner section (1).
16. Install sockets (11) into upper skirt mounting points.
Fig. 176: Identifying Foil
Fig. 177: Identifying Sockets
17. Install grille clips (12).

18. Install bumper.
19. Clip in grille (13).
Fig. 178: Identifying Grille Clips
Converting front bumper - AZ88.00-P-0001-02EF
Vehicles as of 1.9.02
1. Disassemble standard bumpers

Leave PTS sensors connected to PTS wiring harness
Do not damage paint.
2. Install mounting clips (12) for air inlet grille into present holes of front bumper (1) (13 each).
The openings of the mounting clips (2) should point toward the front of the vehicle.
Fig. 179: Identifying Front Bumper Mounting Clips
3. Install intermediate elements (3) of standard bumper on left and right side of front bumper (1).
4. Clip towing eye cover (5) into front bumper and mount catch strap (6).
5. Lay center impact damper (7), left impact damper (8) and right impact damper (9) into front bumper (1).
Fig. 180: Identifying Intermediate Elements, Impact Damper And Towing Eye Cover
6. Install two sheet metal nuts on bracket of HCS cover (16).

7. Fasten HCS cover (16) with two sheet metal screws (18).
Ensure that the gap around HCS cover (16) is uniform all the way around.
Fig. 181: Identifying HCS Cover With Sheet Metal Screws
8. Clip left and right protective moldings (17) into front bumper (1).
Fig. 182: Identifying Protective Moldings On Front Bumper
9.1 Vehicles with Parktronic system (PTS) Code 220a

 Route PTS wiring harness (10) removed from the standard bumper in left impact damper (8) and
center impact damper (7) as shown in figure.
 Clip inner section (11) into front bumper (1).
 Route PTS wiring harness (10) in inner section (11) and in right impact damper.
Fig. 183: Identifying PTS Wiring Harness Routing
10.1 Vehicles with Parktronic system (PTS) Code 220a

 Fasten front bumper PTS connector (X26/27) to front bumper (1) with two spreading rivets (14).
 Insert front bumper PTS sensor unit (A42) into mounts of protective molding.
Before inserting sensors, check decoupling rings, replace if damaged. The gaps of the sensors in the
protective molding (except on the protective molding) should be uniform.
Fig. 184: Identifying PTS Connector And PTS Sensor Unit
11 Clip left seal (12) and right seal (13) into front bumper (1).
The seals are preshaped and therefore not interchangeable.
Fig. 185: Identifying Seal On Bumper
12 Install sleeves (4) in front bumper (1).
Fig. 186: Identifying Sleeves In Front Bumper
13 Install license plate cover (15) on outside of front bumper (1) and prepare for assembly.
Use license plate cover (15) as template for marking holes.
The distance (a) between the license plate cover and the right/left moldings must be uniform. Align
license plate cover (15) at contour of front bumper (1) (see arrows).
14 Drill four holes for mounting the license plate cover and fasten to front bumper (1) with four screws
(F5x18).
Tighten screws only with screwdriver.
Fig. 187: Aligning License Plate Cover At Contour Of Front Bumper
15 Clip right, center and left air inlet grille into mounting clips.
Install air inlet grille after installing front bumper. Before clipping in grille ensure that the grille is
seated properly in the mounting clips.
Converting rear bumper - AZ88.00-P-0001-03E
Model 220
Preparation
1. Remove standard rear bumper.

2. Remove cross member (1) and inner element (2).
3. Remove impact dampers (3).
4. Remove side mount (4).
5. Remove upper rail (5).
6. Remove antenna (6) as well as antenna mount (7).
7. Remove keyless go antenna (8).
9. Remove moldings (10).
Fig. 188: Exploded View Of Rear Bumper
Assembly
11. Glue adapter rail (12) to impact damper (3) with double adhesive strip.
12. Reinstall bumper in opposite order.
Converting side paneling - AZ88.00-P-0001-04F
Model 220
Preparation
1. Remove standard side paneling.
Assembly
2. Glue on adhesive foil (1) and (2).
3. Install rubber lip (3).
4. Install seals (4) and (5).
5. Reinstall side paneling in opposite order.
Fig. 189: Exploded View Of Side Paneling
Retrofit AMG paneling parts - AZ88.00-P-0001K
MODEL 215
The paneling parts supplied with the accessories and spare parts are
primed and must be painted in the same color as the vehicle before
being installed.
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, Model 215.375 /376 /378. OF88.00-P-
certificate * For Germany only 1000-01CB
Remove
Remove front
1
bumper
AR88.20-P-
Model 215.373/ 374/ 375/ 378.
2000M
Remove fog
2 Fog lamps are eliminated and replaced with enclosed fog lamps
lamp
AR82.10-P-
5103N
Remove rear
3
bumper
AR88.20-P-
2200NA
Install
Convert front Except code (803) Model year 2003. AZ88.00-P-
3
bumper Model refinement vehicles up to model year 2003. 0001-02J
With code (803) Model year 2003. AZ88.00-P-
Model refinement vehicles as of model year 2003. 0001-02JA
Converting AZ88.00-P-
4
side paneling 0001-04K
Convert rear AZ88.00-P-
5
bumper 0001-03J
Install front
6
bumper
AR88.20-P-
Model 215.373/ 374/ 375/ 378.
2000M
Install rear
7
bumper
AR88.20-P-
2200NA

B6 603
Complete front bumper: Up to model refinement without code 803 1
6008
B6 603
Complete set of side paneling: For all vehicles 1
6014
B6 603
Complete front bumper: As of model refinement with code 803 1
6600
Up to model refinement without code 803 1
A215
885 05 ECE covering (order according to national version) 1
81
A215
885 06 Switzerland covering (order according to national version) 1
81
A215
885 07 Italy covering (order according to national version) 1
81
A215
885 08 Japan covering (order according to national version) 1
81
A215
885 09 USA covering (order according to national version) 1
81
As of model refinement with code 803 1
A215
885 15 ECE covering (order according to national version) 1
81
A215
885 16 Switzerland covering (order according to national version) 1
81
A215
885 17 Italy covering (order according to national version) 1
81
A215
885 18 Japan covering (order according to national version) 1
81
A215
885 19 USA covering (order according to national version) 1
81
Additionally order with USA, Japan or Canada:
A202
990 02 Bolt (mount covering) 4
21
Complete rear bumper: All vehicles up to model refinement, code 803 and all
B6 603
vehicles as of model refinement, code 803 except CL 55 AMG compressor 1
6009
(215.374) and vehicles with rear muffler accessories
B6 603 Complete rear bumper CL 55 AMG compressor (215.374) or vehicles with rear
1
6601 muffler accessories and two double-end pipes
Additionally order on CL 55 AMG compressor (215.374) or vehicles with rear
muffler accessories and two double-end pipes:
A215
885 08 Bottom section paneling 1
25
Converting front bumper - AZ88.00-P-0001-02J
Except model year 2003 code 803.
Preparation
1. Remove standard bumper

2. Remove headlamp (1).
3. Remove inner section (2), impact dampers (3)
(3), remove Parktronic wiring harness (4).

4. Remove towing bracket cover (5) and headlamp cleaning system round cover plate (6)
5. Remove protective strips (7), license plate cover (8), grille (9).
Assembly
6. Assemble bumper in reverse order.
Fig. 190: Exploded View Of Front Bumper
Converting front bumper - AZ88.00-P-0001-02JA
With model year 2003 code 803.
1. Disassemble standard bumpers
Leave PTS sensors connected to PTS wiring harness
Do not damage paint.
2. Glue strips of adhesive tape (12) on both stays on left and right in front bumper (1).
Fig. 191: Identifying Adhesive Tape On Front Bumper
2 Install sleeve (4) and socket (3) on left and right on front bumper (1) as shown in figure.
Fig. 192: Identifying Sleeve And Socket On Bumper
3 Insert mounting clips (2) for air inlet grille into present holes (13 each).
The openings of the mounting clips (2) should point toward the front of the vehicle.
Fig. 193: Identifying Mounting Clips On Bumper
4 Install sheet metal nuts (13) for HCS cover and left and right fog lamp on front bumper (1).
Fig. 194: Identifying Sheet Metal Nuts On Front Bumper
5 Fasten mount (21) to front bumper (1) on left and right with two pop rivets.
Mounts (21) vary for left and right.
6 Clip intermediate element (7) into front bumper (1) on left and right.
Fig. 195: Identifying Intermediate Element And Mount On Front Bumper
7 Clip protective molding (18) into bumper (1) on left and right.
Fig. 196: Identifying Protective Molding On Bumper
8 Install HCS cover (22) into front bumper (1) on left and right and fasten with screws (20).
9 Clip towing eye cover (5) in and secure with catch strap (6).
Fig. 197: Identifying HCS Cover, Towing Eye Cover And Catch Strap
10 Lay center impact damper (8), left impact damper (9) and right impact damper (23) into front bumper
(1).
11 Clip inner section (11) into front bumper (1).
On vehicles with Parktronic system (PTS) code 220a route wiring harness into specified recesses of
the left (9) and right (23) impact damper as well as the inner section (11).
Fig. 198: Identifying Impact Damper On Bumper
12.1 Vehicles with Parktronic system (PTS) code 220a

 Fasten front bumper PTS connector (X26/27) to front bumper (1) with two spreading rivets (14)
(left figure).
 Insert front bumper PTS sensor unit (A42) into mounts of protective molding (right figure).
Before inserting sensors, check decoupling rings. Replace if damaged.
Fig. 199: Identifying Front Bumper PTS Connector And PTS Sensor Unit
13 Position left and right fog lamp (16) in bumper and fasten with screws (17).
Fig. 200: Identifying Fog Lamp And Screws
14 Clip air inlet grille (19) into mounting clips on left and right.
Air inlet grille varies on left and right. Install center air inlet grille after installing bumper.
Fig. 201: Identifying Protective Molding On Bumper
15 Install license plate cover (15) on outside of front bumper (1) and prepare for assembly.
Use license plate cover (15) as template for marking holes.
The distance (a) between the license plate cover and the right/left moldings must be uniform.
Align license plate cover (15) at contour of front bumper (1) (see arrows).
16 Drill four holes for mounting license plate cover and fasten to front bumper (1) with four screws
(F5x18).
Tighten screws only with screwdriver.

Fig. 202: Aligning License Plate Cover At Contour Of Front Bumper
Converting rear bumper - AZ88.00-P-0001-03J
Preparation
1. Remove cross member (1) and inner section (2)

2. Remove impact damper (3).
3. Remove side mounts (4).
4. Remove upper rails (5).
5. Remove keyless go antenna (6).
7. Remove molding strips (8).
Fig. 203: Exploded View Of Rear Bumper
Assembly
9. Glue adapter rail (10) to impact damper (3) with double adhesive tape.
10. Reinstall bumper in opposite order.
11.1 On CL 55 AMG compressor (215.374) or vehicles with rear muffler accessory with two double
end pipes
 Clean contact surface (12) for paneling bottom section of rear bumper (11).
The area to be glued on the rear bumper (11) must be free of dust and grease. For cleaning use mixture
of IPA (Isopropanol alcohol) and water with a ratio of 50 : 50
Fig. 204: Identifying Contact Surface For Paneling Bottom Section Of Rear Bumper
12.1 On CL 55 AMG compressor (215.374) or vehicles with accessory rear muffler with two double
end pipes.
 Position paneling bottom section (13) to end pipe sections, firmly glue into recess in center firmly
press on over full surface
Avoid damage to paintwork.
 Drill holes (dia. 5 mm) in both end pipe cutouts and fasten paneling bottom section (13) to bumper
(11) with two spreading rivets (14) each.
Fig. 205: Identifying Paneling Bottom Section And Spreading Rivets On Bumper
Converting side trim panel - AZ88.00-P-0001-04K
Preparation
1. Remove standard side trim panels.

2. Fit side trim panels in reverse sequence.
Fig. 206: Exploded View Of Side Trim Panel
RETROFITTING TRUNK LID EMERGENCY RELEASE - AZ88.50-P-0002
Retrofitting trunk lid emergency release - AZ88.50-P-0002M
MODEL 220 with CODE (491) U.S. version
Fig. 207: Identifying Fuse And Relay Box, SAM Control Module And Trunk Lid Components
up to 31.8.99
Fig. 208: Identifying Trunk Lid Lock And Cover - Up To 31.8.99
as of 1.9.99
Fig. 209: Identifying Trunk Lid Lock And Micro Switch - As Of 1.9.99
The electric trunk lid emergency release

When the battery is
does not operate when:
removed/disconnected ((e.g.: temporary
vehicle shutdown) it is necessary to
the battery is disconnected or

remove the striker eye.
discharged
The function "Lock trunk lid
separately" (90° position for trunk lid lock)
is no longer present after the trunk lid
Before retrofitting, check trunk lid remote
opening feature for proper operation
ON vehicles as of end no. A181 312 it is
only necessary to install the trunk interior
pushbutton and to deactivate the 90°
position trunk lid lock
Remove
Remove trunk lid pressure lock and trunk
1
lid paneling
Remove trunk lid lock and striker eye, AR88.50-P-
install and adjust 5020M
up to 31.8.99
Remove paneling (10) from trunk lid lock The separate trunk lid locking function
2.1
(9) and cut off driver (arrow) (trunk lid lock in 90° position) is then
no longer available
as of 1.9.99
Remove 90° position microswitch (S88/2) The 90° position microswitch (S88/2) is
2.2 on trunk lid lock (9) and tie back connector no longer installed.
with electric lead The separate trunk lid locking function
(trunk lid lock in 90° position) is then
no longer available
3 Remove paneling in trunk up to end no. A181311
It is not necessary to remove the trunk AR68.30-P-
Removing and installing paneling in trunk
end panel. 4600M
Remove SAM control module with fuse
4 up to end no. A181311
and relay box (K40/5, N10/8) in rear
Remove, install rear SAM control module AR54.21-P-
Do not disconnect lines.
up to end no. A181311
Completely remove trunk lid wiring Disconnect clip (5) and pull out length
5 compensation (6) toward rear.
harness (2)
Disconnect connectors on body and
trunk lid side.
Install
6 Install new trunk lid wiring harness (2) Position tie-out (3) for trunk lid interior
button (1) as shown in drawing.
AZ88.50-P-
7 Retrofit lead (4) for trunk interior button up to end no. A181311 0002-05M
Wiring harness repair kit Fig. 211
AZ88.50-P-
8 Retrofit trunk interior button (1)
0002-06M
Enter fuse assignment in fuse assignment
plan
10 Fit remaining parts to vehicle When installing trunk lid paneling,
connect trunk interior button.
11 Carry out operational check
Notes on electric trunk lid emergency AH88.50-P-
release 0001-01A
Place insert sheet for trunk lid emergency Order number see parts ordering
12
release in Owner's Manual notes.
Fig. 210: Identifying Wiring Harness Repair Kit (220 589 01 99 00)

A 203 821 35
Switch 1
58
A 220 820 87
Wiring harness for trunk lid interior actuation (model 220 1
15
A 002 545 63
Fuse holder 1
01
A 011 545 84
Contact spring 1
26
A 008 545 55
MQS contact 1
26
2.5 m red/white (rt/ws) lead, 0.5 mm 1
5 A fuse 1
Insert sheet for Owner's Manual, electric kit (can be ordered from printshop
6515955813 1
Storopack, Hotline telephone number: +49-7123/64242)
Retrofitting trunk lid emergency release wiring harness - AZ88.50-P-0002-05M
Model 215 with code 491 up to end no. A013239 Model 220 with code 491 up to end no. A181312
1. Attach connector to red/white ((rt/ws) lead, 0.5mm 2 ) length approx. 2.5 m and connect to auxiliary fuse
holder.
Use jacket.
2. Insert fuse holder (1) into plug-in location 59 of fuse and relay module in rear (K40/5).
Install 5 A fuse.
Fig. 212: Identifying Fuse Holder And Fuse And Relay Module In Rear
3. Route lead (1) along present wiring harnesses to trunk and tie with cable straps.
Fig. 213: Identifying Lead Wiring Harnesses
4. Route lead (1) along present wiring harnesses to connector (X8/4).

5. Attach connector to lead (1) and connect to chamber 6 of connector.
If plug-in location is already connected, disconnect lead and tie back with insulation.
6. Tie lead (1).

Fig. 214: Identifying Connector With Lead Wiring Harness
3 Housing longitudinal compensation
Retrofitting trunk interior button - AZ88.50-P-0002-06M
Models 215, 220 with code 491
Model 220
1.1 Mark cutout on paneling as shown in drawing.

2.1 Cut out paneling.
Fig. 215: Specifications For Marking Cutout On Paneling - Model 220
Model 215
1.2 Mark cutout on paneling as shown in drawing.

2.2 Cut out paneling.
Fig. 216: Specifications For Marking Cutout On Paneling - Model 215
3 Install trunk interior button (1) in trunk lid paneling from front and fasten from rear with retaining ring.
Ensure that seat is correct (collar on trunk interior button (1) should make contact with paneling
around entire circumference).
Fig. 217: Identifying Trunk Interior Button And Retaining Ring
Retrofitting trunk lid emergency release - AZ88.50-P-0002N
MODEL 215 with CODE (491) U.S. version

Fig. 218: Identifying Fuse And Relay Box, SAM Control Module And Trunk Lid Components
up to 31.8.99
Fig. 219: Identifying Trunk Lid Lock And Cover - Up To 31.8.99
as of 1.9.99
Fig. 220: Identifying Trunk Lid Lock And Micro Switch - As Of 1.9.99
The electric trunk lid emergency release

When the battery is
does not operate when:
removed/disconnected ((e.g.: temporary
vehicle shutdown) it is necessary to
 the battery is disconnected or
remove the striker eye.
discharged
The function "Lock trunk lid
separately" (90° position of trunk lid lock)
is no longer present after the trunk lid
Before retrofitting, check trunk lid remote
opening feature for proper operation
On vehicles as of end no. A013 239 it is
only necessary to install the trunk interior
pushbutton and to deactivate the 90°
position trunk lid lock
Remove
Remove trunk lid pressure lock and trunk
1
lid paneling
Remove trunk lid lock and striker eye, AR88.50-P-
install and adjust 5020M
up to 31.8.99
Remove paneling (10) from trunk lid lock The separate trunk lid locking function
2.1
(9) and cut off driver (arrow) (trunk lid lock in 90° position) is then no
longer available
as of 1.9.99
The 90° position microswitch (S88/2) is
Remove 90° position microswitch (S88/2)
no longer installed.
2.2 on trunk lid lock (9) and tie back connector
The separate trunk lid locking function
with electric lead
(trunk lid lock in 90° position) is then no
longer available
3 Remove paneling in trunk up to end no. A013238
It is not necessary to remove the trunk AR68.30-P-
Removing and installing paneling in trunk
end panel. 4600M
Remove SAM control module with fuse
and relay box (K40/5, N10/8) in rear
Remove, install rear SAM control module AR54.21-P-
Do not disconnect lines.
5 Remove side wall paneling up to end no. A013238
AR68.30-P-
Removing and installing side wall paneling
1450N

Completely remove trunk lid wiring Disconnect clip (5) and pull out length
harness (2) compensation (6) toward rear.
6 Disconnect connectors on body and
trunk lid side.
Install
7 Install new trunk lid wiring harness (2) Position tie-out (3) for trunk lid interior
button (1) as shown in drawing.
AZ88.50-P-
8 Retrofit lead (4) for trunk interior button up to end no. A013238 0002-05M
Wiring harness repair kit Fig. 211
AZ88.50-P-
9 Retrofit trunk interior button (1)
0002-06M
Enter fuse assignment in fuse assignment
plan
When installing trunk lid paneling,
11 Fit remaining parts to vehicle
connect trunk interior button.
Notes on electric trunk lid emergency AH88.50-P-
release 0001-01A
Place insert sheet for trunk lid emergency Order number see parts ordering
13
release in Owner's Manual notes.

A 203 821 35
Switch 1
58
A 215 820 21
Wiring harness for trunk lid interior actuation (model 215) 1
15
A 002 545 63
Fuse holder 1
01
A 011 545 84
Contact spring 1
26
A 008 545 55 MQS contact 1

26
2.5 m red/white (rt/ws) lead, 0.5 mm 1
5 A fuse 1
Insert sheet for Owner's Manual, electric kit (can be ordered from printshop
6515955813 1
Storopack, Hotline telephone number: +49-7123/64242)

RENEW STOP BUFFER ON TRUNK LID - SM88.50-P-0002A
MODEL 220.### #A up to 001072
OPERATION NO. OF OPERATION TEXTS OR OF STANDARD TEXTS AND FLAT RATES

Division Op. Operation text
no.
RENEW STOP BUFFER LEFT AND ACCOUNTING NO. 00 902 2 work units (0.2
P 023196
RIGHT 01 hrs)
Removal
1 Open trunk lid
2 Remove stop buffer Left and right
Installation
Left and right
3 Install stop buffer
New version must be coated!
4 Close trunk lid
PART ORDERING NOTES

220 988 03 11 Buffer 2
COMPONENT MODIFICATIONS
ELIMINATION OF 90° POSITION IN TRUNK LID HANDLE - BT88.50-P-1000
Elimination of 90° position in trunk lid handle - BT88.50-P-1000-01M
MODEL 220 as of 5.11.03
90° position on trunk lid handle eliminated
The rotation motion of the selector drum (2) is limited by a stop (3) on the housing of the trunk lid handle
(1).Then, it is no longer possible to turn the lock cylinder with the mechanical key to the 90° position.
Simultaneously the trunk lid contact switch is eliminated in the trunk lid handle (1).
Fig. 222: Identifying Selector Drum And Stop On Housing Of Trunk Lid Handle
Elimination of 90° position in trunk lid handle - BT88.50-P-1000-01N
MODEL 215.### ## as of 043784
90° position on trunk lid handle eliminated
The rotation motion of the selector drum (2) is limited by a stop (arrow) on the housing of the trunk lid handle
(1). The cam (2) hits against a stop (arrow) on the housing Then it is no longer possible to turn the lock cylinder
with the mechanical key to the 90° position. Simultaneously the trunk lid contact switch is eliminated in the
trunk lid handle (1).
The figure besides shows the window broken out of the trunk lid handle cover for better illustration.
Fig. 223: Identifying Cam, Selector Drum And Trunk Lid Handle
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-1000-01B
Model 171, 199, 210, 211, 220, 230, 240
FENDER
Number Designation Model Model Model Model
171 199 210 211
BA88.10-P-1001-
Nut to pennant holder Nm - - 5 -
01B
BA88.10-P-1002-
Nut/screw of fender to body Nm 8 - - 10
01B
BA88.10-P-1003-
Nut for fender on adjustment bolt 8- - -
01B
BA88.10-P-1004- Adjustment bolt on longitudinal
3- - -
01B member
FENDER
BA88.10-P-1001-01B Nut to pennant holder Nm 5 - -
BA88.10-P-1002-01B Nut/screw of fender to body Nm - 8 8
BA88.10-P-1003-01B Nut for fender on adjustment bolt Nm - - -
BA88.10-P-1004-01B Adjustment bolt on longitudinal member Nm - - -
BUMPER - BA88.20-P-1000-01A
Model 168, 170, 202, 203, 208, 210, 215, 220
MODIFICATION NOTES
21.3.01 Figure modified from 45 Figure in line 1010 for
Nm to 55 Nm model 203 modified
BUMPER
Number Designation Model 168 Model 170 Model 202 Model 203 Model
208.3/4
BA88.20-P- Nut of front Nm - 10 20 20 20
1001-01A bumper to
cross member
BA88.20-P- Nut for rear Nm - 10 20 6 8
1002-01A bumper on
rear center
section
BA88.20-P- Bolt of front Nm - - - - 2
1003-01A bumper to
headlight
housing
BA88.20-P- Bolt of front Nm - - - 4 3
1004-01A bumper to
side of fender
on inside
BA88.20-P- Screw with Nm - - - 8 5
1005-01A seal for rear
bumper on
side of fender
BA88.20-P- Bolt of front Nm 3 - - 4 -
1006-01A bumper to
cross member
BA88.20-P- Bolt of rear Nm 3 - - - -
1007-01A bumper to
rear center
section
BA88.20-P- Bolt of fog Nm - - - 3 -
1008-01A light to
bumper
BA88.20-P- Bolt of Nm - - - 6 -
1009-01A bumper to
side wall in
area of rear
light
BA88.20-P- Nut/screw for Nm - - - 55 -
1010-01A rear bumper
on
longitudinal
member
BUMPER
BA88.20-P- Nut of front Nm - 20 - -
1001-01A bumper to
cross member
BA88.20-P- Nut for rear Nm 6 20 50 50
1002-01A bumper on rear
center section
BA88.20-P- Bolt of front Nm - - - -
1003-01A bumper to
headlight
housing
BA88.20-P- Bolt of front Nm 4 - - -
1004-01A bumper to side
of fender on
inside
BA88.20-P- Screw with seal Nm 8 - - -
1005-01A for rear bumper
on side of
fender
BA88.20-P- Bolt of front Nm 4 - - -
1006-01A bumper to
cross member
BA88.20-P- Bolt of rear Nm - - - -
1007-01A bumper to rear
center section
BA88.20-P- Bolt of fog Nm 3 - - -
1008-01A light to bumper
BA88.20-P- Bolt of bumper Nm 8 - - -
1009-01A to side wall in
area of rear
light
BA88.20-P- Nut/screw for Nm 45 - - -
1010-01A rear bumper on
longitudinal
member
ENGINE HOOD - BA88.40-P-1000-01D
Model 199, 215, 230, 220, 461, 463
ENGINE HOOD
199 215 220 230
BA88.40-P-1001- Bolt for engine hood hinge on engine
Nm 6 8 8 10
01D hood
BA88.40-P-1002- Screw for engine hood hinge on
Nm 8 8 8 10
01D body
BA88.40-P-1003- Bolt on upper section of engine hood
Nm - 8 8 8
01D catch
BA88.40-P-1004-
Bolt on engine hood catch Nm - 8 8 8
01D
BA88.40-P-1005-
Bolt on safety hook Nm 8 8 8 10
01D
BA88.40-P-1006-
Bolt on guide roller Nm 25 - - -
01D
BA88.40-P-1007-
Bolt on hood guide to frame Nm 8 - - -
01D
BA88.40-P-1008-
Bolt on upper hood guide Nm 12,5 - - -
01D
BA88.40-P-1009-
Bolt on lower hood guide Nm 12,5 - - -
01D
ENGINE HOOD
Number Designation Model 461.302/304/ 331/332/334/ 342/344/345/ Model
346, model 463.244/243/ 245/246/247/ 463.270/271
248/249/250/ 254/303/309/ 322/323/332/
333/340/341
Bolt for engine
BA88.40-P-
hood hinge on Nm - -
1001-01D
engine hood
Screw for engine
BA88.40-P-
hood hinge on Nm - -
1002-01D
body
Bolt on upper
BA88.40-P-
section of engine Nm - -
1003-01D
hood catch
BA88.40-P- Bolt on engine
Nm 8 8
1004-01D hood catch
BA88.40-P- Bolt on safety
Nm - -
1005-01D hook
BA88.40-P- Bolt on guide
Nm - -
1006-01D roller
BA88.40-P- Bolt on hood
Nm - -
1007-01D guide to frame
BA88.40-P- Bolt on upper
Nm - -
1008-01D hood guide
BA88.40-P- Bolt on lower
Nm - -
1009-01D hood guide
TRUNK LID - BA88.50-P-1000-01A
Model 170, 171, 199, 202, 203, 208, 210, 211, 215, 220, 230
TRUNK LID
Number Designation Model 170 Model 171 Model 199 Model 202 Model 203
BA88.50-P- Bolt at trunk Nm - - 20 10 10
1001-01A lid hinge to
side wall
BA88.50-P- Screw to Nm - - - 10 10
1002-01A trunk lid lock
BA88.50-P- Nut to Nm - - - 25 25
1003-01A eccentric bolt
BA88.50-P- Bolt to Nm - - - 10 10
1004-01A locking eye
BA88.50-P- Bolt, trunk Nm 8 9 - - -
1005-01A lid lock to
trunk lid
BA88.50-P- Bolt, locking Nm 8 - - - -
1006-01A lug to trunk
lid
BA88.50-P- Bolt, locking Nm 10 9 - - -
1007-01A eye to
tubular frame
BA88.50-P- Bolt, striker Nm 10 - - - -
1008-01A to tubular
frame
BA88.50-P- Bolt, hinge Nm 25 - 20 - 8
1009-01A bracket to
trunk lid
BA88.50-P- Bolt, hinge Nm 25 9 - - -
1010-01A lever to
tubular frame
BA88.50-P- Bolt, tubular Nm 25 20 - - -
1011-01A frame hinge
to rear center
section
BA88.50-P- Bolt, strut of Nm 8 - - - -
1012-01A wiring
harness to
hinge lever
BA88.50-P- Bolt, trunk Nm - - - - -
1013-01A lid auxiliary
lock to trunk
lid
BA88.50-P- Nut, hinge Nm - 20 - - -
1014-01A lever to trunk
lid
BA88.50-P- Bolt, locking Nm - - - - -
1015-01A wedge to
trunk lid
BA88.50-P- Bolt, handle Nm - 9 - - -
1016-01A plate to trunk
lid
BA88.50-P- Nut on trunk Nm - - - - -
rear shelf
BA88.50-P- Nut, Nm - - - - -
1018-01A actuation
bracket of
remote trunk
closing to
hinge bracket
of trunk lid
BA88.50-P- Nut, remote Nm - - - - -
1019-01A trunk closing
to C-pillar
bolt-on point
BA88.50-P- Nut, remote Nm - - - - -
to bolt-on
point of rear
shelf sheet
metal
BA88.50-P- Bolt, guide Nm - 10 - - -
1021-01A bolt to side
wall
BA88.50-P- Bolt, height Nm - - - - -
1022-01A limiter to
carrier plate
BA88.50-P- Ball head Nm - 20 - - -
1023-01A bolt to trunk
lid
BA88.50-P- Bolt, Nm - - - - -
1024-01A retaining
plate to
hydraulic
distributor
TRUNK LID
Number Designation Model Model 209 Model 210 Model 211 Model 215
208.3/4
BA88.50-P- Bolt at trunk Nm 10 - 10 - 9
side wall
BA88.50-P- Bolt on trunk Nm 10 9 10 - 9
1002-01A lid lock
BA88.50-P- Nut to Nm 25 - 25 - -
1003-01A eccentric bolt
BA88.50-P- Bolt to Nm 10 9 10 9 9
1004-01A locking eye
BA88.50-P- Bolt, trunk Nm 10 - - 9 -
1005-01A lid lock to
trunk lid
BA88.50-P- Bolt, locking Nm - - - - 9
1006-01A lug to trunk
lid
1007-01A eye to
tubular frame
BA88.50-P- Bolt, striker Nm - - - - -
1008-01A to tubular
frame
BA88.50-P- Bolt, hinge Nm - 8 (±2) - 8 9
lid
BA88.50-P- Bolt, hinge Nm - - - - -
1010-01A lever to
tubular frame
BA88.50-P- Bolt, tubular Nm - - - - -
1011-01A frame hinge
to rear center
section
BA88.50-P- Bolt, strut of Nm - - - - -
1012-01A wiring
harness to
hinge lever
BA88.50-P- Bolt, trunk Nm - - - 9 9
1013-01A lid auxiliary
lock to trunk
lid
BA88.50-P- Nut, hinge Nm - - - - -
lid
1015-01A wedge to
trunk lid
BA88.50-P- Bolt, handle Nm - - - 9 -
1016-01A plate to trunk
lid
BA88.50-P- Nut, trunk lid Nm - - - 19 -
1017-01A hinge to rear
shelf
BA88.50-P- Nut, Nm - - - 9 -
1018-01A actuation
bracket of
remote trunk
closing to
hinge bracket
of trunk lid
BA88.50-P- Nut, remote Nm - - - 9 -
to C-pillar
bolt-on point
BA88.50-P- Nut, remote Nm - - - 9 -
to bolt-on
point of rear
shelf sheet
metal
BA88.50-P- Bolt, guide Nm - - - - -
1021-01A bolt to side
wall
BA88.50-P- Bolt, height Nm - - - - -
1022-01A limiter on
carrier plate
BA88.50-P- Ball head Nm - - - - -
1023-01A bolt to trunk
lid
BA88.50-P- Bolt, Nm - - - - -
1024-01A retaining
plate to
hydraulic
distributor
TRUNK LID
BA88.50-P-1001- Bolt at trunk lid Nm 9 9
01A hinge to side wall
BA88.50-P-1002- Bolt on trunk lid Nm 9 9
01A lock
BA88.50-P-1003- Nut to eccentric bolt Nm - -
01A
BA88.50-P-1004- Bolt to locking eye Nm 9 9
01A
BA88.50-P-1005- Bolt, trunk lid lock Nm - -
01A to trunk lid
BA88.50-P-1006- Bolt, locking lug to Nm 9 -
01A trunk lid
BA88.50-P-1007- Bolt, locking eye to Nm - -
01A tubular frame
BA88.50-P-1008- Bolt, striker to Nm - -
01A tubular frame
BA88.50-P-1009- Bolt, hinge lever to Nm 9 -
01A trunk lid
BA88.50-P-1010- Bolt, hinge lever to Nm - 10
01A tubular frame
BA88.50-P-1011- Bolt, tubular frame Nm - 23
01A hinge to rear center
section
BA88.50-P-1012- Bolt, strut of wiring Nm - -
01A harness to hinge
lever
BA88.50-P-1013- Bolt, trunk lid Nm 9 9
01A auxiliary lock to
trunk lid
BA88.50-P-1014- Nut, hinge lever to Nm - 23
01A trunk lid
BA88.50-P-1015- Bolt, locking wedge Nm - 8
01A to trunk lid
BA88.50-P-1016- Bolt, handle plate to Nm - 9
01A trunk lid
BA88.50-P-1017- Nut on trunk lid Nm - -
01A hinge to rear shelf
BA88.50-P-1018- Nut, actuation Nm - -
01A bracket of remote
trunk closing to
hinge bracket of
trunk lid
BA88.50-P-1019- Nut, remote trunk Nm - -
01A closing to C-pillar
bolt-on point
BA88.50-P-1020- Nut, remote trunk Nm - -
01A closing to bolt-on
point of rear shelf
sheet metal
BA88.50-P-1021- Bolt, guide bolt to Nm - -
01A side wall
BA88.50-P-1022- Bolt, height limiter Nm - 4
01A on carrier plate
BA88.50-P-1023- Ball head bolt to Nm - -
01A trunk lid
BA88.50-P-1024- Bolt, retaining plate Nm - 2
01A to hydraulic
distributor
Doors - 215 & 220 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: DOORS - AH72.00-Z-9999AZ
MODEL all
Notes on sealant pattern MODELS 220.175 /178 AH72.10-P-0001-01MC

for front inner door panel with CODE (Z04) Light
armoring
Notes on sealant pattern MODELS 220.175 /178 AH72.12-P-0001-01MC
for rear inner door panel with CODE (Z04) Light
armoring
Notes on sealant pattern MODEL 220.875 /878 AH72.12-P-0001-01MP
for rear inner door panel
Notes on sealant pattern MODEL 220.875 /878 AH72.14-P-0001-01MP
for center inner door
panel
Notes on adjusting MODEL 171.4 AH72.10-P-0002-01A
window
Notes on bolts with right- MODEL 203 AH72.12-P-1002-01P
hand and left-hand thread
on rear door handle
NOTES ON SEALANT PATTERN FOR FRONT INNER DOOR PANEL - AH72.10-P-0001-01MC
MODEL 220 with CODE Z04
Provide sealing profile according to diagram.

Fig. 1: Identifying Sealant Pattern For Front Inner Door Panel
NOTES ON SEALANT PATTERN FOR REAR INNER DOOR PANEL - AH72.12-P-0001-01MC
MODEL 220 with CODE Z04
Provide sealing profile according to diagram.
Fig. 2: Identifying Sealant Pattern For Rear Inner Door Panel
BASIC KNOWLEDGE
POWER WINDOWS (PW), FUNCTION - GF72.29-P-0003
Power windows (PW), function - GF72.29-P-0003B
MODEL 215
Fig. 3: Power Windows (Pw) Function Diagram - Model 215
 Voltage too low or too high

 Circuit 15 ON or circuit 15R ON
Function
The power window feature allows the front and rear side windows to be opened and closed.
There are two actuation possibilities:
 Manual window up/down feature

 One-touch up/down feature
The short stroke function ensures that the doors and the frameless side windows can be opened and closed
without malfunction.
With the convenience feature it is possible to open or close all four side windows with the remote control key.
Soft start/soft stop
Actuation of the power window motors starts and stops with reduced power. This control module function
serves for reducing power window mechanical wear. When the motor actuation starts the control module power
is approx. 15 %. It is linearly increased to 100 %. The power is reduced from 100 % to 70 % starting at an
inside opening of approx. 30 mm before reaching the upper or lower stop.
The power is increased/decreased over a period of t = 250 ms.
Opening/closing windows in front doors, function GF72.29-P-2000B

Opening/closing rear windows, function, GF67.39-P-3001A
Power window manual up/down feature, function GF72.29-P-3006B
Power window one-touch up/down feature, function GF72.29-P-3007B
Convenience opening, power windows, function GF72.29-P-3004S
Power window short stroke, function GF72.29-P-4005A
Power windows (PW), function - GF72.29-P-0003S
MODEL 220
Fig. 4: Power Windows Function Diagram - Model 220
Function
The power windows allow opening and closing of the windows in the front and rear doors.
Two types of actuation are possible:
 Manual opening/closing
 Automatic one-touch down feature
All windows in the front and rear doors can be opened and closed with the remote control key or the lock
switches ( , only) via the convenience feature .
Power windows (PW), location of components GF72.29-P-0003-01S

Opening/closing windows in front doors, function GF72.29-P-2000S
Opening/closing windows in rear doors, function GF72.29-P-2001S
Convenience closing, power windows, function GF72.29-P-3005S
Power windows (PW), location of components - GF72.29-P-0003-01S
Location of components (illustrated on vehicles with left-hand steering)

Fig. 5: Identifying Power Windows Components Location
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF POWER WINDOWS (PW) - GF72.29-P-

0998
Table of contents, function description of power windows (PW) - GF72.29-P-0998AZ
MODEL 215
Power windows (PW), function &.2. (GF72.29-P-0003B)

Opening/closing windows in front doors, function GF72.29-P-2000B
Opening/closing rear windows, function GF67.39-P-3001A
Child protection, function GF72.29-P-3008B
Power window position recognition, function GF72.29-P-4000S
Power window synchronization, function GF72.29-P-4003S
Power window desynchronization, function GF72.29-P-4002S
Power window pinch protection, function GF72.29-P-4004B
Front driver-side door control module, location/purpose/design/function GF72.29-P-4105S
Front passenger-side door control module, location/purpose/design/function GF72.29-P-4106S
Rear control module, location/purpose/design GF91.29-P-2111A
Front power window motor, location/function GF72.29-P-4108A
Rear power window motor, location/function GF72.29-P-4109A
Driver-side power window switch group, location/purpose/design/function GF72.29-P-4112S
Rear center console power window switch combination, location/function GF72.29-P-4110A
Table of contents, function description of power windows (PW) - GF72.29-P-0998SZ
MODEL 220
Power windows (PW), location of components GF72.29-P-0003-01S

Power windows (PW), function GF72.29-P-0003S
Opening/closing windows in front doors, function GF72.29-P-2000S
Opening/closing windows in rear doors, function GF72.29-P-2001S
Manual opening/closing, function GF72.29-P-3006S
Automatic one-touch up/down feature, function GF72.29-P-3007S
Child protection, function GF72.29-P-3008S
Position recognition, power windows, function GF72.29-P-4000S
Desynchronizing power windows, function GF72.29-P-4002S
Synchronizing power windows, function GF72.29-P-4003S
Pinch protection, power windows, function GF72.29-P-4004S
Rear door control module, location/purpose/design/function GF72.29-P-4102S
Power window switch, rear doors, location/purpose/design/function GF72.29-P-4104S
Front power window motor, location/function GF72.29-P-4108S
Rear power window motor, location/function GF72.29-P-4109S
Left front power window switch group, location/purpose/design/function GF72.29-P-4112S
OPENING/CLOSING WINDOWS IN FRONT DOORS, FUNCTION - GF72.29-P-2000
Opening/closing windows in front doors, function - GF72.29-P-2000B
MODEL 215
The power window in the driver's door is operated with the left front power window switch (S20/1s1) (right-
hand steering: right front power window switch (S20/1s2) in the driver-side power window switch group
(S20/1) .
The power window in the passenger door is operated with the right front power window switch (S20/1s2)
(right-hand steering: left front power window switch (S20/1s1) or with the passenger-side power window
switch (S21/2) .
The one-touch up/down feature opens or closes the window completely; with the manual up/down feature
the window moves up or down as long as the switch is actuated.
The short stroke function ensures that the doors and the frameless side windows can be opened and closed
without malfunction.
Power window manual up/down, function GF72.29-P-3006B

Power window one-touch up/down, function GF72.29-P-3007B
Opening/closing windows in front doors, function - GF72.29-P-2000S
MODEL 220
The power window in the driver's door is actuated with the left front power window switch (S20/1s1)
(vehicles with right-hand steering: right front power window switch (S20/1s2) in the left front power window
switch group (S20/1) .
The power window in the passenger door is actuated with the right front power window switch (S20/1s2)
(vehicles with right-hand steering: left front power window switch (S20/1s1) or with the right front power
window switch (S21/2) .
The automatic one-touch up/down feature opens or closes the window completely; with the manual
opening/closing feature the window moves up or down as long as the switch is actuated.

OPENING/CLOSING WINDOWS IN REAR DOORS, FUNCTION - GF72.29-P-2001S
MODEL 220
The rear power windows are actuated in the rear doors with the left rear power window switch (S21/3)/right
rear power window switch (S21/4) .
In addition they can be actuated via the left front power window switch group (S20/1) with the left rear
power window switch (S21/1s3)/right rear power window switch (S21/1s4) .
The automatic one-touch up/down feature opens and closes the window completely.
With the manual closing/opening feature the window moves up or down as long as the switch is actuated.
With the rear power window safety switch (S20/1s5) in the left front power window switch group (S20/1) it
is possible to disable operation of the rear power windows with the switches (S21/3) and (S21/4) .

Child protection, function GF72.29-P-3008S
CONVENIENCE OPENING, POWER WINDOWS, FUNCTION - GF72.29-P-3004S
MODEL 215, 220
 Voltage not too low or too high and

 All doors closed (status: unlocked) and
 Ignition starter key in position "0" or removed and
 "Unlock" button on remote control key (A8/1) pressed for longer than 1 s ( , : key in "unlock"
position)
Function
The affected control modules (model 220: N69/1, N69/2, N69/3, N69/4; model 215: N69/1, N69/2 and N22/6)
receive the signal/CAN message for convenience opening and then actuate the corresponding power window
motors (M10/3, M10/4, M10/5, M10/6) . The motors are actuated as long as the button on the remote control
key is pressed, however, max. 25 s.
The power window convenience opening feature functions even when the windows are not synchronized .
The convenience opening feature is interrupted when
 the request via CAN bus is no longer received or

 the function prerequisites specified above are no longer fulfilled.
Moreover, when the convenience opening feature is actuated the sliding roof is opened and the seat
ventilation (special equipment) is switched on.
GF80.45-P-
Convenience feature (CF), function
0003S
GF72.29-P-
Convenience closing, power windows, function
3005S
GF72.29-P-
Power window synchronization, function
4003S
Front driver-side door control module, GF72.29-P-
Front passenger-side door control module, GF72.29-P-
Only model GF72.29-P-
Rear door control module, location/purpose/design/function
220 4102S
Rear control module, location/purpose/design
215 2111A
CONVENIENCE CLOSING, POWER WINDOWS, FUNCTION - GF72.29-P-3005S
MODEL 215, 220

 All doors closed (status: unlocked) and
 Ignition starter key in position "0" or removed and
 "Lock" button on remote control key (A8/1) pressed for longer than 1 s ( , : key in "lock" position)
Function
The affected control modules (model 220: N69/1, N69/2, N69/3, N69/4; model 215: N69/1, N69/2 and N22/6)
receive the signal/CAN message for convenience closing and then actuate the corresponding power window
motors (M10/3, M10/4, M10/5, M10/6) . The motors are actuated as long as the button on the remote control
key is pressed, however, max. 25 s.
The power window convenience closing feature functions even when the windows are not synchronized .
The convenience closing feature is interrupted when
 the request via CAN bus is no longer received or

 blocking/pinching is recognized or
 the function prerequisites specified above are no longer fulfilled.
Moreover, when the convenience closing feature is triggered the sliding/pop-up roof is closed.

Model GF72.29-P-
Pinch protection, power windows, function
215 4004B
Model
GF72.29-P-4004S
220
Convenience feature (CF), function GF80.45-P-0003S
Front passenger-side door control module,
GF72.29-P-4106S
Model
220
Model GF91.29-P-
215 2111A
POWER WINDOW MANUAL UP/DOWN FEATURE, FUNCTION - GF72.29-P-3006
Power window manual up/down feature, function - GF72.29-P-3006B
MODEL 215

Function
The manual up/down feature is triggered by pressing the power window switch to the first catch point in the
"open" or "close" direction. The corresponding left front door control module (N69/1)/right front door
control module (N69/2) then actuates the driver-side power window motor (M10/3)/front passenger side
power window motor (M10/4) , and the rear control module (N22/6) actuates the left rear power window
motor (M10/5) and the right rear power window motor (M10/6) as long as the corresponding button is
pressed.

Manual opening/closing, function - GF72.29-P-3006S
MODEL 220

Function
The manual up/down function is actuated by pressing the power window switch up to the first catch point in
the direction "open" or "close". The corresponding door control module (N69/1, N69/2, N69/3 or N69/4) then
actuates the power window motor (M10/3, M10/4, M10/5 or M10/6) as long as the switch is actuated.

POWER WINDOW ONE-TOUCH UP/DOWN FEATURE, FUNCTION - GF72.29-P-3007
Power window one-touch up/down feature, function - GF72.29-P-3007B
MODEL 215
 Voltage not too high or too low and

 Power windows synchronized
 Function not inhibited (version coding)
Function
The one-touch up/down feature is triggered by momentarily pressing the power window switch past the first
catch point in the "close" or "open" direction.
The corresponding left front door control module (N69/1)/right front door control module (N69/2)/rear
control module / N22/6) reads in the switch status and actuates the associated power window motor (M10/3,
M10/4, M10/5 or M10/6) until the position recognition feature indicates that the window is completely closed
or opened.
On non-synchronized windows the manual up/down feature is accomplished instead of the one-
touch up/down feature.
When the front side window is opened the associated rear side window can be closed only to the short
stroke position.
Function termination
The one-touch up/down feature is terminated when

 the power window switch is actuated again or
 the pinch protection actuates while the window is rolling up
 the function prerequisites are no longer fulfilled.

Power window pinch protection, function GF72.29-P-4004S
Automatic one-touch up/down feature, function - GF72.29-P-3007S
MODEL 220

 Power window synchronized
 Function not disabled, version coding
Function
The automatic one touch up/down feature is triggered by momentarily pressing the power window switch past
the first catch point in direction "close" or "open". The corresponding door control module (N69/1, N69/2,
N69/3 orN69/4) reads in the switch state and actuates the power window motor (M10/3, M10/4, M10/5 or
M10/6 ) until it recognizes via the position recognition that the window is completely closed or open.
If the window is not synchronized the manual opening/closing mode is used instead of the automatic
one touch up/down feature.
Function interruption
The automatic one touch up/down feature is interrupted when
 the power window switch is actuated again or

 the pinch protection is actuated as the window closes or
 the function prerequisites are no longer fulfilled.
Pinch protection, power windows, function GF72.29-P-4004S
CHILD PROTECTION, FUNCTION - GF72.29-P-3008
Child protection, function - GF72.29-P-3008B
MODEL 215
Child protection, function
With the rear power window safety switch (S20/1s5) located in the driver-side power window switch group
(S20/1) it is possible to inhibit operation of the left rear power window switch (S21/15s1) and right rear
power window switch (S21/15s2) located in the rear center console (child protection).
The safety switch position is read in by the left front door control module (N69/1) (right-hand steering: right
front door control module (N69/2) and then relayed to the rear control module (N22/6) switching off the
corresponding switch .
Rear center console power window switch combination, location/function GF72.29-P-4110A

Child protection, function - GF72.29-P-3008S
MODEL 220
Child protection feature
The function of the rear power window switch (S21/3, S21/4) in the rear doors can be disabled with the rear
power window safety switch (S20/1s5) located in the left front power window switch group (S20/1) (child
protection).
The position of the safety switch is read in by the left front door control module (N69/1) (vehicles with right-
hand steering: right front door control module (N69/2)), and relayed to the left rear door control module
(N69/3) and the right rear door control module (N69/4) via the CAN bus, disabling the rear power window
switches in the rear doors.
POWER WINDOW POSITION RECOGNITION, FUNCTION - GF72.29-P-4000S
MODEL 215, 220
Direction of rotation recognition
Fig. 6: Direction Of Rotation Recognition
Function
Two hall sensors each (b1, b2) are located on the shafts of the power window motors (M10/3, M10/4, M10/5,
M10/6) . These hall sensors react to motion of the magnet outputting one rectangular pulse per rotation of the
motor shaft. The corresponding control modules (model 220: N69/1, N69/2, N69/3, N69/4; model 215: N69/1,
N69/2 and N22/6) sense these pulses and evaluate them for rotation direction and position recognition.
Rotation direction recognition
The control module in question recognizes the direction of rotation of the power window motor from the time
offset between the pulses from hall sensor b1 and the pulses from hall sensor b2.
Position recognition
The control module counts the pulses from the 2nd hall sensor considering the direction of rotation of the
motor. The value in the position counter increases as the window closes. When the window opens the value in
the position counter decreases. The upper mechanical stop is defined as the zero position, i.e. when the window
is completely rolled up the counter should be set to zero. The zero position is set by synchronization . When
the zero position in the opening direction is exceeded the counter value is negative and thereby invalid. In this
case resynchronization is accomplished.

GF72.29-P-4106S
Model
220
Model GF91.29-P-
215 2111A
Model
220
Model GF72.29-P-
215 4108A
Model
220
Model GF72.29-P-
215 4109A
POWER WINDOW DESYNCHRONIZATION, FUNCTION - GF72.29-P-4002S
MODEL 215, 220
The counter value for position measuring becomes invalid with desychronization .
Function Desynchronization is performed when
 the control modules (model 220: N69/1, N69/2, N69/3, N69/4; model 215: N69/1, N69/2, N22/6) are
disconnected from the power supply e.g. by disconnecting the battery, removing or installing the control
module) or
 when an error is recognized in the position recognition .
In all these cases there is no longer any relationship between the position recognition counter value and the
actual window position, making it necessary to synchronize the window.
The function of the power window is reduced in the desychronized state. The one-touch up/down feature is
not possible.

GF72.29-P-4106S
Model
220
Model GF91.29-P-
215 2111A
POWER WINDOW SYNCHRONIZATION, FUNCTION - GF72.29-P-4003S
MODEL 215, 220
Synchronization links the position recognition value in the associated control module with the actual position
of the window.
The following control modules must be synchronized:
 Left front door control module (N69/1)

 Right front door control module (N69/2)
Only on model 220:
 Left rear door control module (N69/3)

 Right rear door control module (N69/4)
Only on model 215:
 Rear control module (N22/6)
Synchronization is required following desychronization .
If the window is not synchronized the control module has no information on the side window position and in
which direction the power window motors (M10/3, M10/4, M10/5, M10/6) should be turned to close the
window. For this reason synchronization is a prerequisite for the power window one-touch up/down feature .
Synchronizing
Position window in question with power window switch to upper block position and continue to actuate
switch. The control module then sets the counter for position recognition to zero when it recognizes lock-up of
the motor for min. 0.3 s. The window is then synchronized, i.e., the control module can now switch off the
motor before reaching the mechanical stop when opening and closing the window.
Resychronization
Resynchronization is accomplished when an error occurs in the position recognition, e.g. the position counter
status is negative.
GF72.29-P-
Position recognition, power windows, function
4000S
GF72.29-P-
Power window desynchronization, function
4002S
Front driver-side door control module, GF72.29-P-
Front passenger-side door control module, GF72.29-P-
Right front door control module, location/purpose/design/function
220 4102S
215 2111A
GF72.29-P-
Power window switch, rear doors, location/purpose/design/function
4112S
Power window switch, rear doors, location/purpose/design/function
220 4104S
Rear center console power window switch combination, Only model GF72.29-P-
location/function 215 4110A
POWER WINDOW PINCH PROTECTION, FUNCTION - GF72.29-P-4004
Power window pinch protection, function - GF72.29-P-4004B
MODEL 215
Function
The pinch protection feature is only active in combination with the one-touch up/down feature. It only
functions in the upper opening area of the window from 4 to 230 mm. The pinch protection is not effective in
combination with the manual up/down feature.
If the left front door control module (N69/1)/right front door control module (N69/2) or the rear control
module (N22/6) recognizes pinching by comparing the hall signals received (number, pulse duration, space
duration) with the stored reference values it stops actuation of the corresponding power window motor
(M10/3, M10/4, M10/5, M10/6) and moves the window down approx. 5 cm (reversing feature).
If the power window switch was actuated in the "close" direction at the time pinching was recognized, the
window stops rolling up immediately. The window then rolls back down approx. 1 cm when the switch is
released.
Reference value adaptation in control module
Since the power window mechanical system becomes hard to move after a certain period of time the door
control modules (N69/1, N69/2) and rear control module (N22/6) adapt during each up/down operation in the
synchronized state. For this purpose the pulse pattern of the hall signals received (number, pulse duration, space
duration) is compared with the last received and stored data (old reference values) and is stored as the new
reference if it is within the permissible tolerance range.
This adaptation is not accomplished when
 pinching is recognized,
 the power windows lock up.
The stored values are also maintained following disconnection of the power supply or desynchronization.

Pinch protection, power windows, function - GF72.29-P-4004S
MODEL 220
Function
The pinch protection feature is only active with the automatic one-touch up feature . It is only effective in the
upper opening area of the window from 4 to 230 mm. In the manual closing mode the pinch protection has no
effect.
If the door control module recognizes that something is being pinched by the window by comparing the pulses
received from the Hall sensors (number, pulse duration, pulse/space ratio) with the stored reference values, it
stops actuation of the power window motor (M10/3, M10/4, M10/5 or M10/6) and moves the window back
down (reverses the window) approx. 5 cm.
If the power window switch still was in the close position at the time of pinching, the close function is stopped
immediately. After releasing the switch the window moves back down approx. 1 cm only.
Adaptation of reference values in control module
Since the power windows normally become harder to move in the course of time adaptation is accomplished in
the door control module (N69/1, N69/2, N69/3 or N69/4) each time the window is opened/closed in the
synchronized state. For this purpose the pulse pattern of the previously received signals from the Hall sensors
(number, pulse duration, pulse/space ratio) is compared with the data stored and received last (old reference
values) and stored as a new reference, if it is within the permissible tolerance range.
This adaptation is not accomplished when

 pinching is recognized
 the power window is locked up.
The values remain stored even when the power window is disconnected from the power supply or
desynchronized.

POWER WINDOW SHORT STROKE, FUNCTION - GF72.29-P-4005A
MODEL 215
 Corresponding power window synchronized
Opening/closing driver/passenger door
To facilitate opening the driver or passenger door the corresponding side window is moved to the short stroke
position (approx. 4 mm below the end position "Window closed").
Motion is initialized by the left front door contact switch (S17/3)/right front door contact switch (S17/4) .
After the door is closed the corresponding side window moves to the end position "window closed" ensuring
that the window closes tightly (avoids wind noises while driving).
Opening/closing driver/passenger window
When the left or right front window is opened the associated rear side window is lowered automatically approx.
4 mm. This ensures malfunction-free operation of the front side window.
When the front side window is closed, the rear side window also closes completely.
(Prerequisite: rear side window still in short stroke position).
If side windows are not synchronized the associated rear side windows are only lowered to the short stroke
position; they are not closed.
When the front side window is opened the associated rear side window can only be closed to the short stroke
position.
REAR DOOR CONTROL MODULE ARRANGEMENT/PURPOSE/DESIGN/FUNCTION - GF72.29-P-

4102S
MODEL 220
Rear door GF72.29-

control module P-4102-
position 01S
Rear door GF72.29-
control module P-4102-
task 03S
GF72.29-
In combination with automatic air conditioning P-4102-03I
The initialization/electronic analysis system of the of the motors for the
rear left (M10/5) and rear right (M10/6) window regulators is located in
Rear door
the rear left (N69/3) and rear right (N69/4) door control modules . In
control module
addition, the control electronics for the seat adjustment, the heated seats and
design
the seat ventilation, together with the relevant control switches, are
integrated into these.
Function of The door control modules receive and transmit CAN messages, read
rear door switching statuses in, compare these data with stored values, and initialize
control module connected consumers.
Electric seat
adjustment GF91.29-
(ESA) P-0004S
function
Heated seats GF91.30-
(HS) function P-0003S
Seat GF91.30-
ventilation P-0002S
Electric power
windows GF72.29-
(EFH) P-0003S
function
Interior GF82.20-
lighting (IBL) P-0002S
function
Rear door control module, location - GF72.29-P-4102-01S
Model 220
The left rear door control module (N69/3) and the right rear door control module (N69/4) are located in the
left/right rear door below the door liner.
Illustration:
Fig. 7: Identifying Rear Door Control Module Location
Rear door control module, purpose - GF72.29-P-4102-03I
Purpose
The rear door control modules sense the window positions in the rear doors and transfer the information to the
passenger compartment bus (CAN-B).
The automatic AC push-button control module reads in the signals for the rear door window positions via the
CAN B bus to achieve better control when the windows are open.
When the convenience locking feature is activated by pressing the recirculated air button ( ) or the activated
charcoal filter button ( ) for > or = 1.5 s a signal is sent via the CAN B bus to the rear door control modules,
whereby the window positions are stored and all open windows are closed with the automatic one-touch up
feature.
When the button is pressed again for > or = 1.5 s the windows move back to the previously stored position.
Rear door control module, purpose - GF72.29-P-4102-03S
Model 220
The left rear door control module (N69/3) and right rear door control module (N69/4) serve for control of
 the left rear power window motor (M10/5)/right rear power window motor (M10/6),
 the solenoid valves for power locking
 the cigar lighter,
 the interior lights and the push-button unit illumination.
The door control modules read in the following switch states:
 Left rear power window switch (S20/1s3)/right rear power window switch (S20/1s4)
 Power seat adjustment switch
 Heated seat switch
 Seat ventilation switch
 Memory switch for storing and calling settings for the rear bench seat/rear bucket seats
 Left rear door power locking drive pawl microswitch (S86/3)/right rear door power locking drive pawl
microswitch (S87/5)
POWER WINDOW SWITCH, REAR DOORS, LOCATION/PURPOSE/DESIGN/FUNCTION -

GF72.29-P-4104S
MODEL 220
Power window switch, GF72.29-P-

rear doors, location 4104-01S
Power window switch, The switches serve for entry of the commands for opening
rear doors, purpose and closing the corresponding windows.
Power window switch, The switches are designed as rocker-type switches with five
rear doors, design mechanical positions.
Power window switch, GF72.29-P-
rear doors, function 4104-02S
Power window switch, rear doors, location - GF72.29-P-4104-01S
Model 220
The left rear power window switch (S21/3) and right rear power window switch (S21/4) are located in the
door liner on the corresponding rear door.
Fig. 8: Identifying Left And Right Rear Power Window Switch
Power window switch, rear doors, function - GF72.29-P-4104-02S
Model 220
The position of the rocker switch is voltage-coded by resistors. The coded voltage is read in by the left rear
door control module (N69/3)/right rear door control module (N69/4) .
The rocker switches have five mechanical positions:
Center position neutral

First catch (up) manual UP
Second catch (up) automatic UP
First catch (down) manual DOWN
Second catch (down) automatic DOWN
LEFT FRONT DOOR CONTROL MODULE, LOCATION/PURPOSE/DESIGN/FUNCTION -

GF72.29-P-4105S
MODEL 215, 220
Left front door control GF72.29-P-

module, location 4105-02S
Left front door control GF72.29-P-
Left-hand steering
module, purpose 4105-03S
GF72.29-P-
Right-hand steering
4105-03SA
Model 215 in combination with automatic air GF72.29-P-

conditioning 4105-03N
Model 220 in combination with automatic air GF72.29-P-
conditioning 4105-03I
The following is integrated into the door control module:
 Electronic actuation/evaluation circuitry for left front

Left front door control power window motor (M10/3) (vehicles with right-hand
module, design steering: right front power window motor (M10/4)
 Electronic actuation circuitry for driver's seat adjustment,
heating and seat ventilation with associated switches for
control
Function
Central locking (CL), GF80.20-P-
function 0005S
Power windows (PW), GF72.29-P-
Model 215
function 0003B
GF72.29-P-
Model 220
0003S
Electric seat adjustment GF91.29-P-
(ESA), function 0004S
Electric seat ventilation, GF91.30-P-
function 0002S
Heated seats (HS), GF91.30-P-
function 0003S
Power windows (PW), GF72.29-P-
function 0003S
Electrically adjustable
GF88.79-P-
exterior rearview mirror
0008S
(EAS), function
Interior lighting (IL), GF82.20-P-
function 0002S
GF82.10-P-
Exterior lighting
0003A
Convenience feature GF80.45-P-
(CF), function 0003S
GF91.29-P-
Memory switch
0001S
GF88.79-P-
Heated mirrors
2000S
Exterior rearview mirror GF88.79-P-
dimming feature 2003S
Left front door control module, location - GF72.29-P-4105-02S

Models 215, 220
The left front door control module (N69/1) is located in the driver's door below the door liner.
Fig. 9: Identifying Left Front Door Control Module Location - Illustrated On Model 220
Left front door control module, purpose - GF72.29-P-4105-03I
Purpose
The left front door control module senses the window position in the left front door and transfers the
information to the passenger compartment bus (CAN-B).
The automatic AC push-button control module reads in the signal for the left front window position via the
CAN B bus in order to achieve better control when the window is open.
charcoal filter button ( ) for > or = 1.5 s a signal is sent via the CAN B bus to the left front door control
module, whereby the window position is stored and the open window is closed with the automatic up feature.
When the button is pressed again for > or = 1.5 s the window moves back to the previously stored position.
The left front door control module reads in the dew point temperature via the CAN B bus allowing economical
operation of the exterior rearview mirror heater.
The dew point is calculated on the basis of input signals from the multifunction sensor and is transferred to the
CAN B bus via the automatic AC push-button control module.
Front diver-side door control module, purpose - GF72.29-P-4105-03N
Purpose
The front driver-side door control module senses the window position in the driver's door and stores this
information on the passenger compartment bus (CAN B).
The automatic air conditioning push-button control module reads in the signals for the window position in the
driver's door over the CAN B bus to achieve better control quality with the window open.
The door control module reads in the dew point temperature over the CAN B bus for efficient operation of the
outside rearview mirror defroster.
The dew point is a value calculated from the input signals of the multi-function sensor and is stored on the CAN
B bus by the automatic air conditioning push-button control module.
Left front door control module, purpose - GF72.29-P-4105-03S
Vehicles with left-hand steering only
The left front door control module (N69/1) connected to the CAN B bus serves for
 control of the left front power window motor (M10/3)

 control of all other power window motors (M10/4, M10/5, M10/6) via the CAN bus and the affected door
control modules (N69/2, N69/3, N69/4)
 control and operation of the left electrically adjustable and heated exterior rearview mirror (M21/1)
 operation of the right electrically adjustable and heated exterior rearview mirror (M21/2) via CAN bus
and the right front door control module (N69/2)
 actuation of interior lights and push-button unit illumination
 actuation of turn signal lamps in the left exterior rearview mirror
 actuation of the solenoid valve for power locking and
The door control module reads in the following switch states/signals:
 Power window switch including rear power window safety switch (S20/1s5) in the left front power
window switch group (S20/1)
 Remote trunk release switch (S20/1s6) in the left front power window switch group (S20/1)
 Left front door lock switch (CF) (S86/1)
 Seat adjustment switch, driver's seat
 Heated seat switch, driver's seat
 Seat ventilation switch, driver's seat
 Memory switch with associated "ergonomic" button for storing and calling positions for driver's seat,
interior and exterior rearview mirrors as well as steering column
 Left front door power locking drive pawl microswitch (S86/2)
 Potentiometer for position recognition of the left electrically adjustable and heated exterior rearview
mirror (M21/1)
 Left front door IR receiver (A26/1)
Left front door control module, purpose - GF72.29-P-4105-03SA
Vehicles with right-hand steering only
The right front door control module (N69/2) connected to the CAN B bus serves for
 control of the right front power window motor (M10/4)

 control of all other power window motors (M10/3, M10/5, M10/6) via the CAN bus and the affected door
control modules (N69/1, N69/3, N69/4)
 control and operation of the right heated exterior rearview mirror (M21/2)
 operation of the left electrically adjustable and heated exterior rearview mirror (M21/1) via CAN bus and
the left front door control module (N69/1)
 actuation of turn signal lamps in the left exterior rearview mirror
 Power window switch including rear power window safety switch (S20/1s5) in the left front power
window switch group (S20/1)
 Remote trunk release switch (S20/1s6) in the left front power window switch group (S20/1)
 Right front door lock switch (CF) (S87/1)
 Seat adjustment switch, driver's seat
 Heated seat switch, driver's seat
 Seat ventilation switch, driver's seat
 Memory switch with associated "ergonomic" button for storing and calling positions for driver's seat,
interior and exterior rearview mirrors as well as steering column
 Right front door power locking drive pawl microswitch (S87/4)
 Potentiometer for position recognition of the left electrically adjustable and heated exterior rearview
mirror (M21/2)
 Right front door IR receiver (A26/2)
FRONT PASSENGER SIDE DOOR CONTROL MODULE

ARRANGEMENT/PURPOSE/DESIGN/FUNCTION - GF72.29-P-4106S
MODEL 215, 220
Front passenger GF72.29-

side door control P-4106-
module position 02S
Front passenger GF72.29-
side door control Left-hand steering P-4106-
module task 03S
GF72.29-
Right-hand steering P-4106-
03SA
GF72.29-
Model 220 in combination with automatic air conditioning P-4106-03I
GF72.29-
Model 215 in combination with automatic air conditioning P-4106-
03N
The door control module contains the initialization/electronic analysis
system for the motor for the front right window regulator (M10/4)
Front passenger
(right-hand steering: motor for front left window regulator (M10/3). In
side door control
addition, the control electronics for the driver's side seat adjustment, the
module design
heated seats and the seat ventilation, together with the relevant control
switches, are integrated into this.
Function
Central locking GF80.20-
(CL) function P-0005S
Electric seat
GF91.29-
adjustment (ESA)
P-0004S
function
Seat ventilation GF91.30-
function P-0002S
Heated seats (HS) GF91.30-
function P-0003S
Electric power
GF72.29-
windows (EFH) Model 215
P-0003B
function
GF72.29-
Model 220
P-0003S
Convenience
GF80.45-
feature (CF)
P-0003S
function
Memory switch GF91.29-
function P-0001S
Heated mirrors GF88.79-
function P-2000S
Exterior lighting GF82.10-
function P-0003A
Interior lighting GF82.20-
(IBL) function P-0002S
Right front door control module, location - GF72.29-P-4106-02S
Models 215, 220
The right front door control module (N69/2) (vehicles with right-hand steering: left front door control module
(N69/1)) is located in the passenger door below the door liner.
Fig. 10: Identifying Right Front Door Control Module Location - Models 215, 220
Right front door control module, purpose - GF72.29-P-4106-03I
Purpose
The right front door control module senses the window position in the right front door and transfers the
information to the passenger compartment bus (CAN-B).
The automatic AC push-button control module reads in the signal for the right front door window position via
the CAN B bus in order to achieve better control when the window is open.
charcoal filter button ( ) for > or = 1.5 s a signal is sent via the CAN B bus to the right front door control
module, whereby the window position is stored and the open window is closed with the automatic up feature.
When the button is pressed again for > or = 1.5 s the window moves back the previously stored position.
The right front door control module reads in the dew point temperature via the CAN B bus allowing economical
operation of the exterior rearview mirror heater.
The dew point is calculated on the basis of input signals from the multifunction sensor and is transferred to the
CAN B bus via the automatic AC push-button control module.
Front passenger-side door control module, purpose - GF72.29-P-4106-03N
Purpose
The front passenger-side door control module senses the window position in the passenger door and stores this
information on the passenger compartment bus (CAN B).
The automatic air conditioning push-button control module reads in the signals for the window position in the
passenger door over the CAN B bus to achieve better control quality with the window open.
The door control module reads in the dew point temperature over the CAN B bus for efficient operation of the
outside rearview mirror defroster.
The dew point is a value calculated from the input signals of the multi-function sensor and is stored on the CAN
B bus by the automatic air conditioning push-button control module.
Right front door control module, purpose - GF72.29-P-4106-03S
Vehicles with left-hand steering Models 215, 220
The right front door control module (N69/2) connected to the CAN B bus serves for
 control of the right front power window motor (M10/4)

 control of the right electrically adjustable and heated exterior rearview mirror (M21/2) whereby control of
the left front door control module (N69/1) is accomplished via the CAN
 Right front power window switch (S21/2)

 Right front door lock switch (CF) (S87/1)
 Seat adjustment switch, passenger seat
 Heated seat switch, passenger seat
 Seat ventilation switch, passenger seat
 Memory switch for storing and calling passenger seat positions
 Right front door power locking drive pawl microswitch (S87/4)
 Right electrically adjustable and heated exterior rearview mirror (M21/2)
 Right front door IR receiver (A26/2)
Right front door control module, purpose - GF72.29-P-4106-03SA

Vehicles with right-hand steering Models 215, 220
The left front door control module (N69/1) connected to the CAN B bus serves for
 control of the left front power window motor (M10/3)

 control of the left electrically adjustable and heated exterior rearview mirror (M21/1) whereby control of
the right front door control module (N69/2) is accomplished via the CAN
 Right front power window switch (S21/2)

 Left front door lock switch (CF) (S86/1)
 Seat adjustment switch, passenger seat
 Heated seat switch, passenger seat
 Seat ventilation switch, passenger seat
 Memory switch for storing and calling passenger seat positions
 Left front door power locking drive pawl microswitch (S86/2)
 Right electrically adjustable and heated exterior rearview mirror (M21/1)
 Left front door IR receiver (A26/1)
FRONT POWER WINDOW MOTOR, LOCATION/FUNCTION - GF72.29-P-4108
Front power window motor, location/function - GF72.29-P-4108A
MODEL 215
Front power window motor, location
Fig. 11: Identifying Front Power Window Motor Location

Front power The motors installed are DC motors which turn to the left or right depending on the
window motor, polarity of the armature voltage. They are equipped each with an overheat protection
function switch and with two hall sensors for position recognition.
Front power window motor, location/function - GF72.29-P-4108S
MODEL 220
Front power window motor, location GF72.29-P-4108-01S

Front power window motor, function GF72.29-P-4108-02S
Front power window motor, location - GF72.29-P-4108-01S
Model 220
The left front power window motor (M10/3)/right front power window motor (M10/4) is located in the
driver's door / passenger door below the door liner.
Fig. 12: Identifying Front Power Window Motor Location
Front power window motor, function - GF72.29-P-4108-02S
Model 220
Function
The left front power window motor (M10/3) and the right front power window motor (M10/4) are DC
motors which rotate clockwise or counter-clockwise depending on the polarity of the armature voltage.
The motors are actuated by the left front door control module (N69/1)/right front door control module
(N69/2) . Each motor has a thermostatic protection switch and two Hall sensors each for position recognition.
REAR POWER WINDOW MOTOR, LOCATION/FUNCTION - GF72.29-P-4109
Rear power window motor, location/function - GF72.29-P-4109A
MODEL 215
Rear power window motor, location
Fig. 13: Identifying Rear Power Window Motor Location
Rear power The motors installed are DC motors which turn to the left or right depending on the
window motor, polarity of the armature voltage. They are equipped each with an overheat protection
function switch and with two hall sensors for position recognition.
Rear power window motor, location/function - GF72.29-P-4109S
MODEL 220
Rear power window motor, location GF72.29-P-4109-01S

Rear power window motor, function GF72.29-P-4109-02S
Rear power window motor, location - GF72.29-P-4109-01S
Model 220
The left rear power window motor (M10/5)/right rear power window motor (M10/6) are located in the
left/right rear door below the door liner.
Fig. 14: Identifying Rear Power Window Motor Location
Rear power window motor, function - GF72.29-P-4109-02S
Model 220
Function
The left rear power window motor (M10/5) and the right rear power window motor (M10/6) are DC
motors which rotate clockwise or counter-clockwise depending on the polarity of the armature voltage.
The motors are actuated by the left rear door control module (N69/3)/right rear door control module
(N69/4) . Each motor has a thermostatic protection switch and two Hall sensors each for position recognition.
REAR CENTER CONSOLE POWER WINDOW SWITCH COMBINATION, LOCATION/FUNCTION

- GF72.29-P-4110A
MODEL 215
Fig. 15: Identifying Center Console Power Window Switches
The position of the two rocker switches is voltage coded with

Power window switch combination
resistors. The coded voltage is read in by the rear control module
in rear center console, function
(N22/6).
LEFT FRONT POWER WINDOW SWITCH GROUP, LOCATION/PURPOSE/DESIGN/FUNCTION -
GF72.29-P-4112S
MODEL 220
Left front power

GF72.29-P-
window switch
4112-01S
group, location
Left front power
GF72.29-P-
window switch
4112-03S
group, purpose
The power window switches are toggle switches with five mechanical
Left front power
stages; the power window safety switch (S20/1s5) is a sliding switch
window switch
with two switch positions; the remote trunk release switch (S20/1s6) is
group, design
a normally open switch which can be actuated by pulling upward.
Left front power
GF72.29-P-
window switch
4112-02S
group, function
Left front power window switch group, location - GF72.29-P-4112-01S
Model 220
The left front power window switch group (S20/1) is located in the driver's door.
Fig. 16: Identifying Front Power Window Switch Group Location
Left front power window switch group, function - GF72.29-P-4112-02S

Model 220
Function
The switch positions for the power window switches (S20/1s1, S20/1s2, S20/1s3, S20/1s4) are voltage-coded
by resistors in the left front power window switch group (S20/1) . The coded voltage is read in by the left
front door control module (N69/1) .
The switches have five mechanical positions:
Center position neutral

First catch (up) manual UP
Second catch (up) automatic UP
First catch (down) manual DOWN
Second catch (down) automatic DOWN
Left front power window switch group, purpose - GF72.29-P-4112-03S
Model 220
The power window switches in the left front power window switch group (S20/1) serve for entry of
commands for opening and closing the corresponding window. Control of the rear power window with the left
rear power window switch (S21/3) and right rear right power window (S21/4) can be disabled with the
power window safety switch (S20/1s5) . The trunk lid can be released with the remote trunk release switch
(S20/1s6) . The switch status is displayed by an LED.
FRONT DOOR CONTROL MODULE, DRIVER'S SIDE, LOCATION/DESIGN - GF72.29-P-4115S
MODEL 215, 220 as of 1.9.02
Location shown on model 220 with left-hand steering

Fig. 17: Identifying Door Control Module, Driver's Side Location
Left front door

The left front door control module (N69/1) is located in the driver's door below the
control module,
inner paneling.
location
Left front door The door control module connected to the CAN bus serves to control the power
control module, window motor, the outside rearview mirror, to actuate the lamps of the inner and
purpose switch illumination and to control the solenoid valve for power closing.
FRONT DOOR CONTROL MODULE, FRONT PASSENGER SIDE, LOCATION/DESIGN - GF72.29-

P-4116S
MODEL 215, 220 as of 1.9.02
Location shown on model 220 with left-hand steering

Fig. 18: Identifying Front Door Control Module Front Passenger Side Location
Right front door The right front door control module (N69/2) (right-hand steering: left front door
control module, control module (N69/1)) is located in the front passenger door below the inner
location paneling.
Right front door The door control module connected to the CAN bus serves to control the power
control module, window motor, the outside rearview mirror, to actuate the lamps of the inner and
purpose switch illumination and to control the solenoid valve for power closing.
TROUBLE DIAGNOSIS
WIND NOISES AT DRIVER AND PASSENGER DOORS - AF72.10-P-1102BG
MODEL 215
Damage Cause Remedy

code
72 001 39 Cause 1 Remedy 1
Wind noises at door handle can be
Only up to VIN 018067
heard in passenger compartment
AR72.10-P-
1 Remove door liner on front door
1000N
2 Remove inner and outer shaft seal
3 Position shaped foam block (1) into
rear upper door corner from bottom
Cause 2 Remedy 2
Foam seal too small on rear side
window Only up to VIN 004263
AR67.30-P-
1 Remove rear side window glass
4000N
2 Replace foam seal (2)
Fig. 19: Identifying Shaped Foam Block And Foam Rubber Seal Location

215 727 01 90 Left shaped foam block (vapor barrier) 1
215 727 02 90 Right shaped foam block (vapor barrier) 1
215 673 05 98 Foam tape 2
FAILURE OF ILLUMINATION FOR SEAT ADJUSTMENT, MIRROR ADJUSTMENT AND POWER

WINDOWS - AF72.29-P-2000A
MODEL 215.### #A as of 009713 up to 010142
MODIFICATION NOTES
7.11.00 Supersedes STIP 82.20-002 dated 10.11.2000
Damage Cause Remedy

code
72 220
Left front Left/right
door door control AR72.29-P-
72 230 unit 1000N
Right defective. 1 Remove/install/replace left/right door control unit.
front door
When the illumination is switched on and the engine
is running, the illumination for the seat adjustment switch, the Order
mirror adjustment and the power windows can fail when the replacement
left or right power window switch is actuated. The parts with ES2
illumination switches back on again after approx. 6 seconds.
2 Normalize power windows.

A 215 820 77 10 Door control unit (left-hand steering) As required
A 215 820 82 10 Door control unit (left-hand steering) As required
A 215 820 78 10 Door control unit (right-hand steering) As required
A 215 820 81 10 Door control unit (right-hand steering) As required
ELECTRIC POWER WINDOW DRIVE FAILURE - AF72.29-P-6000B
MODEL 220.### ## up to 316070, 215.### ## up to 032099, 203.### #A up to 399349, 203.### #F up to

326375, 203.### #R up to 073429
MODIFICATION NOTES
29.3.00 Supersedes STIP 72.19-012
dated 21.03.2000

72 222 Tension in power 1 Check seal for soiling and
window drive. clean and lubricate if
necessary
Power window Window should run AR72.29-P-1860M
motor locks up during easily (without sluggishness in
raising. Window seals)
reverses or locks up
during automatic
raising. Failure of
power window motor.
2 Remove/install/replace
power window motor

220 820 46 42 Right power window motor As required
220 820 45 42 Left power window motor As required
OUTSIDE REARVIEW MIRROR MALFUNCTION - AF72.29-P-6005A
MODEL 220
MODIFICATION NOTES
2.5.01 Replaces STIP 88.70-007 dated 30.05.2001 Content updated
Damage Cause Remedy

code
As of VIN end number 219160, door
Software error in door control unit
72 23 ER control units with new software are installed
on passenger side
(Q08 and higher).
When backing into a
parking space the outside rearview
On older vehicles: ?
mirror on the passenger side moves
to the park position.
The current driving position is stored
before the park position is assumed. 1.1 Remove/install/replace door control unit AR72.29-
This driving position is resumed on passenger side. P-1000M
afterwards.
The position of the mirror is detected
by means of a potentiometer (analog Replacing the door control unit will
signal). To allow the position to be only remedy the problem "Front passenger
stored in the door control unit, this outside mirror no longer returns precisely to
analog signal must be converted into its driving position".
a digital signal.
In the case of complaints, for
A certain degree of inaccuracy is example:
associated with this analog/digital "Front passenger outside mirror moves to
conversion. This inaccuracy may limit stop when returning to driving position"
increase after several analog/digital or "Front passenger outside mirror moves to a
conversions. completely implausible position when
returning to driving position": ?
As a result, the resumed driving
position may deviate from the 1.2 Check outside mirror motor.
position set by the customer.
"Front passenger outside mirror stops at park
position": ?
1.3 Check the following conditions (which
have to be fulfilled):
 Reverse gear should no longer be

engaged.
 Mirror selection switch must be set to
front passenger side.
220 821 98 Door control unit (+ color code 7C45) as of Q-status Q08, vehicles with memory As
51 (left-hand drive vehicles) required
220 821 97 Door control unit (+ color code 7C45) as of Q-status Q08, vehicles with memory As
51 (right-hand drive vehicles) required
Door control unit (+ color code 7C45) as of Q-status Q02, vehicles without
220 821 32 As
memory (left-hand drive vehicles)
58 required
Replaces part no. 220 821 92 51.
Door control unit (+ color code 7C45) as of Q-status Q02, vehicles without
220 821 31 memory (right-hand drive vehicles) As
58 required
Replaces part no. 220 821 91 51.
MALFUNCTION OF CLOSING ASSIST - AF72.29-P-6006A
MODEL 215, 220
MODIFICATION NOTES
17.12.01 Replaces STIP 72.19-015 dated 14.12.2001
Damage Cause Remedy

code
Door
control
unit
72 220 EZ
Fault code B1602 "Power closing solenoid
(left front)
valve is faulty; open circuit" is stored in the door 1 Delete fault memory of door
72 230 EZ
control unit and the closing assist for the associated control unit concerned.
(right
door no longer functions.
front)
73 220 EZ
(rear
door)
Door
lock: 2 Check power closing solenoid
72 111 73 valve using DAS.
The power closing function of the associated door will
(front To do so, use the DAS to
remain deactivated for as long as fault code B1602 in
door) monitor the actual values of the
the door control unit is current and/or stored.
73 111 73 power closing solenoid valve in the
(rear door control unit.
door)
Cause 1: Procedure:
Check the door control unit using

the DAS:
 Actual values
 Power closing solenoid valve
The fault B1602 will be stored in the door control unit
if connector 8 (power closing valve) is disconnected The actual value for the power
from the left/right front or left/right rear door control closing solenoid valve is set to
unit although the door control unit is still being supplied "OFF" if the door is open or
with voltage (battery is connected and connector 1 for completely closed.
voltage supply of the door control unit is connected). Close door to first detent.
While the door is being pulled
closed, the actual value changes to
"ON" for approx. 2 seconds.
If the actual values are OK and the
power closing function is working
properly, neither the door control
unit nor the door lock should be
As a result, power closing ceases to function. replaced.
The fault was in fault code B1602
stored in the door control unit (see
Causes).
Power closing does not
Cause 2: function even after the fault code
has been deleted: ?
3 Use DAS to check that power
closing is functioning.
The fault B1602 will be stored in the door control unit Open the vehicle using the DAS:
if, when the door control unit is replaced, first the
voltage supply (connector 1) and then connector 8  Functions covering all control
(power closing valve) is connected to the left/right front units
or left/right rear door control unit.  Convenience systems
 Power closing
 Function test
Carry out function test step by step

As a result, power closing ceases to function. in the way described.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: DOORS - AR72.00-Z-9215AA
MODEL 215
AR72.10-P-
Remove/install front door MODEL 215
0500N
Adjust front door MODEL 215 AR72.10-P-
0550N
AR72.10-P-
Remove/install door lining on front door MODEL 215
1000N
AR72.10-P-
Remove/install front door foil MODEL 215
1010N
AR72.10-P-
Remove/install inner sealing rail MODEL 170, 208.3, 215
1600G
AR72.10-P-
Removing and installing sealing rail on outside MODEL 215
1700N
Removing and installing window lift mechanism AR72.10-P-
MODEL 215
in front door 1800N
Removing and installing crank window in front AR72.10-P-
MODEL 215
door 1900N
AR72.10-P-
Adjust front door crank window MODEL 215
1950N
AR72.10-P-
Removing and installing multi-joint hinge MODEL 215
2110N
AR72.10-P-
Removing and installing door sealing frame MODEL 215
2120N
Removing and installing exterior door handle on AR72.10-P-
MODEL 215, 220
front door 2400M
Removing and installing exterior door handle on MODEL 215, 220 with CODE AR72.10-P-
front door (889) Keyless go 2400N
AR72.10-P-
Remove/install front door lock MODEL 215
4011N
Removing and installing front power window AR72.29-P-
MODEL 215
switches 0100N
Removing and installing switch module for power AR72.29-P-
MODEL 215
window switches 0120N
AR72.29-P-
Removing and installing front door control module MODEL 215
1000N
Removing and installing power window motor in AR72.29-P-
MODEL 215
front door 1860N
TESTING AND REPAIR WORK: PASSENGER CARS: DOORS - AR72.00-Z-9220AA
MODEL 220
AR72.10-P-
Remove/install inner door panel MODEL 220.1 /8 with CODE (Z07) Top protection
0104MB
MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
Remove, install inner door panel
armoring 0104MC
AR72.10-P-
Remove/install front door MODEL 220
0500M
AR72.10-P-
Adjust front door MODEL 220
0550M
Remove/install door lining on MODEL 220 except CODE (Z07) Top protection AR72.10-P-
front door except CODE (Z04) Light armoring 1000M
AR72.10-P-
Remove/install front door lining MODEL 220.1 /8 with CODE (Z07) Top protection
1000MB
Remove/install door lining on MODEL 220.174 /175 /176 /178 with CODE (Z04) AR72.10-P-
front door Light armoring 1000MC
Remove, install door foil on front
door armoring 1010MC
MODEL 220.1 /8 with CODE (Z07) Top protection AR72.10-P-
Remove/install window guide rail
Rear guide rail 1500MB
MODEL 220.1 /8 with CODE (Z07) Top protection AR72.10-P-
Remove/install window guide rail
Front guide rail 1500MBA
AR72.10-P-
Remove/install inner sealing rail MODEL 202, 210, 220, 240
1600E
AR72.10-P-
Remove/install outer sealing rail MODEL 202, 210, 220, 240
1700E
Remove/install power window on AR72.10-P-
MODEL 220
front door 1800M
Remove/install front door power MODEL 220.175 /178 with CODE (Z07) Top AR72.10-P-
window protection 1800MB
Removing and installing front door MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
power window armoring 1800MC
Remove/install front door crank AR72.10-P-
MODEL 220
window 1900M
Remove/install sealing for crank MODEL 220.1 /8 with CODE (Z07) Top protection AR72.10-P-
window on front door outer sealing 1905MB
window on front door Inner sealing 1905MBA
AR72.10-P-
Remove/install front door window MODEL 220.1 /8 with CODE (Z07) Top protection
1910MB
Remove, install window in front MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
AR72.10-P-
Adjust front door window MODEL 220.1 /8 with CODE (Z07) Top protection
1921MB
Adjusting crank window in front AR72.10-P-
MODEL 220
door 1950M
Removing and installing door AR72.10-P-
MODEL 220
catch 2100M
Removing and installing door MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
catch armoring 2100MC
AR72.10-P-
Remove/install door sealing frame MODEL 220
2120M
MODEL 220.175 /178 with CODE (Z07) Top AR72.10-P-
Remove/install front door damper
protection 2200MB
Remove, install front door damper
armoring 2200MC
Removing and installing exterior AR72.10-P-
MODEL 215, 220
door handle on front door 2400M
Remove/install exterior door MODEL 220.175 /178 with CODE (Z04) Light AR72.10-P-
handle on front door armoring with CODE (Z07) Top protection 2400MB
Removing and installing exterior AR72.10-P-
MODEL 215, 220 with CODE (889) Keyless go
door handle on front door 2400N
Removing and installing front door AR72.10-P-
MODEL 220
lock 4011M
Remove/install front door lock
protection 4011MB
Removing and installing front door MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
lock armoring 4011MC
Remove/install hinge strap of front MODEL 220.175 /178 with CODE (Z07) Top AR72.10-P-
door handle protection 4012MB
Remove, install bearing bracket of MODELS 220.175 /178 with CODE (Z04) Light AR72.10-P-
front door handle armoring 4012MC
Remove/install rear door inner AR72.12-P-
door panel 0104MB
Remove, install rear door inner MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
door panel armoring 0104MC
Remove/install door foil on rear AR72.12-P-
door 0105MB
Remove, install door foil on rear MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
Remove/install door foil on rear AR72.12-P-
MODELS 220.875 /878
door 0105MP
AR72.12-P-
Remove/install rear door MODEL 220
0600M
AR72.12-P-
Adjust rear door MODEL 220
0650M
Remove/install door lining on rear AR72.12-P-
MODEL 220 ...
door 1010M
AR72.12-P-
Remove/install rear door lining MODEL 220.1 /8 with CODE (Z07) Top protection
1010MB
Removing and installing rear door MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
liner armoring 1010MC
Remove/install door lining on rear MODEL 220.875 /878 with code (P082) Curtains AR72.12-P-
door electrically adjustable 1010MP
Remove/install sealing strip on AR72.12-P-
MODEL 203, 209, 220 ...
door bottom edge 1019P
Remove/install sealing strip on AR72.12-P-
MODEL 203, 209, 220 ...
door bottom edge 1019PA
Remove/install window guide rail AR72.12-P-
for rear door 1500MB
Remove/install power window on AR72.12-P-
MODEL 220
rear door 1810M
Remove/install rear door window AR72.12-P-
lifter 1810MB
power window armoring 1810MC
Remove/install crank window in AR72.12-P-
MODEL 220
rear door 1910M
window on rear door Outer sealing 1911MB
window on rear door Inner sealing 1911MBA
AR72.12-P-
Remove/install rear door window MODEL 220.1 /8 with CODE (Z07) Top protection
1920MB
Remove, install window in rear MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
Adjust rear door window
protection 1921MB
Remove/install rear door triangular AR72.12-P-
window 1940MB
Remove, install rear door MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
triangular window armoring 1940MC
Remove/install fixed window in AR72.12-P-
MODEL 220
rear door 1970M
Remove, install rear door catch
armoring 2100MC
Remove/install rear door damper
protection 2200MB
Remove, install rear door damper
armoring 2200MC
Removing and installing outer AR72.12-P-
MODEL 220 up to 31.8.99
door handle on rear door 2410M
Removing and installing outer AR72.12-P-
door handle on rear door 2410MA
Remove/install outer rear door MODEL 220.175 /178 with CODE (Z04) Light AR72.12-P-
handle armoring with CODE (Z07) Top protection 2410MB
Removing and installing door lock AR72.12-P-
MODEL 220 up to 31.8.99
on rear door 2510M
Removing and installing door lock AR72.12-P-
on rear door 2510MA
Remove/install rear door lock
protection 2510MB
lock armoring 2510MC
Remove/install hinge strap for rear MODEL 220.175 /178 with CODE (Z07) Top AR72.12-P-
door handle protection 4012MB
Remove, install bearing bracket for MODELS 220.175 /178 with CODE (Z04) Light AR72.12-P-
rear door handle armoring 4012MC
AR72.14-P-
Remove/install center door MODEL 220.875/ 878
0010MP
AR72.14-P-
Adjust center door MODEL 220.875/ 878
0015MP
AR72.14-P-
Remove/install adjustment plate MODEL 220.875/ 878
0020MP
MODELS 220.875 /878
center door lock 0102MP
Remove/install door foil on center AR72.14-P-
MODEL 220.8 with CODE (Z07) Top protection
door 0105MB
Remove/install door foil on center AR72.14-P-
MODELS 220.875 /878
door 0105MP
Remove/install inner door panel on AR72.14-P-
center door 0140MB
Remove/install window in center AR72.14-P-
door 0150MB
Remove/install rubber seal for MODEL 220.8 with CODE (Z07) Top protection AR72.14-P-
window guide from center door Outer rubber seal 0200MB
Remove/install rubber seal for MODEL 220.8 with CODE (Z07) Top protection AR72.14-P-
window guide from center door Inner rubber seal 0200MBA
Remove/install sealing rail on AR72.14-P-
outer center door 0250MB
Remove/install switches for power AR72.29-P-
MODEL 220
window in rear doors 0002M
Remove/install front power AR72.29-P-
MODEL 220
window switches 0100M
Remove/install front door power AR72.29-P-
MODEL 220
window switch group 0110M
Remove/install front door control AR72.29-P-
MODEL 220
module 1000M
Removing and installing rear door AR72.29-P-
MODEL 220
control module 1100M
Remove/install front door power AR72.29-P-
MODEL 220
window motor 1860M
Remove/install rear door power AR72.29-P-
MODEL 220
window motor 1880M
Remove/install power window and AR72.29-P-
MODEL 220.875 /878 to dividing wall
motor 5622MP
REMOVE/INSTALL INNER DOOR PANEL - AR72.10-P-0104
Remove/install inner door panel - AR72.10-P-0104MB
Fig. 20: Identifying Inner Door Panel Remove/Install Components - Top Protection
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.
Notes on performing repair, body
AH91.00-P-
work and welding on vehicles with
0002-01M
airbags and ETR units
Legal requirements for handling and
AH91.00-P-
storing airbags and emergency
0004-01A
tensioning retractors
AR72.10-P-
1 Remove front door lining
1000MB
3 Disconnect plug (4) from driver

sidebag squib (R12/9) or front
passenger sidebag squib (R12/10)
on sidebag unit
Detach electric and pneumatic lines
4
from inner door panel (1)
Unscrew bolts at circumference of Installation: Observe installation
5
inner door panel (1) position of screws.
Remove inner door panel (1) while Installation: Remove old sealing
6 guiding operating cable (2) and strip from inner door panel (1) and install
release linkage (3). new sealing strip.
*BR00.45-Z-
Sealing strip
1036-01A
REPAIR MATERIALS
BR00.45-Z-1036-01A Sealing strip A 140 989 00 98
Remove, install inner door panel - AR72.10-P-0104MC
MODELS 220.175 /178 with CODE (Z04) Light armoring
Fig. 21: Identifying Inner Door Panel Remove/Install Components - Light Armoring
Remove
Operations involving work on glass panes Secure windshield and windows from
and windows are potentially dangerous; dropping down; use only the lifting AS67.00-Z-
use caution to avoid allowing hands or tools specified for such operations. 0003-01A
feet to become caught. Wear safety shoes.
MODEL 210 with Code Z04, Code
Instructions for avoiding damage to
Z06 AH67.00-P-
windows installed in special high-security
MODEL 220 with Code Z04, Code 0003-01FB
vehicles
Z07
AR72.10-P-
1 Remove door liner from front door
1000MC
AR72.10-P-
2 Remove front door foil
1010MC
Remove foil under side airbag AR91.60-P-
3 Remove front door side airbag unit
unit. 0690MC
4 Remove armor plate (2) from door lock Detach Bowden cable.
5 Detach door release knob (3)
6 Detach inner sealing rail (4)
Detach electric cable for side airbag unit
7 and pneumatic line for door lock from Install lines in correct position
inner door panel (1)
Position window so that the bolts (5) are
8 Connect door control module.
accessible
9 Secure window with clamping pliers Use protective foil.
Tensioning clamp Fig. 22
Lower power window to approx. 5 mm
11 Connect door control module.
before the limit stop
12 Unscrew bolts at inner door panel (1)
Do not bend inner door panel when
13 Detach inner door panel (1)
removing.
Install
Remove sealant from inner door panel (1)
14
and door panel
15 Apply sealing profile to door panel +Refer to: ?
AH72.10-P-
Sealant pattern on front door panel
0001-01MC
*BR00.45-Z-
Sealing strip Ø 5 mm
1036-01A
Position window so that it is open approx.
16 Tensioning clamp Fig. 22
10 mm and secure using clamping pliers
Locking rod must be installed
in door lock.
Position inner door panel so that the
17 Insert inner door panel (1)
bores for the door lining clips are
located in the center of the recess
clearances (arrow).
18 Position bolts in inner door panel (1) and Re-tighten bolts prior to
tighten installing the door foil.
Remove excess sealant from the cutouts
19 (arrow) in the inner door panel using a
blade
Connect door control module,
position window and power window
20 Screw in bolts (5) accordingly.
Ensure correct seating of window in
power window.
*BA72.10-P-
1006-01EA
Attach electric and pneumatic lines on
21 Replace cable connectors.
inner door panel (1)
22 Attach inner sealing rail (4)
23 Attach door release knob (3)
24 Install armor plate (2) on door lock Attach Bowden cable.
*BA72.10-P-
1003-01EA
Attach foil under side airbag AR91.60-P-
25 Install front door side airbag unit
unit. 0690MC
*BR00.45-Z-
1036-01A
AR72.10-P-
26 Install front door foil
1010MC
AR72.10-P-
27 Install door liner in front door
1000MC
FRONT DOOR TIGHTENING TORQUE

Number Designation MODEL 220 with CODE
Z04
BA72.10-P-1003- Bolt for outer door lock armor plate to front M6 Nm 8
01EA door M8 Nm 23
BA72.10-P-1006-
Bolt for power window to window Nm 8
01EA

REPAIR MATERIALS
REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500
Remove/install front door - AR72.10-P-0500M
MODEL 220
Fig. 23: Identifying Front Door Remove/Install Components - Model 220
MODIFICATION NOTES
28.3.07 Notes on replacing a door added
Remove/install
Press molding strip (1) out of door control
1 Fig. 24
unit cover (2) with assembly wedge
Remove door handle cover (3) from door
2
handle
Unscrew screws from door control unit cover Except CODE (Z07) Top AR72.10-P-
3 (2) and press door control unit cover (2) off protection except CODE (Z04)
1000M
of front door liner (4) with assembly wedge Light armoring
Fig. 24
Disconnect connectors from door control unit
4
and remove paneling
5 Unclip protective hose (5) from A-pillar
Remove CL line and electrical connectors Remove door lining from inner
6 door panel in area of cable and
from front and route through wiring duct (6)
connectors with assembly wedge.
Fig. 24
Unscrew bolts on door retaining strap (7) *BA72.10-P-
7
from A-pillar 1004-01E
Remove door with aid of
8 Unscrew nuts (8) from door hinges second person, avoid damaging
paint.
*BA72.10-P-
1004-01E
Lift front door and remove upward,
simultaneously pull CL line out of front door
9
through cable duct (6) together with electrical
lines
When replacing a door?
When replacing a door, perform
10 Set down front door seam sealing and cavity
preservation.
Check rubber seal for corrosion
and clean if necessary
Treat door frame in area of contact
*BR00.45-Z-
surface of rubber seal with MB
1003-05A
preservative
11 Install in the reverse order Fig. 25
Following installation,
check gap dimensions throughout.
AR60.00-P-
0700-01M
Gaps on hoods, doors and lids.
*BE60.00-P-
1002-01A
If applicable, adjust front AR72.10-P-
door 0550M
220.875/878
Front door to A- Dimension
mm 8.0 (± 0.5) 6.5 (± 0.5)
pillar "B"
Dimension
Front door to fender mm 5.0 (± 0.5) 5.0 (± 0.5)
"H"
Front door to rear Dimension mm 5.0 (± 0.5) -

door "I"
Dimension
Front door to roof mm 8.0 (± 0.5) 6.5 (± 0.5)
"C"
Rear door to top of Dimension
mm 5.0 (± 0.5) 5.0 (± 0.5)
side section "D"
Rear door to side Dimension
BE60.00-P- Gap mm 5.0 (± 0.5) 5.0 (±0.5)
section, bottom "J"
1002-01A dimension
Dimension
Fender to A-pillar mm - -
"Q"
Dimension
mm - -
Front door to rear "P"
fender AR60.00-P- AR60.00-P-0700-
See picture
0700-01M 01MP

BA72.10-P-1003-01E Nut on door hinge Nm 25
BA72.10-P-1004-01E Screw for door holder on body Nm 14
REPAIR MATERIALS
Remove/install front door - AR72.10-P-0500N

MODEL 215
Fig. 26: Identifying Front Door Remove/Install Components (1 Of 2)
Fig. 27: Identifying Front Door Remove/Install Components (2 Of 2)
Remove/Install
Risk of injury. Injuries may result Store airbag unit with deployment face
when performing testing or repair work up, do not subject to temperatures above AS91.00-Z-
on airbag or emergency tensioning 100 °C. When working on these units, 0001-01A
retractor units. disconnect the power supply.
Danger when processing magnesium AS60.00-Z-
components 0005-01N
OS60.00-P-
Recycling of magnesium components
0002-01N
AR72.10-P-
2 Remove/install door liner on front door
1000N
Remove sound deadening mat (2)
3 above the CL line (3) and the electrical
lines
Unplug the connector from
4 driver/passenger side airbag squib
(R12/9; R12/10)
5 Disconnect CL line (3)
Disconnect left; right (X1/6; X1/7) in-
6
door speaker connector
Open CL line (3) and electrical line tie
7 Installation: Replace tie strap
straps
Unclip protective tube (4) from front
8
door (1)
Pull the CL line (3), together with the
9 electrical lines from the front door (1)
via the cable duct (5)
Secure the door with the assistance of *BA72.10-P-
Unscrew bolts (7) from multi-joint
10 a second person, avoid damaging the
hinge (6) 1001-01E
paint
Fig. 29
Remove the front door (1) to the rear
11 Do not damage paintwork
and lay down
When replacing a door, carry out seam
sealing and cavity preservation
12 Install in the reverse order Following installation, check joint Fig. 25

dimensions throughout
Joint dimensions on hoods, doors *BE60.00-P-
and covers 1002-01A
AR72.10-P-
If applicable, adjust front door 0550N
Dimension
Front door to A-pillar mm -
"B"
Front door to fender mm 4.5 (± 0.5)
Dimension
"H"
Front door to rear door Dimension "I" mm -
Dimension
Front door to roof mm -
"C"
Rear door to upper side Dimension
mm -
section "D"
BE60.00-P-1002- Gap Rear door to lower side
01A dimension Dimension "J" mm -
section
Dimension
Fender to A-pillar mm -
"Q"
Dimension
mm 4.5 (± 0.5)
"P"
Front door to rear fender
AR60.00-P-0700-
Fig., see
01N

BA72.10-P-1001-01E Bolt, door hinge to A-pillar Nm 32
Fig. 28: Identifying Feeler Gage (129 589 03 21 00)
ADJUST FRONT DOOR - AR72.10-P-0550
Adjust front door - AR72.10-P-0550M
MODEL 220
Fig. 30: Identifying Front Door Contour To Front Fender, Contour To Rear Fender And Contour To A-
Pillar And Roof Paneling
Fig. 31: Identifying Front Door Bolts And Hinge On Inner Door Panel
Fig. 32: Identifying Front Door Bolts And Hinge On Body

Fig. 33: Identifying Front Door Striker Eye And Bolts
Inspect, set
1 Remove striker eye
Inspect sizes of gaps at door all
2 Fig. 25
round
AR60.00-P-
0700-01M
Gap dimensions on hoods, doors and lids *BE60.00-P-
1002-01A
Loosen bolts (5) from A-pillar and
*BA72.10-P-
3 adjust gap dimension by moving Loosen bolts (5) only until it is possible to move the 1001-01E
front door front door
Loosen bolts (3) from inner door
panel and adjust driver's door Loosen bolts (3) only until it is possible to *BA72.10-P-
4 move the front door. Door paneling (A) should be 1002-01E
contour on hinge side by moving
front door. flush with contour of front fender or should be
located max. 1 mm deeper.
Tighten only so that is remains possible to
5 Install striker eye (7)
move the striker eye (7)
Completely close front door and
6 adjust contour on striker eye by Door paneling (B) should be flush with rear
door or should extend max. 1 mm.
moving striker eye (7)
*BA72.10-P-
7 Tighten bolts (8) on striker eye (7)
1006-01E
Check contour and fit at window
frame (C) in relation to roof The outer contour of the window frame
8
paneling and front wall pillar, should be flush with the roof paneling.
adjust if possible
9 Check door for easy motion
Dimension
Front door to A-pillar mm 8.0 (± 0.5)
"B"
Dimension
Front door to fender mm 5.0 (± 0.5)
"H"
Front door to rear door Dimension "I" mm 5.0 (± 0.5)
Dimension
Front door to roof mm 5.0 (± 0.5)
"C"
Rear door to upper side Dimension
BE60.00-P-1002- Gap mm 5.0 (± 0.5)
section "D"
01A dimension
Rear door to lower side
Dimension "J" mm 5.0 (± 0.5)
section
Dimension
Fender to A-pillar mm -
"Q"
Dimension
Front door to rear fender mm -
"P"
AR60.00-P-0700-
Fig., see
01M

BA72.10-P-1002-01E Bolt, door hinge to inner door panel Nm 35
BA72.10-P-1006-01E Bolt to striker eye Nm 25
Special tools
Adjust front door - AR72.10-P-0550N
MODEL 215
Fig. 35: Identifying Front Door Adjust Components - Model 215 (1 Of 3)

Check
AR88.10-P-
1 Remove front fender
1000N
Unclip clips (8) from multiple-joint
2
hinge (9) and remove cover (10)
3 Remove striker eye (2)
Check gaps on front door (1) all the Gap dimensions on hoods, doors and
4
way around. covers.
Fig. 25
*BE60.00-P-
1002-01A
*BE60.00-P-
1006-01A
Adjust
Loosen bolts (3) from inner door Loosen bolts (3) only so that it is
panel (4) and adjust contour of front possible to move the front door (1)Door paneling *BA72.10-P-
5
door on hinge side by moving front should be flush with contour of front fender or 1002-01E
door (1). should be located max.
1 mm deeper.
Measured from bead of front door (arrow) to
Adjust dimension "D" with front door A-pillar *BE72.10-P-
6
(1) closed Do not loosen bolted connection on control lever 1002-01C
(11).
7 Loosen bolts (5) from A-pillar (6)

and adjust gap by moving front door Loosen bolts (5) only so that it is *BA72.10-P-
(1) possible to move the front door (1) 1001-01E
When an unfinished door is used adjust
*BE72.10-P-
allowance "E" between front door and rear
1003-01C
fender.
Tighten bolts (9) only so that it is
8 Install striker eye (2)
possible to move the striker eye (2).
Completely close front door and
Door paneling (B) should be flush with
9 adjust contour on striker eye (2) by
rear side wall or should extend max. 1 mm.
moving striker eye (2)
*BA72.10-P-
10 Tighten screws (8) on striker eye (7)
1006-01E
Check crank window adjustment, if AR72.10-P-
12
necessary adjust 1950N
BE60.00-P- Gap dimension Front door to A- Dimension "B" mm -
1002-01A pillar
Front door to Dimension "H" 4.5 (± 0.5)
fender
Front door to rear Dimension "I" mm -
door
Front door to Dimension "C" mm -
roof
Rear door to Dimension "D" mm -
upper side
section
Rear door to Dimension "J" mm -
lower side
section
Fender to A- Dimension "Q" mm -
pillar
Front door to rear Dimension "P" mm 4.5 (± 0.5)
fender
Fig., see BE60.00-P-
1006-01A
AR60.00-P- Gap dimension Roof to Dimension "S" mm -
0700-01N windshield frame
Roof to rear Dimension "T" mm -
window frame
Fig., see -

BA72.10-P-1002-01E Bolt, door hinge to inner door panel Nm 32
BA72.10-P-1006-01E Bolt to striker eye Nm 28
FRONT DOOR TEST VALUES

Dimension "D" mm 74
BE72.10-P-1002-01C Allowance, front door to A-pillar
Fig., see AR72.10-P-0550N
Dimension "E" mm 1
BE72.10-P-1003-01C Allowance, front door to rear fender
Fig., see AR72.10-P-0550N
REMOVE/INSTALL DOOR LINING ON FRONT DOOR - AR72.10-P-1000
Remove/install door lining on front door - AR72.10-P-1000M
MODEL 220 except CODE (Z07) Top protection except CODE (Z04) Light armoring

Fig. 39: Identifying Lining On Front Door Remove/Install Components - Shown On Model 220 Up To
VIN: 316716
VIN: 316716
Shown on model 220 As of VIN: 316717

Fig. 41: Identifying Lining On Front Door Remove/Install Components - Shown On Model 220 As Of
VIN: 316717
VIN: 316716
Remove/Install
Fig.
1 Press trim strip (1) out of covering (2)
24
Remove door handle cover (3) from
2.1 Up to VIN :316716
door handle
2.2 Remove door opener cover (16) As of VIN: 316717
3.1 Unclip cap (17) Up to VIN :316716
4 Remove screws (15)
Fig.
5 Press covering (2) off of door lining (2)
24
Disconnect electrical connector from left
6 front door control unit (N69/1) and right For this purpose, remove covering (2)
front door control unit (N69/2)
For this purpose, pull cover on switch
Unclip cover on switch group (5) with
7 group (5) downward at bottom edge until cover
switch group from door lining (4)
on switch group (5) can be removed
Unscrew bolt (6) from round cover plate For this purpose, remove round cover
8
(7) plate (7)
Unscrew bolts (10, 11) from inner door
9
handle
10 Remove screw (13) For this purpose, remove cover (12)
Move mounting wedge (14) directly to
Press door lining (4) off of inner door fastening clips (9) and ensure that the retainer
11
panel (8) tabs on the fastening clip (9) do not tear out of the
door lining (4)
Fig.
24
Lift door lining (4) at top on sealing rail Installation: Remove fastening clips
12 out of retaining clips and simultaneously remaining on inner door panel (8) and install at
pull away from inner door panel (8) corresponding point on door lining (4)
Fig.
24
Unhook Bowden cable from inside door
13
opener
Disconnect electrical connectors from
14 door lining (4) and lay down door lining
(4)
Installation: Replace damaged door foil
15 Check door foil and fastening clips (9)
and fastening clips (9)
Remove/install front door lining - AR72.10-P-1000MB
Shown on model 220 up to vehicle identification end no.: 316717

Fig. 44: Identifying Front Door Lining Remove/Install Components - Shown On Model 220 (1 Of 3)
Shown on model 220 up to vehicle identification end no.: 316717
Shown on model 220 as of vehicle identification end no.: 316717
Remove/install
Press trim strip (1) off of door control unit Fig.
1
covering (2). 24
2.1 Remove door opener cover (18) As of vehicle identification end no.: 316717
Fig.
24
3 Remove bolts (3)
Press door control unit covering (2) off of Fig.
4
door lining (10) 24
Disconnect electrical connector from left
front door control unit (N69/1) or right
5
front door control unit (N69/2) and remove
door control unit covering (2).
6.1 Up to vehicle identification end no.: 316717
handle
Fig.
24
7.1 Remove covering (5) from door handle Up to vehicle identification end no.: 316717
Fig.
24
8 Unscrew bolts (6, 7) from door handle
10 Unscrew bolt (4)
Unscrew bolt (11) from lock cover plate
11
(12) and remove lock cover plate (12)
Unscrew bolts (13) from trim (15) and
12
remove trim (15) downward
13 Remove bolts (17)
Move assembly wedge (14) directly to
Press door lining (10) off of inner door mounting clips (16), otherwise, the retaining
14
panel and remove upward. tabs for the mounting clips (16) can tear out of
the door lining (10).
Fig.
24
Unhook operating cable from inside door
15
opener
Disconnect electrical connector on door
16
lining (10) and lay down door lining (10).
Installation: Remove mounting clips
Check door foil and mounting clips (16), (16) remaining on the inner door panel and
17
replace door foil if necessary. install at corresponding position on door lining
(10). Replace damaged mounting clips (16).
Remove/install door lining on front door - AR72.10-P-1000MC
MODEL 220.174 /175 /176 /178 with CODE (Z04) Light armoring
Fig. 48: Identifying Door Lining On Front Door Remove/Install Components - Shown On Model 220 (1
Of 2)
Shown on model 220 up to FIN: 316716
Fig. 49: Identifying Door Lining On Front Door Remove/Install Components - Shown On Model 220 (2
Of 2)
Shown on model 220 As of VIN:
Remove/Install
1 Unscrew bolts (1)
Remove trim strip (1) from door control
2 Fig. 24
module cover (6)
3.1 Remove cover for door handle (3) Up to VIN :316716
Fig. 24
3.2 Remove door opener cover (15) As of VIN: 316717
Fig. 24
4.1 Unclip cover (4) Up to VIN :316716
Fig. 24
5 Unscrew bolts (5).
Press door control module cover (6) off of
6 Fig. 24
door lining (14)
Disconnect connector from left front door
control module (N69/1) or right front door
7
control module (N69/2) and remove door
control module cover (6)
Unscrew bolt (7) and remove lock rosette
8
(8)
9 Unscrew bolt from door handle (9) Installation: Install bolt (9)
with washer.
Unclip SRS cover (11) and unscrew bolt
10
(10)
Move mounting wedge directly to
mounting clips (13), otherwise the
11 Pry off door lining (14) from door panel
retaining tabs for the mounting clips
(13) can tear out of the door lining ().
Fig. 24
12 Unhook cable from inner door opener
Remove mounting clips (13)
Disconnect connector from door lining remaining on door panel and insert at
13
(14) and lay down door lining (14) corresponding position on door lining
(14)
Replace damaged mounting
clips (13).
14 Check door foil and mounting clips (13)
Replace door foil, see ?
Remove/install front door foil
AR72.10-
Model 220.175/178
P-1010MC
Remove/install door lining on front door - AR72.10-P-1000N
MODEL 215
Fig. 51: Identifying Door Lining On Front Door Remove/Install Components (1 Of 2)

Fig. 52: Identifying Door Lining On Front Door Remove/Install Components (2 Of 2)
Remove/Install
AS60.00-
Danger when processing magnesium
Z-0005-
components
01N
Press cover (10) off with mounting wedge
1 Fig. 24
(11)
Unscrew bolts (3) from cover (2) and
2
remove cover (2)
Unscrew bolt (5) from rosette lock (4) and
3
remove it (4)
Remove covers (6) and unscrew bolts (7)
4
below
Unscrew bolt (15) from ventilation grille
5
(12) and remove ventilation grille (12)
Press locking rail for door control unit
6 cover (13) toward rear in direction of arrow
and unlock door control unit cover (13).
Disconnect connectors from left/right door
control unit (N69/1, N69/2) and remove
7
door control unit cover (13) together with
left/right door control unit (N69/1, N69/2)
Installation: Ensure that the
Unlock release lever (8) in direction of
8 release lever (8) arrests on the inner
arrow
door panel (16).
Press door lining (1) off of inner door panel Move mounting wedge (11) directly
9 onto the clip retainer (9) and ensure Fig. 24
(16) with mounting wedge (11)
that the retainer tabs of clip retainer (9)
do not tear out of the door lining (1).
Lift door lining (1) out of retaining clips at
top of sealing rail with mounting wedge
10 Fig. 24
(11) and simultaneously remove from inner
door panel (16).
Unhook Bowden cable from inside door
11
opener
Replace damaged door foil and clip
12 Check door foil and clip retainers (9)
retainers (9).
Installation: Remove clip
retainers (9) remaining on inner door
panel (16) and install at corresponding
point of door lining (1).
REMOVE/INSTALL FRONT DOOR FOIL - AR72.10-P-1010
Remove, install door foil on front door - AR72.10-P-1010MC
Fig. 54: Identifying Door Foil On Front Door Remove/Install Components
Remove
Remove door liner from front AR72.10-P-
1
door 1000MC
Drill off rivets (3) from door
2
lining bracket (2)
3 Detach door lining bracket (2)
4 Detach door foil (1) Door foil is damaged when removed.
Remove residual sealing strip
5
from inner door panel
Install
Attach sealing strip (A and B) *BR00.45-Z-
6 Sealing strip Ø 5 mm
to inner door panel 1036-01A
*BR00.45-Z-
1060-02A
Ensure correct routing of loudspeaker
Adhere door foil (1) to inner cable and Bowden cable (arrows).
7
door panel Press on door foil securely using roller to
ensure optimum sealing.
Roller Fig. 55
Insert door lining bracket (2)
8
and rivet on
AR72.10-P-
1000MC
Fig. 55: Identifying Roller (168 589 05 63 00)
REPAIR MATERIALS
BR00.45-Z-1060-02A Window installation repair kit 126 670 01 93
Remove/install front door foil - AR72.10-P-1010N
MODEL 215
Fig. 56: Identifying Front Door Foil Remove/Install Components
Remove/install
Remove door lining from AR72.10-P-
1
front door. 1000N
Remove sidebag (5) from AR91.60-P-
2
front door (3) 0690M
Disconnect left/right door
3 speaker group connector
(H4/1x1; H4/2x1)
Unscrew bolts (4) and
4 remove woofer speaker
(H4/1h2;H4/2h2)
Unhook door speaker wiring
5
harness from door foil (1)
Installation: Ensure that door foil (1) is
Remove door foil (1) from matched exactly on the inner door panel (2)The
6
inner door panel (2) holes in the inner door panel (2) for the clip retainers
at the door lining must not be concealed.
Remove glue residues and glue door foil on with *BR00.45-Z-
butyl cord glue, replace door foil if damaged 1086-01A
REPAIR MATERIALS
BR00.45-Z-1086-01A Sealing cord A 005 989 12 71 10
REMOVE/INSTALL WINDOW GUIDE RAIL - AR72.10-P-1500
Remove/install window guide rail - AR72.10-P-1500MB
Rear guide rail

Fig. 57: Identifying Window Guide Rail Remove/Install Components - Rear Guide Rail
Remove
1 Close window
AR72.10-P-
1000MB
AR72.10-P-
3 Remove inner door panel
0104MB
Remove armor plate from front door AR72.10-P-
4
handle 2400-01MB
Loosen rubber seal from window guide
5
rail (2)
Carefully loosen textile profile from
6
window guide rail (2)
Unscrew bolts (1) from window guide
7 rail (2) and remove window guide rail
(2)
Install
Install window guide rail (2) and screw
8
in hand-tight with bolts (1)
9 Open and close window once
*BA72.10-P-
10 Tighten bolts (1)
1001-01EA
Check textile profile for
Glue textile profile in window guide rail *BR00.45-Z-
11 wear and damage, replace if
(2) 1003-02A
necessary.
Glue rubber seal into window guide rail *BR00.45-Z-
12
(2) 1003-02A
AR72.10-P-
13 Install armor plate for front door handle
2400-01MB
*BA72.10-P-
1002-01EA
AR72.10-P-
14 Install inner door panel
0104MB
AR72.10-P-
15 Install door lining in front door
1000MB

Number Designation Model 220 with code Z07
BA72.10-P-1001-01EA Bolt, window guide rail to door Nm 9
BA72.10-P-1002-01EA Bolt, armor plate to window door handle Nm 28
REPAIR MATERIALS
BR00.45-Z-1003-02A Universal adhesive A 000 989 82 71
Remove/install window guide rail - AR72.10-P-1500MBA
Front guide rail
Fig. 58: Identifying Window Guide Rail Remove/Install Components - Front Guide Rail
Remove
1 Close window
AR72.10-P-
2 Remove door lining on front door (4)
1000MB
AR72.10-P-
0104MB
Carefully loosen sealing from window
4
guide rail (1)
Check textile profile for
Carefully loosen textile profile from
5 wear and damage, replace if
window guide rail (1)
necessary.
Unscrew bolts (2, 3) from window guide
6
rail (1) and remove window guide rail (1)
Install
Insert window guide rail (1) into front
7 door and screw in hand-tight with bolts
(2, 3)
8 Open and close window once
*BA72.10-P-
9 Tighten bolt (2) and bolt (3)
1001-01EA
*BR00.45-Z-
Glue textile profile into window guide 1025-04A
10
rail (1) *BR00.45-Z-
1087-02A
*BR00.45-Z-
1025-04A
11 Glue sealing to window guide rail (1)
*BR00.45-Z-
1087-02A
AR72.10-P-
0104MB
AR72.10-P-
13 Install door lining on front door (4)
1000MB

REPAIR MATERIALS
BR00.45-Z-1087-02A Adhesives A 004 989 25 71
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL INNER SEALING RAIL - AR72.10-P-1600
Remove/install inner sealing rail - AR72.10-P-1600E
MODEL 202, 210, 220, 240

Shown on model 202
Fig. 59: Identifying Inner Sealing Rail Components - Shown On Model 202
Remove/install
1.1 Open crank window Vehicles with
mechanical window lift
mechanism.
1.2 Open window Vehicles with
power windows.
2.1 Remove window crank Model 202 AR72.10-P-1100GV
Only with
mechanism.
3 Remove front door lining Model 202 AR72.10-P-1000E
Model 210 AR72.10-P-1000F
Model 220 AR72.10-P-1000M
Model 240 AR72.10-P-1000HA
4 Remove rear door lining Model 202 AR72.12-P-1010E
Model 210 AR72.12-P-1010F
Model 220 AR72.12-P-1010M
Model 240.0 AR72.12-P-1010H
Model 240.1 AR72.12-P-1010HA
5 Press sealing rail (1) off Mounting wedge Fig. 24
of inner door panel with Insert assembly
assembly wedge wedge directly next to
clips (2)
6 Check clips (2), replace if Clips (2) are
necessary attached to inner door
panel.
Special tools
Remove/install inner sealing rail - AR72.10-P-1600G
MODEL 170, 208.3, 215
Shown on Model 170
Fig. 61: Identifying Inner Sealing Rail Remove/Install Components - Shown On Model 170
Remove, Install
1 Open crank window
2 Remove door liner from Model 170 AR72.10-P-1000G
front door
Model 208.3 AR72.10-P-1000K
Model 215 AR72.10-P-1000N
3 Press sealing rail (1) off Fig. 24
of inner door panel with Move assembly
installation wedge (3) and wedge (3) directly next to
remove clips (2).
4 Check clips (2), 5 each, Clips (2) are
for damage. attached to inner door
panel.
Installation:
Replace defective clips
(2).
REMOVE/INSTALL OUTER SEALING RAIL - AR72.10-P-1700
Remove/install outer sealing rail - AR72.10-P-1700E
MODEL 202, 210, 220, 240
Illustrated on driver's door on model 202
Fig. 63: Identifying Outer Sealing Rail Components - Illustrated On Driver's Door On Model 202
Remove, Install
1.1 Open crank window Vehicles with
mechanism.
1.2 Open window Vehicles with
power windows.
2 Press trim strip (1) off of Fig. 24
outer window ledge Avoid damaging paint.
3 Press sealing rail (2) off Fig. 24
of window shaft Insert installation
wedge directly next to
clip.
4 Check retaining clips (3 Clip (3) is
and 5) and replace, if riveted on.
necessary On models 202 and 210
the clip (3) can only be
replaced after removing
cover (6).
Clips (5) are installed on
window shaft.
order
Special tools
Removing and installing sealing rail on outside - AR72.10-P-1700N
MODEL 215
Fig. 65: Identifying Sealing Rail On Outside Remove/Install Components
1 Completely open crank window
Unscrew screws (5) and remove cover
2
(6)
Insert installation wedge directly next Fig.

Press off molding strip (1) with
3 to clip.
installation wedge 24
Avoid damaging paintwork of paneling on
mirror triangle
Press off sealing rail (2) with Fig.
4
installation wedge Check clamps (3), replace if necessary 24

REMOVE/INSTALL POWER WINDOW ON FRONT DOOR - AR72.10-P-1800
Remove/install power window on front door - AR72.10-P-1800M
MODEL 220
Fig. 67: Identifying Left And Right Front Door Power Window Motor Connector
Remove, Install
AR72.10-P-
1 Remove/install front door liner
1000M
Remove insulating mat from inner door
2
panel, glue on
AR72.10-P-
3 Remove crank window
1900M
Remove left/right front power window
4 motor connector (M10/3x1, M10/4x1)
from power window motor
To drill out use Ø 4.8 mm dia. bit and
do not damage inner door panel. Use
punch to drive out remaining rivet
residues.
Drill pop rivets (arrows) out of inner
5 Remove rivet residues and chips from
door panel or cut out
door, danger of rust.
Installation:
Rivet power window (1) to inner door
panel flush with new pop rivets.
Unhook power window (1) out of inner Installation: Hook window lift
6 door panel and remove downward mechanism onto inner door panel with the
through assembly opening. four assembly hooks
Remove/install front door power window - AR72.10-P-1800MB
Fig. 69: Identifying Front Door Power Window Remove/Install Components
Remove/install
Risk of injury caused by hands or feet Secure windows to prevent them from
AS67.00-Z-
being pinched or crushed when working falling, use only the prescribed lifting
0003-01A
on windshield or windows tools, always wear safety shoes.
Notes on avoiding damage to windows AH67.00-P-
installed in special high-security 0003-01FB
vehicles
1 Close window (9)
AR72.10-P-
1000MB
3 Remove door foil from front door
AR72.10-P-
0104MB
AR72.10-P-
5 Remove front door handle armor plate
2400-01MB
*BA72.10-P-
1002-01EA
Cover door frame in area of clamping
Secure window (9) against falling down
6 pliers with suitable equipment to avoid
with clamping pliers.
damaging paint.
Fig. 22
Catch oil running out. Plug
openings on hydraulic cylinder (4) and
Unscrew hollow bolts (1) from
7 hydraulic lines (3).
hydraulic cylinder (4)
Installation: Install new sealing
rings (2).
*BA72.10-P-
1005-01EA
Unscrew screws (7) from window (9)
and remove reinforcement (8); if
Installation: Use screw locking *BR00.45-Z-
8 necessary, lower power window slightly
compound. 1011-02A
with manual window lifter actuation
(10).
Lower power window down to bottom
9 stop with manual window lifter
actuation (10).
Unscrew bolts (5) from circumference
of carrier plate with power window (6) Installation: Replace self-locking bolts
10
and remove carrier plate with power (5).
window (6)
*BA72.10-P-
1004-01EA
The hydraulic unit with the oil

reservoir and the valve block are housed
Check hydraulic oil level of hydraulic in the spare tire well in the trunk.
12
window lift system, correct if necessary The oil level in the oil reservoir should
not fall below the minimum mark when
the side window is closed and must not
exceed the maximum mark when the side
window is open.

BA72.10-P-1002-01EA Bolt, door handle armor plate at window Nm 28
BA72.10-P-1004-01EA Screw for carrier plate on front door Nm 28
BA72.10-P-1005-01EA Banjo bolt to hydraulic cylinder Nm 7
REPAIR MATERIALS
BR00.45-Z-1011-02A Quick glue A 003 989 31 71
Removing and installing front door power window - AR72.10-P-1800MC
Fig. 71: Identifying Power Window And Inner Door Panel
Remove/install
AR72.10-P-
1 Remove inner door panel (2) 0104MC
Installation: Ensure correct installation
2 Drill out rivets (arrows) position of the rivets, otherwise the window may
be damaged.
Detach power window (1)
3
Removing and installing window lift mechanism in front door - AR72.10-P-1800N
MODEL 215
Fig. 72: Identifying Window Lift Mechanism In Front Door Remove/Install Components
AR72.10-P-
1 Remove door paneling in front door
1000N
Disconnect left/right door loudspeaker connector
2
(X1/6; X1/7)
Unscrew screws (10) and remove woofer speakers
3 Fig. 29
(H4/1h2; H4/2h2)
4 Pull off insulating mat in area of inner door panel
AR72.10-P-
5 Remove crank window from front door 1900N
Remove front left/right power window motors (M10/3; AR72.29-P-
6
M10/4) 1860N
Unscrew nut (6) and unhook power window (1) from *BA72.10-P-
7
inner door panel (2) 1009-01E
Remove caps (4) on nuts (3) on bottom door panel (5) *BA72.10-P-
8
and unscrews nuts (3) 1009-01E
Adjust crank window on 1950N
front door
Loosen nut (8) and unhook power window (1) from *BA72.10-P-
9
mount (9) 1009-01E
Adjust crank window on 1950N
front door
10 Press mounting sleeves (7) through inner door panel
Lift power window (1) until stud bolts (1a) on bottom
door panel (5) are unhooked and remove power
11
window (1) through installation opening in inner door
panel (2)

BA72.10-P-1009-01E Screw for power window on front door on inner door panel Nm 9
REMOVE/INSTALL FRONT DOOR CRANK WINDOW - AR72.10-P-1900
Remove/install front door crank window - AR72.10-P-1900M
MODEL 220
Fig. 74: Identifying Front Door Crank Window Remove/Install Components(1 Of 2)
Fig. 75: Identifying Front Door Crank Window Remove/Install Components(2 Of 2)
Remove, Install
Remove/install front door AR72.10-P-
1
liner 1000M
Remove insulating mat in Installation:
2 bottom area of inner door Before installing insulating mat, check crank window
panel (1) for easy motion
AR72.10-P-
3 Remove inner sealing rail
1600E
Remove trim strip with AR72.10-P-
4
outer sealing rail 1700E
Removal:
5 Unscrew bolt (2) Open crank window (1) until assembly openings (5) of
inner door panel and mounting screws (2) are
accessible
Installation:
When installing screws (2):?
AR72.10-P-
Adjust crank window (1) for front door
1950M
Move crank window (1) Thereby move crank window (1) upward until
6 out of mounts on power mounting lugs for crank window (1) slide out of power
window (4) window mounts (4)
For this purpose tilt crank window (1) toward
front and pull out of front window guide rail downward
Remove crank window
7 and turn until rear edge of crank window (1) can be
(1) out of door shaft.
removed from door shaft
Installation:
*BR00.45-Z-
Clean crank window (1) with MB auto glass cleaner
1007-04A
REPAIR MATERIALS
BR00.45-Z-1007-04A Cleaner A 001 986 38 71
Removing and installing crank window in front door - AR72.10-P-1900N
MODEL 215
Fig. 76: Identifying Crank Window In Front Door Remove/Install Components (1 Of 2)

Fig. 77: Identifying Crank Window In Front Door Remove/Install Components (2 Of 2)
Injury hazard from unsecured windows Secure windows against falling AS67.00-Z-
pinching hands. down. 0002-01A
AR72.10-P-
1 Remove door paneling in front door
1000N
Disconnect left/right door loudspeaker
2
connector (X1/6, X1/7)
Unscrew screws (10) and remove woofer
3 Fig. 29
speakers (H4/1h2, H4/2h2)
Pull off insulating mat in bottom area of
4
inner door panel
AR72.10-P-
1600E
Remove molding strip with sealing rail on AR72.10-P-
6
outside 1700N
Open crank window (1) until mounting
screws (4) are accessible through the
7
installation openings in the inner door panel
(3)
*BA72.10-P-
1010-01E
Fig. 29
Installation:
When mounting screws (4):?
AR72.10-P-
Adjust crank window on front door
1950N
Remove crank window (1) from window Installation: Clean crank *BR00.45-Z-
9 window (1) with MB motor vehicle 1007-04A
shaft
glass cleaning agent

BA72.10-P-1010-01E Screw for crank window in front door on window lift mechanism Nm 9
REPAIR MATERIALS
BR00.45-Z-1007-04A Cleaner A 001 986 38 71
REMOVE/INSTALL SEALING FOR CRANK WINDOW ON FRONT DOOR - AR72.10-P-1905
Remove/install sealing for crank window on front door - AR72.10-P-1905MB
outer sealing
Fig. 79: Identifying Sealing For Crank Window On Front Door - Outer Sealing
Remove/install
Remove window in front door AR72.10-P-
1
(2) 1910MB
Remove sealing (1) for Carefully loosen sealing (1) from window
2 window guide from front door guide to prevent damaging sealing (1).Replace
(2) sealing (1) if damaged, see: ?
Fabricate sealing (1) for crank window on front AR72.10-P-
door (2) 1905-01MB
Fabricate sealing for crank window on front door - AR72.10-P-1905-01MB
Use old sealing (1) as reference for fabrication of new sealing (1) on window guide.
1. Insert sealing (1) for window guide into window frame.
Fig. 80: Identifying Insert Sealing For Window Guide Into Window Frame
2. Cut sealing (1) in area of door lock (arrow) so that lock mechanism (2) is not blocked by the sealing (1)
3. Cut off excess length of sealing (1) at rear at lower end of guide rail.
4. Cut off excess length of sealing (1) at front at lower end of guide rail
Fig. 81: Identifying Cut Sealing Area Of Door Lock And Lock Mechanism
Remove/install sealing for crank window on front door - AR72.10-P-1905MBA

Inner sealing
Fig. 82: Identifying Sealing For Crank Window On Front Door - Inner Sealing
Remove/install
AR72.10-P-
1 Remove window in front door (2)
1910MB
Carefully loosen sealing (1) from
Remove sealing (1) for window window guide to prevent damaging sealing
2
guide from front door (2) (1).
Replace sealing (1) if damaged, see: ?
AR72.10-P-
Fabricate sealing (1) for crank window on 1905-01MBA
front door (2) *BR00.45-Z-
1065-02A
*BR00.45-Z-
Installation: Clean sealing (1) and 1087-02A
window guide and glue in sealing (1). *BR00.45-Z-
1025-04A
REPAIR MATERIALS
Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
BR00.45-Z-1065-02A Loctite 401 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1087-02A Adhesives A 004 989 25 71
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Fabricate sealing for crank window on front door - AR72.10-P-1905-01MBA

REPAIR MATERIALS
Arabellastrasse 17
81925 Munchen
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
1. Cut all three sections (A, B, C) to length.
Cut sections (A) and (C) off to approx. 53 cm Cut off section (B) to approx. 105 cm.
2. Measure dimension (D) of corresponding section on front door (2) and cut sections (A, B, C) to correct
width.
Fig. 83: Measuring Dimension Of Corresponding Section On Front Door And Cut Sections
3. Miter sections (A) and (B) and glue together.

4. Position sections (A) and (B) in window frame and miter transition of sections (B) and (C) and glue
together
Fig. 84: Positioning Sections (A) And (B) In Window Frame And Miter Transition Of Sections
5. Transfer length of vertical sections from old sealing to new sealing
REMOVE/INSTALL FRONT DOOR WINDOW - AR72.10-P-1910
Remove/install front door window - AR72.10-P-1910MB
Fig. 85: Identifying Front Door Window Remove/Install Components
Remove/install
Risk of injury caused by hands or feet Secure windows against dropping,
AS67.00-Z-
being jammed or crushed when working use only specified lifting tools, wear
0003-01A
on windshield or windows protective shoes.
installed in special high-security vehicles 0003-01FB
1 Close window (1)
AR72.10-P-
2 Remove outer sealing rail
1700E
AR72.10-P-
1000MB
AR72.10-P-
0104MB
AR72.10-P-
5 Remove front door handle armor plate
2400-01MB
*BA72.10-P-
1002-01EA
Cover door frame in area of
Secure window (1) against dropping by
6 clamping pliers with suitable
applying clamping pliers.
equipment to avoid damaging paint.
Fig. 22
Unscrew bolts (2) on window (1) from If necessary, lower window
7 sliding rail (4) and remove reinforcement lifter slightly using the manual
(3). window lifter actuation (5).
Installation: Replace bolts *BR00.45-Z-
(2) and secure with securing agent. 1011-02A
Lower window lifter down to end stop
8
with manual window lifter actuation (5)
AR72.10-P-
9 Remove window (1) of front door (6)
1920-01MB
Fig. 22
Installation: Install window AR72.10-P-
(1) of front door (6) 1920-02MB
Fig. 22

REPAIR MATERIALS
BR00.45-Z-1011-02A Quick glue A 003 989 31 71
Remove, install window in front door - AR72.10-P-1910MC
Fig. 87: Identifying Window In Front Door Remove/Install Components
Remove/install
Operations involving work on glass panes and Secure windshield and windows from
windows are potentially dangerous; use dropping down; use only the lifting AS67.00-Z-
caution to avoid allowing hands or feet to tools specified for such operations. 0003-01A
become caught. Wear safety shoes.

Instructions for avoiding damage to windows Z06 AH67.00-P-
installed in special high-security vehicles MODEL 220 with Code Z04, Code 0003-01FB
Z07
AR72.10-P-
1000MC
AR72.10-P-
2 Remove front door foil
1010MC
AR72.10-P-
1700E
4 Remove inner sealing rail (5)
AR91.60-P-
5 Remove front door side airbag unit
0690MC
6 Detach armor plate (2) at window (1) Lower power window
*BA72.10-P-
1007-01EA
Position window (1) so that the bolts (4) are
7 Connect door control module
accessible
8 Secure window using clamping pliers Use protective foil
Lower power window to approx. 5 mm before
10
the limit stop
Detach clamping pliers from window, remove Move front window down,
11
window then up, remove from outside.

Number Designation MODEL 220 with CODE Z04
BA72.10-P-1007-01EA Bolt for armor plate to power window Nm 23
REMOVE/INSTALL FRONT DOOR WINDOW - AR72.10-P-1920
Remove front door window - AR72.10-P-1920-01MB

To avoid damage, two or three persons must work together to remove window.
1. Loosen clamping pliers and open window until window can be tilted slightly.
Fig. 90: Loosening Clamping Pliers And Open Window
2. Turn window in direction of A-pillar, move out of window guide rail and move upward.
Fig. 91: Turning Window In Direction Of A-Pillar
3. Continue to turn window in direction of A-pillar, move upward and simultaneously move corner of
window outward out of door.
4. Continue to turn window in direction of A-pillar, move upward and remove window out of door.
Install front door window - AR72.10-P-1920-02MB
To avoid damage, two or three persons must work together to remove window.
1. With at least two persons working together, install window by first guiding window lower corner first
from outside into door.
Fig. 95: Installing Window By Guiding Window Lower Corner
2. Turn window in direction of door lock and simultaneously move in downward.
Fig. 96: Turning Window In Direction Of Door Lock
3. Continue to turn window in direction of door lock and simultaneously move in downward.
Fig. 97: Turning Window In Direction Of Door Lock
4. Move window into window guide rail and move upward.

5. Secure window with clamping pliers .
Fig. 98: Securing Window With Clamping Pliers
ADJUST FRONT DOOR WINDOW - AR72.10-P-1921MB

Fig. 99: Identifying Front Door Window Adjusting Components (1 Of 2)
Fig. 100: Identifying Front Door Window Adjusting Components (2 Of 2)
Remove
Risk of injury caused by moving
Keep all body parts and limbs away from AS00.00-Z-
parts that can pinch, crush or , in
moving mechanical components. 0009-01A
extreme cases even sever extremities.
Notes on avoiding damage to windows
AH67.00-P-
installed in special high-security
0003-01FB
vehicles
AR72.10-P-
0104MB
Check
Connect vehicle wiring harness to door
2
control unit installed in door lining
3 Switch on ignition
When flock coating is abraded.
Carefully open or close window (4) Loosen bolts (1) and correct adjustment of
using left front power window switch, window (4) using suitable tool (arrows). If
4 right front power window switch and the distance in the window guide area (A)
check whether textile profile rubs in is too great, loosen bolts (1) and correct
area of window guide (A) adjustment of window (4) using suitable
tool (arrows).
Close window (4) with left front power
Limit stop roller (3) should:
window switch or right front power
5 Be approx. 2 mm away from the toothed
window switch to upper stop and
quadrant; if necessary move limit stop (3)
determine distance from limit stop
by loosening bolt (2).
roller (3) to toothed quadrant
Open and close window (4) with left
front power window switch or right
If the distance between the front
front power window switch, determine
window guide (5), rear window guide rail
6 distance (B) on window, check over
(7) is too great, loosen bolt (6) and adjust
entire length of front window guide rail
gap dimension (B) using shims.
(5) and rear window guide rail (7),
adjust if necessary.
*BA72.10-
P-1001-
01EA
Check distance between front window If the distance between the front
guide rail (5) (arrow), rear window window guide rail (5) and rear window
7
guide rail (7) and front door (8), adjust guide rail (7) is not at least 2 mm to the
if necessary front door (8), adjust distance.
*BA72.10-
P-1001-
01EA
Check distance between window (4)
Window (4) should not hit against
8 and all detachable parts on front door
any detachable parts.
(8), adjust if necessary
Disconnect vehicle wiring harness from
10
door control unit
Install
AR72.10-P-
0104MB
ADJUSTING CRANK WINDOW IN FRONT DOOR - AR72.10-P-1950
Adjusting crank window in front door - AR72.10-P-1950M
MODEL 220
Fig. 101: Identifying Crank Window Adjusting Components In Front Door - Model 220
Checking
When the crank window is adjusted
correctly, the edge of the glass runs parallel to
Check installed position of crank
1 the contour of the front wall pillar and roof
window on window frame
panelling, illustration on left. The crank
window should not be completely closed.
Illustration on left, the crank window
Check installed position on vertical
2 (1) should fit in the window guide rail
window guide rail
completely
AR72.10-
3 Remove door lining on front door
P-1000M
4 Pull off sound deadening mat
Adjusting
Loosen bolts (2), correct crank
window (1) upwards or downwards,
5 at the same time press backwards
into the vertical window guide rail
and tighten bolts (2)
Check crank window for ease of
6 movement
Adjust front door crank window - AR72.10-P-1950N
MODEL 215
Fig. 102: Identifying Crank Window Adjusting Components In Front Door - Model 215 (1 Of 2)
Fig. 103: Identifying Crank Window Adjusting Components In Front Door - Model 215 (2 Of 2)
Setting
The crank window can be adjusted
with the door liner installed
Check adjustment of front door and AR72.10-P-
1
adjust if necessary 0550N
Unscrew screw (3) and remove
molding (2) toward rear. Remove
2
adhesive strip above assembly
openings in door paneling
Remove cover (7) (4 each) from Adjustment screws (6) as well as
3 window lift mounting nuts (9) are accessible
bottom door panel (8)
through openings in the bottom door panel (8).
Door and side window must be closed
4 Mark side window along shaft seal
completely
5 Open door
Actuate door contact switch with
6
plastic wedge
The marking difference should not be
Check marking on closed side
7 greater than 1.5 mm. In the event of higher
window when door is open
deviation correct door.
Adjust upper end stop of crank If the upper end stop is adjusted
8 window (1) with adjustment screws correctly the front glass edge is flush with the
(6) mirror triangle on the front door (arrows).
Loosen both nuts (9) until window *BA72.10-
9
guide rails can be moved P-1009-01E
Loosen screws (4) from outside by turning

Check the inclination and position to right .
of the crank window (1) in the After the screws (4) are loosened the
longitudinal direction and correct if
inclination and the longitudinal direction of Fig. 104
10
necessary; for this purpose close the crank window can be corrected on the
crank window (1) to 20 mm below window lift rails.
sealing frame and loosen screws (4)If the crank window (1) is adjusted correctly,
the upper glass edge runs parallel to the sealing
frame.
*BA72.10-
11 Fully tighten bolts (4)
P-1010-01E
With the window lift guide rails it is
possible to increase or decrease the tension of
Adjust tension of crank window (1) the crank window on the sealing frame on the
12 coupe roof. Adjust crank window so that the
with window lift guide rails
upper corner of the glass touches the sealing
frame of the B-pillar with the door lock in the
first arrest stage.
Tighten both nuts (9) on the *BA72.10-
13
window lift guide rails P-1009-01E
Close front door and check crank
It should be possible to pull out a
window for leakage and easy
14 paper strip pinched between the crank window
motion, if necessary repeat
and B-pillar sealing frame.
adjustment
15 Install covers (7) (4 each)
Glue adhesive strip over assembly Check adhesive strip, replace if
16
openings and install molding (2) necessary.
Check gap and transition between
crank window on front door and AR67.30-P-
17
rear crank window in area of rear 4200N
window stay and adjust

BA72.10-P-1009-01E Screw of power window of front door to inner door panel NM 9
BA72.10-P-1010-01E Screw of crank window of front door to power window NM 9
REMOVING AND INSTALLING DOOR CATCH - AR72.10-P-2100
Removing and installing door catch - AR72.10-P-2100M
MODEL 220
Fig. 105: Identifying Door Catch
AR72.10-P-
1 Detach/attach door lining at front door
1000M
AR72.12-P-
at rear door
1010M
Pull off sound deadening mat in front area of
2
inner door panel
Remove screws (1) from A-pillar and B-pillar, *BA72.10-P-
3 Screw at A-pillar
respectively 1004-01E
*BA72.12-P-
Screw at B-pillar 1004-01D
AR82.62-P-
4.1 Remove/install door speaker in front door
7845I
Hold door catch tight from
5 Remove screws (2) from door inside for this step
Screw to inner door panel *BA72.10-P-
of front door 1005-01E
Screw to inner door panel *BA72.12-P-
of rear door 1005-01D
Remove door retaining strap through
6
installation opening in inner door panel

BA72.10-P-1004-01E Screw for door retaining strap on body NM 14
BA72.10-P-1005-01E Bolt for door catch to inner door panel NM 10
REAR DOOR TIGHTENING TORQUE

BA72.12-P-1004-01D Screw for door retaining strap on body NM 14
BA72.12-P-1005-01D Bolt for door catch to inner door panel NM 10
Removing and installing door catch - AR72.10-P-2100MC

Fig. 106: Identifying Door Catch And Bolt
Remove/install
1 Remove inner door panel AR72.10-P-0104MC
2 Remove bolt (2)
3 Unscrew screws (3, 4)
4 Remove door catch (1)
REMOVING AND INSTALLING MULTI-JOINT HINGE - AR72.10-P-2110N
MODEL 215
Fig. 107: Identifying Multi-Joint Hinge Clips And Cover

Fig. 108: Identifying Multi-Joint Hinge, Bolts And Retaining Mechanism
Fig. 109: Identifying Multi-Joint Hinge And Bolts
AR72.10-P-
1 Remove front door
0500N
AR88.10-P-
2 Remove front fender
1000N
3 Unclip clips (5) from multi-joint
hinge (1) and remove cover (6)
Unbolt bolts (3) from retaining plate
4
(2) and remove retaining plate (2)
Unbolt bolts (4) from multi-joint
*BA72.10-P-
5 hinge (1) and remove multi-joint
1001-01E
hinge (1)
Fig. 29
Installation : Remove retaining
6 Install in reverse order mechanism (7) when installing new
component.
Check front fender and front door Hood, door and cover gap dimensions If AR60.00-P-
7
gap dimensions no exact fit: ? 0700-01N
AR72.10-P-
Adjust front door
0550N

BA72.10-P-1001-01E Screw for door hinge on A-pillar Nm 32
REMOVE/INSTALL DOOR SEALING FRAME - AR72.10-P-2120
Remove/install door sealing frame - AR72.10-P-2120M
MODEL 220
Fig. 111: Identifying Door Sealing Frame Remove/Install Components
Remove/Install
Always replace door

sealing frame after installation.
Do not use any sharp-pointed
1 Remove old door sealing frame (2) tools in order to avoid damaging
paintwork
Remove glue residues from door frame (1) and
2
degrease subsurface with naphtha
Remove protective strip (3) from gluing surface on
3
new door sealing frame (2) starting with shaped bow.
Position new door sealing frame (2) with shaped bow
Ensure that door sealing
4 first on upper corner of door (arrow A) and press
frame (2) is seated properly.
down lightly
Pay attention to slight bow
Remove protective strip (3) continuously from gluing
5 surface and completely position door sealing frame (arrow B) on door hinge
Do not stretch door sealing frame
(2)
(2)
Uniformly press on door sealing frame (2) with hand Fig.
6 Hand roller
roller (4) 55
Removing and installing door sealing frame - AR72.10-P-2120N
MODEL 215
Fig. 113: Identifying Door Sealing Frame Components (1 Of 2)

Fig. 114: Identifying Door Sealing Frame Components (2 Of 2)
AR72.10-P-
1700N
Unclip paneling (6) with installation
2 Installation wedge Fig. 24
wedge (7)
Do not use sharp tools to avoid
3 Remove old door sealing frame (1)
damaging paint
Remove glue residues from front door (3)
4 and remove grease from subsurface with
naphtha
First press new door sealing frame (1) into
5 door frame on side of front door lock
(arrow A)
Remove protective strap (4) continuously Clip mounting clip (5) into
6 from gluing surface and completely attach door frame. Ensure that door sealing
door sealing frame (1) frame (2) is seated properly.
Uniformly press on door sealing frame (1)
7 Hand roller Fig. 55
with hand roller
Pull seal (2) over mirror triangle and hook Connect seal (2) with door
8
into mirror triangle (arrow B) sealing frame (1) (arrow C)
REMOVE/INSTALL FRONT DOOR DAMPER - AR72.10-P-2200
Remove/install front door damper - AR72.10-P-2200MB
Fig. 117: Identifying Front Door Damper Remove/Install Components - Top Protection
Remove/Install
1
door 1000MB
2 Remove speaker (1)
Remove retainers (5) and bolts
3 Carefully loosen insulating mat (2).
(4) with washers (6)
Installation: The noticeable unevenness
on the door damper housing (3) must point
4 Remove door damper (3) upward.
The new door damper (3) should have the same
length as the previous one.
Remove, install front door damper - AR72.10-P-2200MC
Fig. 118: Identifying Front Door Damper Remove/Install Components - Light Armoring
1
door 1000MC
Remove retainer (4) and
3 remove bolt (3) with washer At A-pillar and door armor plate.
(5)
on the damper housing (arrow) must point
4 Remove door damper
upward.
Check gasket on door panel, replace if necessary.
REMOVE/INSTALL EXTERIOR DOOR HANDLE ON FRONT DOOR - AR72.10-P-2400
Removing and installing exterior door handle on front door - AR72.10-P-2400M
MODEL 215, 220

Fig. 119: Identifying Exterior Door Handle On Front Door Remove/Install Components (1 Of 3)
Model 215
Removal
Remove cap from
1.1 installation opening (13) in Model 220
narrow side of door
Unscrew screws (15) and
1.2 Model 215
remove cover (16)
Remove door sealing frame
(12) from installation
2.2 Model 215
opening (13) in narrow side
of door
3 Unscrew Torx screw (6) Remove Torx screw (6). Secure against falling Fig. 29
down.
Slightly pivot guide (2) toward rear and then pull out
toward outside. Simultaneously pull out handle (1)
4 Remove guide (2) slightly
Disconnect driver's door
5 infrared receiver connector
(X8/13)
Remove handle (1) with Pull handle (1) with bases (4) and (5) out of hinge
6
bases (4) and (5) strap (8) toward rear
AR72.10-P-
7 Remove door liner Model 220
1000M
AR72.10-P-
Model 215
1000N
Pull off insulating mat in
8
area of door lock
First open retainer for release handle, unscrew screw
(9) from handle recess and remove hinge strap (8)
9 Remove hinge strap (8)
with release handle through installation opening in
inner door panel
Installation
Insert hinge strap (8) with release handle through
installation opening in inner door panel and insert
10 Install hinge strap (8)
release handle into control lever retainer. Turn screw
(9) into handle recess
Install handle (1) in hinge Ensure that the lever on the handle slides behind
11 strap (8) together with bases the actuation lever (11) on the bracket so that the
(4) and (5) lock can be unlocked
Simultaneously insert driver's door infrared receiver
connector (X8/13).
12 Insert guide (2) When inserting the guide (2) ensure that the
rotating rod (3) is moved into the door lock (14) in
*BA72.10-P-
Tighten guide with Torx
13 Secure Torx screw (6) against falling down 1007-01E
screw (6)
Fig. 29
Adjust clearance between
Press release handle with retainer opened up
14 handle (1) and actuation
lever (12) until resistance can be felt. Then lock retainer
Pull handle (1) until resistance can be felt *BE72.10-P-
15 Check clearance
clearly 1001-01C
16 Glue on insulating mat Replace damaged insulating mat
AR72.10-P-
17 Install door liner Model 220
1000M
AR72.10-P-
Model 215
1000N
Press door sealing frame (12) Model 215
18.1 into installation opening (13) Ensure that door sealing frame (12) is
in narrow side of door seated properly
Install cover (16), for this
19.1 Model 215
purpose screw in screws (15)
Insert installation opening
19.2 (13) cap into narrow side of Model 220
door
ADJUSTMENT VALUES FOR SIDE DOOR

BE72.10-P-1001-01C Clearance mm 2 (± 1) 2 (± 1)

BA72.10-P-1007-01E Screw for front door handle Nm 3 3
Remove/install exterior door handle on front door - AR72.10-P-2400MB
MODEL 220.175 /178 with CODE (Z04) Light armoring with CODE (Z07) Top protection
Fig. 123: Identifying Exterior Door Handle On Front Door Remove/Install Components
Remove/Install
*BA72.10-P-
1 Remove armor plate (3)
1003-01EA
Remove plug (1) and unscrew screws below Bolt is secured from
2
with socket wrench (2) falling out.
*BA72.10-P-
1007-01E
Remove left front IR receiver (A26/1) or
3 right front IR receiver (A26/2) and
disconnect connector (7)
Move door handle (5) in direction of door Installation: Check
4 seals (4, 6) for damage, replace if
lock and remove
necessary.

Number Designation Model 220 with Model 220 with
code Z07 code Z04
BA72.10-P-1003- Bolt for outer door lock armor plate M6 Nm 7 8
01EA to front door M8 Nm 28 23

BA72.10-P-1007-01E Screw for front door handle Nm 3
Removing and installing exterior door handle on front door - AR72.10-P-2400N
MODEL 215, 220 with CODE (889) Keyless go
Model 215
Removal
1.1 Remove cap from Model

installation opening (13) in
narrow side of door
Unscrew screws (15) and
1.2 Model 215
remove cover (16)
Remove door sealing frame
(12) from installation
2.2 Model 215
opening (13) in narrow side
of door
3 Unscrew Torx screw (6) Remove Torx screw (6). Secure against falling Fig. 29
down
Slightly pivot guide (2) toward rear and then pull out
toward outside. Simultaneously pull out handle (1)
4 Remove guide (2)
slightly
Disconnect driver's door
5 infrared receiver connector
(X8/13)
AR72.10-P-
6 Remove door liner Model 220
1000M
AR72.10-P-
Model 215
1000N
Disconnect keyless go
7
connector on hinge strap (8)
Remove handle (1) with Pull handle (1) with bases (4) and (5) out of hinge
8
bases (4) and (5) strap (8) toward rear
Pull off insulating mat in
9
area of door lock
First open retainer for release handle, unscrew screw
(9) from handle recess and remove hinge strap (8)
10 Remove hinge strap (8)
with release handle through installation opening in
inner door panel
Disconnect keyless go
11 connector on inner door Remove cable strap
panel
Install
Insert hinge strap (8) with release handle through
installation opening in inner door panel and insert
12 Install hinge strap (8)
release handle into control lever retainer. Turn screw
(9) into handle recess
Contact keyless go
13 connector on inner door Replace cable strap
panel
14 Insert handle (1) with bases Ensure that the lever on the handle slides behind
(4) and (5) into hinge strap the actuation lever (11) on the bracket so that the
(8) lock can be unlocked
Contact keyless go
15 connector on bearing bracket
(8)
Simultaneously insert driver door infrared receiver
connector (X8/13).
16 Install guide (2) When inserting the guide (2) ensure that the
rotating rod (3) is moved into the door lock (14) in
*BA72.10-P-
Tighten guide with Torx
17 Secure Torx screw (6) against falling down 1007-01E
screw (6)
Fig. 29
Press release handle up with retainer opened
18 handle (1) and actuation
lever (12) until resistance can be felt. Then lock retainer
Pull handle (1) until resistance can be felt *BE72.10-P-
19 Check clearance
clearly 1001-01C
AR72.10-P-
21 Install door liner Model 220
1000M
AR72.10-P-
Model 215
1000N
Press door sealing frame Model 215
22.1 (12) into installation opening Ensure that door sealing frame (12) is seated
(13) in narrow side of door correctly
Install cover (16), for this
23.1 purpose screw in screws Model 215
(15)
Install cap for installation
23.2 opening (13) in narrow side Model 220
of door
CHECK VALUES FOR FRONT DOOR

BE72.10-P-1001-01C Clearance mm 2 (± 1) 2 (±1)

BA72.10-P-1007-01E Screw for front door handle Nm 3 3
Remove/install front door handle armor plate - AR72.10-P-2400-01MB

1. Unscrew bolts (1) from armor plate (2) and remove armor plate (2) with sleeve (3)
Note installation position of bolts (1) and sleeve (3).
Fig. 129: Identifying Armor Plate With Sleeve
REMOVING AND INSTALLING FRONT DOOR LOCK - AR72.10-P-4011

Removing and installing front door lock - AR72.10-P-4011M
MODEL 220
Fig. 130: Identifying Front Door Lock Remove/Install Components (1 Of 2)
Removing
AR72.10-P-
1 Remove door liner on front door
1000M
Remove crank operated window AR72.10-P-
2 on front door 1900M
Unhook Bowden cable (1) for
3 inside door opener onto door lock Unclip holder (8) on lock
(6) and remove
Open retainer (4) for unlocking
4
bar (3)
Press IRCL line (5) off door lock
5
IRCL element
Use 4.8 mm dia. drill for drilling out, taking
care not to damage the inner door panel. Drive
6 Drill out blind rivets (arrows) out remains of rivets with suitable drift.
Remove remains of rivets and swarf from
door, danger of rusting
Unhook window lift guide rail (9)
7 from inner door panel and push to
one side
8 Unscrew lock fixing screws (11)
Lock cover is permanently attached to
9 Unscrew lock cover screw (10) the door lock and cannot be removed
separately
Remove door lock (6) via access
10
cover
Installing
Insert door lock (6) via access
11
cover
*BA72.10-P-
12 Screw in lock fixing screws (11)
1008-01E
Screw in and tighten screw (10)
13
for lock cover
Hook window lift guide rail (9)
14 onto inner door panel with the two
mounting hooks
Rivet window lift guide rail (9)
15 flush with inner door panel with
4.8 mm blind rivets (arrows)
Connect central locking line (5) to
16 central locking element on door
lock
With retainer (4) open, push
Close retainer (4) for unlocking
17 unlocking bar upwards until resistance can be
bar (3)
felt. Then close retainer again
Hang Bowden cable (1) onto door
18 Clip holder (8) to door lock
lock (6)
AR72.10-P-
19 Install crank window 1900M
Adjust crank window on front AR72.10-P-
20
door 1950M
Check clearance and correct if *BE72.10-P-
21
necessary 1001-01C
Fix sound deadener to inner door
23
panel
AR72.10-P-
24 Install door liner on front door
1000M

BA72.10-P-1008-01E Screw on door lock Nm 10

BE72.10-P-1001-01C Clearance mm 2 (±1)
Remove/install front door lock - AR72.10-P-4011MB

Fig. 133: Identifying Front Door Lock Remove/Install Components - Top Protection
Remove/Install
1 Close window.
2
door 1000MB
AR72.10-P-
3 Remove door inner panel
0104MB
Remove armor plate from front AR72.10-P-
4
door handle 2400-01MB
*BA72.10-
P-1002-
01EA
Remove armor plates from front AR72.10-P-
5
door lock 4011-01MB
*BA72.10-
P-1003-
01EA
AR72.10-P-
6 Remove window guide rail
1500MB
Remove exterior door handle on AR72.10-P-
7
front door 2400MB
Installation: Check clearance by
pulling door handle until resistance can be felt, *BE72.10-P-
adjust if necessary. Thereby press release rod 1001-01C
(3) upward with retainer (4) open until
resistance can be felt. Then close retainer (4)
again.
Loosen hinge strap from front AR72.10-P-
8
door handle 4012MB
Unhook control cable (1) for inner
door actuation from door lock (6),
9
unclip mount (7) from door lock
and remove control cable (1)
Open retainer (4) for release rod
10
(3)
Unhook retaining rod (2) and
11
remove
Remove vacuum line (5) from CL
12
element for door lock
*BA72.10-
13 Unscrew screws (8, 9) P-1008-
01EB
Carefully pull door lock (6) Installation : When installing door
14 downward and remove door lock lock ensure that the release rod (3) is installed
(6) from door opening in the retainer (4) while moving in.
TEST VALUES FOR FRONT DOOR

BE72.10-P-1001-01C Clearance mm 2 (±1)

Number Designation Model 220 with code Z04, Z07
BA72.10-P-1008-01EB Bolt at door lock Nm 7

Z07
BA72.10-P-1002-
Screw for armor plate on window door handle Nm 28
01EA
01EA door M8 Nm 28
Remove/install armor plate for front door lock - AR72.10-P-4011-01MB

Z07
M6 Nm 7
BA72.10-P-1003- Bolt for outer door lock armor plate to front
01EA door M8 Nm 28
1. Unscrew screws (1) from armor plate (2) and remove armor plate (2) from door (5)
2. Unscrew screws (4) from armor plate (3) and remove armor plate (3) from door (5)
3. Install in reverse sequence.
Fig. 134: Identifying Armor Plate And Screw
Removing and installing front door lock - AR72.10-P-4011MC
Fig. 135: Identifying Front Door Lock Remove/Install Components - Light Armoring
Remove/install
Remove, install inner door AR72.10-P-
1
panel 0104MC
Remove outer door handle AR72.10-P-
2
from front door 2400MB
pulling the door handle until there is noticeable
resistance. *BE72.10-P-
Adjust if necessary ? 1001-01C
With retainer (5) open, press release rod (6)
upward until there is noticeable resistance.
Then close the retainer (5) again.
*BA72.10-P-
1008-01E
Detach locking bar (2) from
4
door lock
Detach, remove Bowden
5
cable (3) from door lock
Detach gasket (4) of window
6
guide upward
7 Open retainer (5)
Guide wiring harness through grommet.
8 Remove door lock Installation: Guide release rod (6) into retainer
(5).

BA72.10-P-1008-01E Screw at door lock Nm 10

BE72.10-P-1001-01C Gap mm 2 (±1)
Remove/install front door lock - AR72.10-P-4011N
MODEL 215

Remove
AR72.10-P-
1 Remove door lining from front door.
1000N
AR91.60-P-
2 Remove sidebag from front door
0690M
Disconnect left/right door speaker group
3
connector (H4/1x1; H4/2x1)
Unscrew bolts (7) and remove woofer speaker
4 Fig. 29
(H4/1h2; H4/2h2)
AR72.10-P-
5 Remove door foil from front door
1010N
AR72.10-P-
6 Remove crank operated window on front door
1900N
Remove cap (11) above nut (12) from door
7
floor panel (13) and unscrew nut (12)
Loosen nut (8) and unhook rear window lift
8
guide rail (10) from bracket (9)
Lift rear window lift guide rail (10) until the
stud bolts (10a) on the door floor panel (13)
9
are unhooked and then lay rear window lift
guide rail (10) down in door at front
Unhook Bowden cable (6) from inside door Unclip bracket (5) from door
10
opener from door lock (1) and remove lock (1)
Fold open retainer (14) for release rod and
11
unhook release rod (15)
12 Disconnect CL line (3)
AR72.10-P-
13 Remove lock cylinder guide
2400N
14 Unscrew bolt on lock cover (4)
15 Unscrew lock mounting bolts (2) Fig. 29
16 Take out door lock (1) through access cover
Install
17 Insert door lock (1) through access cover
*BA72.10-P-
18 Screw in lock mounting bolts (2)
1008-01E
Fig. 29
19 Screw in lock cover bolt (4)
AR72.10-P-
20 Install lock cylinder guide
2400N
21 Connect CL line (3)
With retainer (14) open,
22 Hook release rod (15) into retainer (14) press release rod upward until
resistance can be felt. Then close
retainer (14) again and lock
Hook Bowden cable (6) for inside door opener Clip bracket (5) into door lock
23
into door lock (1) (1)
Install rear window guide rail (10) on door Hook stud (10a) into door floor
24
floor panel (13) panel.
Hook rear window lift guide rail (10) into Do not tighten nut (8) so AR72.10-P-
25 that it is still possible to adjust the 1950N
bracket (9) and screw in nut (8)
crank window.
Do not tighten nut (12) so
26 Screw in nut (12) that it is still possible to adjust the
crank window.
AR72.10-P-
27 Install crank window in front door
1900N
Insert cap (11) above nut (12) into door floor
28
panel (13)
*BE72.10-P-
29 Check clearance, correct if necessary
1001-01C
AR72.10-P-
31 Install door foil on front door
1010N
Insert woofer speaker (H4/1h2; H4/2h2) and
32
screw in bolt (7)
Connect left, right door speaker group
33
connector (H4/1x1; H4/2x1)
AR91.60-P-
34 Install sidebag in front door 0690M
AR72.10-P-
35 Install door lining in front door
1000N

BE72.10-P-1001-01C Gap mm 2 (±1)

BA72.10-P-1008-01E Bolt to door lock Nm 8
REMOVE/INSTALL BEARING BRACKET, HINGE STRAP - AR72.10-P-4012
Remove/install hinge strap of front door handle - AR72.10-P-4012MB
Fig. 140: Identifying Hinge Strap Of Front Door Handle Remove/Install Components
Remove/install
AR72.10-P-
1000MB
AR72.10-P-
2 Remove door inner panel
0104MB
Remove armor plate from front door AR72.10-P-
3
handle 2400-01MB
*BA72.10-P-
1002-01EA
Remove armor plates from front door AR72.10-P-
4
lock 4011-01MB
*BA72.10-P-
1003-01EA
AR72.10-P-
5 Remove window guide rail
1500MB
Remove exterior door handle on front AR72.10-P-
6
door 2400MB
AR72.10-P-
7 Remove front door lock
4011MB
Installation: Check plastic
socket (2) for damage, replace if
Unscrew screw (1), move hinge strap necessary.
8 (3) in direction of door lock and Insert hinge strap (3) only, do not yet
remove through door opening position and tighten screw (1), so that
door lock can be installed in the release
rod

Z07
BA72.10-P-1002-
Screw for armor plate on window door handle Nm 28
01EA
01EA door M8 Nm 28
Remove, install bearing bracket of front door handle - AR72.10-P-4012MC

Fig. 141: Identifying Bearing Bracket Of Front Door Handle Remove/Install Components
Remove/Install
AR72.10-P-
1 Remove front door lock
4011MC
Unscrew bolt (2) and remove Bolt (2) is accessible from
2
washer (3) outside.
3 Remove bearing bracket (1) inward
REMOVE/INSTALL REAR DOOR INNER DOOR PANEL - AR72.12-P-0104
Remove/install rear door inner door panel - AR72.12-P-0104MB

Fig. 142: Identifying Rear Door Inner Door Panel Remove/Install Components
Remove/install
Risk of injury caused by Store airbag units with deployment side
performing testing or repair work facing up; do not expose to temperatures AS91.00-Z-
on airbag or emergency tensioning greater than 100°C. When working on these 0001-01A
retractor units. 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 requirements for handling
AH91.00-P-
and storing airbags and emergency
0004-01A
tensioning retractors
AR72.12-P-
2 Remove door lining from rear door
1010MB
Disconnect connector from left rear
3 sidebag squib or connector from
right rear sidebag squib (4)
Disconnect vacuum line separation
4
point (3)
Remove locking linkage (2) and
6
unhook locking linkage (5)
Unscrew bolts (7, 8) from
Note installation position of bolts (7,
7 circumference of inner door panel
8).
(6)
Loosen inner door panel (6) from
Installation: Remove old sealing
door and remove while guiding
8 strip from inner door panel (6) and install
operating cable and locking linkage
new sealing strip
(2)
*BR00.45-Z-
Sealing strip
1036-01A
REPAIR MATERIALS
Remove, install rear door inner door panel - AR72.12-P-0104MC
Fig. 143: Identifying Rear Door Inner Door Panel
Remove
Operations involving work on glass
Secure windshield and windows from
panes and windows are potentially
dropping down; use only the lifting tools AS67.00-Z-
dangerous; use caution to avoid
specified for such operations. Wear safety 0003-01A
allowing hands or feet to become
shoes.
caught.
Store airbag unit with expulsion area on top,
AS91.00-Z-
Risk of injury when carrying out do not subject to temperatures above 100 °
0001-01A
test or repair work on airbag or C. Interrupt power supply when working on
emergency tensioning retractor units such units.
MODEL 210 with Code Z04, Code Z06 AH67.00-P-
windows installed in special high-
MODEL 220 with Code Z04, Code Z07 0003-01FB
security vehicles
Important instructions for
performing repair, body work and AH91.00-P-
Model 203, 215, 220
welding on vehicles with airbags and 0002-01M
emergency tensioning retractor units
Evaluation of airbag and emergency Models 129 as of 1.7.93, 163, 168, 170, 202
AH91.00-P-
tensioning retractor units in vehicles as of 1.7.93, 203, 208, 210, 215, 220, 463,
0006-01B
involved in an accident 638, 901, 902, 903, 904
Models 124, 129, 140, 163, 168, 170, 202,
Legal regulations concerning the
203, 208, 210, 215, 220, 314, 316, 318, 461, AH91.00-P-
handling and storage of airbag and
463, 638, 901, 902, 903, 904, 950, 952, 953, 0004-01A
emergency tensioning retractors
954, 970, 972, 974, 975, 976
AR72.12-P-
2 Remove door liner from rear door
1010MC
AR72.12-P-
3 Remove rear door foil
0105MC
Detach armor plate (1) from door
4
lock
Drill off rivets (arrow) and detach
5
cover (2)
Detach locking rods (3) from inner
6 door panel (7) and detach from door
lock
Disconnect pneumatic line (4) and
7
detach from inner door panel
8 Disconnect side airbag connector (5)
4 bolts in total.
Connect door control module.
Position window so that 2 bolts are
accessible. Unscrew bolts Adjust power
window again.
Before slackening the last 2 bolts, secure
window using clamping pliers (2nd person
required).
10 Lower power window Connect door control module.
Unscrew bolts in inner door panel
11
(7)
12 Detach inner door panel (7) Do not bend inner door panel when
removing.
Do not damage pneumatic line (4).
Install
Remove residual sealant from inner
13
door panel (7) and door panel
14 Apply sealing strip to door panel +Refer to: ?
AH72.12-P-
Sealant pattern on rear door panel
0001-01MC
*BR00.45-Z-
Sealing strip ø 5 mm
1036-01A
Guide pneumatic line (4) through
grommet. Position inner door panel so that
15 Insert inner door panel (7) the bores for the door lining clips are
located in the center of the recess clearances
(arrow).
Position bolts in inner door panel (7)
16
and tighten
Distance from upper edge of
17 Position window window to door panel approx. 225 mm (2nd
person required)
Position power window
18 Install bolts (6)
accordingly.
*BA72.12-P-
1008-01DA
Remove excess sealing strip from
Re-tighten bolts of inner door panel
19 the cutouts (arrow) in the inner door
(7).
panel using a blade
Route pneumatic line (4) and
20 Ensure correct seating of grommet.
connect
Attach locking rods (3) to inner door
21
panel and attach at door lock
22 Attach cover (2) and rivet on
*BA72.12-P-
23 Attach armor plate (1) at door lock
1003-01DA
25 Connect side airbag connector (5)
AR72.12-P-
26 Install rear door foil
0105MC
AR72.12-P-
27 Install door liner in rear door
1010MC
Connect STAR diagnosis tool, read AD00.00-P-
out DTC memory, erase 2000-04A
*WH58.30-Z-
1048-13A

BA72.12-P-1003-01DA Bolt for door lock armor plate to rear door Nm 8
BA72.12-P-1008-01DA Bolt for power window to window Nm 8

Number Designation
REPAIR MATERIALS
REMOVE/INSTALL DOOR FOIL ON REAR DOOR - AR72.12-P-0105
Remove/install door foil on rear door - AR72.12-P-0105MB

Fig. 145: Identifying Door Foil On Rear Door Remove/Install Components
Remove
AR72.12-P-
1 Remove rear door lining
1010MB
Remove electrical line for speaker (2) and
3 hydraulic lines for power window from inner
door panel in area of door foil (1) (arrow).
Replace door foil (1) if
4 Detach door foil (1)
damaged during removal
Remove remaining sealing strip (3) from
5
rear door
Install
The bonding area must be free of *BR00.45-Z-
6 Attach sealing strip (3) to rear door grease and dry to maximize 1036-01A
adhesive force of sealing strip (3).
Firmly press door foil (1) to
7 Glue on new door foil (1)
Cut out door foil (1) in area of speaker (2) Ensure that mounting holes
8
and mounting holes of door lining clips are completely free.
9 Install speaker (2)
Install electrical line for speaker and
10 hydraulic lines for power window on inner
door panel in area of door foil (1) (arrow).
AR72.12-P-
11 Install door lining on rear door
1010MB
REPAIR MATERIALS
Remove, install door foil on rear door - AR72.12-P-0105MC
Fig. 146: Identifying Door Foil On Rear Door Remove/Install Components
Remove
Remove door liner from rear AR72.12-P-
1
door 1010MC
2 Detach door foil (1) Door foil is damaged when removed.
Remove residual sealant from
3
inner door panel
Install
Attach sealing strip (A and B) *BR00.45-Z-
4 Sealing strip Ø5 mm
to inner door panel 1036-01A
*BR00.45-Z-
Sealing strip Ø10 mm
1060-02A
Ensure correct routing of loudspeaker
Adhere door foil (1) to inner cable and Bowden cable.
5
door panel Press on door foil securely using roller to
Roller Fig. 55
AR72.10-P-
1000MC
REPAIR MATERIALS
BR00.45-Z-1060-02A Window installation repair kit 126 670 01 93
REMOVE/INSTALL REAR DOOR - AR72.12-P-0600M
MODEL 220
Fig. 148: Identifying Rear Door Remove/Install Components
MODIFICATION NOTES
8.5.06 Nut on door hinge Model 220 *BA72.12-P-1003-01D
Remove/install
Press molding strip (1) out of door control
1 Fig. 24
unit cover (2) with assembly wedge
2
handle
Unscrew door control unit cover (2) from
AR72.12-P-
3 door lining (4) and press out with mounting
1010M
wedge
Fig. 24
Disconnect door control unit connectors and
4
remove cover
5 Unclip protective hose (5) from B-pillar
Disconnect CL line and electrical connectors
6 from rear door and route through cable duct Remove door liner (4) from inner Fig. 24
(6) door panel in area of cable and plug
connections with mounting wedge
Unscrew screws for door retaining strap (7) *BA72.12-P-
7
from B-pillar 1004-01D
Remove door with aid of second *BA72.12-P-
8 Unscrew nuts (8) from door hinges
person, avoid damaging paint 1003-01D
Lift rear door and remove upward,
simultaneously pull CL line out of rear door
9
through cable duct (6) together with
electrical lines
10 Set down rear door Avoid damaging paint
When replacing a door, carry out
seam sealing and cavity
preservation
11 Install in the reverse order Following installation, check joint Fig. 25

dimensions throughout
AR60.00-P-
Gaps on hoods, doors and 0700-01M
lids *BE60.00-P-
1002-01A
If necessary, adjust rear AR72.12-P-
door 0650M
220.875/878
Front door to A- Dimension
mm 8,0 (±0,5) 6,5 (±0,5)
pillar "B"
Dimension
Front door to fender mm 5,0 (±0,5) 5,0 (±0,5)
"H"
Front door to rear Dimension
mm 5,0 (±0,5) -
door "I"
Dimension
Front door to roof mm 8,0 (± 0,5) 6,5 (±0,5)
"C"
Rear door to top of Dimension
mm 5,0 (±0,5) 5,0 (± 0,5)
side section "D"
Rear door to side Dimension
mm 5,0 (±0,5) 5,0 (±0,5)
BE60.00-P- Gap section, bottom "J"
"Q"
mm - -
fender "P"
AR60.00-P- AR60.00-P-0700-
See picture
0700-01M 01MP

BA72.12-P-1003-01D Nut on door hinge Nm 25
BA72.12-P-1004-01D Screw for door holder on body Nm 14
Fig. 149: Identifying Wedge Tool (110 589 03 59 00)
ADJUST REAR DOOR - AR72.12-P-0650M
MODEL 220
Fig. 151: Identifying Rear Door Adjusting Components (1 Of 2)
Fig. 152: Identifying Rear Door Adjusting Components (2 Of 2)
Adjust
1 Remove striker eye (7)
2 Inspect sizes of gaps at door all round Fig. 25
AR60.00-P-
Gap dimensions on hoods, doors 0700-01M
and lids *BE60.00-P-
1002-01A
Loosen screws (5) from B-pillar, adjust *BA72.12-P-
3 Loosen screws (5) only until it is possible
gap dimension by moving rear door 1001-01D
to move the rear door
Loosen screws (3) on inner door panel and Loosen screws (5) only until it is possible
*BA72.12-P-
4 adjust rear door contour on hinge side by to move the rear door
1002-01D
moving rear door
Door paneling (D) should be flush
with front door contour or should be located
max. 1 mm deeper
Install striker eye (7) Tighten screws (8) so
5 that it remains possible to move the striker
eye (7)
Completely close rear door and adjust The door paneling (E) should be flush with
6 contour on striker eye (7) by moving rear fender paneling or should extend max.
striker eye (7) 1 mm.
*BA72.12-P-
7 Tighten screws (8) on striker eye (7)
1006-01D
Check contour and fit at window frame (F) The outer contour of the window
8 in relation to roof paneling and rear pillar, frame should be flush with the roof
adjust if necessary paneling.
220.875/878
Dimension
Front door to A-pillar mm 8.0 (±0.5) 6.5 (±0.5)
"B"
Dimension
Front door to fender mm 5.0 (±0.5) 5.0 (±0.5)
"H"
mm 5.0 (±0.5) -
door "I"
Dimension
Front door to roof mm 8.0 (±0.5) 6.5 (±0.5)
"C"
BE60.00-P- Size of Rear door to top of Dimension
mm 5.0 (±0.5) 5.0 (±0.5)
1002-01A gap side section "D"
Rear door to lower Dimension
mm 5.0 (±0.5) 5.0 (±0.5)
side section "J"
Dimension
"Q"
mm - -
fender "P"
AR60.00-P- AR60.00-P-0700-
Fig. see
0700-01M 01MP

BA72.12-P-1001-01D Screw for door hinge on B-pillar Nm 35
BA72.12-P-1002-01D Screw for door hinge on inner door panel Nm 35
BA72.12-P-1006-01D Bolt to striker eye Nm 25
Special tools
REMOVE/INSTALL REAR DOOR LINING - AR72.12-P-1010
Remove/install door lining on rear door - AR72.12-P-1010M
MODEL 220.026 /028 /063 /065 /070 /073 /074 /075 /128 /165 /170 /173 /174 /176 /179
MODEL 220.175 /178 except CODE (Z04) Light armoring except CODE (979) Special protection version
MODEL 220.875 /878 except CODE (P082) Electrically adjustable curtains
Fig. 154: Identifying Door Liner On Rear Door Remove/Install Components - Model 220 (1 Of 3)
Remove/Install
Press trim strip (1) off of door control module Fig.
1 Mounting wedge
covering (2) with mounting wedges (5) 24
2
handle
Unscrew bolts (15) and press door control
3 module covering (2) out of door lining (4) with
mounting wedges (5) and remove
Disconnect connectors from left rear door
control module (N69/3) and right door control
4
module (N69/4) and remove door control
module covering (2)
Unscrew bolt (6) from lock cover plate (7) and
5
remove lock trim surround (7)
6 Remove cover (12) and unscrew bolt (13)
Press door lining (4) off of inner door panel (8) Move mounting wedges (5)
7
with mounting wedges (5) directly to clip retainer (9) so that the
retainer tab of the clip retainer do not tear
out off the door lining.
Pry door lining (4) out of retaining clamps on
at top of sealing rail with mounting wedges (5)
8
and simultaneously remove from inner door
panel.
9 Unhook control cable from inside door opener
Disconnect electrical connectors from door
10
lining (4) and lay down door lining (4)
Check
Replace damaged insulating mat
11 Check insulating mat and clip retainers (9)
and clip retainers.
Installation: Remove clip
retainers still on inner door panel (9) and
install at corresponding point on door
lining.
Remove/install rear door lining - AR72.12-P-1010MB

Fig. 158: Identifying Rear Door Lining Remove/Install Components
Remove/install
Press trim strip (1) off of door control unit Fig.
1
covering (2) using mounting wedge (8) 24
Unscrew bolts (15) and press out door Fig.
2
control unit covering (2) from door lining (4) 24
Disconnect connector from left front door
control unit (N69/3) or right front door
3.1 Model 220.1
control unit (N69/4) and remove door control
unit covering (2)
Disconnect connector from driver-side rear
door control unit (N69/3) or passenger-side
3.2 Model 220.8
rear door control unit (N69/4) and remove
door control unit covering (2)
4
handle
5 Remove cover (5) from door handle
6 Unscrew bolts (10, 11) from door handle
Detach cover (12) and unscrew bolt (13)
7
underneath
Unscrew bolt (6) from lock cover plate (7)
8
and remove lock cover plate (7)
9 Remove bolts (14)
Press door lining (4) off of inner door panel Move mounting wedge (8) directly to
10 mounting clips (9), otherwise, the retainer
with mounting wedge (8) and move out
upward tabs for the mounting clips (9) can tear out of
the door lining (4).
Fig.
24
Unhook operating cable from inside door
11
opener
Disconnect electrical connectors from door
12
lining (4) and lay down door lining (4)
Installation: Remove mounting
clips (9) remaining on inner door panel and
13 Check mounting clips (9)
install at corresponding points on door lining,
replace damaged mounting clips (9).
Removing and installing rear door liner - AR72.12-P-1010MC

Fig. 160: Identifying Rear Door Liner Remove/Install Components
Remove/install
Pry off trim strip (1) from door control Fig.
1
module cover (2) 24
Unscrew bolts (15) and press out door
Fig.
2 control module cover (2) from door
24
lining (4) and remove
Disconnect connector from door control
3 module on left, right (N69/3, N69/4) and
detach door control module cover (2)
4
handle
Remove cover (5) from inner door
5
handle
Unscrew bolt (10) and (11) from inner
6
door handle
Detach cover (12) and unscrew bolt (13)
7
underneath
Unscrew bolt (6) from lock flange (7)
8
and detach lock flange
9 Unscrew bolts (14)
Slide cover (16) downward, unscrew bolt Only for vehicle with sun blind.
10 (18) and detach guide (17) Do not damage cover (16).
Pry off door lining (4) from inner door Move assembly wedge (8) directly onto each Fig.
11 fastening clip (9) and ensure that the retainer tabs 24
panel and move out upward
of the fastening clips do not tear out of the door
lining (4).
Unhook control cable from door interior
12
actuating mechanism
Check sound deadener and fastening Replace damaged sound deadener and fastening
13
clips (9) clips.
Installation:
Fastening clips (9) remaining on the inner door
panel must be removed and attached to the
corresponding position on the door lining (4).
REMOVE/INSTALL SEALING STRIP ON DOOR BOTTOM EDGE - AR72.12-P-1019
Remove/install sealing strip on door bottom edge - AR72.12-P-1019P
MODEL 203.### (except 203.7) #A up to 480000, 203.### (except 203.7) #F up to 380000, 203.### (except
203.7) #R up to 091200, 209.### #F up to 040000, 209.### #T up to 000430, 220.### #A up to 334894,
203.### (except 203.7) #A as of 745749, 203.### (except 203.7) #F as of 648300, 203.### (except 203.7) #R
as of 173714, 209.### #F as of 147224, 209.### #T as of 004944, 220.### #A as of 374525
Fig. 162: Identifying Sealing Strip On Door Bottom Edge

Remove
hoods, doors, trunk of moving parts.
lid/rear-end door or
sliding roof.
1 Remove sealing strip Sealing strip must
from doors be replaced
When performing
service measure also
replace sealing strip
Long wedge Fig. 163
2 Thoroughly clean door To ensure proper *BR00.45-Z-1052-04A
with silicon remover and adhesion, there must be no
dry with compressed air cleaning agent residues
remaining.
Install
3 Fill new sealing strip with Insert nozzle of *BR00.45-Z-1068-01A
sealant sealant cartridge as far
into the sealing strip as
possible (figure A).
The sealing strip
is sufficiently filled if the
material is clearly visible.
4 Install sealing strip to Remove excess
door material using a plastic
wedge.
Mounting wedge Fig. 24
5 Clean door and sealing Remove excess *BR00.45-Z-1052-04A
strip after assembly material with rag and
silicon remover

REPAIR MATERIALS
BR00.45-Z-1068-01A Terostat-934 sealant A 004 989 29 20
BR00.45-Z-1052-04A Silicone remover Prosol Lacke + Farben GmbH
Order No. 3295 Schneidmuhlweg 12
63741 Aschaffenburg
Germany
Tel. +49 6021 3480-0
Fax +49 6021 3480-40
www.prosol-farben.de
Remove/install sealing strip on door bottom edge - AR72.12-P-1019PA
MODEL 203.### (except 203.7) #A as of 480000 up to 745749, 203.### (except 203.7) #F as of 380000 up
to 648300, 203.### (except 203.7) #R as of 091200 up to 173714, 209.### #F as of 040000 up to 147224,
209.### #T as of 000430 up to 004944, 220.### #A as of 334894 up to 374525
Fig. 165: Identifying Sealing Strip On Door Bottom Edge
Remove
hoods, doors, trunk of moving parts.
lid/rear-end door or
sliding roof.
1 Remove sealing strip
from doors
2 Thoroughly clean sealing To ensure proper *BR00.45-Z-1052-04A
strip and doors with adhesion, there must be no
silicone remover and wax or cleaning agent
blow dry with compressed residues remaining.
air
Install
3 Fill sealing strip with Insert nozzle of *BR00.45-Z-1068-01A
sealant sealant cartridge as far
into the sealing strip as
possible (figure A).
The sealing strip
is sufficiently filled if the
material is clearly visible.
4 Install sealing strip to Remove excess
door material using a plastic
wedge.
Mounting wedge Fig. 24
5 Clean door and sealing Remove excess *BR00.45-Z-1052-04A
strip after assembly material with rag and
silicon remover
REPAIR MATERIALS
BR00.45-Z-1068-01A Terostat-934 sealant A 004 989 29 20
BR00.45-Z-1052-04A Silicone remover Prosol Lacke + Farben GmbH
Order No. 3295 Schneidmuhlweg 12
63741 Aschaffenburg
Germany
Tel. +49 6021 3480-0
Fax +49 6021 3480-40
www.prosol-farben.de
REMOVE/INSTALL WINDOW GUIDE RAIL FOR REAR DOOR - AR72.12-P-1500MB
Fig. 167: Identifying Window Guide Rail For Rear Door Remove/Install Components
Remove
Notes on avoiding damage to
AH67.00-P-
0003-01FB
security vehicles
1 Close window.
Remove door lining from rear AR72.12-P-
2
door 1010MB
AR72.12-P-
3 Remove rear door inner door panel
0104MB
Remove rear door handle armor AR72.12-P-
4
plate 2410-01MB
Carefully loosen textile profile
5
from lower window guide rail (5)
Unscrew bolts (1, 2) and remove
6
lower guide rail (5)
Carefully open window with Secure window against tilting to prevent
7
manual window lifter actuation (7) damaging window
Carefully loosen textile profile
8
from upper window guide rail (6)
9 Unscrew bolts (3, 4)
Carefully loosen upper window guide rail
10 Carefully tilt upper window guide (6) from seal of triangular window (glued) to
rail (6) in direction of B-pillar and avoid damage.
remove upward Replace damaged seal for triangular window,
see: ?
AR72.12-P-
Remove/install rear door triangular window
1940MB
Install
Install upper window guide rail (6)
11 with textile profile and position Do not yet glue textile profile.
bolts (3, 4)
AR72.12-P-
Adjust upper window guide rail 1500-01MB
12
(6) *BE72.12-P-
1001-01BA
Tighten bolts (3, 4) at upper
*BA72.12-P-
13 window guide rail (6) and glue
1001-01DA
textile profile
*BR00.45-Z-
MB universal glue
1003-02A
Carefully close window with
14
manual window lifter actuation (7)
Install upper window guide rail (5) *BA72.12-P-
15
and glue rubber profile 1001-01DA
*BR00.45-Z-
MB universal glue
1003-02A
Install rear door handle armor AR72.12-P-
16
plate 2410-01MB
*BA72.12-P-
1002-01DA
*BA72.12-P-
1007-01DA
AR72.12-P-
17 Install rear door inner panel
0104MB
AR72.12-P-
1010MB

Dimension "a" mm 698
BE72.12-P-1001-01BA Distance
For picture, seen -

BA72.12-P-1001-01DA Bolt, window guide rail to rear door Nm 9
BA72.12-P-1002-01DA Bolt, door handle armor plate to door Nm 28
BA72.12-P-1007-01DA Bolt, window guide rail at angle Nm 9
REPAIR MATERIALS
Adjust rear door window guide rail - AR72.12-P-1500-01MB

Number Designation Model 220 with Code Z07
For picture, see -
1. Determine gap (a) between window guide (front) (2) and upper guide rail (3) and correct if necessary.
The gap (a) can be corrected by moving upper guide rail (3).
It should not be less than specification over the entire length of the upper guide rail (3) to ensure fault-free
operation of the window (1)
Fig. 168: Identifying Gap Between Window Guide And Upper Guide Rail
REMOVE/INSTALL POWER WINDOW ON REAR DOOR - AR72.12-P-1810
Remove/install power window on rear door - AR72.12-P-1810M

MODEL 220
Fig. 169: Identifying Power Window On Rear Door Remove/Install Components (1 Of 2)
Fig. 170: Identifying Power Window On Rear Door Remove/Install Components (2 Of 2)
Remove, Install
Remove/install door liner on rear AR72.12-P-
1
door 1010M
Remove insulating mat from inner
2
door panel
Removal:
Open crank window (2) until the mounting
screw (3) is accessible in the assembly
3 Unscrew mounting screw (3) opening (4) of the power window guide rail
Installation:
Install screw (3) so that the crank window (2)
can be moved up and down properly
Move crank window (2) completely
4 Secure against falling down with assembly Fig. 24
upward
wedges.
To drill out use Ø 4.8 mm dia. bit and do
not damage inner door panel. Use punch to
drive out remaining rivet residues.
Drill pop rivet (arrows) out of inner Remove rivet residues and chips from door,
5
door panel or cut out danger of rust
Installation:
Rivet power window (1) to inner door panel
flush with new pop rivets.
Remove power window motor
6 connector (M10/6x1, M10/5x1)
from power window motor
Unhook power window (1) from
Installation: Hook power window in
7 inner door panel and remove
at inner door panel with assembly hook
through assembly opening.
Remove/install rear door window lifter - AR72.12-P-1810MB

Fig. 172: Identifying Rear Door Window Lifter Remove/Install Components
Remove/install
Risk of injury caused by hands or
Secure windows against dropping, use only AS67.00-Z-
feet being jammed or crushed when
specified lifting tools, wear protective shoes. 0003-01A
working on windshield or windows
Notes on avoiding damage to
AH67.00-P-
0003-01FB
security vehicles
1 Close window.
AR72.12-P-
1010MB
AR72.12-P-
3 Remove door foil from rear door
0105MB
AR72.12-P-
0104MB
Cover door frame in area of clamping
Secure window against falling down
5 pliers with suitable equipment to avoid
with clamping pliers
damaging paint.
Fig. 22
Catch oil running out. Plug
openings on hydraulic cylinder (8) and
Unscrew hollow bolts (5) from
6 hydraulic lines (7).
hydraulic cylinder (8)
Installation: Replace sealing rings
(6).
*BA72.12-P-
1006-01DA
If necessary slightly lower window
7 lifter with manual window lifter actuation
reinforcement (4)
(9)
Installation: Secure bolts (2) with *BR00.45-Z-
securing agent. 1011-02A
Lower window lifter with manual
8 window lifter actuation (9) down to
bottom stop.
Unscrew bolts (1) from
circumference of carrier plate with
9 Installation: Install new bolts (1).
window lifter (3) and remove carrier
plate with window lifter (3)
*BA72.12-P-
1005-01DA
The hydraulic unit with the oil
reservoir and the valve block are housed in
the spare wheel well in the trunk.
Check hydraulic oil level of The oil level in the oil reservoir should not
11
hydraulic power window system fall below the minimum mark when the side
window is closed and must not exceed the
maximum mark when the side window is
open.

BA72.12-P-1005-01DA Bolt, carrier plate to rear door Nm 28
BA72.12-P-1006-01DA Banjo bolt to hydraulic cylinder Nm 7
REPAIR MATERIALS
BR00.45-Z-1011-02A Quick glue A 003 989 31 71
Removing and installing rear door power window - AR72.12-P-1810MC

Fig. 174: Identifying Rear Door Power Window Remove/Install Components
Remove/install
AR72.12-P-
1 Remove inner door panel (2)
0104MC
Installation: Ensure correct installation
2 Drill out rivets (arrows) position of the rivets, otherwise the window may
be damaged.
Detach power window (1)
3
REMOVE/INSTALL CRANK WINDOW IN REAR DOOR - AR72.12-P-1910M
MODEL 220
Fig. 175: Identifying Crank Window In Rear Door Remove/Install Components
Remove, Install
1
door 1010M
000 Installation:
Remove insulating mat from Before installing insulating mat, check crank
2
inner door panel window for easy motion
Replace damaged insulating mat
AR72.10-P-
1600E
Remove trim strip with outer AR72.10-P-
4
sealing rail 1700E
Removal:
Open crank window (2) until the mounting screw
(3) of the window guide rail in the assembly
5 Unscrew bolt (3) opening (4) is accessible
Installation:
Install screw (3) so that the crank window (2)
can be moved up and down properly
Slide crank window (2) First move crank window (2) out of window
6
downward and position in door guide rail
Remove window guide rail (5) only in
Remove window rail guide (5) area of window stay AR72.12-P-
7
together with window stay (1) Installation: 1970M
Coat window guide rail (5) with soap solution.
Turn crank window (2) until it
can be removed out of window
8
shaft upward
REMOVE/INSTALL SEALING FOR CRANK WINDOW ON REAR DOOR - AR72.12-P-1911
Remove/install sealing for crank window on rear door - AR72.12-P-1911MB
Outer sealing
Fig. 176: Identifying Sealing For Crank Window On Rear Door Remove/Install Components
Remove/install
AR72.12-P-
1 Remove rear door window (2)
1920MB
Carefully loosen sealing (1) from
Remove sealing (1) for window window guide to prevent damaging sealing
2
guide out of rear door (2) (1).
Replace sealing (1); if damaged, see: ?
AR72.12-P-
Fabricate sealing (1) for crank window on 1911-01MB
rear door (2) *BR00.45-Z-
1065-02A
REPAIR MATERIALS

Arabellastrasse 17
81925 Munchen
Germany
BR00.45-Z-1065-02A Loctite 401
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
Fabricate sealing for crank window on rear door - AR72.12-P-1911-01MB
REPAIR MATERIALS
Arabellastrasse 17
81925 Munchen
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
1. Do not work on area (A) on sealing (1) located towards front of vehicle (arrow X).
2. Cut out rubber profile (2) for sealing (1) in area (B) up to approx. 2 cm following radius (3).
Fig. 177: Identifying Sealing Area On Window Guide

3. Fabricate profile (4) to be glued in out of rubber profile cut out previously.
4. Glue in profile (4) so that it extends sealing (1) approx. 2 cm
5. Insert sealing (1) for window guide into window frame.
6. Transfer length of vertical sections from old sealing (1) to new sealing (1).
Fig. 178: Inserting Sealing For Window Guide Into Window Frame
Remove/install sealing for crank window on rear door - AR72.12-P-1911MBA
Inner sealing
Fig. 179: Identifying Sealing For Crank Window On Rear Door Remove/Install Components
Remove/install
Remove rear door AR72.12-P-
1
window 1920MB
Carefully loosen sealing (1) from window guide
2 Remove sealing (1). to prevent damaging sealing (1).
Replace sealing (1); if damaged, see: ?
AR72.12-P-1911-
01MBA
Fabricate sealing (1) for crank window in rear door
*BR00.45-Z-1065-
02A
Installation: Clean sealing (1) and window *BR00.45-Z-1087-
guide and glue in sealing (1). 02A
*BR00.45-Z-1025-
04A
3
order
REPAIR MATERIALS
Arabellastrasse 17
81925 Munchen
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1087-02A Adhesives A 004 989 25 71
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Fabricate sealing for crank window on rear door - AR72.12-P-1911-01MBA
REPAIR MATERIALS
Arabellastrasse 17
81925 Munchen
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
1. Cut sealing (1) down to a length of 220 cm
2. Cut sealing to dimension (D)
Fig. 180: Identifying Cut Sealing Dimension And Cut Sealing Length
3. Hold sealing (1) in area (A, B) in window frame and cut sealing (1) up to raised bead (2) and glue fitted
triangle (3) (from residual material) into sealing (1)
Fig. 181: Identifying Sealing Area In Window Frame
4. Fasten sealing (1) in area (A, B) in window frame and mark between areas (B, C) on raised bead (2)
(arrow), loosen sealing (1) and cut miter out of raised bead (2) for sealing (1) at marked point.
5. Glue sealing (1) in area (B, C) together at miter.
Fig. 182: Identifying Fasten Sealing Area In Window Frame
REMOVE/INSTALL REAR DOOR WINDOW - AR72.12-P-1920
Remove/install rear door window - AR72.12-P-1920MB
Fig. 183: Identifying Rear Door Window Remove/Install Components

Remove/install
AS67.00-Z-
being jammed or crushed when working use only specified lifting tools, wear
0003-01A
on windshield or windows protective shoes.
Cover door frame in area of
Close window (3) and secure with
1 clamping pliers with suitable
clamping pliers
equipment to avoid damaging paint.
Fig. 22
AR72.12-P-
1010MB
AR72.12-P-
0104MB
AR72.12-P-
4 Remove window lifter from rear door
1810MB
AR72.12-P-
5 Remove rear door handle armor plate
2410-01MB
*BA72.12-P-
1002-01DA
*BA72.12-P-
1007-01DA
Do not yet remove upper AR72.12-P-
6 Remove lower window guide rail (2)
window guide rail (1). 1500MB
Install wooden block (4) for supporting
7
window (3) in rear door
Hard wood for supporting rear door WF58.50-P-
window 7212-01MB
Carefully lower window (3), set down on
8 wooden block (4) and secure against
falling out
AR72.12-P-
9 Remove upper window guide rail (1)
1500MB
Remove window (3) with
10 Remove window (3)
aid of helper

Remove, install window in rear door - AR72.12-P-1920MC
Fig. 185: Identifying Rear Door Window Remove/Install Components
Remove/install
Operations involving work on glass panes and Secure windshield and windows from
windows are potentially dangerous; use dropping down; use only the lifting tools AS67.00-Z-
caution to avoid allowing hands or feet to specified for such operations. Wear 0003-01A
become caught. safety shoes.
Instructions for avoiding damage to windows MODEL 210 with Code Z04, Code Z06 AH67.00-P-
installed in special high-security vehicles MODEL 220 with Code Z04, Code Z07 0003-01FB
AR72.12-P-
0104MC
AR72.10-P-
2 Remove trim strip with outer sealing rail
1700E
Window must be secured by the

window separator bar to prevent it from
3 Lower window (1) completely
falling out.
Detach gaskets (arrows) in area of window
4 Gaskets are adhered, do not damage.
separator bar
Installation: MB special *BR00.45-Z-
adhesive 1002-02A
5 Detach paneling (2) Paneling is adhered, do not damage.
Installation: MB special *BR00.45-Z-
adhesive 1002-02A
Bracket (5) only for vehicles
6 Unscrew bolts (3, 4), detach bracket (5)
with sun blind.
Secure window. Do not damage
7 Remove window separator bar (6)
gasket at the triangular window.
8 Remove window (1)
REPAIR MATERIALS
BR00.45-Z-1002-02A Special glue A 000 989 92 71
ADJUST REAR DOOR WINDOW - AR72.12-P-1921MB
Fig. 186: Identifying Rear Door Window Adjusting Components
If "jerking" or "tilting" of the rear

Check window operation (1) by window is noticed, readjust upper window
1
opening and closing guide rail (3).
2 Open rear window (1)
*BE72.12-P-
3 Measure gap (a)
1001-01BA
Carefully loosen textile profile in
4
upper area of window guide rail (3)
5 Slacken bolts (5, 6)
Adjust dimension (a) by moving upper The dimension (a) should not be less *BE72.12-P-
6
guide rail (3) over the entire length of the upper guide rail. 1001-01BA
Tighten screws (5 and 6) at upper
*BA72.12-P-
7 window guide rail (3) and glue textile
1001-01DA
profile
*BR00.45-Z-
MB universal glue
1003-02A
Check window operation (1) by
8
opening and closing

Fig. see -

BA72.12-P-1001-01DA Screw for window guide rail on rear door Nm 9
REPAIR MATERIALS
REMOVE/INSTALL REAR DOOR TRIANGULAR WINDOW - AR72.12-P-1940
Remove/install rear door triangular window - AR72.12-P-1940MB

Fig. 187: Identifying Rear Door Triangular Window Remove/Install Components
Remove
AS67.00-Z-
being jammed or crushed when working on use only specified lifting tools, wear
0003-01A
windshield or windows protective shoes.
1 Open window
AR72.12-P-
1010MB
AR72.12-P-
0104MB
AR72.12-P-
4 Remove window guide rail from rear door
1500MB
AR72.10-P-
1700E
Triangular window (1) is
Pull triangular window (1) with seal (2) out
6 installed in door frame with sealing
of door frame in direction of B-pillar
compound.
Fig. 22
Remove seal (2) from triangular window
7
(1)
Remove remaining sealing compound from
8
triangular window (1) and door frame
Install
9 Fit new seal (2) on triangular window (1)
Seal door frame in installation area of
10 triangular window (1) with sealing See Fig. 187.
compound (arrows).
*BR00.45-Z-
Adhesive tape
1014-01A
Install triangular window (1) with seal (2) Press triangular window (1)
11
into door frame into door frame as far as possible.
Fig. 22
AR72.12-P-
12 Install window guide rail for rear door
1500MB
AR72.12-P-
13 Install rear door inner panel
0104MB
AR72.12-P-
1010MB
AR72.10-P-
15 Install outer sealing rail
1700E
seal all the way around to triangular
16 window (1), door frame and window guide See Fig. 187.
(arrows).
*BR00.45-Z-
Sealing adhesive
1005-02A
REPAIR MATERIALS
BR00.45-Z-1014-01A Adhesive tape A 000 989 98 85
BR00.45-Z-1005-02A Sealing adhesive A 004 989 53 71
Remove, install rear door triangular window - AR72.12-P-1940MC

Fig. 189: Identifying Rear Door Triangular Window Remove/Install Components
Remove
Operations involving work on glass panes Secure windshield and windows from
and windows are potentially dangerous; dropping down; use only the lifting AS67.00-Z-
use caution to avoid allowing hands or feettools specified for such operations. 0003-01A
to become caught. Wear safety shoes.
Z06 AH67.00-P-
windows installed in special high-security
MODEL 220 with Code Z04, Code 0003-01FB
vehicles
Z07
AR72.12-P-
1 Remove window in rear door
1920MC
2 Pull out triangular window (1) Tensioning clamp Fig. 22
Install
Fit new gasket (2) on triangular window
3.1 If necessary
(1)
Seal door frame assembly in installation *BR00.45-Z-
4 see Fig. 189
area of triangular window using sealant 1014-01A
Insert triangular window (1) with gasket Press triangular window into
5 the door frame assembly as far as
(2)
possible.
AR72.12-P-
6 Install window in rear door
1920MC
Seal gasket (2) all around with respect to *BR00.45-Z-
7 see Fig. 189
the triangular window (1) 1005-02A
Fig. 190: Identifying Clamping Pliers (170 220 589 04 31 00)
REPAIR MATERIALS
BR00.45-Z-1005-02A Sealing adhesive A 004 989 53 71
REMOVE/INSTALL FIXED WINDOW IN REAR DOOR - AR72.12-P-1970M
MODEL 220
Fig. 191: Identifying Rear Door Fixed Window Remove/Install Components
Remove, Install
AR72.12-P-
1010M
Installation:
Before installing insulating mat, check
Remove insulating mat from inner
2 crank window for easy motion
door panel
Replace damaged insulating
mat
AR72.10-P-
1600E
Remove trim strip with outer sealing AR72.10-P-
4
rail 1700E
5 Remove crank window in rear door
Do not remove crank window, AR72.12-P-
position in door 1910M
Remove window guide rail from Installation:
6 Coat window guide rail with soap
window stay (1)
solution.
7 Unscrew screws (2 and 3)
8 Remove window web (1) Avoid damaging paint
Pull fixed window (4) out toward front Before installing coat rubber
9
together with rubber frame (5) frame (5) with soap solution
REMOVE, INSTALL REAR DOOR CATCH - AR72.12-P-2100MC
Fig. 192: Identifying Rear Door Catch Remove/Install Components
Remove/install
1 Remove rear door inner door panel AR72.12-P-0104MC
2 Remove bolt (2)
3 Unscrew screws (3, 4)
4 Remove door catch (1)
REMOVE/INSTALL REAR DOOR DAMPER - AR72.12-P-2200
Remove/install rear door damper - AR72.12-P-2200MB

Fig. 193: Identifying Rear Door Damper Remove/Install Components
Remove/install
Remove door lining from AR72.12-P-
1
rear door 1010MB
Carefully loosen Installation: Check insulating mat (2) and
2
insulating mat (2) sealing tape for damage, replace if necessary.
Remove retainers (5) and
3
bolts (4) with washers (6)
Installation: The noticeable unevenness on the
4 Remove door damper (3) damper housing (3) must point upward. The new door
damper (3) should have the same length as the previous
one.
5
order
Remove, install rear door damper - AR72.12-P-2200MC
Fig. 194: Identifying Rear Door Damper Remove/Install Components
1
door 1010MC
Remove retainer (4) and
3 remove bolt (3) with washer At the A-pillar and the door armor plate
(5)
4 Remove door damper on the damper housing (arrow) must point
upward.
Check gasket on door panel, replace if necessary.
REMOVING AND INSTALLING OUTER DOOR HANDLE ON REAR DOOR - AR72.12-P-2410
Removing and installing outer door handle on rear door - AR72.12-P-2410M
MODEL 220 up to 31.8.99
Fig. 195: Identifying Outer Door Handle On Rear Door Remove/Install Components (1 Of 2)
Fig. 196: Identifying Outer Door Handle On Rear Door Remove/Install Components (2 Of 2)
Removing
Pull door sealing frame
1 (12) out of channel in
area of door lock (13)
Loosen torx screw (3) Accessible through opening (11) on narrow side
2
approx. 5 turns of door (arrow)
Pivot guide (2) slightly backward and then pull out to
3 Remove guide (2) outside, simultaneously pull up handle (1) slightly.
For this purpose pull handle (1) out of bearing bracket to
4 Remove handle (1)
rear together with base (4) and remove from door passage
5 Remove base (5)
Remove insulating mat
6
in area of door lock.
Remove door liner from AR72.12-P-
7
rear door. 1010M
Unscrew screws from Open retainer for release rod (10) AR72.12-P-
8
door lock (13) Door lock can remain in door 2510M
Unscrew screws (7) from door handle recess.
Remove bearing
9 Remove bearing bracket (6) together with release rod (10)
bracket (6)
through installation opening in inner door panel.
Installing
Install bearing bracket (6) together with release rod (10)
Install bearing bracket through installation opening in inner door panel and insert
10
(6) release rod (10) into retainer on door lock (13). Screw in
screws (7) in door handle recess
Screw in screws in door *BA72.12-P-
11
lock (13) 1007-01D
12 Install base (5)
Insert handle (1) into Ensure that the lever on the handle (1) slides behind
13 bearing bracket (6) with the actuation lever (9) of the bearing bracket (6) to allow
base (4) the door lock to be unlocked.
14 Install guide (2)
Turn in Torx screw (3) *BA72.12-P-
15
WAF 4 mm and tighten 1008-01D
Install door sealing
16
frame (12)
Adjust clearance Push release rod (10) upward until resistance can
17 between handle (1) and be felt with retainer open.
actuation lever (9) Then relock retainer
18 Check clearance Pull handle (1) until resistance can be clearly felt *BE72.12-P-
1001-01B
Carry out operational
19
check
Install door liner on AR72.12-P-
21
rear door 1010M
15
check
TEST AND ADJUSTMENT VALUES FOR REAR DOOR

BE72.12-P-1001-01B Clearance mm 2 ± 1

BA72.12-P-1007-01D Screw on door lock Nm 10
BA72.12-P-1008-01D Screw for door handle on rear door Nm 3
Removing and installing outer door handle on rear door - AR72.12-P-2410MA
Fig. 197: Identifying Outer Door Handle On Rear Door Remove/Install Components
Fig. 198: Identifying Door Lock And Narrow Side Door
Fig. 199: Identifying Insulating Mat
Removing
Remove cover on opening
1
(11) above door lock (33)
Loosen Torx screw (3)
2 Accessible through opening (11).
approx. 5 turns
Remove door liner from AR72.12-P-
3
rear door 1010M
4 Remove door insulation
Depending on vehicle equipment also AR72.12-P-
5 Disconnect connectors
Keyless go antenna. 2410-04MA
Slightly pivot guide (2) to rear and then pull out to
6 Remove guide (2) outside, simultaneously pull up handle (1) slightly.
Avoid damaging paint.
For this purpose pull handle (1) out of bearing bracket
7 Remove handle (1) to rear together with base (4) and remove from door
passage.
8 Remove base (5)
Remove insulating mat
9
(16) in area of door lock
Unscrew screw (7) on
10
door handle recess
Remove connecting rods AR72.12-P-
11
to door lock 2410-03MA
Remove bearing bracket Remove bearing bracket (6) through installation
12
(6) opening in inner door panel.
Installing
Install bearing bracket (6) in inner door panel through
13 Install bearing bracket (6)
installation opening.
Install release rod (10) in retainer. Install connecting
Install connecting rods to AR72.12-P-
14 rod (11) in retaining lug and catch.
door lock 2410-03MA
Screw in screws (7) in door handle recess.
Screw in screws of door *BA72.12-P-
15
lock (33) 1007-01D
Lock retainer on release
16
rod
17 Install base (5)
Install handle (1) in Ensure that the lever on the handle (1) slides
18 bearing bracket (6) behind the actuation lever (9) of the bearing bracket
together with base (4) (6) to allow the door lock to be unlocked.
19 Install guide (2)
Turn in Torx screw (3) *BA72.12-P-
20
WAF4 mm and tighten 1008-01D
Pull handle (1) until resistance can clearly be *BE72.12-P-
21 Check clearance
felt 1001-01B
If required press release rod (10) upward
22 handle (1) and actuation retainer by opening retainer until resistance can be
felt.
lever (9)
Then relock retainer.
23
check
24 Insert insulating mat (16)
25 Glue on door insulation
Install door liner on rear AR72.12-P-
26
door 1010M
27
check
TEST AND ADJUSTMENT VALUES FOR REAR DOOR


BA72.12-P-1008-01D Screw for door handle on rear door Nm 3
Removing and installing connecting rods to door lock - AR72.12-P-2410-03MA
1. Unscrew sheet metal screw (13) and remove spacer (12) from bearing bracket (6).
2. Press lug for retainer (14) to outside (arrow) and remove release rod (10) from retainer (14).
3. Unhook connecting rod (11) from retaining lug (15) on door lock.
The connecting rod (11) can only be unhooked when the bearing bracket (6) is loose.
Fig. 200: Identifying Sheet Metal Screw, Spacer And Bearing Bracket
Removing and installing connectors - AR72.12-P-2410-04MA
Disconnect connectors depending on vehicle equipment
1. Unscrew mounting screws (20) from Keyless go rear door antenna (A2/39, A2/40), carefully unclip
antenna and lay down to side.
Fig. 201: Identifying Mounting Screws And Antenna Connectors
2. Remove coupling (21) out of coupling strip together with gray leads and disconnect clutch.
3. Unclip separation point (22) from vacuum line and remove vacuum line.
4. Remove cover (23) and disconnect capacitive sensor and push contact connector (S47/1x1).
5. Remove microswitch (24) from door lock.
Fig. 202: Identifying Coupling And Separation Point
Remove/install outer rear door handle - AR72.12-P-2410MB
MODEL 220.175 /178 with CODE (Z04) Light armoring with CODE (Z07) Top protection
Fig. 203: Identifying Outer Rear Door Handle Remove/Install Components
Remove/install
Remove plug (1) and unscrew bolt
1 Bolt is secured from falling out.
underneath
*BA72.12-P-
1008-01D
2 Remove cover (2)
Move door handle (3) in direction Installation: Check subsurfaces (4
3
of door lock and remove and 5) for damage, replace if necessary.

BA72.12-P-1008-01D Bolt for rear door handle Nm 3
Remove/install rear door handle armor plate - AR72.12-P-2410-01MB

1. Unscrew bolts (1, 4) from bracket (2) of window guide rail and remove bracket (2)
2. Unscrew bolt (1) from armor plate (3) and remove armor plate (3).
Fig. 204: Identifying Armor Plate Bolts
REMOVING AND INSTALLING DOOR LOCK ON REAR DOOR - AR72.12-P-2510

Removing and installing door lock on rear door - AR72.12-P-2510M
MODEL 220 up to 31.8.99
Fig. 205: Identifying Door Lock On Rear Door Remove/Install Components (1 Of 2)
Removing
Removing and installing door liner AR72.12-P-
1
on rear door 1010M
Remove insulating mat in area of
2 door lock (3)
For this purpose unhook control cable (1)
Remove control cable (1) for inner
3 from door lock (3) first and unclip holder
door actuation
(4) from door lock
Unclip cover (5) for transfer lever
4
(11) from inner door panel
Remove retaining rod (2) together For this purpose unscrew screw (9) and
5 with transfer lever (11) and unclip spreading clip on transfer lever (11)
retaining rod (12) from inner door panel
Remove outer door handle from It is not possible to remove the AR72.12-P-
6 bearing bracket (6) when the door lock (3) 2410M
rear door
is installed
Unscrew bearing bracket (6) and Unscrew screws from door handle recess
7
push upward and open retainer for release rod (10)
Remove CL line (7) from door lock
8
(3)
9 Unscrew door lock (3) For this purpose unscrew screws (8)
Remove door lock (3) from inner
10 door panel through installation
opening
Installing
Install door lock (3) on inner door First insert bearing bracket (8) in
11
panel through installation opening door above door lock
*BA72.12-P-
12 Screw in screws (8) in door lock (3)
Tighten front screws (8) first 1007-01D
13 Install CL line (7) on door lock (3)
Install release rod (10) in door lock (3)
14 Install bearing bracket (6) retainer Screw in screws in door handle
recess
Install outer door handle on rear AR72.12-P-
15
door 2410M
Install retaining rod (2) together For this purpose clip spreading clip on
16 with transfer lever (11) and transfer lever (11) into inner door panel and
retaining rod (12) screw in screw (9)
Clip cover (5) for transfer lever (11)
17
into inner door panel
For this purpose hook control cable (1) into
Install control cable (1) for inner
18 door lock (3) first and clip holder (4) in on
door actuation
door lock (3)
Push release rod (10) upward until
Adjust clearance between door
19 resistance can be felt with retainer open.
handle and actuation lever
Then relock retainer
*BE72.12-P-
20 Check clearance
Pull door handle until resistance 1001-01B
can clearly be felt.
21 Glue on insulating mat
AR72.12-P-
22 Install door liner on rear door
1010M

TEST AND ADJUSTMENT VALUES FOR FRONT DOOR

Removing and installing door lock on rear door - AR72.12-P-2510MA

Removing
Removing and installing door AR72.12-P-
1
liner on rear door 1010M
2 Remove door insulation
For this purpose unhook control cable (31)
Remove control cable (31) for
3 from holder (34) first and then unclip from
inner door actuation
door lock (33).
Unclip cover (35) for transfer
4
lever (40) from inner door panel
For this purpose unscrew plastic screw (39)
Install retaining rod (32) together
5 and unclip spreading clip on transfer lever (40)
with transfer lever (40)
from inner door panel
Remove CL line (37) from
6
separation point (41)
Remove outer door handle from AR72.12-P-
7
rear door 2410MA
8 Unscrew door lock (33) For this purpose unscrew three screws (38)
Remove door lock (33) from
9 inner door panel through
installation opening
Installing
Install door lock (33) on inner
10 door panel through installation
opening
11
Screw in screws (38) in door lock *BA72.12-P-
(33) Tighten front screws (38) first 1007-01D
Install CL line (37) on separation
12
point (41)
Install outer door handle on rear AR72.12-P-
13
door 2410MA
For this purpose clip spreading clip on transfer
Install retaining rod (32) together
14 lever (40) into inner door panel and screw in
with transfer lever (40)
plastic screw (39)
Clip cover (35) for transfer lever
15
(40) into inner door panel
For this purpose hook control cable (31) into
Install control cable (31) for inner
16 door lock (33) first and clip holder (34) in on
door actuation
door lock.
Pull door handle until resistance can
17 Check clearance
clearly be felt
18 Glue on door insulation
AR72.12-P-
19 Install door liner on rear door
1010M

TEST AND ADJUSTMENT VALUES FOR FRONT DOOR

BE72.12-P-1001-01B Clearance mm 2 ±1
Remove/install rear door lock - AR72.12-P-2510MB

Fig. 209: Identifying Rear Door Lock Remove/Install Components - Top Protection
Remove/install
1
door 1010MB
Remove rear door inner door AR72.12-P-
2
panel 0104MB
Remove armor plates from rear AR72.12-P-
3
door lock 2510-01MB
*BA72.12-
P-1003-
01DA
*BA72.12-
P-1004-
01DA
Remove armor plate from rear AR72.12-P-
4
*BA72.12-
P-1002-
01DA
*BA72.12-
P-1007-
01DA
Remove exterior door handle on AR72.12-P-
5
rear door 2410MB
pulling door handle until resistance can be felt,
adjust if necessary. Thereby press release rod *BE72.12-P-
(7) upward with retainer (6) open until 1001-01B
resistance can be felt. Then close retainer (6)
again.
Unhook control cable (2) for inner
door actuation from door lock (4),
6
unclip mount from door lock (4)
and remove control cable (2)
Unhook retaining rod (1) from
7
door lock (4) and remove
Remove vacuum lead (3) from CL
8
element
Open retainer (6) for release rod
9
(7)
*BA72.12-
P-1007-01D
Carefully pull door lock (4) Installation : When installing door
11 downward and remove door lock lock (4) ensure that the release rod (7) is
(4) through door opening installed in the retainer (6) while moving in.
CHECK AND ADJUSTMENT VALUES FOR REAR DOOR

BE72.12-P-1001-01B Clearance mm 2 ±1

BA72.12-P-1007-01D Bolt at door lock Nm 10

Z07
BA72.12-P-1002-
Bolt for door lock armor plate to door Nm 28
01DA
BA72.12-P-1003-
Bolt for door lock armor plate to rear door Nm 28
01DA
BA72.12-P-1004- Screw for armor plate on door lock for armor plate
Nm 28
01DA door handle
BA72.12-P-1007-
Screw for window guide rail on bracket Nm 9
01DA
Remove/install armor plate for rear door lock - AR72.12-P-2510-01MB

Z07
BA72.12-P-1003- Bolt for door lock armor plate to rear door Nm 28

01DA
BA72.12-P-1004- Screw for door lock armor plate on door handle
Nm 28
01DA armor plate
1. Unscrew screws (1, 3) from armor plate (2) and remove armor plate (2).
2. Install in reverse sequence.
Fig. 210: Identifying Armor Plate Screws
Removing and installing rear door lock - AR72.12-P-2510MC
Fig. 211: Identifying Rear Door Lock Remove/Install Components - Light Armoring
Remove/install
Remove outer rear door AR72.12-P-
1
handle 2410MB
pulling the door handle until there is noticeable
resistance. *BE72.12-P-
Adjust if necessary ? 1001-01B
With retainer (4) open, press release rod upward
until there is noticeable resistance.
Then close the retainer (4) again.
AR72.12-P-
0104MC
*BA72.12-P-
3 Remove armor plate (1)
1002-01DA
*BA72.12-P-
1007-01D
Detach, remove Bowden
5
cable (3) from door lock
6 Open retainer (4)
Installation: Guide release rod of
7 Remove door lock (5)
bearing bracket into the retainer (4).
INSPECTION AND SETTING DATA OF REAR DOOR

BE72.12-P-1001-01B Gap mm 2 ± 1

BA72.12-P-1007-01D Screw at door lock Nm 10

BA72.12-P-1002-01DA Bolt for door lock armor plate to door Nm 23
REMOVE/INSTALL HINGE STRAP/BEARING BRACKET FOR REAR DOOR HANDLE - AR72.12-

P-4012
Remove/install hinge strap for rear door handle - AR72.12-P-4012MB

Fig. 212: Identifying Hinge Strap Rear Door Handle Remove/Install Components
Remove/install
1
door 1010MB
Remove rear door inner door AR72.12-P-
2
panel 0104MB
Remove armor plates from rear AR72.12-P-
3
door lock 2510-01MB
*BA72.12-P-
1003-01DA
*BA72.12-P-
1004-01DA
Remove armor plate from rear AR72.12-P-
4
*BA72.12-P-
1002-01DA
*BA72.12-P-
1007-01DA
Remove exterior door handle AR72.12-P-
5
on rear door 2410MB
Installation: Check clearance by pulling
door handle until resistance can be felt, adjust if *BE72.12-P-
necessary. Thereby press release rod upward with 1001-01B
retainer open until resistance can be felt. Then
close retainer again.
Remove door lock from rear AR72.12-P-
6
door 2510MB
Unscrew screw (1) and move Installation: Check plastic socket (2),
hinge strap (3) in direction of replace if necessary.
door lock and remove through Insert hinge strap (3) only, do not yet position and
7 door opening tighten screw (1), so that door lock can be
installed in the release rod


Z07
BA72.12-P-1002-
Bolt for door lock armor plate to door Nm 28
01DA
BA72.12-P-1003-
Bolt for door lock armor plate to rear door Nm 28
01DA
BA72.12-P-1004- Screw for armor plate on door lock for armor plate
Nm 28
01DA door handle
BA72.12-P-1007-
Screw for window guide rail on bracket Nm 9
01DA
Remove, install bearing bracket for rear door handle - AR72.12-P-4012MC
Fig. 213: Identifying Rear Door Handle Bearing Bracket Remove/Install Components
Remove/install
1 Remove door lock from rear door AR72.12-P-2510MC
3 Remove bearing bracket (2) inward
REMOVE/INSTALL SWITCHES FOR POWER WINDOW IN REAR DOORS - AR72.29-P-0002M

MODEL 220
Fig. 214: Identifying Rear Doors Power Window Switches Remove/Install Components
Remove, Install
Press molding strip (1) out of door
1 control module cover (2) on driver's door Fig. 24
with assembly wedge (6)
2
handle
Unscrew door control module cover (2)
AR72.10-P-
3 from door liner (4) of driver's door and
1000M
press off with assembly wedge (6)
Fig. 24
For this purpose open ashtray in rear
door and lift switch cover (5) until
Unclip switch cover (5) from door liner switch cover (5) can be pivoted over
4
(4) switch
Move switch cover (5) out of retaining
clip (arrow) and remove switch cover (5)
Disconnect connector from left/right
5 power window switch (S20/1s3,
S20/1s4)
Unclip left/right power window switch For this purpose press retaining lugs
6
(S20/1s3, S20/1s4) from ashtray housing for switch (arrow) together with suitable
tool and remove switch toward rear
8 Carry out function check
REMOVE/INSTALL FRONT POWER WINDOW SWITCHES - AR72.29-P-0100
Remove/install front power window switches - AR72.29-P-0100M
MODEL 220
Fig. 216: Identifying Front Power Window Switches Remove/Install Components
Remove, Install
Unclip switch cover (1) with right
For this purpose lift switch cover (1) at bottom edge
front power window switch
1 (arrow) until switch cover (1) can be removed with right
(S19s1) from door liner (2) on
front power window switch (S19s1)
passenger door
2 Disconnect right front power

window switch connector from
right front power window (S19s1)
Remove switch cover from right For this purpose press retaining lugs (arrows) for right
3 front power window switch (S19s1) together with suitable
front power window switch
(S19s1) tool until right front power window switch (S19s1) can be
pressed out of switch cover toward inside.
Removing and installing front power window switches - AR72.29-P-0100N
MODEL 215
Fig. 217: Identifying Front Power Window Switches Remove/Install Components
Remove door liner (2) AR72.10-
1
from passenger door P-1000N
Remove right front For this purpose press retaining lugs (arrow) on right
power window switch front power window switch (S19s1) together with suitable
2
(S19s1) from door liner tool until right front power window switch (S19s1) can be
(2) removed from the switch cover (1) toward inside
Check for proper
4
function
REMOVE/INSTALL FRONT DOOR POWER WINDOW SWITCH GROUP - AR72.29-P-0110M
MODEL 220
Fig. 218: Identifying Front Door Power Window Switch Group Remove/Install Components
Remove, Install
Press molding strip (1) out of
door control module cover
1 Fig. 24
(2) on driver's door with
assembly wedge (6)
Remove door handle cover
2 (3) from door handle in
direction of arrow
Unscrew door control
module cover (2) from door
AR72.10-
3 liner (4) of driver's door and
P-1000M
press off with assembly
wedge (6)
Fig. 24
Unclip switch group cover For this purpose slightly press cover in at bottom
(5) with switch group for edge (arrow) and lift until cover can be removed
4
power window, driver's side together with switch group for power window, driver's
(S20/1) from door liner side (S20/1)
Remove power window
switch group connector,
5
driver's side from door
control module
For this purpose press retaining lugs (arrows) for

Remove switch group cover power window switch group, driver's side (S20/1)
(5) from power window together with suitable tool until power window switch
switch group, driver's side group, driver's side (S20/1) can be removed out of
(S20/1) switch group cover (5) toward inside
6
Power window switch group, driver's side (S20/1)
can only be replaced completely
REMOVING AND INSTALLING SWITCH MODULE FOR POWER WINDOW SWITCHES -

AR72.29-P-0120N
MODEL 215
Fig. 220: Identifying Power Window Switches Switch Module Remove/Install Components (1 Of 2)
Fig. 221: Identifying Power Window Switches Switch Module Remove/Install Components (2 Of 2)
Remove door liner (2) on front AR72.10-
1
door P-1000N
Remove spring washers (4),
unscrew screws (5) and
2
remove door liner bottom
section (5) from door liner (2)
Unhook switch group cover
(1) with driver-side power
3 window switch group (S20/1) Do not damage clamping bracket (6)
from door liner bottom section
(3)
For this purpose press retaining lugs (arrow) on
driver-side power window switch group (S20/1)
Remove switch group cover together with suitable tool until driver-side power
4 (1) from driver-side power window switch group (S20/1) can be removed from
window switch group (S20/1) the switch group cover (5) toward inside.
Driver-side power window switch group (S20/1)
can only be replaced completely.
REMOVE/INSTALL FRONT DOOR CONTROL MODULE - AR72.29-P-1000

Remove/install front door control module - AR72.29-P-1000M
MODEL 220
Fig. 222: Identifying Front Door Control Module Remove/Install Components
Remove/Install
Remove door control module (2) cover The mount was modified with
1
from door liner (4) model refinement as of VIN: 316716.
Model 220 except 220 with code (Z04)
Light armoring AR72.10-P-
except 220 with code (Z07) 1000M
Maximum protection
AR72.10-P-
Model 220 with code (Z04) Light armoring
1000MB
Model 220 with code (Z07) Maximum AR72.10-P-
protection 1000MC
Fig. 24
Unclip left front door control module Press retaining clips on front door
(N69/1) or right front door control control module together and simultaneously
2
module (N69/2) from door control press front door control module out of door
module cover (2) control module cover (2).

Removing and installing front door control module - AR72.29-P-1000N
MODEL 215
Fig. 224: Identifying Front Door Control Module Remove/Install Components
Unscrew screw (4) from ventilation
1 grille (3) and remove ventilation grille
(3) from door liner (5)
Press locking rail (2) for door control
module cover (1) back in direction of
2
arrow and release door control module
cover (1)
Disconnect front left/right door control
modules (N69/1, N69/2) connectors and
3 remove door control module cover (1)
together with front left/right door
control modules (N69/1, N69/2)
For this purpose press mounting clamps (7) on front
Unclip front left/right door control left/right door control modules (N69/1, N69/2)
4 modules (N69/1, N69/2) from door together with suitable tool and simultaneously press
control module cover (1) front left/right door control modules (N69/1, N69/2)
out of mount (6) of door control module cover (1)
REMOVING AND INSTALLING REAR DOOR CONTROL MODULE - AR72.29-P-1100M
MODEL 220
Fig. 225: Identifying Rear Door Control Module Remove/Install Components
Press trim strip (1) out of door
1 control module finisher (2) Fig. 24
using assembly wedge (5)
Remove door handle cover (3)
2
from door handle
Unscrew door control module
finisher (2) from door lining AR72.12-
3
(4) and press out using P-1010M
assembly wedge (5)
Fig. 24
Disconnect the connectors
from left/right rear door
4 control module (N69/3,
N69/4) and remove door
control module cover (2)
For this purpose, press mounting clips arrow on
Unclip left/right rear door
left/right rear door control module (N69/3, N69/4)
control module (N69/3,
5 together with suitable tool and simultaneously press
N69/4) from door control
left/right rear door control module (N69/3, N69/4)
module cover (2)
out of door control module cover (2)
REMOVE/INSTALL FRONT DOOR POWER WINDOW MOTOR - AR72.29-P-1860
Remove/install front door power window motor - AR72.29-P-1860M
MODEL 220
Fig. 227: Identifying Front Door Power Window Motor Remove/Install Components
Remove, Install
AR72.10-P-
1 Remove door lining from front door
1000M
From bottom to top
Partially remove insulating mat from inner door
2 until inner Torx screws (1)
panel
are visible
Disconnect left/right power window motor
3 connector (M10/3x1, M10/4x1) from left/right front
power window motor (M10/3, M10/4)
4 Unscrew Torx socket bolts (1) Fig. 228
Fig. 29
Protect motor against

falling down
*BA72.29-P-
1001-01A
Remove left/right power window motor (M10/3, Before installing
5
M10/4) from power window and door grease gear on motor lightly
ELECTRIC SYSTEM-SIDE DOORS TIGHTENING TORQUE

BA72.29-P-1001-01A Bolt of motor of electric window lifter of front door NM 5
Fig. 229: Identifying Internal Torx Set (000 589 01 10 00)
Removing and installing power window motor in front door - AR72.29-P-1860N
MODEL 215
Fig. 230: Identifying Front Door Power Window Motor Remove/Install Components
AR72.10-P-
1 Remove door liner in front door
1000N
Pull insulating mat on inner door panel off over
2 left/right power window motors (M10/3x1,
M10/4x1)
3 connectors (M10/3x1, M10/4x1) from left/right
power window motors (M10/3, M10/4)
*BA72.29-P-
4 Unscrew inner Torx screws (1)
1001-01A
Fig. 29
Protect power window Fig. 228

motors from falling.
Remove front left/right power window motors Installation: Coat *BR00.45-Z-
5 (M10/3, M10/4) on inner door panel from power gear on motor with Isoflex
1012-06A
window mounts (2) Topas L 32
7 Check power windows for proper function

BA72.29-P-1001-01A Screw for electric power window motor in front door Nm 4.5
Fig. 232: Torx Bit Set (000 589 01 10 00)
REPAIR MATERIALS
BR00.45-Z-1012-06A Lock cylinder grease spray 50 ml A 002 989 06 51
REMOVE/INSTALL REAR DOOR POWER WINDOW MOTOR - AR72.29-P-1880M
MODEL 220
1. Internal Torx drive bolt
Fig. 233: Identifying Internal Torx Drive Bolt

Remove, Install
AR72.12-P-
1010M
From bottom to
Partially remove insulating mat from inner door
2 top until inner Torx screws
panel
are visible.
3 connector (M10/5x1, M10/6x1) from left/right rear
power window motor (M10/5, M10/6)
4 Unscrew Torx socket bolts (1) Fig. 228
Fig. 29
Protect motor against
falling down
*BA72.29-P-
1002-01A
Remove left/right rear power window motor Before installing
5 grease gear on motor
(M10/5, M10/6) from power window and door
lightly

BA72.29-P-1002-01A Bolt of motor of electric window lifter of rear door NM 5
Fig. 235: Identifying Internal Torx Set (000 589 01 10 00)

TEST AND ADJUSTMENT VALUES: PASSENGER CARS: DOORS - BE72.00-Z-9999AZ
MODEL all
Adjustment values for MODEL 202, 203, 209, BE72.10-P-1000-01A

front door 210, 240
Adjustment values for MODEL 215, 220, 230 BE72.10-P-1000-01C
front door
Adjustment values for MODEL 219 BE72.10-P-1000-01E
front door
Front door adjustment MODEL 171.4 BE72.10-P-1000-01F
values
Adjustment values for MODEL 216 MODEL BE72.10-P-1000-01G
front door 221 except CODE (Z07)
Top protection
Adjustment values for MODEL 221 with CODE BE72.10-P-1000-01H
front door (Z07) Top protection
Rear door MODEL 203, 220, 240... BE72.12-P-1000-01B
Rear door MODEL 220 with CODE BE72.12-P-1000-01BA
(Z07) highest protection
Rear door MODEL 219 BE72.12-P-1000-01C
Rear door MODEL 221 except BE72.12-P-1000-01D
CODE (Z07) Top
protection
Rear door MODEL 221 with CODE BE72.12-P-1000-01E
Rear-end door MODEL 168, 203 BE72.20-P-1000-02A
ADJUSTMENT VALUES FOR FRONT DOOR - BE72.10-P-1000-01C
Models 215, 220, 230

Number Designation Model 215 Model Model
220 230
BE72.10-P-
Clearance mm 2 (± 1) 2 (± 1) 2 (± 1)
1001-01C
Dimension
mm 74 - -
BE72.10-P- "D"
Distance from front door to A-pillar
1002-01C AR72.10-P-
Fig. see --
0550N
Dimension
"E" mm 1 - -
BE72.10-P- Lead distance from front door to rear
1003-01C fender AR72.10-P-
Fig. see --
0550N
Dimension
BE72.10-P- Distance from top edge of front crank "A" mm - - 3...4
1004-01C window glass to roof contour
Fig. see - --
REAR DOOR - BE72.12-P-1000
Rear door - BE72.12-P-1000-01B
Model 203, 220, 240

203.0/2 220 240 240
BE72.12-P-
Clearance mm - 2±1 - -
1001-01B
BE72.12-P- Gap between power window clip and
mm 0 (+0.1) - - -
1002-01B crank window glass surface
BE72.12-P- Dimension "a" between window frame and
mm - - 2 2
1003-01B front window guide rail
BE72.12-P- Dimension "b" between window frame
mm - - - 2
1004-01B and rear window guide rail
Rear door - BE72.12-P-1000-01BA
Model 220 with code Z07

Fig. see -
MAINTENANCE
CHECK DOOR DAMPER AND LOCKING EYES - AP72.00-P-7251M
MODEL 220.175 /176 /178 with CODE (Z04) Light armoring
MODEL 220.175 /176 /178 with CODE (Z07) Top protection

Fig. 236: Identifying Door Damper Rubber Seal, Piston Rod And Striker Eye
Check
Ensure that the vehicle is clear of obstacles otherwise the body may
be damaged when a door is opened.
Check locking
1 Open doors in sequence and check locking eyes (1) for
eyes (1)
damage and firm seating. Damaged locking eyes (1) must be replaced
subject to separate repair order after consultation with the customer.
Ensure that the vehicle is clear of obstacles otherwise the body may
be damaged when a door is opened.
Check door
damper (2) for Open the doors 2 to 3 times in a controlled manner. Then open
2 the door again, the damper function must start approx. in the last
proper
operation quarter of the opening travel. If no noticeable damper function starts,
the door damper (2) must be replaced subject to a separate repair order,
after consultation with the customer
Check door Check door damper rubber seals (4) for cracks, porosity and
3 damper rubber tight seating. If defects are detectable the rubber seals must be replaced
seals (4) after consultation with the customer.
Lubricate piston
4 Coat a light lubrication layer on the complete piston rods (3).
rods (3)
*BR00.45-
Vaseline
Z-1015-06A
REPAIR MATERIALS
BR00.45-Z-1015-06A Vaseline -

RETROFITTING DOOR CONTROL MODULE WITH MEMORY UNIT - AN72.29-P-0001M
MODEL 220 with CODE (249b) Automatic dimming inside rearview and outside rearview mirror
(driver)
Fig. 237: Identifying Door Control Module Components With Memory Unit (1 Of 2)
Fig. 238: Identifying Door Control Module Components With Memory Unit (2 Of 2)
Removal
1 Remove door control module
AR72.29-P-
1000M
Transfer inside mirror adjustment switch. Remove heated seat switch
2
and install on new door control module.
Installation
Clip door control module cover for memory switch (2) and left/right
3 front door control module with memory switch (N69/1, N69/2)
together.
Install left/right front door control module with memory switch
4
(N69/1, N69/2) and door control module cover (2)
AR72.29-P-
1000M
5 Reassemble vehicle
6 Code control modules with STAR diagnosis
When the scope of equipment is changed enter code or designation of
8
the corresponding special equipment on the vehicle data card Code 275

FG 82 Left seat adjustment switch with program, according to color 1
FG 82 Right seat adjustment switch with program, according to color 1
FG 72 Switch cover for left door according to equipment 1
FG 72 Switch cover for right door according to equipment 1
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
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
Front door - BA72.10-P-1000-01E
Model 215, 220,240
MODIFICATION NOTES
5.2.02 Value changed from 10 Nm to 14 Nm Value in series 1004,1005 for model 220 modified
11.2.02 Value changed from 14 Nm to 10 Nm Value in series 1005 for model 220 modified
2.2.04 Specification changed from 20 Nm to 25 Nm Value modified in series 1003 for model 220

Number Designation Model Model Model
215 220 240
BA72.10-P-1001-
Bolt, door hinge to A-pillar Nm 32 35 32
01E
BA72.10-P-1002-
Bolt, door hinge to inner door panel Nm 32 35 32
01E
BA72.10-P-1003-
Nut on door hinge Nm - 25 -
01E
BA72.10-P-1004-
Bolt, door catch to body Nm - 14 8
01E
BA72.10-P-1005-
Bolt, door catch to inner door panel Nm - 10 8
01E
BA72.10-P-1006-
Bolt to striker eye Nm 28 25 28
01E
BA72.10-P-1007-
Bolt, door handle of front door Nm 3 3 3
01E
BA72.10-P-1008-
Bolt at door lock Nm 8 10 8
01E
BA72.10-P-1009- Bolt, power window of front door to inner door
Nm 9 - 8
01E panel
BA72.10-P-1010- Bolt, crank window of front door to power
Nm 9 - -
01E window
BA72.10-P-1011-
Bolt, window to front power window Nm - - 8
01E
Front door - BA72.10-P-1000-01EA
Model 220 with codes Z04, Z07

code Z07 code Z04
BA72.10-P-1001-
Screw for window guide rail to door NM 9 -
01EA
BA72.10-P-1002- Screw for door handle armor plate to
NM 28 -
01EA window
BA72.10-P-1003- Screw for outer door lock armor M6 NM 7 8
01EA plate to front door M8 NM 28 23
BA72.10-P-1004-
Screw for support plate to front door NM 28 -
01EA
BA72.10-P-1005-
Banjo bolt to hydraulic cylinder NM 7 -
01EA
BA72.10-P-1006-
Screw for power window to window NM - 8
01EA
BA72.10-P-1007-
Screw for armor plate to power window NM - 23
01EA
Front door - BA72.10-P-1000-01EB
Model 220

Number Designation MODEL 220 with CODES Z04, Z07
BA72.10-P-1008-01EB Bolt at door lock NM 7
REAR DOOR - BA72.12-P-1000
Rear door - BA72.12-P-1000-01D
Models 220, 240
MODIFICATION NOTES
8.5.06 Nut on door hinge Model 220

220 240
BA72.12-P-1001-
Bolt, door hinge to B-pillar Nm 35 32
01D
BA72.12-P-1002-
Screw for door hinge on inner door panel Nm 35 32
01D
BA72.12-P-1003-
Nut on door hinge Nm 25 -
01D
BA72.12-P-1004-
Screw for door holder on body Nm 14 8
01D
BA72.12-P-1005-
01D Bolt for door holder to inner door panel Nm 10 8
BA72.12-P-1006-
Bolt to locking eye Nm 25 28
01D
BA72.12-P-1007-
Screw at door lock Nm 10 8
01D
BA72.12-P-1008-
Bolt for rear door handle Nm 3 3
01D
BA72.12-P-1009- Screw for power window at rear door to inner door
Nm - 8
01D panel
BA72.12-P-1010-
Screw for window on rear window lift mechanism Nm - 8
01D
Rear door - BA72.12-P-1000-01DA
Model 220 with codes Z04, Z07

code Z07 code Z04
BA72.12-P-1001-
Screw for window guide rail to rear door NM 9 -
01DA
BA72.12-P-1002- Screw for door handle armor plate to
NM 28 23
01DA door
BA72.12-P-1003- Screw for door lock armor plate to rear
NM 28 8
01DA door
BA72.12-P-1004- Screw for door lock armor plate to door
NM 28 23
01DA handle armor plate
BA72.12-P-1005-
Screw for support plate to rear door NM 28 -
01DA
BA72.12-P-1006-
Banjo bolt to hydraulic cylinder NM 7 -
01DA
BA72.12-P-1007-
Screw for window guide rail to angle NM 9 -
01DA
BA72.12-P-1008-
Screw for power window to window NM - 8
01DA
ELECTRICAL SYSTEM - SIDE DOORS - BA72.29-P-1000-01A
MODEL 163, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 219.3, 220, 230
ELECTRIC SYSTEM - SIDE DOORS

BA72.29-P- Bolt, front Nm 9 5 13 4.5
1001-01A door power
window motor
BA72.29-P- Screw of Nm - 5 - -
1002-01A motor of
electric
window lifter
of rear door
ELECTRIC SYSTEM - SIDE DOORS

BA72.29-P- Bolt, front Nm 4.5 13 4.8 13
1001-01A door power
window motor
BA72.29-P- Screw of Nm - 13 4.5 -
1002-01A motor of
electric
window lifter
of rear door
ELECTRIC SIDE DOORS

BA72.29-P- Bolt, front Nm 13 4.5 4.5 4.5
1001-01A door power
window motor
BA72.29-P- Screw of Nm 13 4.5 4.5 -
1002-01A motor of
electric
window lifter
of rear door
ELECTRIC SIDE DOORS

Number Designation Model 219.3 Model 220 Model 230
BA72.29-P-1001- Bolt, front door Nm 5 5 4.5
01A power window
motor
BA72.29-P-1002- Screw of motor Nm 5 5 -
01A of electric
window lifter of
rear door
MERCEDES-BENZ
S320, S420, S500 & S600
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS
Component Component Location
Combination Relay On left rear corner of engine compartment.
High Pressure/Return Pump Relay On left rear of engine compartment.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES
Fuse Box On left rear corner of engine compartment. See Fig.
1.
Rear Fuse Box In luggage compartment, behind right trim panel.
See Fig. 1 .
CONTROL UNITS
CONTROL UNITS
AIR Control Module On left front of engine compartment, on frame rail.
See Fig. 1 .
AIR Relay Module On left rear of engine compartment.
Anti-Theft Alarm (ATA) Control Module On right side of luggage compartment, behind trim
panel. See Fig. 1 .
ASR/ETS/ESP Hydraulic Unit On left side of engine compartment.
ASR/SPS Control Module In module box, on right rear of engine compartment.
See Fig. 1 .
Base Module (BM) In module box, on right rear of engine compartment.
See Fig. 1 .
CF Relay Module In left rear of engine compartment.
DAS Control Module Behind instrument cluster.
Daytime Running Light Control Module Behind center of dash.
Engine Control Module (ME-SFI) (S320 & S420 & In module box, on right rear of engine compartment.
S500) See Fig. 1 .
Engine Control Module (ME-SFI) (Left) (S600) In module box, on right rear of engine compartment.
See Fig. 1 .
Engine Control Module (ME-SFI) (Right) (S600) In module box, on right rear of engine compartment.
See Fig. 1 .
ESP/SPS Control Module In module box, on right rear of engine compartment.
See Fig. 1 .
External Light Failure Monitoring Module In left rear of engine compartment.
Fuel Pump (FP) Relay Module On right side of trunk. See Fig. 1 .
HCS Relay Module In left rear of engine compartment.
Headlight Range Control Module In front of passenger's footwell.
Horn Relay Module In left rear of engine compartment.
HS Control Modules (2) (Front & Rear) Beneath rear seat.
MSC Control Module On front of passenger's footwell.
Parktronic System (PTS) Control Module Below right rear seat. See Fig. 1 .
Rear Window Defrost Relay Module On right rear of trunk.
Remote Control (RCL) Module On right side of luggage compartment, behind trim
panel.
Seat Belt Extender Control Module Behind left rear side cover panel.
Seat Belt Reminder Control Module Behind left center of dash.
SRS Control Module Beneath front of center console. See Fig. 1 .
Starter Lock-Out Relay Module In left rear corner of engine compartment.
Transmission Control Module In module box, on right rear of engine compartment.
See Fig. 1 .
MOTORS
MOTORS
AIR Pump On lower right front of engine.
ASR/ESP Charging Pump In left front fender, behind molding.
Automatic Antenna On left side of trunk.
Auxiliary Fans (2) On front of engine compartment.
Electronic Accelerator (EA)/ Cruise Control (CC)/ On left side of engine beneath intake manifold.
Idle Speed Control (ISC) Actuator (S320)
Electronic Accelerator (EA)/ Cruise Control (CC)/ On top center of engine.
Idle Speed Control (ISC) Actuator (S420 & S500)
Electronic Accelerator (EA)/ Cruise Control (CC)/ On right side of engine.
Idle Speed Control (ISC) Actuator (Left) (S600)
Electronic Accelerator (EA)/ Cruise Control (CC)/ On left side of engine.
Idle Speed Control (ISC) Actuator (Right) (S600)
ESC Motor Group Above accelerator pedal.
Fuel Pump (FP) Assembly On right underside of vehicle, forward of rear axle.
Rear Blower Motor Below center console.
Washer Pump On washer fluid reservoir.
Wiper Motor On top left of firewall.
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS
ABS Lateral Acceleration Sensor Beneath center of rear seat.
Body Acceleration Sensor (Left Front) On top of left front wheel arch.
Body Acceleration Sensor (Right Front) On top of right front wheel arch.
Body Acceleration Sensor (Right Rear) On right front of trunk floor.
Camshaft Hall Effect Sensor (S320) On left front of cylinder head.
Camshaft Hall Effect Sensor (S420 & S500) On right front of left cylinder head.
Camshaft Hall Effect Sensor (Left) (S600) On front of right cylinder head.
Camshaft Hall Effect Sensor (Right) (S600) On front of left cylinder head.
CKP Sensor (S420 & S500) On left rear of engine.
CKP Sensor (Left) (S600) On left rear of engine.
CKP Sensor (Right) (S600) On right rear of engine.
DM Pressure Sensor (S320) On top left front of engine.
DM Pressure Sensor (S420 & S500) On top front center of engine.
Engine Coolant Temperature Sensor (S320) On top left front corner of engine.
Engine Coolant Temperature Sensor (S420 & S500) On top front of engine.
Engine Coolant Temperature (ECT) Sensor (Left) On left front of engine.
(S600)
Engine Coolant Temperature (ECT) Sensor (Right) On right front of engine.
(S600)
ESP Brake Pressure Sensor In rear of left front wheel well.
Evaporator Temperature Sensor On left side of evaporator housing, above
accelerator pedal.
Front Axle Level Sensor On right side of front sway bar.
Front VSS Sensor (Left) On left front wheel hub assembly.
Front VSS Sensor (Right) On right front wheel hub assembly.
Fuel Level Sensor On top, left of fuel tank.
Fuel Tank Pressure Sensor On top of fuel level sensor, in fuel tank.
Heater Core Temperature Sensors Behind center of dashboard, below radio.
Hot Film MAF Sensor (S320) On air intake duct.
Hot Film MAF Sensor (S420 & S500) On top center of engine.
Hot Film MAF Sensor (Left) (S600) On right side air intake.
Hot Film MAF Sensor (Right) (S600) On left side air intake.
IAT Sensor (S320) On center of engine, in air intake duct.
IAT Sensor (S420 & S500) On center of engine, in air intake.
IAT Sensor (Left) (S600) On right side air intake.
IAT Sensor (Right) (S600) On left side air intake.
In-Car Temperature Sensor (A/C) In dome light assembly.
Knock Sensor No. 1 (S320) On left side of engine, toward front of engine.
Knock Sensor No. 1 (S420 & S500) On lower left side of engine.
Knock Sensor No. 1 (Left) (S600) On top of engine in left side of valley, toward front
of engine.
Knock Sensor No. 1 (Right) (S600) On top of engine in right side of valley, toward front
of engine.
Knock Sensor No. 2 (S320) On left side of engine, toward rear of engine.
Knock Sensor No. 2 (S420 & S500) On lower right side of engine.
Knock Sensor No. 2 (Left) (S600) On top of engine in left side of valley, toward rear
of engine.
Knock Sensor No. 2 (Right) (S600) On top of engine in right side of valley, toward rear
of engine.
Left Rear Heater Core Temperature Sensor In rear of center console.
Left Side Air Bag Sensor Beneath driver's seat, on crossmember.
Oil Pressure Sensor On lower left rear of engine.
Outside Temperature Indicator Sensor In left side of front bumper.
Oxygen Sensor No. 1 (Before TWC) (S320) On exhaust pipe, before TWC.
Oxygen Sensor No. 1 (Left) (Before TWC) (S420 & On left exhaust pipe, in front of TWC.
S500)
Oxygen Sensor No. 1 (Left) (Before TWC) (S600) On left exhaust pipe, in front of TWC.
Oxygen Sensor No. 1 (Right) (Before TWC) (S420 On right exhaust pipe, in front of TWC.
& S500)
Oxygen Sensor No. 1 (Right) (Before TWC) (S600) On right exhaust pipe, in front of TWC.
Oxygen Sensor No. 2 (After TWC) (S320) On rear of TWC.
Oxygen Sensor No. 2 (Left) (After TWC) (S420 & On left exhaust pipe, after TWC.
S500)
Oxygen Sensor No. 2 (Left) (After TWC) (S600) On left exhaust pipe, after TWC.
Oxygen Sensor No. 2 (Right) (After TWC) (S420 & On right exhaust pipe, after TWC.
S500)
Oxygen Sensor No. 2 (Right) (After TWC) (S600) On right exhaust pipe, after TWC.
Parktronic System (PTS) Bumper Sensors (Front) On front bumper.
(6)
Parktronic System (PTS) Bumper Sensors (Rear) (4) On rear bumper.
Pedal Value Sensor In right rear of engine compartment.
Pressure Sensor (S420 & S500) On top front of engine.
Pressure Sensor (Left) (S600) On left front of engine.
Pressure Sensor (Right) (S600) On left front of engine.
Rain Sensor On top center of windshield, integrated with
speaker/mirror assembly. See Fig. 1 .
Rear Axle Level Sensor On rear sway bar, right of differential.
Rear Evaporator Temperature Sensor In rear of center console.
Rear VSS Sensor (Left) On left rear wheel hub assembly.
Rear VSS Sensor (Right) On right rear wheel hub assembly.
Refrigerant Pressure Sensor In left front corner of engine compartment.
Refrigerant Temperature Sensor In left front corner of engine compartment.
Right Rear Heater Core Temperature Sensor In rear of center console.
Right Side Air Bag Sensor Beneath front passenger's seat, on crossmember.
Steering Angle Sensor In top of steering column.
Sun Sensor Top center of dash.
Yaw Rate Sensor On left side of trunk. See Fig. 1 .
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES
Adjustable Camshaft Timing Solenoid (S320) On left front of engine.
Adjustable Camshaft Timing Solenoid (Left) (S420 On left front of engine.
& S500)
Adjustable Camshaft Timing Solenoid (Right) On right front of engine.
(S420 & S500)
Adjustable Camshaft Timing Solenoid (Left) (S600) On left front of engine.
Adjustable Camshaft Timing Solenoid (Right) On right front of engine.
(S600)
AIR Pump Switchover Valve (S320) On top center front of engine.
AIR Pump Switchover Valve (S420 & S500) On top center front of engine.
AIR Pump Switchover Valve (S600) On right side of engine, near MAF sensor.
Seat Belt Comfort Feature Solenoid (Left & Right) In bottom of respective "B" pillar.
SWITCHES
SWITCHES
ECL Switch On bottom of coolant reservoir.
Engine Hood Switch On right front of engine compartment.
Heated Washer Thermo Switch On underside rear of hood.
Kickdown Switch Under accelerator pedal.
Oil Level Switch (S320) On left side of oil pan.
Oil Level Switch (S420 & S500) On right side of oil pan.
Oil Level Switch (S600) On right side of oil pan.
Parking Brake Switch At top of parking brake assembly.
Stoplight Switch At top of brake pedal.
Transmission Range Recognition Switch (Voltage On gear shift selector assembly.
Coded)
Trunk Lid Lock Switch In trunk latch switch.
MISCELLANEOUS
MISCELLANEOUS
Alarm Horn In right front of engine compartment.
CA Supply Pump In left front of trunk.
CTEL Transmitter-Receiver On left side of trunk. See Fig. 1 .
Data Link Connector (DLC) (DTC Readout) On right side of engine compartment. See Fig. 1 .
Data Link Connector (DLC) (OBD II) On underdash panel in driver's footwell. See Fig. 1 .
Electrolytic Capacitor (Charging System) In left side of passenger's footwell.
Electrolytic Capacitor (Rear Defogger) On right "C" pillar, under trim panel.
Electromagnetic AIR Pump Clutch (S600) On lower right front of engine.
Heater Supply Unit In left front of engine compartment.
Left Front Door IR Receiver In driver's door handle.
Rear Heater Supply Unit In rear of right front wheel well, in fender.
Right Front Door IR Receiver In passenger's door handle.
SRS Test Connector In passenger's footwell.
Trunk Lid IR Receiver On trunk lid left of lock.
CONNECTORS
CONNECTORS
X1/6 At left kick panel.
X1/7 At right kick panel.
X4 (2-Pin) At left rear of engine compartment, at fuse & relay
box.
X4/5 (1-Pin) At right side of luggage compartment.
X4/10 At right rear of engine compartment.
X4/17 At left top of left front footwell.
X4/20 (4-Pin) At left rear of engine compartment, at fuse & relay
box.
X4/23 (2-Pin) Under foot plate at right front footwell.
X4/28 Under steering column.
X6 Under center of dash.
X8/6 At top front of left front door.
X8/7 At top front of left front door.
X9 (1-Pin) At left rear of engine compartment.
X11 At left middle of engine compartment.
X11/2 (9-Pin) At left middle of engine compartment.
X11/3 (9-Pin) At right rear of engine compartment.
X11/4 (35-Pin) At right rear of engine compartment.
X11/7 (4-Pin) At center of heater intake plenum.
X11/13 (12-Pin) At center of heater intake plenum.
X11/14 (2 or 4-Pin) At right side of heater intake plenum.
X11/15 (16-Pin) At right kick panel.
X11/21 (3-Pin) At right side of heater intake plenum.
X11/22 (16-Pin) Under left side of dash.
X11/26 At left side of luggage compartment.
X18 At left top of left front footwell.
X20/1 At right top of rear partition panel.
X20/3 (4-Pin) At left rear of engine compartment.
X21/1 At left top of left front footwell.
X22/8 At right side of left front footwell.
X22/9 (4-Pin) At right front of left front footwell.
X24 (6-Pin) At left rear of engine compartment.
X26 At left rear of engine compartment.
X26/2 (36-Pin) At right side of engine compartment.
X26/27 Behind left side of front bumper.
X27 At right rear of engine compartment.
X27/6 Near coolant reservoir.
X28/4 (2-Pin) Under steering column.
X28/5 (2-Pin) Behind steering wheel.
X29/1 (2-Pin) In glove box.
X29/2 (2-Pin) Under center of dash.
X29/3 Behind center face vents.
X33/14 (16-Pin) Under right front foot plate.
X34/3 In right front door jamb.
X34/5 At right rear door jamb.
X35/3 At left "B" pillar.
X35/4 At right "B" pillar.
At right side of heater intake plenum.
X35/21 Behind right headlamp.
X35/22 (1-Pin) At left kick panel.
X35/26 Under right front foot plate.
X35/27 Under right side of dash.
X35/28 At right rear of luggage compartment.
X35/63 In control module box.
X35/64 (18-Pin) Under right front foot plate.
X35/65 At left rear of engine compartment.
X36/3 (2-Pin) Under rear seat, at right side of propeller shaft
tunnel.
X39/4 (4-Pin) Under left front of center console.
X39/10 (12-Pin) Under right front of center console.
X39/14 Under right front of center console.
X39/36 (4-Pin) Under center console, left of shifter lever.
X42/13 (1-Pin) Behind radio.
X42/15 At right front of engine compartment.
X43 (3-Pin) Behind center of dash.
X44/4 Under rear seat cushion.
X47/2 At right rear of engine.
X49/2 (10-Pin) At right side of left front footwell.
X49/4 (1-Pin) In fuse & relay box.
X50/1 (4-Pin) At right side of left front footwell.
X54/7 Behind left side of dash.
X55/3 Under front of left front seat.
X55/4 Under front of left front seat.
X59/1 (2-Pin) At left middle of engine compartment.
X62/7 At left side of engine compartment.
X62/8 Under right rear of vehicle, near fuel filter.
X62/14 At left front wheel.
X62/15 At right front wheel.
X83/1 (2-Pin) At left front of right front footwell.
X83/8 (1-Pin) At left side of engine compartment.
X83/13 Under steering column.
GROUNDS
GROUNDS
W1 Behind instrument cluster.
W3 At left front wheelwell, near ignition coil. See Fig.
1.
W3/1 At right front wheelwell, near ignition coil. See Fig.
1.
W3/2 At left side of engine compartment. See Fig. 1 .
W3/3 At right side of engine compartment. See Fig. 1 .
W6 At left side of luggage compartment. See Fig. 1 .
W6/1 At left rear of luggage compartment. See Fig. 1 .
W7/1 At right rear of luggage compartment. See Fig. 1 .
W9/1 Behind left headlamp. See Fig. 1 .
W9/2 Behind right headlamp. See Fig. 1 .
W10 At right rear of luggage compartment. See Fig. 1 .
W11 At top middle of engine. See Fig. 1 .
W11/1 At left rear bottom of engine. See Fig. 1 .
W12 In front of shifter lever. See Fig. 1 .
W13/1 Under left "C" pillar trim. See Fig. 1 .
W14 At left side of engine compartment. See Fig. 1 .
W15 At right kick panel. See Fig. 1 .
W15/1 At right kick panel. See Fig. 1 .
W16 At right side of engine compartment. See Fig. 1 .
W16/2 At left side of engine compartment. See Fig. 1 .
W17 Under right side of rear seat. See Fig. 1 .
W26 In front of shifter lever. See Fig. 1 .
W28/1 On sill panel, below left front door. See Fig. 1 .
W28/2 On sill panel, below right front door. See Fig. 1 .
W29 At left "A" pillar. See Fig. 1 .
W29/1 At left "A" pillar. See Fig. 1 .
W29/2 At right kick panel. See Fig. 1 .
W29/4 At right "C" pillar. See Fig. 1 .
W30 At left rear bottom of engine. See Fig. 1 .
W31 At left side of luggage compartment. See Fig. 1 .
W36 At right kick panel. See Fig. 1 .
SPLICES
SPLICES
Z3 In left interior harness, at sill panel, under left rear
door.
Z3/1 In dash harness, at center of dash.
Z3/4 In left engine compartment harness, at fuse & relay
box.
Z3/12 In left interior harness, at sill panel, under left front
door.
Z3/13 In left interior harness, at sill panel, under left "B"
pillar.
Z3/29 In right interior harness, at sill panel, below right
rear door.
Z3/31 In body harness, behind center console.
Z4/3 In luggage compartment harness, on left side of
compartment.
Z6/8 In right engine harness, at right rear of engine
compartment.
Z6/18 In left engine compartment harness, at middle of
engine.
Z6/21 In left engine compartment harness, at front of fuse
& relay box.
engine.
engine.
rear door.
box.
Z7/26 In body harness, under left front seat.
compartment.
compartment.
Z7/38 In left engine compartment harness, at middle front
of engine.
Z7/39 In left engine compartment harness, at middle front
of engine.
Z8 In left engine compartment harness, at front of fuse
& relay box.
compartment.
compartment.
compartment.
compartment.
compartment.
compartment.
"B" pillar.
rear door.
compartment.
compartment.
compartment.
Z29 In left engine compartment harness, at fuse & relay
box.
box.
box.
Z30/5 In left interior harness, at sill panel, under left rear
door.
door.
door.
compartment.
compartment.
Z38 In right interior harness, at sill panel, below right
rear door.
Z81 In body harness, under left front seat.
rear door.
compartment.
"B" pillar.
Z94 In right engine harness, at right rear of engine
compartment.
compartment.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
Fig. 1: Vehicle Overview
Electrical System - Basic Knowledge - Body - 215 & 220 Chassis
BASIC KNOWLEDGE
BASIC POSITION FINDING, FUNCTION - GF82.61-P-3006CA
MODEL 215, 220 with CODE (352a) COMAND operating and display system with CODE (494a) USA
version
Basic position finding
Fig. 1: Identifying Basic Position Finding
Basic position finding (compound position finding) is the basic function of continuous position finding. When
the ignition is switched on it is carried out continuously by the navigation processor and is independent of the
DVD map. After the ignition is switched off, the current position is stored for the duration of the run on period.
The following information is calculated with the aid of basic position finding:
 Distance traveled
 Direction of travel (forward or reverse)
 Vehicle orientation
Basic position finding is carried out approx. once per second.
Distance traveled
Information from the left front rpm sensor (L6/1) and right front rpm sensor (L6/2) of the non-driven wheels is
passed to the ESP, SPS [PML] and BAS control unit (N47-5) and (CAN-C) navigation processor via discrete
wiring and the engine compartment CAN (CAN-C), respectively.
The evaluation of the rpm signals gives the distance traveled.
In vehicles as of 1.9.03, the navigation processor (N41/1) is installed as a separate control unit on the left-
hand side of the trunk.
Direction of travel
The navigation processor recognizes the direction of motion (forward or reverse) from the reverse signal.
Vehicle orientation
The navigation processor calculates the vehicle's orientation (compass direction) using the difference between
the rpm sensor signals, the data from the yaw rate sensor and the sequence of the locations calculated using
GPS. The difference in the calculated mileage and the mileage actually covered between two turn-off points is
used to automatically recalibrate the tire circumference (necessary due to tire wear).
Errors with basic position finding
Rolling backwards without the reverse gear engaged is evaluated as forwards motion, and may lead to an error
in position finding.
Rolling with the ignition switched off or vehicle transportation also falsify position finding.
However, the calculated position is automatically corrected by the navigation processor when the GPS data is
received.
Navigation is not possible if the driver removes the navigation DVD from the drive.
Calibration
Wheel calibration is necessary following a tire change. The appropriate information must be entered:
 Tire size (e.g. 225/60/16)

 New depth of tire tread (approx. 5 - 10 mm)
 Used tires (depth of tread approx. 3 - 5 mm)
This information is entered using STAR DIAGNOSIS. A special calibration trip is not required.
Global positioning GF82.61-P-3007BA

system (GPS) position
finding, function
GLOBAL POSITIONING SYSTEM (GPS) POSITION FINDING, FUNCTION - GF82.61-P-3007BA
version
Global positioning system position finding

Fig. 2: Identifying Global Positioning System Position Finding
The global positioning system (GPS) is a satellite supported position finding system established by the US
Defense Department.
It is a toll-free service available throughout the world. Currently several satellites are on different orbits of the
earth. The GPS satellites constantly transmit time and position data.
4 satellites are needed for the first position calculation, then 3 receivable satellites are sufficient.
GPS position finding is particularly valuable when driving outside of the digitized map area and after vehicle
has been transported (e.g. train, ferry or towing).
A new GPS position (after interruption of the satellite reception) can take several minutes (up to 20 minutes
when the equipment is first set up).
GPS position finding, function
The navigation processor calculates the location of the vehicle and the accuracy of positioning from the satellite
signals received and amplified by the GPS antenna (A2/23) (model 215) or (A2/49a2) (model 220).
Actual calculation is based primarily on measurement of the transmission times of the signals transmitted
synchronously by the various satellites. An important prerequisite here is that the satellite clocks and receiver
clocks are synchronized.
For this purpose, the receiver has an automatic time correction feature which again is made possible with the aid
of the satellite signals. When the navigation processor determines that basic location finding is less precise than
GPS location finding, the currently calculated position is corrected with the aid of the GPS data.
In addition, the vehicle's course of travel is determined with the aid of the sequence of the locations calculated
with GPS.
Every minute, approximately 50 GPS recalculations of the location take place.

Possible GPS signal reception interference
As GPS operates in the GHz range (microwaves) and the signals are weak, reception interference may occur
due to:
 Atmospheric interference, e.g. weather, water vapor, fog

 Multiple reception from reflection of signals, e.g. from building walls
 Signal shadows, e.g. in built-up areas, tunnels, high buildings, trees
GPS reception therefore requires a clear view of the sky. The accuracy of GPS location finding is approx. 100
m or better.
Map-based position GF82.61-P-3008BA

finding, function
MAP-BASED POSITION FINDING, FUNCTION - GF82.61-P-3008BA
version
Map-based position finding
Fig. 3: Identifying Map-Based Position Finding
Function
The navigation processor continuously follows the position of the vehicle on the DVD map. Up to 10 alternative
paths are calculated in the digitized range of the DVD map. If the route taken by the driver deviates from the
calculated paths, the basic position finding coordinates are corrected as necessary.
Map-based position finding is only available in the digitized area of the DVD map. Any deviation from the
route can be recognized and corrected automatically by comparing the calculated position of the vehicle with
the DVD map.
Global positioning system antenna, Model 215 GF82.61-P-4106B

GPS/telephone roof antenna, Model 220 with GF82.70-P-4111A
location/task/design/function codes 347, 353, 853,
854, 855
ROUTE CALCULATION, FUNCTION - GF82.61-P-3011DA
version
After the driver has entered the destination using the COMAND operating, display and control unit (A40/3), the
navigation processor calculates and constantly updates the route. The route can only be calculated within the
digitized map areas. The calculated route is the required for navigation.
Route calculation
The navigation processor calculates the route with the help of the DVD map data, the destination entered by the
driver and the current position of the vehicle. For the calculation the processor takes into account the roads and
attributes read from the DVD map such as one-way streets, turn prohibitions, road classes, etc.).
Here, it is possible for the driver to indicate how the route should be calculated.
The route is then calculated to give the fastest route (shortest driving time). The navigation processor informs
the driver that the route has been recalculated taking traffic messages into consideration.
The driver can use the "my selection" function to exclude the following from the route calculation:
 FREEWAY
 FERRY
 TOLL ROADS
Following the calculation of the route, the navigation processor generates a list of roads and junctions to be
driven along. This route list is used for navigation. This list can also be accessed from the "Information" menu.
As of 1.9.02 toll roads are shown in a different color on the map.
Route updating
If the driver deviates from the calculated route, the navigation processor calculates a new route list. The current
position and the direction of travel are taken into consideration, and the new route is optimized accordingly.
The message "New Route" appears on the display.
Trips outside the digitized map area
If the vehicle leaves the digitized DVD map area (e.g. driving on a dirt road or in a parking garage), a route
cannot be calculated or updated.
"OFF ROAD" appears on the display.
Upon leaving the map boundary (e.g. foreign country), the message "OFF MAP" appears.
Destinations which are outside of the digitized map area cannot be taken into consideration when calculating the
route.
Circumventing traffic jams with "Traffic jam" button function
Following a traffic jam message via a traffic information radio channel, a route which circumvents the traffic
jam can be calculated before the relevant stretch is reached. To do this, the driver must press the "DETR" button
and select the following settings:
 The length of the traffic jam, including the distance to the start of the traffic jam must be entered
 The corresponding stretch must be blocked in the detailed route list.
The "Traffic jam" function is available for Federal and State highways as well as for inner city areas.
Navigation, function GF82.61-P-3012CA
NAVIGATION, FUNCTION - GF82.61-P-3012CA
version
Digitized and non digitized DVD map areas
1. 1 Vehicle position within the digitized DVD map area

2. 2 Vehicle position within the DVD map limits but outside the digitized map area
("OFF ROAD", company premises, path across a field, etc.)
3. 3 Vehicle position outside the DVD map limits
("OFF MAP", abroad)
The road network shown is illustrated in a highly simplified manner.

Fig. 4: Identifying Digitized DVD Map Area And Non-Digitized DVD Map Areas
Navigation is the generation and output of driving recommendations, in order to guide the driver to the desired
destination. Prerequisites for this are:
 Continuous position finding is in operation (accomplished automatically),

 Driver entered the destination
 Route calculation takes place.
The navigation processor continuously compares the route calculation data with the continuous position finding
data and derives from this measures for further navigation. Depending on the position of the vehicle, a
distinction can be made between two navigation modes (see Figure):
 Destination within digitized
DVD map area
 Restricted navigation outside the digitized DVD map area
Navigation in digitized GF82.61-P-4000BA

map area, function
NAVIGATION IN DIGITIZED MAP AREA, FUNCTION - GF82.61-P-4000BA
version
In the case of journeys within the digitized map area, the following information, which is calculated by the
navigation processor, is available to the user:
 The current route and position of the vehicle on a digital map (graphically depicted)
 Route list
 Distance from the destination and estimated time of arrival
 Direction recommendation
 Arrow indicating the driving direction
 Name of the road currently being traveled along
 Name of the next road into which the vehicle should turn
 Distance from the next junction (specified in units of length or as a bar graph)
As of 1.6.01 the compass directions North, South, East and West are specified (by graphical representation
and voice output). The compass direction is displayed only in the case of numbered roads. No data and display
of the compass direction is given in the case of roads designated by name (e.g. within towns).
The graphical signals for map depiction are generated by the navigation processor. Three types of depiction are
possible:
 Symbolic display (route control symbols)

 Map display
 Combination of map and symbolic display
The scale of the map can be changed in stages (500 m/cm to 500 km/cm). Moreover it is possible to select
whether the map is aligned in the direction of travel or facing North.
Additional COMAND functions were added as of 1.6.01. The DVD type (with the latest fine geometry) is
automatically detected and the graphic is displayed in a second optimized set of line thicknesses.
Actual navigation is assisted significantly by the voice output.
Navigation in non- GF82.61-P-4001BA

digitized map area,
function
NAVIGATION IN NON-DIGITIZED MAP AREA, FUNCTION - GF82.61-P-4001BA
version
When traveling outside of the digitized map area (e.g. company grounds, parking lots, dirt roads,...), however
still within the DVD map boundaries, the navigation processor switches over to "Navigation in non-digitized
map area".
The message "OFF ROAD" appears on the COMAND operating, display and control unit (A40/3) display.
If the vehicle is outside the DVD map limit (outside the country), the message "OFF MAP" appears.
In both cases, only the basic position finding (compound position finding) continues to operate with correction
using the GPS data.
(Limited) navigation can be conducted only with specification of the:
 Distance from the destination as the crow flies

 Direction to the destination (as an arrow)
After reentering the digitized map area, the system automatically continues with "Navigation in digitized map
area". The GPS position is used to help determine the roads on which the vehicle could be located. During this
process a slight delay in the navigation may occur.
In the event of the message "OFF MAP", comprehensive navigation can be continued after inserting a
relevant DVD for abroad
As of 1.9.02 the street map is faded in when the OFF-ROAD mode is entered and route information is
displayed during the OFF-ROAD mode.
Operating, display and control unit, up to 31.8.02 GF82.85-P-3114D

as of 1.9.02 GF82.85-P-3114DA
Navigation processor, as of 1.9.03 GF82.85-P-3103BA
GLOBAL POSITIONING SYSTEM ANTENNA, LOCATION/PURPOSE/DESIGN/FUNCTION -

GF82.61-P-4106
Global positioning system antenna, location/purpose/design/function - GF82.61-P-4106B
MODEL 215 with CODE (352a) COMAND operating and display system
Fig. 5: Identifying Global Positioning System Antenna
Global positioning GF82.61-P-4106-01B

system antenna, location
Global positioning Receiving and amplifying
system antenna, purpose global positioning system
(GPS) satellite signals.
Global positioning The GPS antenna consists
system antenna, design of a micro-wave antenna
(reception frequency in
giga-Hz range) and an
(integrated) antenna
amplifier.
The power is supplied by
the coaxial antenna cable
(phantom feed).
Global positioning GF82.61-P-4106-04B
system antenna, function
Global positioning system antenna, location - GF82.61-P-4106-01B
Model 215 with code 352

Fig. 6: Identifying Global Positioning System Antenna Location
Global positioning system antenna, function - GF82.61-P-4106-04B
The satellite signals received by the GPS antenna (A2/23) are amplified by the integrated antenna amplifier.
The output signal is relayed to the GPS receiver by a coaxial antenna cable. The GPS receiver is integrated into
the COMAND operating, display and control module (A40/3) .
The GPS antenna (A2/23) serves only for receiving GPS signals; signals are not transmitted.
Global positioning system antenna, location/purpose/design/function - GF82.61-P-4106C
MODEL 215 with CODE (348a) EMERGENCY CALL system with CODE (498) Japanese version with
CODE (494a) US version
Global positioning GF82.61-P-4106-01C

system antenna (GPS),
location
Global positioning Reception and
system antenna (GPS), amplification of the
purpose global positioning system
system antenna (GPS), of a microwave antenna
design (reception frequency in
antenna amplifier. Power
is supplied via the coaxial
antenna cable.
Global positioning GF82.61-P-4106-04C
function
Global positioning system antenna, location - GF82.61-P-4106-01C
Fig. 7: Identifying Global Positioning System Antenna Location
Global positioning system antenna, function - GF82.61-P-4106-04C
Function
The satellite signals received by the GPS antenna (A2/23) are amplified by the installed antenna amplifier. The
output signal is transmitted to the global positioning system control module via the co-axial antenna cable. The
power for the antenna amplifiers is supplied via the co-axial connector cable. Operating voltage and satellite
signals are transmitted simultaneously. They are decoupled by appropriate filters, reciprocal influence of the
signals is excluded.
The antenna signal is in an extremely high frequency range (microwave). Already slight damage of the
antenna cable (kinks) can lead to reduced reception. The satellites can only be received outdoors. They spread
in the same manner as light The GPS antenna (A2/23) serves only for reception of GPS signals; signals are
not transmitted.
Global positioning system antenna, location/purpose/design/function - GF82.61-P-4106D
MODEL 215 with CODE (347) TELE AID emergency call system (D2B)
Global positioning GF82.61-P-4106-01D
location
system antenna (GPS), amplification of the
location global positioning system
system antenna (GPS), of a microwave antenna
location (reception frequency in
antenna amplifier. Power
is supplied via the coaxial
antenna cable.
Global positioning GF82.61-P-4106-04D
location
Global positioning system antenna arrangement - GF82.61-P-4106-01D
Fig. 8: Identifying Global Positioning System Antenna Arrangement
Global positioning system antenna, function - GF82.61-P-4106-04D
The satellite signals received by the global positioning system (GPS) antenna (A2/23) are amplified in the
integrated antenna amplifier.
The output signal is transferred to the GPS receiver via the coaxial antenna cable.
The GPS receiver is integrated into the operating/display unit with control module (A40).
The GPS antenna (A2/23) serves only for receiving GPS signals; no signals are transmitted.
Global positioning system antenna location/purpose/design/function - GF82.61-P-4106P
MODELS 203, 210, 220 with CODE (855) TELE AID with CODE (930) Taxi emergency call system
MODELS 208.3, 215 with CODE (855) TELE AID
Model 203
The Global Positioning System (GPS) antenna is stuck to the rear window in the 203 model
Fig. 9: Identifying Global Positioning System Antenna Function - Models 203, 210, 220 With Code (855)
Tele Aid With Code (930)
Global positioning Model 215 GF82.61-P-4106-01D

system antenna, location
Models 208.3, 210, 220 GF82.61-P-4106-01E
system antenna, purpose amplification of the
global positioning system
system antenna, design of a microwave antenna
(receive frequency in
gigahertz range) and an
antenna booster. The
power supply comes from
the coaxial antenna cable.
An antenna splitter may
be required depending on
the configuration.
Global positioning GF82.61-P-4106-04P
system antenna, function
Global positioning system antenna arrangement - GF82.61-P-4106-01E
Shown on model 210
(Installation is in the vicinity of the rear vehicle roof in all models)
The roof antenna consists of a CTEL antenna A2/49a1 and a GPS antenna A2/49a2.
Fig. 10: Identifying Global Positioning System Antenna Arrangement
Global positioning system antenna function - GF82.61-P-4106-04P
The satellite signals received by the GPS antenna (A2/23, A2/49a2) are amplified by the integrated antenna
amplifier and sent to the GPS receiver, where the signals are processed.
The feed to the GPS receiver is configuration-dependent.
In the configuration with radio, the output signal is forwarded to the GPS receiver via a coaxial antenna cable in
the CTEL and TELE AID, D2B transmitter/receiver (A35/17) .
In the configuration with COMAND, another GPS receiver is integrated in the operating, display and control
module (A40/3) .
The output signal is sent to the GPS receivers via a coaxial antenna cable. The antenna output signal is sent to
the CTEL and TELE AID, D2B transmitter/receiver unit (A35/17) and the operating, display and control
module (A40/3) via an antenna splitter.
The GPS antenna (A2/23, A2/49a2) is only used to receive GPS signals; no signals are transmitted.
ANTENNA SYSTEM (ATS), FUNCTION - GF82.62-P-0001
Antenna system (ATS), function - GF82.62-P-0001A
MODEL 220
Antenna system block diagram Shown with the following vehicle equipment:
Fig. 11: Antenna System Block Diagram - Model 220
General information
The design of the various antennae is adapted to their special reception/transmission ranges.
A distinction must be made between passive and active antennas:
Passive antennas do not require a power supply, they are therefore not capable of direct amplification of the
radio signals received.
Examples:
 All antennae in the rear window

 Telephone antenna (A2/49a1)
Active antennas have a power supply. They feature an integrated amplifier.
Example:
 GPS antenna (A2/49a2)
The power supply is supplied by separate leads or via the coaxial leads which serve simultaneously for signal
transmission (so-called phantom feed). In this case, no separate leads are required for the power supply.
Another difference between the antennae is that many antennae are only used for reception while others are
used for both receiving and transmitting.
Examples:
Reception only:
 GPS antenna (A2/49a2)
Transmission and reception:
 Telephone antenna (A2/49a1)
The detailed descriptions of the individual systems and components are given in the reference documents
listed below.
Cockpit Management and Data System With COMAND GF82.85-P-0003A

(COMAND), function operating and
display system (code
352a)
Without USA
version (code 494a)
With COMAND GF82.85-P-0003B
operating and
352a)
With USA version
(code 494a)
Keyless Go function With Keyless Go GF80.61-P-0005S
(code 889) up to
09/2002
With Keyless Go GF80.61-P-0005SM
(code 889) as of
10/2002
Keyless Go antenna, With Keyless Go GF82.62-P-4100S
location/task/design/function (code 889) up to
09/2002
(code 889) as of
10/2002
Triggering heater mode with radio With stationary GF83.70-P-3057A
remote control immediately - Function heater (code 228) up
to 31.05.2000
With stationary GF83.70-P-3057B
heater (code 228) as
of 01.06.2000 up to
31.08.02
With stationary GF83.70-P-3057M
heater (code 228) as
of 01.09.2002
Rear window antenna GF82.62-P-3106A
GPS/CTEL roof antenna GF82.70-P-4111A
Antenna splitter, With TELE AID GF82.85-P-3107A
location/task/design/function [Telematic Alarm
Identification on
Demand] emergency
call system (D2B)
(code 347) and
COMAND operating
and display system
(code 352a)
TELE AID spare antenna, With TELE AID GF82.95-P-4102A
location/task/design/function emergency call
system (D2B) (code
347)
Antenna system (ATS), function - GF82.62-P-0001B
MODEL 215
Antenna system block diagram Shown with the following vehicle equipment:
Fig. 12: Antenna System Block Diagram - Model 215
Preliminary remarks
In the present description only the antenna system for Audio, TV, telephone and navigation is described.
General information
The design of the various antennae is adapted to their special reception/transmission ranges.
A distinction must be made between passive and active antennas:
Passive antennas do not require a voltage supply, they can therefore not directly amplify the radio signal
received.
Examples:
 All antennae in the rear window

 telephone antenna (A2/22)
Active antennas are supplied with power. They feature an integrated amplifier.
Example:
 GPS antenna (A2/23)
The power supply is supplied by separate leads or via the coaxial leads which serve simultaneously for signal
transmission (so-called phantom feed). In this case, no separate leads are required for the power supply.
Another difference between the antennae is that many antennae are only used for reception while others are
used for both receiving and transmitting.
Examples:
Reception only:
 GPS antenna (A2/23)
Transmission and reception:
 telephone antenna (A2/22)
The detailed descriptions of the individual systems and components are given in the reference documents
listed below.
Cockpit Management and Data System With COMAND GF82.85-P-0003A

(COMAND), function operating and
352a)
Without USA
version (code 494a)
Without Japanese
version (code 498)
With COMAND GF82.85-P-0003B
operating and
352a)
With USA version
(code 494a)
Rear window antennas, GF82.62-P-3106A
Telephone antenna, location/task GF82.62-P-4105A
Global positioning system antenna, GF82.61-P-4106B
Antenna splitter, With COMAND GF82.85-P-3107A
location/task/design/function operating and
352a)
TELE AID (D2B)
(code 347)
Keyless Go antenna, With Keyless Go GF82.62-P-4100S
location/task/design/function (code 889) up to
09/2002
(code 889) as of
10/2002
LOUDSPEAKER SYSTEM (LS), TECHNICAL DATA FOR LOUDSPEAKER/SOUND SYSTEM -
GF82.62-P-0002
Loudspeaker system (LS), technical data for loudspeaker/sound system - GF82.62-P-0002-02I
BOSE SOUND SYSTEM

Component Power rating Frequency Resistance Speaker diameter
Ø
Left/right audio 5 x 40W - - -
power amplifier 1 x 100W
(N40/3)
Left front door
speaker group
(H4/1) and right
front door speaker
group (H4/2) with
speaker h1 (tweeter
in mirror triangle)
40 W 4000-20000 Hz 4 ohms 40 mm
Speaker h2 (woofer)
40 W 60-10000 Hz 2 ohms 168 mm
Left rear door
speaker group
(H4/3) and right rear
door speaker group
(H4/4) with speaker
h1 (tweeter in door
control module
cover)
40 W 40-20000 Hz 4 ohms 40mm
Speaker h2 (woofer)
40 W 60-20000 Hz 2 ohms 168 mm
Center cockpit 15 W 120-10000 Hz 8 ohms 80 mm
speaker (centerfill)
H4/27
Bass speaker H4/17 100 W 20-80 Hz 0.5 ohms 260 mm
Loudspeaker system (LS), technical data loudspeaker/sound system - GF82.62-P-0002-02N
BOSE SOUND SYSTEM

Component Capacity Frequency Resistance Loudspeaker, dia.
Left/right 5 x 40W - - -
loudspeaker 1 x 100W
amplifier control
module (N40/3)
Left front door
speaker group
(H4/1) and right
front door speaker
group (H4/2) with
h1 loudspeaker
(tweeter on mirror
triangle)
h2 loudspeaker 40 W 4000-20000 Hz 8 ohms 38 mm
(woofer below
mirror triangle)
40 W 60-10000 Hz 2 ohms 168 mm
h3 loudspeaker
(center tweeter)
40W 100-15000 Hz 2 ohms 168 mm
H4/27
Bass speaker H4/17 100 W 20-80 Hz 0.5 ohms 260 mm
(on rear shelf)
Loudspeaker system (LS), technical data for standard loudspeaker - GF82.62-P-0002-03I
STANDARD SPEAKER SYSTEM

Component Power rating Frequency Resistance Speaker diameter
Ø
Left front door
speaker group
(H4/1) and right
front door speaker
group (H4/2) with
speaker h1 (tweeter
in mirror triangle)
25 W 5000-20000 Hz 8 ohms 38 mm
Speaker h2 (woofer)
25 W 60-10000 Hz 4 ohms 168 mm
Left rear door
speaker group
(H4/3) and right rear
door speaker group
(H4/4) with speaker
h1 (tweeter in door
control module
cover)
25 W 5000-20000 Hz 8 ohms 38 mm
Speaker h2 (woofer) 25 W 60-10000 Hz 4 ohms 168 mm
H4/27
Bass speaker H4/17 2 x 25 W 30-120 Hz 2 x 4 ohms 260 mm
Loudspeaker system (LS), technical data standard loudspeakers - GF82.62-P-0002-03N
STANDARD LOUDSPEAKER SYSTEM

Component Capacity Frequency Resistance Loudspeaker, dia.
Left front door
speaker group
(H4/1) and right
front door speaker
group (H4/2) with
h1 loudspeaker
(tweeter on mirror
triangle)
h2 loudspeaker 25 W 4000-20000 Hz 8 ohms 38 mm
(woofer below
mirror triangle)
25 W 60-10000 Hz 4 ohms 168 mm
h3 loudspeaker
(center tweeter)
25W 100-15000 Hz 4 ohms 140 mm
H4/27
Bass speaker H4/17 2 x 25 W 30-120 Hz 2 x 4 ohms 260 mm
(on rear shelf)
SPEAKERS, AMPLIFIER, ANTENNA AS-BUILT CONFIGURATION - GF82.62-P-0800ZZ
MODEL 163, 170, 202, 208, 210, 215, 220
Speakers/sound system, Model 163 GF82.62-P-0002-02GH

technical data
Model 170 GF82.62-P-0002-02C
Model 202 GF82.62-P-0002-02A
Model 208 GF82.62-P-0002-02E
Model 210 GF82.62-P-0002-02D
Model 215 GF82.62-P-0002-02N
Model 220 GF82.62-P-0002-02I
Speakers/standard, technical Model 170 GF82.62-P-0002-03C
data
Model 202 GF82.62-P-0002-03A
Model 208, 210 GF82.62-P-0002-03D
Model 215 GF82.62-P-0002-03N
Model 220 GF82.62-P-0002-03I
CONTENTS - FUNCTION DESCRIPTION OF ANTENNA SYSTEM (ATS) - GF82.62-P-0999A
Models 215, 220
Antenna system (ATS), function Model 215 GF82.62-P-0001B

Model 220 GF82.62-P-0001A
Rear window antenna GF82.62-P-3106A
Telephone antenna, location/task Model 215 GF82.62-P-4105A
GPS/CTEL roof antenna Model 220 GF82.70-P-4111A
Antenna splitter, COMAND operating GF82.85-P-3107A
location/task/design/function and display system
(code 352a) and code
347 (TELE AID)
TELE AID spare antenna, On model 215 with GF82.95-P-4102A
location/task/design/function TELE AID
emergency call
system (D2B) (code
347) and model 220
with TELE AID
emergency call
system (D2B) (code
347) or taxi call for
help (code 930)
Keyless Go antenna, Keyless Go (code GF82.62-P-4100S
location/task/design/function 889) up to 09/2002
Keyless Go (code GF82.62-P-4100SM
889) as of 10/2002
SOUND AMPLIFIER, LOCATION/TASK/DESIGN/FUNCTION - GF82.62-P-3100
Sound amplifier, location/task/design/function - GF82.62-P-3100A
MODEL 215, 220 up to 31.8.03 with CODE (810) Sound system with CODE (352a) COMAND operating
and display system
Location shown on model 215 as of 1.9.02

Fig. 13: Identifying Sound Amplifier Location - Shown On Model 215 As Of 1.9.02
Sound amplifier, With code 498 GF82.62-P-3100-01B

location
Except code 498 GF82.62-P-3100-01A
Sound amplifier, Processing (sound adjustments)
purpose and amplification of all audio
signals (radio, cassette, CD,
voice output during navigation
etc.).
Sound amplifier, design  Interface to digital data
bus (D2B)
 Connection for sound
amplifier microphone
(B25/6) for Vehicle
Noise Compensation
 Digital filter technology
 6 outputs for left front,
right front, left rear, right
rear, Center speaker and
Woofer
Sound amplifier, GF82.62-P-3100-04A
function
Sound amplifier, location - GF82.62-P-3100-01A
Shown on Model 220

Fig. 14: Identifying Sound Amplifier Location - Shown On Model 220
Sound amplifier, function - GF82.62-P-3100-04A
Model 215, 220 with code 810
On vehicles as of 1.9.03 all audio signals and video signals of the audio/TV components are transmitted by
the Media Oriented Systems Transport (MOST).
Sound amplifier, function
Data exchange of the sound amplifier (A2/13) takes place via the D2B (Digital Data Bus) with the following
signal sources:
 Radio (A2)
 COMAND operating, display and control unit (A40/3)
In the process both the control information and the signals of the audio sources (Radio, AUX connection for
external audio sources, CD, navigation voice output) are transmitted via the Digital Data Bus (D2B).
Signal processing
In order to make possible the diverse adjustments to the sound, the sound amplifier (A2/13) has a digital signal
processor which carries out the complete signal filtering.
Compared with conventional analog filters, digital filters have the following basic advantages:
 The filter parameters (sound adjustments) do not change in the course of time; this means exact
reproducibility of all adjustments.
 Lower noise.
 The cost of components is reduced considerably as the filter parameters are adjusted by the software and
not by varying component values (resistances, capacitances or inductivities). This also increases the
number of possible filter adjustments
Sound optimization
Each of the 6 amplifier channels is provided with individual compensation which corrects the vehicle-specific
acoustics if necessary. In addition further sound optimizations and effects such as e.g. "voice-emphasized" or
"Room sound" can be called up.
Bass, treble, volume, balance, fader and the dynamic loudness function can be individually set.
Noise suppression
The output level of the 6 output stages is monitored constantly.
Regulation is such that distortions are minimized.
Automatic Vehicle Noise Compensation (VNC)
The noise level inside the vehicle is measured using the sound amplifier microphone (B25/6) which is
connected directly to the sound amplifier (A2/13). The volume of the music output signal is continuously
adapted to this noise level.
For this purpose the sound amplifier (A2/13) must detect which signals of the measured level are driving noise
and which are audio signals. This takes place through a comparison of output signals from the sound amplifier
(A2/13) with the measured signal, i.e., the difference between the two signals is the driving noise level.
Diagnosis
The sound amplifier (A2/13) can set up the following messages which are relevant for the diagnosis:
 Operating status
 Undervoltage
 Internal fault in the sound amplifier (A2/13)
The messages are transmitted via Digital Data Bus (D2B) to the COMAND operating, display and control unit
(A40/3) or radio (A2) and can be read out there via the diagnostic line (K-line).
Sound amplifier, location/task/design/function - GF82.62-P-3100AB
MODEL 215, 220 as of 1.9.03 with CODE (810) Sound system with CODE (352a) COMAND operating
and display system
Location illustrated on model 215

Fig. 15: Identifying Sound Amplifier Location - Illustrated On Model 215
Sound amplifier, With code 498 GF82.62-P-3100-01B

location
Except code 498 GF82.62-P-3100-01A
Sound amplifier, task Processing (tone setting) and
amplifying all the audio signals
(radio, cassette, CD, voice
output of navigation system,
etc.)
Sound amplifier, design  Interface to Media
Oriented System
Transport (MOST)
 Connection for sound
amplifier microphone
(B25/6) for vehicle noise
compensation
 Digital filter technology
 6 outputs for speakers,
center speaker, woofer
Sound amplifier, GF82.62-P-3100-04A
function
SOUND AMPLIFIER MICROPHONE, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.62-P-

3101A
MODEL 215, 220 with CODE (352a) COMAND operating and display system with CODE (810) Sound
system

Fig. 16: Identifying Sound Amplifier Microphone Location - Illustrated On Model 220
Sound amplifier In area of overhead

microphone, location control panel
Sound amplifier Measure noise level in
microphone, purpose vehicle passenger
compartment.
Sound amplifier Design: capacitor
microphone, design microphone; therefore
requires power supply
from the sound amplifier
(A2/13) .
Sound amplifier The sound amplifier
microphone, function microphone (B25/6)
continuously receives the
sound waves generated
by all noises via a
diaphragm and converts
them into an analog,
electrical signal. This
signal is evaluated by the
sound amplifier
(A2/13) .
AUDIO GATEWAY CONTROL UNIT, DESIGN - GF82.62-P-3102-03SZ
The audio gateway control unit (N93/1) is characterized by the following design:
 Radio receiver (AM/FM)

 Interface of Controller Area Network Bus class B (interior) (CAN-B) and the Media Oriented System
Transport (MOST)
 MOST central diagnostic interface
ANTENNA AMPLIFIER, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.62-P-3105A
MODEL 215, 220
Antenna amplifier, GF82.62-P-3105-01A

location
purpose
Antenna amplifier, design Model 215, GF82.62-P-3105-03A
Model 220 with infrared
protection glass
Model 220 with green GF82.62-P-3105-03B
glass
function
Antenna amplifier, location - GF82.62-P-3105-01A
Models 215, 220
Fig. 17: Identifying Antenna Amplifier Location - Illustrated On Model 220
Antenna amplifier module, purpose - GF82.62-P-3105-02A

Models 215, 220
The purpose of the rear window antenna amplifier module (A2/12) is to connect the rear window antennas,
automatically selecting the optimal FM antenna (antenna diversity) and amplifying and filtering all antenna
signals for the following frequency bands:
 AM, FM, TV
 Signal for radio frequency central locking (RCL)
 Telestart for stationary heater (not for and )
 DAB (only for , in preparation)
Antenna amplifier, design - GF82.62-P-3105-03A
Model 215, Model 220 with infrared protection window glass
Fig. 18: Rear Window Antenna Amplifier Module Block Diagram
The following components are integrated into the rear window antenna amplifier module (A2/12) (see block
diagram):
 Amplifier for AM antenna

 Filter and amplifier with diversity system for 4 FM antennas
 Reception unit for radio frequency central locking (RCL)
 Filter and amplifier for TV antennas (optional)
The processed signals are transferred to the corresponding control modules via the coaxial connection sockets
Connecting antennas
Between the rear window antennas and the rear window antenna amplifier module (A2/12) a silicon material
with extremely good conductive properties is used for electrical contact. The silicon material is pressed against
the silver surfaces of the antennas by spring force.
The rear window is always equipped with all antennas regardless of the special equipment installed. However,
there are differences in the national versions of the rear window antenna amplifier module (A2/12) ( ,
,...) and the TV option.
On model 220 the rear window antenna amplifier module (A2/12) version also depends on the rear window
glass (infrared protection or green glass).
Observe repair notes when installing and removing rear window.
Antenna amplifier, design - GF82.62-P-3105-03B
Model 220
On rear windows with green glass
Fig. 19: Top Rear Window Antenna Amplifier Block Diagram
The following assemblies are integrated into the top rear window antenna amplifier (A2/12) (see block
diagram):
 Amplifier for one AM antenna
 Filter and amplifier with diversity system for the FM antennas
 Receiver for RF remote control central locking (RCL)
 Filter and amplifier for TV antennas
The edited signals are tapped from the corresponding control modules via co-axial connection sockets
Regardless of special equipment the rear window is always equipped with all antennas. However with the
rear window antenna amplifier module (A2/12) the national versions ( , ...), the rear window
version and the version with TV system differ.
Antenna connections
An extremely good conducting silicon material is used as the electrical connection material between the rear
window antennas and the top rear window antenna amplifier (A2/12) .The silicon material is pressed against
the silver surface of the antennas by spring force.
Observe repair instructions for removing and installing rear window.
Antenna amplifier, function - GF82.62-P-3105-04A
Models 215, 220
Filtering and amplifying high frequency signals
The electrical filters select the desired frequency bands (AM, FM, TV,...) from the high frequency signals
coming from the rear window antennas. These filters are designed differently depending on the national version
(e.g. , ,...) since the transmission frequencies depend on the specific country. The frequency bands
filtered out are then amplified selectively and transmitted by the coaxial leads to the corresponding control
modules, e.g.:
 Radio (A2) or COMAND operating, display and control module (A40/3n1) or

 Overhead control panel control module (N70)
Demodulation of RCL signals
The signals for the radio frequency central locking (RCL) are demodulated and digitalized by the rear window
antenna amplifier module (A2/12) . The data prepared in this manner are transmitted to the overhead control
panel control module (N70) by a separate data line and there stored on the CAN interior compartment.
During demodulation the information signal (e.g. the RCL signal) is separated from the high frequency
carrier (transmitter frequency).
Antenna diversity function

The diversity processor integrated into A2/12 switches over between the rear window FM antennas depending
on the reception to achieve the best possible reception.
 First the radio (A2) or A40/3n1 receives the signals of the active FM antenna from the rear window
antenna amplifier module (A2/12) .
 A2 or A40/3n1 generates the IF reference signal from the FM signals received and transfers it back to the
rear window antenna amplifier module (A2/12) via a separate cable.
 After demodulation, the diversity processor in the rear window antenna amplifier module (A2/12)
checks whether the IF signal contains no interference. If interference is present, it automatically switches
over to the next of the four FM antennas in the rear window.
 The switchover speed depends on the frequency of the interference occurring. This prevents continuous
switching between the antennas when FM reception is very poor which could cause interference itself.
REAR WINDOW ANTENNAS, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.62-P-3106A
MODEL 215, 220
Rear window antennas, Model 215 GF82.62-P-3106-01D

location
Model 220 GF82.62-P-3106-01A
On rear windows with green
glass
Model 220 GF82.62-P-3106-01B
On rear windows with infrared
protection glass
Rear window antennas, Reception of the following
purpose radio frequency signals:
 AM, FM, TV,

 RCL (radio frequency
central locking),
 TELESTART (radio
frequency remote control
stationary heater, not for
and )
 DAB (only for , in
preparation)
Rear window antennas, GF82.62-P-3106-03B
design
Rear window antennas, GF82.62-P-3106-04B
function
Rear window antennas, location - GF82.62-P-3106-01A

Model 220
On rear windows with green glass
Fig. 20: Identifying Rear Window Antennas Location
Rear window antennas, location - GF82.62-P-3106-01B
Model 220
On rear windows with infrared protection glass
Fig. 21: Identifying Rear Window Antennas Location - Model 220
Rear window antenna, location - GF82.62-P-3106-01D
Model 215
Fig. 22: Identifying Rear Window Antennas Location - Model 215
Rear window antennas, design - GF82.62-P-3106-03B
Models 215, 220
 The individual antennas are integrated into the rear window between two layers of glass.
 The antenna system is completely separated from the rear window defroster and thereby entirely
decoupled electrically.
 The metallically conductive layer on the infrared protective glass on model 220 influences the rear
window antennas. The rear window antennas are designed differently on vehicles with infrared or green
glass .
Rear window antennas, function - GF82.62-P-3106-04B
Models 215, 220
The radio signals are received by the individual antennas, converted to an alternating electric current and
conducted to the rear window antenna amplifier module (A2/12) by contact rails.
The geometric dimensioning and arrangement of the antennas are optimized to the frequency bands to be
received.
Individual antennas can also be used for several frequency bands simultaneously (e.g. FM and TV).
High frequency signals are not transmitted by the rear window antennas.
AUDIO GATEWAY CONTROL UNIT, LOCATION/TASK/DESIGN - GF82.62-P-3116SZ
MODEL 215.3, 220.0 /1 as of 1.9.03
Shown on MODEL 220

Fig. 23: Identifying Audio Gateway Control Unit Location - Shown On Model 220
Audio gateway control The audio gateway control

unit, location unit (N93/1) is located in
the trunk next to the left-
hand longitudinal member.
Audio gateway control  Media Oriented
unit, task System Transport
(MOST) ring master
 AM/FM receiver
 Interface of
Controller Area
Network bus class B
(interior) (CAN-B)
and the MOST
 MOST central
diagnostic interface
Audio gateway control GF82.62-P-3102-03SZ
unit, design
KEYLESS GO ANTENNA, LOCATION/TASK/DESIGN/FUNCTION - GF82.62-P-4100SM
MODEL 220, 215 as of 1.10.02
Keyless Go antenna, GF82.62-P-4100-01S

location
keyless Go antenna,  Communication between
task the Keyless Go control unit
(N69/5) and the transmitter
key (A8/1).
 Location of transmitter key
(A8/1), inside/ outside the
vehicle
keyless Go design The antennas consist of inductive
conductive loops connected to
the Keyless Go control unit
(N69/5).
keyless Go antenna GF82.62-P-4100-
function 04SM
Keyless Go antenna, location - GF82.62-P-4100-01S
Shown on Model 220
Fig. 24: Identifying Keyless Go Antenna Location - Shown On Model 220
Keyless Go antenna, function - GF82.62-P-4100-04SM
The inductive antennae in the doors, in the rear, in the luggage compartment and in the rear bumper are actuated
by the Keyless Go control unit (N69/5).
Their electromagnetic fields cause the transmitter key (A8/1) to transmit its authorization code via radio to the
right antenna amplifier module (A2/12).
The transmitter key used last is interrogated first.
In addition via these antennae it is established whether transmitter card is outside or inside the vehicle.
The body sheet metal attenuates the antenna fields in the outer area limiting the range in a defined manner. The
range of the antennae outside the vehicle is approx. 1 - 1.5 m. As a result the transmitter card outside the vehicle
can always only be reached by the antennae on one side of the vehicle.
On the other hand, these range sectors overlap in the interior.
This defined range limitation allows the Keyless Go control unit (N69/5) to decide whether the transmitter key
is located inside or outside the vehicle.
Examples:
 Transmitter card located inside the vehicle Transmitter card recognized by antennas on both sides of the
vehicle. The Keyless Go control unit (N69/5) therefore "knows" that the transmitter key is in the vehicle.
 The transmitter key is located outside the vehicle The transmitter key is only detected by antennae on one
side of the vehicle. The Keyless Go control unit (N69/5) therefore "knows" that the transmitter key is in
the vehicle.
TELEPHONE ANTENNA, LOCATION/TASK - GF82.62-P-4105
CTEL antenna, location/purpose - GF82.62-P-4105A
MODEL 215 with CODE (348a) Emergency call system EMERGENCY CALL with CODE (498)
Japanese version with CODE (494a) USA version
Fig. 25: Identifying CTEL Antenna Location
CTEL antenna, location GF82.62-P-4105-01B

CTEL antenna, purpose  Converting electro-
magnetic radio waves
into electrical currents
and vice versa
 Connecting antenna
cable
CTEL antenna, location - GF82.62-P-4105-01B
Model 215
Fig. 26: Identifying CTEL Antenna Location
Cellular telephone antenna, location/purpose - GF82.62-P-4105B
MODEL 215 with CODE (347) TELE AID emergency call system (D2B) with CODE (316) MB GSM
cellular telephone (D2B) with CODE (317) GSM portable cellular telephone (D2B)
Fig. 27: Identifying Cellular Telephone Antenna Location
Cellular telephone GF82.62-P-4105-

antenna, location 01B
Cellular telephone  Converting electromagnetic radio
antenna, task waves into electrical voltages and
vice versa
 Transmitting/receiving telephone
signals (data and voice
information)
 Concentrating the transmission
energy into a beam shape
 Detecting the appropriate
frequency range
Telephone antenna, location/purpose - GF82.62-P-4105C
MODEL 129 with CODE (274) MB D network telephone with CODE (312) D network cellular telephone
with CODE (313) D network cellular telephone with CODE (314a) D network standard telephone with
CODE (316) MB D network telephone (D2B) with CODE (317) D network cellular telephone(D2B)
with CODE (313) D network cellular telephone with CODE (314a) D network standard telephone
MODEL 168 with CODE (312) D network cellular telephone with CODE (317) D network cellular
telephone (D2B)
MODEL 170 with CODE (312) D network cellular telephone with CODE (313) D network cellular
telephone with CODE (314a) D network standard telephone with CODE (316) MB D network telephone
(D2B) with CODE (317) D network cellular telephone (D2B)
with CODE (313) D network cellular telephone with CODE (314a) D network standard telephone with
CODE (316) MB D network telephone (D2B) with CODE (317) D network cellular telephone (D2B)
MODEL 208 with CODE (274) MB D network telephone with CODE (316) Telefon MB-Netz D (D2B)
with CODE (317) Telefon D-Netz Handy (D2B)
MODEL 210 with CODE (274) Telefon MB Netz D with CODE (312) Telefon D-Netz Handy with CODE
(313) Telefon D-Netz "Handy" with CODE (314a) Telefon D-Netz "Standard" with CODE (316) Telefon
MB-Netz D (D2B) with CODE (317) Telefon D-Netz Handy (D2B)
MODEL 220 with CODE (316) Telefon MB-Netz D (D2B) with CODE (317) Telefon D-Netz Handy (D2B)
Fig. 28: Identifying Rod Antenna

Fig. 29: Identifying Roof Antenna
When combined with the navigation system, the roof antenna becomes the CTEL and GPS roof antenna
(A2/49).
Telephone antenna, GF82.62-P-4105-

location 01A
Telephone antenna,  Reception of radio signals
purpose
 Transmission/reception of
telephone signals (data and voice
information)
 Lobar bundling of transmission
energy
 Coverage of appropriate
frequency range
Telephone antenna, location - GF82.62-P-4105-01A
The roof antenna, rod antenna or telephone/GPS antenna is used depending on the model, model year and
equipment. The telephone/GPS antenna is then located at the same position as the roof antenna.
Fig. 30: Identifying Roof Antenna Location - Illustrated On Model 202
Fig. 31: Identifying Rod Antenna Location - Illustrated On Model 202
Telephone antenna, location/purpose - GF82.62-P-4105P
MODEL 163 with CODE (853) MB standard cellular telephone with CODE (854) MB portable cellular
telephone
MODEL 203, 210, 220 with CODE (853) MB standard cellular telephone with CODE (854) MB portable
cellular telephone with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODEL 208.3, 215 with CODE (853) MB standard cellular telephone with CODE (854) MB portable
cellular telephone with CODE (855) TELE AID
Model 203
Fig. 32: Identifying Telephone Antenna Location
Telephone antenna, Model 163 GF82.62-P-4105-01E

location
Model 215 GF82.62-P-4105-01C
Model 208.3, 210, 220 GF82.62-P-4105-01D
Telephone antenna,  Converting electro-
purpose magnetic radio waves
into electric voltages
and vice versa.
 Connecting antenna
cable.
Telephone antenna, location - GF82.62-P-4105-01C

Telephone antenna, location - GF82.62-P-4105-01D
Shown on model 210
Fig. 34: Identifying Telephone Antenna, Location
The roof antenna consists of a telephone component A2/49a1 and a GPS component A2/49a2.
Telephone antenna, location/task - GF82.62-P-4105S
MODELS 215, 220 as of 1.6.04 with CODE (388) "Portable CTEL" UPCI telephone system

Fig. 35: Identifying Telephone Antenna Location - Illustrated On Model 215
Shown on model 220
Fig. 36: Identifying Telephone Antenna Location - Illustrated On Model 220
Telephone antenna, Model 215

location The telephone antenna
(A2/22) is located below
the trunk lid on the right.
Model 220
The telephone antenna
(A2/49a1) is located on
the roof in the rear.
Telephone antenna, The telephone antenna
purpose (A2/22 (model 215),
A2/49a1 (model 220))
transmits and receives
telephone signals and
telestart signals for the
stationary heater with
code (228) stationary
heater.
Telephone antenna, location/task - GF82.62-P-4105SZ
MODEL 215.3 with CODE (383a) Tele-Aid fixed installation telephone
MODEL 215.3 with CODE (359) TELE AID emergency call system
Telephone antenna, The telephone antenna

location (A2/22) is located on the
right in the luggage
compartment lid.
Telephone antenna, Sending and receiving
purpose mobile radio signals.
GPS ANTENNA, LOCATION/TASK - GF82.62-P-4107SZ
MODEL 215.3 with CODE (383a) Tele-Aid fixed installation telephone

MODEL 215.3 with CODE (359) TELE AID emergency call system
Fig. 38: Identifying GPS Antenna Location
GPS antenna, location The GPS antenna (A2/23)

is located on the left in
the luggage compartment
lid.
GPS antenna, task Reception and
amplification of the
global positioning system
SATELLITE RADIO ANTENNA, LOCATION/TASK - GF82.62-P-4109B
MODEL 215, 220 as of 1.9.03 with CODE (352a) COMAND operating and display system with CODE
(494a) USA version
Shown on model 220

Fig. 39: Identifying Satellite Radio Antenna Location - Shown On Model 220
Satellite radio antenna, The SDAR antenna

location (A2/82) is installed on the
outside of the trunk lid as
a dealer-installed optional
extra.
Satellite radio antenna, The task of the SDAR
task antenna (A2/82) is to
receive and pass on the
incoming signals from
the satellites.
CD PLAYER WITH CHANGER, LOCATION/TASK/DESIGN/FUNCTION - GF82.64-P-3113
CD player with changer, location/task/design/function - GF82.64-P-3113B
MODELS 163, 208, 210, 215, 220 with CODE (819) 6-disc CD changer
MODELS 208, 210, 215, 220 with CODE (819a) CD changer with CODE (498) Japanese version
Shown on model 220 (as of 1.9.02)

Fig. 40: Identifying CD Changer (In Trunk) Location
CD player with changer, The CD player with

location changer (in the trunk)
(A2/6) is located in the
trunk near the left side
wall.
Model 163 GF82.64-P-3113-01GI
Models 208, 210 GF82.64-P-3113-01D
Models 215, 220 with GF82.64-P-3113-01F
code 498
Models 215, 220 without GF82.64-P-3113-01E
code 498
CD player with changer,  Playing audio
purpose compact discs (CD)
 Changing CDs
contained in the
magazine
CD player with changer,  6-slot CD changer
design magazine
only: 12-
slot CD changer
magazine
 Digital Data Bus

(D2B) interface
The factory planned

installation position for
the CD changer is vertical,
whereby other installation
positions are possible by
adaptation of the spring
locations.
CD player with changer, Models 208, 210 GF82.64-P-3113-02C
function
Model 215, 220 GF82.64-P-3113-02B
CD player with changer, function - GF82.64-P-3113-02B
Models 208, 210, 215, 220
CD player control
Dependent on the vehicle equipment specification the CD player with changer (in trunk) (A2/6) is controlled
via the Digital Data Bus (D2B), by the
 Radio (A2) or the

 COMAND operating, display and control module (A40/3n1)
The CD player generates reports on the following operating conditions:
 No magazine in CD changer
 Magazine occupation (music CDs only)
 Number of current CD
 Number of current title
 List of occupied slots (CDs)
 Number of titles per CD
 Current operating status (play, pause, etc.)
The messages are sent to the D2B and interpreted by the radio (A2) or the COMAND operating, display and
control module (A40/3n1) .
CD playback
The audio data is digitally stored on the CD ROM. The audio CD is driven by a motor in the CD player. The
laser-optical device scans the side of the rotating CD with no label without touching it and converts the digital-
optical signals into electric signals. Small interruptions to the data flow to the laser optics, caused by scratches
or contamination on the audio CD, are subsequently interpolated by the DA converter and thus compensated
for. The electric signals in the CD changer are then decoded and transmitted via the D2B, depending upon the
vehicle's equipment specification, to the COMAND operating, display and control module (A40/3n1) , the
radio (A2) or the sound amplifier (A2/13) .
Jumps and interruptions during playback
When driving on poor roads and during hefty vibrations it may be that jumps and interruptions occur during
playback. In such cases CD playback should be put on hold until the condition of the road improves.
In the wet or where ambient temperatures fluctuate wildly the CD changer housing may experience a build up in
its humidity level (condensation formation). This may also lead to faults occurring during playback.
Where this happens take steps to ensure that sufficient ventilation is provided for the CD player in the trunk.
CD player with changer, location/task/design/function - GF82.64-P-3113BA
MODEL 215, 220 as of 1.9.03 with CODE (819) 6-disk CD changer with CODE (819a) CD changer
Fig. 41: Identifying CD Player With Changer Location
CD player with changer, The CD player with changer

location (in trunk) (A2/6) is installed
in the trunk near the left side
wall.
The CD player with changer
is installed vertically at the
factory.
CD player with changer,  Play audio CDs with
task the appropriate file
format
 Change audio CDs
contained in the
magazine
CD player with changer,  CD changer magazine
design for 6 CDs
 MOST interface
(Media Oriented
System Transport)
CD player with changer, GF82.64-P-3113-02BA
function
CD player with changer, function - GF82.64-P-3113-02BA
CD player control
The CD player with changer (in the trunk) (A2/6) is controlled by the following components via the Media
Oriented System Transport (MOST) according to the vehicle equipment:
 Radio (A2)
The CD player outputs messages under the following operating conditions:
 No magazine in CD changer
 Magazine occupation (audio CDs only)
 Number of current CD
 Number of current title
 List of occupied CD places
 Number of titles per CD
 Current operating state (acoustic reproduction of radio signals, pause, etc.)
The messages are sent to the Media Oriented System Transport (MOST) and interpreted by the radio (A2) or
COMAND operating, display and control unit (A40/3).
CD playback
The audio data is stored digitally on the CD. The audio CD is driven by a motor in the CD player with changer
(in the trunk) (A2/6). The laser-optical device scans the side of the rotating CD with no label without touching
and converts the digital optical signals into electric signals. Small interruptions to the data flow to the laser
optics, caused by scratches or contamination on the audio CD, are subsequently interpolated by the DA
converter and thus compensated for. The electric signals in the CD changer are then decoded and transmitted
via the Media Oriented System Transport (MOST) depending upon the vehicle's equipment specification, to the
COMAND operating, display and control unit (A40/3n1), the radio (A2) or the sound amplifier (A2/13).
Jumps and interruptions during playback
When driving on poor roads and during hefty vibrations it may be that jumps and interruptions occur during
playback. In such cases, CD operation must wait until the road conditions improve. In wet weather or large
fluctuations in the ambient temperature moisture can accumulate in the housing of the CD player with changer
(in the trunk) (A2/6) (condensation formation). This may also lead to faults occurring during playback. In such
cases it must be ensured that there is sufficient ventilation of the CD player with changer (in the trunk) (A2/6)
and of the trunk itself.
Changing the magazine
The magazine can be accessed using a sliding flap. The user must slide back the flap and press the eject button
to remove the magazine. The magazine is always ejected when the eject button is pressed independent of the
operating status of the CD changer. This function is available as soon as Circuit 30 is ON.
CD PLAYER WITH CHANGER, LOCATION/TASK/DESIGN - GF82.64-P-3114B
MODEL 215, 220 up to 31.8.03 with CODE (819) 6-disk CD changer with CODE (819a) CD changer
Fig. 42: Identifying CD Changer Location
CD player with changer, The CD player with changer

location (in trunk) (A2/6) is installed
in the trunk near the left side
wall.
The CD player with changer
is installed vertically at the
factory.
CD player with changer,  Play audio CDs with
task the appropriate file
format
 Change audio CDs
contained in the
magazine
CD player with changer,  CD changer magazine
design for 6 CDs
 D2B interface (digital
data bus)
VOICE CONTROL SYSTEM (VCS [SBS]), FUNCTION - GF82.70-P-0002
Voice control system (VCS [SBS]), function - GF82.70-P-0002B
MODELS 140, 202,203 up to 23.4.04,208.3, 210,215, 220 up to 31.8.03 with CODE (813) Voice control
system (VCS)
Function
Up to 31.5.00 the voice control system (VCS) in models 140, 202, 208.3, 210, 215, 220 is a functional
extension of the existing telephone system with hands-free system.
As of 1.6.00 the voice control in models 202, 208.3, 210, 215, 220 as for model 203 is extended to include the
existing audio systems.
With VCS, it is possible to operate the car telephone or audio systems by voice without taking the hands from
the steering wheel.
The data transfer is:
 Analog/digital via Controller Area Network (data bus/CAN bus) (CAN) in Models 140, 210 up to 5/31/98
 Analog/digital via CAN and digital data bus (D2B) in Models 202, 203, 208.3, 210 as of 6/1/98, 203, 215,
220
Activation or deactivation are accomplished by actuating the VCS switch (S93/2). The user is acoustically
informed of the activation through a beep and in the event of deactivation via voice output. After an activation
all audio sources that can be influenced are automatically muted. The integrated functions for noise reduction
are intended to help minimize the error recognition rate of the system during voice entry by the user. This
allows driving noises to be recognized by the system and ignored. Moreover, after activation of the VCS, voice
recognition is activated.
Via the hands-free system microphone (B25), it is also possible to operate the systems using precisely defined
spoken commands. Here, voice input should be accomplished from the driver's side because the hands-free
system microphone (B25) points toward the driver.
Voice output can be adjusted using the volume control of the particular vehicle specific component of the audio
system. On models 203, 208.3, 210, 215 and 220 with multifunction steering wheel (MFL) it is also possible to
adjust the volume with the + and - buttons for adjustment of special functions and volume control (S111s1). In
addition to the manual volume setting, a noise-dependent volume control with 3 stages is present for voice
output by the VCS. This is dependent on the ambient noise in the vehicle. It is not possible to adjust the tone.
The VCS also contains a priority control, i.e. should higher, prioritized messages be issued by the voice input
during the operation of individual components of the communication or audio system, then the functions started
by the VCS are interrupted or skipped.
Voice control system (VCS), Model 140 GF82.70-P-0002-01B
arrangement of components Model 210 up to
31.5.98
Model 203 GF82.70-P-0002-01P
Models 202, 208.3, GF82.70-P-0002-01E
215, 220 up to 31.5.00
up to 31.5.00
Models 202.08/ 09/ 18, GF82.70-P-0002-01EA
208.3 from 1.6.00
Model 210 as of 1.6.00 GF82.70-P-0002-01EB
Models 215, 220 as of GF82.70-P-0002-
1.6.00 up to 31.8.03 01EC
Voice control system (VCS) Model 140 GF82.70-P-0002-02B
function diagram Model 210 up to
31.5.98
Models 202, 208.3, GF82.70-P-0002-02E
215, 220 up to 31.5.00
up to 31.5.00
Model 203 GF82.70-P-0002-02P
Models 202, 208.3, 210
as of 1.6.00
Models 215, 220 as of
1.6.00 up to 31.8.03
Activating/accepting call, GF82.70-P-2000B
function
Terminating/ending call, GF82.70-P-2001B
function
Dialing, function Selection and dialog GF82.70-P-3000B
with telephone system
Models 202.08 /09 /18 GF82.70-P-3000C
as of 1.6.00
Model 203
Models 208.3, 210 as
of 1.6.00
1.6.00 up to 31.8.03
Selection and dialog
with audio components
(radio, CD, cassette)
Voice control system (VCS), arrangement of components - GF82.70-P-0002-01E
Shown on model 202.0 (for 202.0, 208.3)

Fig. 43: Identifying Voice Control System (VCS), Arrangement Of Components (Model 202.0)
Fig. 44: Identifying Voice Control System (VCS), Arrangement Of Components (Model 202.1)
Shown on model 210.0 as of 1.6.98

Fig. 45: Identifying Voice Control System (VCS), Arrangement Of Components (Model 210.0 As Of
1.6.98)
Shown on model 210.2 as of 1.6.98
Fig. 46: Identifying Voice Control System (VCS), Arrangement Of Components (Model 210.2 As Of
1.6.98)

Fig. 47: Identifying Voice Control System (VCS), Arrangement Of Components (Model 215)
Shown on MODEL 220
Fig. 48: Identifying Voice Control System (VCS), Arrangement Of Components (Model 220)
Voice control system (VCS), arrangement of components - GF82.70-P-0002-01EC

Fig. 49: Identifying Voice Control System Arrangement Of Components - Illustrated On Model 215
Shown on MODEL 220
Fig. 50: Identifying Voice Control System Arrangement Of Components - Shown On Model 220
Voice control system (VCS) function diagram - GF82.70-P-0002-02E
Models 202, 208.3, 210 as of 1.6.98, 215, 220 with code 316 (MB D-network telephone (D2B))
Fig. 51: Identifying Voice Control System (VCS) Function Diagram (2 Of 5)
Models 202, 208.3, 210, 220 as of 1.6.98 with code 317 (D-net portable CTEL telephone (D2B))
Fig. 52: Identifying Voice Control System (VCS) Function Diagram (3 Of 5)
Voice control system (VCS) function diagram - GF82.70-P-0002-02P
Shown on model 220 with code (316) MB D-network telephone (D2B)
Fig. 53: Identifying Voice Control System Function Diagram - Shown On Model 220 With Code (316)
MB D-Network Telephone (D2B)
Shown on model 220 with code (317) D-net portable CTEL telephone (D2B)
Fig. 54: Identifying Voice Control System Function Diagram - Shown On Model 220 With Code (317) D-
Net Portable CTEL Telephone (D2B)
Voice control system (VCS [SBS]), function - GF82.70-P-0002M
MODELS 215.3, 220.0 /1 as of 1.9.03 with CODE (813) Voice control system (VCS)
Function
As part of the integrated communication and audio systems in the vehicle, a voice control system (VCS) is used
for the audio, communications and navigation systems.
Using the voice control system, spoken command sequences, that can be given without pretraining, i.e.
independently of the speaker, as well as names specified and trained by the user in the speaker dependent mode
can be recognized. The VCS contains a function for suppression of environmental noise, so that a voice
command is possible even at relatively loud driving noise.
On non-activated voice recognizers, vehicle noise can be filtered out from the microphone signals of the hands-
free system by means of high-performance noise suppression.
Thus, even with a relatively loud driving noise, a distinct improvement in hands-free speaking quality can be
achieved. With unclear speakers, the recognition rate can be influenced positively via subsequent training.
The objective of the voice activation system is to relieve the user during the drive and simultaneously increase
control comfort. Thus, the user has access to a number of functions via intuitive actuation. Distractions from the
traffic situation are reduced to a minimum.
Basic performance features of the VCS are:
 Operation of the telephone spectrum via voice command

 Improvement of hands-free speech quality during phone call through 4 microphones with noise
suppression and echo compensation
 Operation of the address book via voice command
 Operation of all audio components via voice command
 Operation of the navigation system via voice command
 Subsequent speaker training
 Voice output for dialog
 Help function for the user
Activation and deactivation is performed by actuating the VCS switch (S93/2); this is signaled to the user
during activation acoustically by means of a beep and for deactivation by means of voice output.
After the activation the radio is muted automatically. The volume setting can be changed by using the
appropriate volume at the appropriate control or via the + and a buttons, setting of specific functions and
volume control (S111s1) at the multifunction steering wheel. Adjustment of the tone and volume with the VCS
is not possible.
In addition to the manual volume setting, a noise-dependent volume control with 3 stages is present for voice
output by the VCS. It depends on the magnitude of the ambient noise level in the vehicle and cannot be
influenced by the user.
The VCS also contains a priority control, i.e. if collisions occur in the control of individual components in the
communication, navigation or audio system, any functions started by the VCS are discontinued or skipped.
Example: the navigation system attempts voice output while the VCS is involved in a dialog with the user. As
the spoken announcement of the navigation system has the highest priority of all systems, the dialog with the
voice control system is interrupted by the system, the spoken announcement (navigation) is made and the
system returns to the dialog (VCS) with the user.
The VCS is designed with a minimum boot software on the system when it is in mint condition. This makes
it possible to quickly boot the system. The actual application software for the particular language is loaded
during the production process. The same procedures are later used to update the VCS (e.g., changing the
language).
User guidance function
In addition to voice recognition the VCS also provides a voice output for user guidance. These outputs are
compressed texts that are recorded in a sound studio within a frequency range of 100 to 3500 Hz. The selection
includes a male and a female voice. The same announcers are used for the VCS and the navigation system.
Help menu, function
To provide a better access to more complex functionalities of the speech recognition systems, a comfortable
help function is required.
It is provided to the user in the following form:
 If an invalid command was entered 3 times.

 Through the "help" command, in which the help function is always executed dependent on the context.
In detailed form this means:
 If the help function is activated in the main menu via the "help" command, all components that can be
actuated via voice command are read aloud.
 If help is requested together with a keyword, such as "radio help", then the possible commands for the
control of the radio (e.g., "station search", "next station") are read aloud.
 If "help" is requested in a submenu without a keyword, only the corresponding menu-related commands
are read aloud.
The help function is executed such that the user is offered the most important commands (categorized according
to relationship and priority). At the end of the help function the VCS returns to the original dialog with the user.
It has to be observed when doing so that, after exiting the help function, the VCS returns to the state it was
in before the help function was activated. Driver requests have different effects depending on the state of the
system. The "radio" command normally switches to radio, however, in the help mode it activates the help texts
for radio control.
Voice control system (VCS), GF82.70-P-0002-01M

arrangement of components
Voice control system (VCS) GF82.70-P-0002-02M
function diagram
Activating/accepting call, GF82.70-P-2000M
function
Terminating/ending call, GF82.70-P-2001M
function
Navigation, function GF82.61-P-2003M
Dialing, function GF82.70-P-3000M
Telephone book, function GF82.70-P-3001M
Station list, function GF82.70-P-3002M
Voice control system (VCS), arrangement of components - GF82.70-P-0002-01M
Shown on model 220
Fig. 55: Identifying Voice Control System Components Arrangement - Shown On Model 220
Voice control system (VCS) function diagram - GF82.70-P-0002-02M

Fig. 56: Voice Control System Function Diagram
TELEPHONE, FUNCTION - GF82.70-P-0003
Telephone (D-network), function - GF82.70-P-0003C
MODEL 129 with CODE (274) MB D-network telephone with CODE (312) D-network portable CTEL
telephone with CODE (313) D-network portable CTEL telephone with CODE (314a) Standard D-
network telephone with CODE (316) MB D-network portable CTEL (D2B) with CODE (317) D-network
portable CTEL telephone (D2B) with CODE (853) MB standard telephone with CODE (854) MB
portable CTEL telephone
network telephone
telephone
MODEL 168 with CODE (312) GSM portable cellular telephone with CODE (317) GSM portable cellular
telephone (D2B) with CODE (854) MB portable cellular telephone
MODEL 170 with CODE (312) GSM portable cellular telephone with CODE (313) D-network portable
cellular telephone with CODE (314a) Standard D-network telephone with CODE (316) MB GSM cellular
telephone (D2B) with CODE (317) GSM portable cellular telephone (D2B)
MODEL 202 with CODE (274) MB D-network telephone with CODE (312) GSM portable cellular
network telephone with CODE (316) MB GSM CTEL telephone (D2B) with CODE (317) GSM portable
CTEL telephone (D2B)
MODEL 202.08 /09 /18 with CODE (854) MB portable CTEL
MODEL 203 with CODE (853) MB standard telephone with CODE (854) MB portable CTEL
MODEL 208 with CODE (274) MB D-network telephone with CODE (316) MB GSM cellular telephone
(D2B) with CODE (317) GSM portable cellular telephone (D2B) with CODE (853) MB standard cellular
telephone with CODE (854) MB portable cellular telephone
telephone with CODE (313) D-network portable cellular telephone with CODE (314a) Standard D-
network telephone with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM portable
cellular telephone (D2B) with CODE (853) MB standard cellular telephone with CODE (854) MB
portable cellular telephone with CODE (316) MB GSM cellular telephone (D2B)
MODEL 215 with CODE (317) GSM portable cellular telephone (D2B) with CODE (853) MB standard
cellular telephone with CODE (854) MB portable cellular telephone
MODEL 220 with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM portable
portable cellular telephone
Function of digital network

Fig. 57: Identifying Telephone (D-Network) Function
D-network, general
The D-network ( Digital network ) is made out according to the GSM standard ( Global S ystem for M obile
Communication.
This allows telephone calls to countries with networks which also operate according to the GSM standard and
whose users have a GSM telephone. Moreover, so-called "roaming contracts" between the countries exist to
regulate telephone traffic. The countries included in these contracts are listed in so-called "roaming lists".
The D-net itself has a honeycomb-type structure for the greatest possible area coverage for mobile subscribers
whereby some areas may no be covered. The individual cells have a radius of 100 m to 35 km. However, the
actual value may be less depending on the maximum traffic volume (e.g. in large cities) or the surface
characteristics (mountains, buildings, etc.). Transmission problems could occur if the user is located in valleys
(dead spot) or in areas with a small number of transmission and reception stations. This can, however, be
eliminated by moving to another location. Each cell has up to 16 carrier frequencies which allow up to seven
conversations per carrier frequency.
Transmission of the voice and data signals is accomplished digitally in the range of 900 -1900 MHz. It allows
increased security against tapping calls and provision of additional services such as:
 Fee display
 conference calls, waiting function
 identification of calling party
 call relaying
Moreover, with ISDN compatibility the D-network offers access possibilities to text and data stations
(corresponding adapters required).
The D-network requires the following operating units:
 Transmission and receiving terminal (BTS=B ase Transceiver S tation, per cell)
 Concentrator (BSC=B ase Station C ontroller, radio switching center, from the one cell to the other)
 Switching center (MSC=M obile S ervice Switching Center, from the one cell to the other)
Each transceiver station (BTS) is connected to the associated mobile service switching center (MSC) via a
concentrator (BSC). The connection between the base transceiver station (BTS) and concentrator (BSC) is
accomplished via radio signal (pulsed signal) and the connection from the concentrator (BSC) to the mobile
service switching center (MSC) via lines (permanently-wired 4-conductor cables).
The following units are included in the mobile switching center (MSC):
 (HLR=H ome L ocation R egister)

 (VLR=V isitor L ocation R egister)
 (AC=A uthentication C enter)
 Equipment identification register (EIR=E quipment I dentification R egister). Apart from this the mobile
service switching center (MSC) also forms the interface for switching the public service telephone
network (PSTN, in Germany to Deutsche Telekom).
The purpose of the units listed is explained in the following examples:
 Telephone (D-network) log-in

 Telephone (D-network) mobile subscriber to public telephone network
 Telephone (D-network) mobile subscriber to mobile subscriber
Each subscriber in the D-network is listed in his mobile service switching center (MSC) or the home location
register (HLR) stored for him. The network access authorization of the mobile subscriber is also checked in the
authentication center (AC) located there.
Moreover, defective or stolen units are identified in the equipment identification register (EIR). This ensures
that such units can be identified immediately when they log into the network. All subscribers from other home
location registers (HLR) or other networks are identified in the visitor location register (VLR)
It is possible to select between two versions:
 Permanently installed
 Portable CTEL
Telephone (D-network) log- GF82.70-P-0003-03C
in
Telephone (D-network), GF82.70-P-0003-04C
mobile subscriber on public
switched telephone network.
Telephone (D-network) GF82.70-P-0003-05C
mobile subscriber to mobile
subscriber
Telephone (D-network), Permanently installed GF82.70-P-0003CE
function MODEL 129, 140, 202,
210
with CODE (274) MB
D-network telephone
with CODE (314a)
Standard D-network
telephone
MODEL 170 with
CODE (314a) Standard
D-network telephone
MODEL 208 with
CODE (274) MB D-
network telephone
MODEL 129, 202, 208, GF82.70-P-0003CA
210, 215, 220 with
CODE (316) MB D-
network telephone
(D2B)
MODEL 129, 163, GF82.70-P-0003CB
202.08 /09 /18, 203, 208,
210, 215, 220 with
CODE (853) MB
standard telephone
Telephone (D-network), Portable CTEL GF82.70-P-0003CF
function MODEL 129, 140, 170,
202, 208, 210 with
CODE (312) D-network
portable CTEL
telephone
with CODE (313) D-
network portable CTEL
telephone
Model 168
with CODE (312) D-
telephone
MODEL 129, 168, 202, GF82.70-P-0003CC
208, 210, 215, 220 with
CODE (317) D-network
portable CTEL
telephone (D2B)
MODEL 129, 163, 168, GF82.70-P-0003CD
202.08 /09 /18, 203, 208,
210, 215, 220 with
CODE (854) MB
portable CTEL
telephone
Start-up/accepting GF82.70-P-2002C
call/completing telephone
call (D-network), function
Shut down/terminating GF82.70-P-2003C
telephone call (D-network),
function
Telephone (GSM), function - GF82.70-P-0003CA
MODEL 129, 202, 208, 210, 215, 220 with CODE (316) MB GSM cellular telephone (D2B)
fixed installation
Fixed installation, function (1st generation D2B-capable telephones)
A call can be set up in different ways depending on the model and equipment specification ( multifunction
steering wheel, voice control system ), provided that the PIN has been entered, the system logged in and ready
(switched on). If the telephone is not needed, it goes into standby mode. The telephone's On/Off
characteristics are controlled by the vehicle's Head Unit (COMAND or radio).
The telephone's transmitter/receiver unit is integrated into the vehicle's optical data bus (D2B) as is the Head
Unit.
The physical connection is made by way of an adapter ( D2B interface ).
The 1st generation of D2B capable telephone fixed systems (as of 1.6.98) the D2B interface (A59) is physically
separated from the CTEL transmitter / receiver (A35) in the vehicle.
Calls are transmitted via the vehicle's telephone antenna .
The differences in the antennas for the telephone systems result from vehicle-specific factors (convertible,
sedan, T-model etc.). This in turn requires the use of different vehicle antennas, speakers etc., depending upon
the type of (vehicle) antenna and its equipment specification an antenna splitter (A28/1) can also be used.
On all models it is possible to conduct a call via the vehicle's handsfree system which greatly enhances driving
safety. Here the call is conducted via the handsfree system microphone (B25) and the handsfree system
speaker , the handset remains in the receptacle. In this case the handset's display shows a sequence of displays,
which inform the user of the operating condition (e.g. menu selection) of the telephone.
In vehicles equipped with a multifunction display additional information is shown on the instrument cluster's
multifunction display, which informs the user about the telephone system's operating state.
The volume of the speaker on the handset and therefore the volume of the handsfree system can be individually
set by the user to suit on the handset, or if fitted by using the multifunction steering wheel.
In order to ensure that the user's voice input via the handsfree system's microphone is not distorted in any way,
the volume of an audio source that is active during the call (radio, COMAND) is automatically lowered for the
duration of the call.
Further information is available in each of the respective owner's manuals.
Telephone (D network) Model 129 as of GF82.70-P-0003-

Location of components 1.6.98 01D
Model 168 GF82.70-P-0003-
01GC
Model 170 GF82.70-P-0003-
01H
Model 202 as of GF82.70-P-0003-
1.6.98 01E
Model 208 GF82.70-P-0003-
01K
Model 210 as of GF82.70-P-0003-
1.6.98 01F
Model 215 GF82.70-P-0003-
01N
Model 220 GF82.70-P-0003-
01A
Telephone (D network), functional with codes 316/317 GF82.70-P-0003-
diagram Models 129 as of 02D
1.6.98, 168, 170, 202
as of 1.6.98, model
208, model 210 as of
1.6.98, model 215,
model 220
On / Off characteristics, function GF82.70-P-2005BA
Interface telephone, The D2B GF82.70-P-3107F
position/task/design/function interface and the
CTEL interface are
identical components
Position / task of handsfree microphone GF82.70-P-4102B
Position / task of handsfree speaker GF82.70-P-4103B
Telephone antenna, position/task GF82.62-P-4105C
Telephone handset (D network), GF82.70-P-4106C
position/task
CTEL transmitter / receiver (D GF82.70-P-4107C
network), position/task
Antenna splitter (D network), GF82.70-P-4109C
position/task
Portable cellular telephone (D GF82.70-P-4110C
Telephone (GSM), location of components - GF82.70-P-0003-01A
Model 220 with Codes 316/317
Fixed installation
Fig. 58: Identifying Telephone Components Location - Fixed Installation
Portable cellular telephone

Fig. 59: Identifying Telephone Components Location - Portable Cellular Telephone
Telephone (D-network), location of components - GF82.70-P-0003-01N
Model 215 up to 31.5.00 with code 316/317
Permanently installed telephone

Fig. 60: Identifying Telephone (D-Network) Components Location - Permanently Installed Telephone
Fig. 61: Identifying Telephone (D-Network) Components Location - Portable Cellular Telephone
Telephone (GSM), function description - GF82.70-P-0003-02D
Function schematic for permanently installed telephone
Fig. 62: Identifying Telephone (GSM), Function Description (1 Of 2)
Function schematic for "cellular telephone"

Fig. 63: Identifying Telephone (GSM), Function Description (2 Of 2)
Telephone (D network) function - GF82.70-P-0003CB
MODELS 129, 163, 203, 208, 210, 215, 220 with CODE (853) MB standard cellular telephone
fixed installation
Permanently installed telephone, function
Installation differs according to model and equipment ( multifunction steering wheel, voice control system ),
a prerequisite being that the system is ready for operation (switched on) after entering the PIN and logging in. If
the CTEL is not required, then it switches into standby mode. The telephone is switched on and off by the
vehicle head unit (COMAND, radio).
The telephone transmitter/receiver is connected to the vehicle optical data bus (D2B) just as is the head unit.
The physical connection is accomplished over an adapter ( D2B interface ).
In the 1st generation of the fixed telephone system with D2B capability (as of 1.6.98) the D2B interface for
fixed installation telephone (A59) is physically separated from the transmitter/receiver (A35) in the vehicle.
From the 2nd generation onward (as of 1.6.00) the interface is integrated in the D2B telephone
transmitter/receiver (A35/13) .
Calls are made via the telephone antenna .

Differences in antennae in the CTEL systems are a consequence of vehicle-specific conditions (convertible,
sedan, T-model etc.). This means that different car antennas, speakers, etc. have to be used, and depending on
the type of (vehicle) antenna and equipment, the antenna splitter (A28/1) may be required.
On all models, there is the facility of being able to hold conversation via the hands-free system of the vehicle
which is beneficial to driving safety. In this case, the call is made via the hands-free system microphone (B25)
and the hands-free system speaker , and the handset remains in the cradle.
The handset display shows a series of messages that provide the user with information about the operating
condition (e.g. menu selection) of the telephone.
In vehicles with a multifunction display, information also appears on the instrument cluster multifunction
display that informs the user of the operating condition of the telephone system.
The volume of the loudspeaker on the handset and therefore also of the hands-free system can be adjusted
individually by the user at the handset or the multifunction steering wheel (if present).
To ensure user voice input which is as clear as possible via the hands-free system microphone, the volume of
the audio source (radio, COMAND) switched on is reduced automatically during a call.
Additional information is contained in the applicable operating instructions.
Telephone (D- Model 129 as of 1.6.00 with codes 853, GF82.70-P-0003-

network), Arrangement 854. 01DA
of components
Model 163 with CODES 853, 854. GF82.70-P-0003-
01Q
Models 202.08/09/18 as of 1.6.00 with GF82.70-P-0003-
code 854. 01EA
Model 203 up to 30.6.02 with codes GF82.70-P-0003-
853/854 01P
Models 209.316/342/ 343/361/365/
375/376 with codes 853854
Model 203 as of 1.7.02 with codes 853, GF82.70-P-0003-
854 01PA
Model 208 with CODES 853, 854. GF82.70-P-0003-
01KA
854 01FA
Model 215 as of 1.6.00 up to 31.8.02 with GF82.70-P-0003-
code 853/854 01NA
854 01NB
Model 220 with codes 316, 317. GF82.70-P-0003-
01A
Model 220 up to 31.8.02 with codes 853, GF82.70-P-0003-
854 01AA
854 01AB
Telephone (D-network) MODEL 129, 163, 203, 210, 215, 220 GF82.70-P-0003-
block diagram with CODE (853) MB telephone Standard 06AA
MODELS, 129 //, 203, 210, 215, 220 with
CODE (853) MB portable CTEL, with
CODE (813) voice control system (VCS).
Telephone (D- MODELS 129, 163, 203, 210, 215, 220 as GF82.70-P-0003-
network), function of 1.6.00 02P
schematic with CODE (853) MB standard telephone,
with CODE (854) MB portable CTEL.
Model 168 as of 202.08 09 18 with CODE
(854)
MB portable CTEL
Models
209.316/342/343/361/365/375/376
with CODE (853) MB standard telephone,
with CODE (854) MB Portable CTEL.
Switch-on/off MODELS 129, 163, 203, 208, 210, 215, GF82.70-P-2005B
characteristics, function 220, 209.316/342/343/361/365/375/376
with CODE (853) MB standard cellular
telephone
with CODE (854) MB portable cellular
telephone
Hands-free Model 129 with CODES 274, 312, 313, GF82.70-P-4102B
microphone, 314a, 316, 317, 853, 854.
location/purpose Model 140 with CODES 274, 312, 313,
314a.
Model 163 with CODES 853, 854.
Model 168 with CODES 312, 317, 854.
Model 170 with CODES, 312, 313, 314a,
316, 317.
Model 202 with CODES 274, 312, 313,
314a, 316, 317, 854.
Model 208 with CODES, 274, 316, 317,
853, 854.
314a, 316, 317, 853, 854.
854.
854.
Hands-free system Model 129 with CODES 274, 312, 313, GF82.70-P-4103B
loudspeaker, 314a, 316, 317, 853, 854.
location/task Model 140 with CODES 274, 312, 313,
314a.
316, 317.
314a, 316, 317, 854.
Model 208 with CODES, 274, 316, 317,
853, 854.
314a, 316, 317, 853, 854.
854.
854.
Models
209.316/342/343/361/365/375/376 with
CODES 853, 854.
CTEL antenna, Model 129 with CODES 274, 312, 313, GF82.62-P-
location/task 314a, 316, 317. 4105C
314a.
316, 317.
314a, 316, 317.
314a, 316, 317.
Model 220 with codes 316, 317.
Telephone handset (D- Model 129 with CODES 274, 314a, 316, GF82.70-P-
network), location/task 853. 4106C
MODEL 140 with CODES 274, 314a.
Model 170 with CODES 314a, 316.
Model 202 with CODES 274, 314a, 316.
Model 210 with CODES 274, 314a, 316,
853.
Telephone Models 129, 163, 203, 208, 210, 215, 220 GF82.70-P-
transmitter/receiver (D- with Code (853) MB standard telephone. 4107D
network), location/task
Antenna splitter (D- Model 129 with CODE (274) MB D- GF82.70-P-4109C
network), location/task network telephone
with CODE (312) D-network portable
CTEL, with CODE (313) D-network
"portable CTEL", with CODE (314a) D-
network "standard" telephone, with
CODE (316) MB D-network telephone
(D2B), with CODE (317) D-network
portable CTEL (D2B).
Model 140 with CODE (274) MB D-
network telephone with CODE (312) D-
network portable CTEL, with CODE
(313) D-network "portable CTEL", with
CODE (314a) D-network "standard"
telephone.
MODEL, 202, with code (313) MB D-
network telephone with code (314a)
Standard D-network telephone with code
(312) MB D-network telephone B
MODEL 208.4 with CODE (274) MB D-
network telephone
Model 210 up to 31.12.96
Portable cellular Model 129 with CODES 312, 313, 317, GF82.70-P-
telephone (D-network), 854. 4110C
location/task Model 140 with CODES 312, 313.
Models 202/08 /09 /18 with CODE 854.
854.
Telephone (D-Network), location of components - GF82.70-P-0003-01AA
Model 220 up to 31.8.02 with code 853/854

Fig. 64: Identifying Telephone Components Location - Permanently Installed Telephone
Fig. 65: Identifying Telephone Components Location - Portable Cellular Telephone

Telephone (D-Network), location of components - GF82.70-P-0003-01AB
Model 220 as of 1.9.02 with code 853/854

The stowage compartment in the center armrest has been modified. The telephone handset (A34) and the
portable CTEL (A34/6) are no longer in the stowage compartment but on a console in the separate small flap in
the armrest (formerly the cup holder).
Telephone (D-Network), location of components with code - GF82.70-P-0003-01NA
Model 215 as of 1.6.00 up to 31.8.02 853/854

Telephone (D-Network), location of components - GF82.70-P-0003-01NB
Model 215 as of 1.9.02 with code 853/854

Telephone (D-network), function schematic - GF82.70-P-0003-02P
MB Standard telephone code (853), illustrated on model 210
Fig. 72: Identifying Telephone (D-Network), Function Schematic - MB Standard Telephone Code (853),
On model 209.4 the telephone antenna is integrated into the trunk lid.
MB portable CTEL code (854), illustrated on model 210
Fig. 73: Identifying Telephone (D-Network), Function Schematic - MB Portable CTEL Code (854),
On model 209.4 the telephone antenna is integrated into the trunk lid.
Telephone (D-network), block diagram - GF82.70-P-0003-06AA
Fixed installation without voice control system (shown on model 203)
Fig. 74: Identifying Telephone (D-Network), Block Diagram - Fixed Installation Without Voice Control
System (Shown On Model 203)
Fixed installation with voice control system (shown on model 203)

Fig. 75: Identifying Telephone (D-Network), Block Diagram - Fixed Installation With Voice Control
System (Shown On Model 203)
Telephone (GSM), function - GF82.70-P-0003CC
MODELS 129, 168, 202, 208, 210, 215, 220 with CODE (317) GSM portable cellular telephone (D2B)
Portable cellular telephone, function
A call can be set up in different ways depending on the model and equipment specification (multifunction
steering wheel, voice control system), provided that the PIN has been entered, the system logged in and ready
(switched on). If the telephone is not needed, it goes into standby mode. The telephone's On/Off
characteristics are controlled by the vehicle's Head Unit (COMAND, radio).
The portable cellular telephone's is integrated into the vehicle's optical data bus (D2B) as is the Head Unit.
The physical connection is made by way of an adapter, D2B interface portable cellular telephone (A59/1) .
Incoming and outgoing calls are transmitted via the telephone antenna . There are differences in the telephone
systems resulting from vehicle-specific factors (convertible, sedan, T-model etc.). This in turn requires the use
of different vehicle antennas, speakers etc., depending upon the type of (vehicle) antenna equipment
specification an antenna splitter can be used (A28/1) .
On all models it is possible to conduct a call via the vehicle's handsfree system which greatly enhances driving
safety. Here the call is conducted via the handsfree system microphone (B25) and the handsfree system
speaker , the portable cellular telephone remains in the receptacle.
In this case the various displays (portable cellular telephone, instrument cluster, COMAND, radio) show a
sequence of displays, which inform the user of the operating condition (e.g. menu selection) of the telephone.
The volume of the speaker on the portable cellular telephone and therefore the volume of the handsfree system
can be individually set by the user to suit on the portable cellular telephone, or if fitted by using the
multifunction steering wheel.
In order to ensure that the user's voice input via the handsfree system's microphone is not distorted in any way,
the volume of an audio source that is active during the call (radio, COMAND) is automatically lowered for the
duration of the call.
Further information is available in each of the respective owner's manuals.
Telephone (D network) Model 129 GF82.70-P-0003-

Location of components 01D
Model 168 GF82.70-P-0003-
01GC
Model 170 GF82.70-P-0003-
01K
Model 202 GF82.70-P-0003-
01E
Model 208 GF82.70-P-0003-
01K
Model 210 GF82.70-P-0003-
01F
Model 215 GF82.70-P-0003-
01N
Model 220 GF82.70-P-0003-
01A
Telephone (D network), functional GF82.70-P-0003-
diagram 02D
On / Off characteristics, function GF82.70-P-2005AA
Interface telephone, Models 129, 168, GF82.70-P-3107E
position/task/design/function 170, 202, 208, 210,
215, 220 with code
317 (portable
cellular telephone)
Handsfree microphone, position/task GF82.70-P-4102B
Handsfree speaker, position/task GF82.70-P-4103B
Telephone antenna, position/task GF82.62-P-4105C
Antenna splitter (D network), GF82.70-P-4109C
position/task
Portable cellular telephone (D GF82.70-P-4110C
Telephone (D network) function - GF82.70-P-0003CD
MODELS 129, 163, 168, 202.08 /09 /18, 203, 208, 210, 215, 220 with CODE (854) MB portable cellular
telephone
Portable cellular telephone, function
Installation differs according to the model and equipment (multifunction steering wheel, voice control system),
a prerequisite being that the system is ready for operation (switched on) after entering the PIN and logging in. If
the CTEL is not required, then it switches into standby mode. The telephone is switched on and off by the
vehicle head unit (COMAND, radio).
The portable cellular telephone is connected to the vehicle optical data bus (D2B) just as is the head unit.
The physical connection takes place via an adapter, the CTEL [TEL] interface (A34/4) .
Incoming and outgoing calls are transmitted via the telephone antenna . Differences in the CTEL systems are a
consequence of vehicle-specific conditions (convertible, sedan, T-model etc.). This means that different car
antennas, speakers, etc. have to be used, and depending on the model and equipment, the antenna splitter
(A28/1) may be required.
It is possible for all models to conduct calls using the vehicle's hands-free system, which greatly enhances
driving safety. In this case, the call is made via the hands-free system microphone (B25) and the hands-free
system speaker , and the portable CTEL remains in the cradle.
The displays (handset, portable cellular telephone, instrument cluster, COMAND, radio) indicate a number of
messages informing the user of the operating state (e.g. menu selection) of the telephone.
The volume of the portable cellular telephone loudspeaker and of the hands-free system can be adjusted
individually by the user at the portable cellular telephone or with the multifunction steering wheel (if installed).
To ensure user voice input which is as clear as possible via the hands-free system microphone, the volume of
the audio source (radio, COMAND) switched on is reduced automatically during a call.
With the new generation of telephones (Nokia) the user can switch networks (D-network or E-network). This is
possible by installing the E-net compensator (A28/3) .
Additional information is contained in the applicable operating instructions.
Telephone (D-network), Model 129 as of 1.6.00 with codes GF82.70-P-

Arrangement of components 853, 854. 0003-01DA
Model 163 with CODES 853, 854. GF82.70-P-
0003-01Q
Model 168 with code 854 GF82.70-P-
0003-01GD
Models 202.08/09/18 as of 1.6.00 GF82.70-P-
with code 854. 0003-01EA
Model 203 up to 30.6.02 with codes GF82.70-P-
853, 854. 0003-01P
Models
209.316/342/343/361/365/375/376
with codes 853, 854.
Model 203 as of 1.7.02 with codes GF82.70-P-
853, 854 0003-01PA
0003-01KA
853, 854 0003-01FA
Model 215 as of 1.6.00 up to 31.8.02 GF82.70-P-
with code 853/854 0003-01NA
853, 854 0003-01NB
853, 854 0003-01AA
853, 854 0003-01AB
Telephone (D-network) block MODEL 129163, 168, 202.08 /09 /, GF82.70-P-
diagram 18, 203, 210, 215, 220 with CODE 0003-06A
(854) MB portable cellular telephone
MODELS 129202.08 09 18, 203,
210, 215, 220 with CODE (854) MB
standard telephone, with CODE (813)
voice control system (VCS).
Models
209.316/342/343/361/365/375/376
Telephone (D-network), MODELS 129, 163, 203, 210, 215, GF82.70-P-
function schematic 220 as of 1.6.00 with CODE (853) 0003-02P
MB standard telephone, with CODE
(854) MB portable CTEL.
Model 168 as of 202.08 09 18 with
CODE (854) MB portable CTEL
Models
209.316/342/343/361/365/375/376
with CODES 853, 854.
Switch-on/off characteristics, MODELS 129, 163, 203, 208, 210, GF82.70-P-
function 215, 220, 2005B
209.316/342/343/361/365/375/376
Telephone interface, Models 129, 163, 168, 202.08 /09 /18, GF82.70-P-
location/task/design/function 203, 208, 210, 215, 220 with code 3107P
854.
Compensator, location/task Models 129, 163, 168, 202.08 /09 /18, GF82.70-P-
203, 208.3, 210, 215, 220 with code 3109P
854.
Hands-free microphone, Model 129 with CODES 274, 312, GF82.70-P-
location/purpose 313, 314a, 316, 317, 853, 854. 4102B
Model 140 with CODES 274, 312,
313, 314a.
854.
Model 170 with CODES, 312, 313,
314a, 316, 317.
313, 314a, 316, 317, 854.
854.
317, 853, 854.
313, 314a, 316, 317, 853, 854.
853, 854.
853, 854.
Hands-free system loudspeaker, Model 129 with CODES 274, 312, GF82.70-P-
location/task 313, 314a, 316, 317, 853, 854. 4103B
313, 314a.
854.
314a, 316, 317.
313, 314a, 316, 317, 854.
317, 853, 854.
313, 314a, 316, 317, 853, 854.
853, 854.
853, 854.
Models
209.316/342/343/361/365/375/376
with CODES 853, 854.
CTEL antenna, location/task Model 129 with CODES 274, 312, GF82.62-P-
313, 314a, 316, 317. 4105C
313, 314a.
314a, 316, 317.
313, 314a, 316, 317.
317.
313, 314a, 316, 317.
Model 220 with codes 316, 317.
Antenna splitter (D-network), Model 129 with CODE (274) MB D- GF82.70-P-
location/task network telephone 4109C
with CODE (312) D-network portable
"portable CTEL", with CODE (314a)
D-network "standard" telephone, with
CODE (316) MB D-network
telephone (D2B), with CODE (317)
D-network portable CTEL (D2B).
Model 140 with CODE (274) MB D-
network telephone with CODE (312)
D-network portable CTEL, with
CODE (313) D-network "portable
CTEL", with CODE (314a) D-
network "standard" telephone.
MODEL, 202, with code (313) MB
D-network telephone with code
(314a) Standard D-network telephone
with code (312) MB D-network
telephone B
MODEL 208.4 with CODE (274) MB
D-network telephone
Model 210 up to 31.12.96
Portable cellular telephone (D- Model 129 with CODES 312, 313, GF82.70-P-
network), location/task 317, 854. 4110C
854.
317.
Model 202 with code 312,313,317
Model 202.08 /09 /18 with CODES
854.
Telephone (D-network), block diagram - GF82.70-P-0003-06A
Portable CTEL, illustrated on model 203
Fig. 76: Identifying Telephone (D-Network), Block Diagram - Portable CTEL, Illustrated On Model 203
Portable CTEL with VCS illustrated on model 203
Fig. 77: Identifying Telephone (D-Network), Block Diagram - Portable CTEL With VCS Illustrated On
Model 203
Fixed installation without VCS illustrated on model 203

Fig. 78: Identifying Telephone (D-Network), Block Diagram - Fixed Installation Without VCS Illustrated
On Model 203
Fixed installation with VCS illustrated on model 203
Fig. 79: Identifying Telephone (D-Network), Block Diagram - Fixed Installation With VCS Illustrated On
Model 203
UNIVERSAL PORTABLE CTEL INTERFACE (UPCI), FUNCTION - GF82.70-P-0004S
 Voltage supply OK.

 MOST ring active.
 Portable CTEL (A34/6) inserted in the UPCI Portable CTEL receiver (Universal Portable CTEL
Interface) (A34/15).
 Enabled SIM card inserted into the portable CTEL (A34/6).
 Correct entry of PIN and successful log-in into the particular network of the service provider.
With the Universal Portable CTEL Interface system (UPCI), all phone calls with the portable CTEL
(A34/6) take place exclusively via the hands-free system.
Calling in "private mode" is only possible with the rear telephone handset (A34/8) (model 220 only).
The universal Portable CTEL Interface (UPCI) control unit (N123/1) makes it possible to alternatively operate
different portable CTELs (A34/6), e.g., Nokia, Siemens, and Motorola, in the vehicle.
To do this, the particular UHI portable CTEL holder (Universal Portable CTEL Interface) (A34/15) has to be
replaced.
Besides, it is also possible to operate Bluetooth-capable devices (e.g., rear telephone handset (A34/8)) (not with
USA version).
The Universal portable CTEL Interface system (UPCI) consists of the following components:
 Universal Portable CTEL Interface (UPCI) control unit (N123/1)

 UHI portable CTEL holder (Universal Portable CTEL Interface) (A34/15)
 Telephone antenna (A2/22 (model 215), A2/49a1 (model 220))
 Telephone/portable CTEL/STH radio remote control antenna splitter (A2/53)
 CTEL compensator (A28/3)
 Portable CTEL (A34/6)
 Handsfree microphone (B25)
 Bluetooth antenna (A2/91) (not with USA version)
 COMAND operating, display and control unit (A40/3) with code (527) COMAND APS (with
navigation).
The particular Portable CTEL (A34/6) is connected to the Media Oriented System Transport (MOST) of the
vehicle via the UHI portable CTEL holder (Universal Portable CTEL Interface) (A34/15) and the Universal
Portable CTEL Interface (UPCI) control unit (N123/1).
The Universal Portable CTEL Interface system (UPCI) includes the following functions:
 Establishing the telephone connections in hands-free mode.

 Establishing the telephone connections in "private mode" (Bluetooth) (not with USA version).
(Only possible with the rear telephone handset (A34/8)).

 WAP (Wireless Application Protocol) (is shown via the portable CTEL (A34/6) only in the display of the
COMAND operating, display and control unit (A40/3)).
 Displaying telephone numbers and call recognition.
 Showing stored telephone numbers from the portable CTEL (A34/6) in the multifunction display (A1p13)
of the instrument cluster (A1) (selection of the menu item "TEL" using the system selection button
(S110s3) and browsing (telephone book function) with the scroll forward/back button (S110s1)).
The Universal portable CTEL Interface system (UPCI) is activated using the on/off button of the portable CTEL
(A34/6).
There is also the option to activate the system automatically through a wake-up pulse via the MOST ring. It can
be started via status "circuit 15 ON", or with Code (527) COMAND APS (with navigation) via the COMAND
operating, display and control unit (A40/3).
The Universal portable CTEL Interface system (UPCI) is deactivated using the on/off button of the portable
CTEL (A34/6) or automatically based on the run-on time set at the portable CTEL (A34/6).
The voice input takes place via the hands-free system microphone (B25). If a voice control system control unit
(A35/11) is installed with code (813) voice control system (VCS), the voice input is transmitted through this
system and the MOST ring to the universal Portable CTEL Interface (UPCI [UHI]) control unit (N123/1).
The voice output takes place via the speaker system. To ensure the greatest possible stability of user voice input
of the user via the hands-free system microphone (B25), the volume of an active audio source (e.g. the CD
player with changer (in trunk) (A2/6)) is automatically muted during a telephone call. The volume of the
speaker system can be adjusted individually by the user. This is possible with the aid of the + and a buttons
integrated in the multifunction steering wheel (MFL), for the adjustment of specific functions and the volume
control (S111s1), or via the portable CTEL (A34/6).
Additional functions can be carried out with the aid of additional buttons at the multifunction steering wheel
(MFL):
 Scroll forward/back pushbutton (S110s1)

 System selection button (S110s3)
 Accept/terminate phone call button (S111s3)
This is shown through a number of displays that inform the user of the operating condition (e.g. "ENTER PIN")
of the portable CTEL (A34/6) in the displays of the following components:
 Portable CTEL (A34/6)

 Multifunction display (A1p13) in the instrument cluster (A1)
 with code (527) COMAND APS (with navigation) in the display of the COMAND operating, display and
control unit (A40/3)
The Universal Portable CTEL Interface system (UPCI) is compatible with the D-net and the E-net. This is
made possible by the installation of the E-net compensator (A28/3), which compensates the damping that occurs
through the higher transmission frequency of the E-net.
Universal Portable CTEL Interface GF82.70-P-0004-01S

(UPCI), location of components
Switch on/off characteristics of the GF82.70-P-2007S
telephone function
Establishing/terminating a call, GF82.70-P-2008S
telephone function
Accepting a call, telephone GF82.70-P-2009S
function
Universal Portable CTEL Interface (UPCI), location of components - GF82.70-P-0004-01S
Shown on model 215
Fig. 80: Identifying Universal Portable CTEL Interface Components Location - Shown On Model 215
Shown on model 220

Fig. 81: Identifying Universal Portable CTEL Interface Components Location - Shown On Model 220
TELEPHONE (CELLULAR MOBILE TELEPHONE NETWORK), FUNCTION, SCOPE - GF82.70-P-

0005S
MODELS 215, 220 with CODE (388) "Portable CTEL" UPCI telephone system
Function of the cellular mobile telephone network

Fig. 82: Cellular Mobile Telephone Network Function Diagram
Cellular mobile telephone network, scope
The cellular mobile telephone network is a digital, cellular radio telephone network based on GSM standard
(G lobal S ystem M obile). The GSM standard provides the standardization of a cellular mobile telephone
system. The goal is to offer a world-wide compatible digital cellular mobile telephone service. The system
digitally transmits the switching of calls, the language and the data. Furthermore, additional services are offered
such as:
 Fee display
 conference calls, waiting function
 identification of calling party
 call relaying
 Fax
 access to text stations and terminals (ISDN-compatible)
The radio transmission in the cellular mobile telephone network takes place depending on the provider or
country in the range of 900 - 1900 MHz between portable CTEL and base transceiver station (BTS) .
Starting at the base transceiver station, all signals are transmitted via cable to the base station controller
(BSC) .
With the cellular mobile telephone network, the base transceiver stations are located so as to create a network of
the mobile subscribers from the honeycomb-shaped radio frequency cells. Radio frequency cells have to work
for a high density of subscribers in densely populated areas, and on the other hand they have to cover large
radio frequency ranges in rural areas. Depending on the requests, these radio frequency cells range between 100
m and 40 km.
A feature of the cellular mobile telephone network is the automatic transmission procedure (handover) from one
radio frequency cell to the next, without the mobile telephone subscriber noticing anything.
If, during a telephone call, the subscriber leaves the range of reach of a base transceiver station and then moves
into the transmission range of the next base transceiver station, the communication can continue without
interruption, although the transmitter of the next base transceiver station uses a different frequency.
This transmission procedure takes place within 5 ms to 10 ms.
Transmission problems could occur if the user is located in valleys (dead spot) or in areas with a small number
of transmission and reception stations. This can, however, be eliminated by moving to another location.
It is possible to make a telephone call with the own cellular phone and SIM card (S ubscriber I dentity M
odule) abroad. The prerequisite is that the particular country offers the GSM standard, that there is a
corresponding contract (roaming contract) between the country and the network operator and that the cellular
phone is dual-band or tri-band capable according to the different frequencies.
A radio frequency cell is formed by the base transceiver station and is the actual transmitting/receiving terminal.
The base transceiver station establishes the connection to the cellular phones, checks the radio transmission and
transmits the information via cable to the base station controller.
With the GSM standard, there are 124 or 372 channels for each base transceiver station depending on the
frequency.
The base station controller is the control unit of the base transceiver station. The base station controller is
switched between the base transceiver stations and the mobile switching center (MSC) . The data for the
language and data communication, as well as monitoring and control information is transmitted here.
Furthermore, the base station controller is the central control point for the automatic transmission method
(handover) from one radio frequency cell to the next.
The cellular mobile switching centers are linked to one another and form the switching system in the mobile
telephone networks with GSM standard. The user and visitor data is stored in different databases and
directories.
Databases and directories in the mobile switching centers (MSC).
 Home location register (HLR)
The following are stored here: subscriber master data such as name, address, telephone number, service
features, number of the caller and party being called, information on time, duration, and fees for the call
as well as data about the radio cells in which a connection was established or terminated.
 Equipment information register (EIR)

The device-specific, electronic identification numbers (IMEI number) of the cellular phones are registered
here. The cellular phone transmits this number during log-in. If the cellular phone has been
disabled/stolen, network access will be denied if applicable.
 Visitor location register (VLR)
The necessary data of a visiting subscriber are stored here for a limited time.
 Authentication center (AC)
Here, the access authorization of the mobile subscriber is checked and the corresponding connection is
established.
The entirety of the public telephone network is called public switched telephone network (PSTN) .
Table of contents for GF82.70-P-0996S

function description of
the Universal Portable
CTEL Interface (UPCI)
Telephone (cellular GF82.70-P-0005-01S
mobile telephone
network) log-in
Telephone (cellular GF82.70-P-0005-02S
mobile telephone
network) cellular mobile
telephone subscribers in
the public telephone
network
Cellular mobile telephone GF82.70-P-0005-03S
subscriber (mobile
telephone network) to
cellular mobile telephone
subscriber
Telephone (cellular mobile telephone network) log-in - GF82.70-P-0005-01S

Fig. 83: Identifying Cellular Mobile Telephone Network Log-In
Cellular mobile telephone network log-in
Requirements:
 SIM card is inserted

 Device is switched on (on/off button)
Enter the personal PIN number (Personal Identification Number) if required (depends on the system). Next, the
telephone establishes a connection with the most favorably located base transceiver station (BTS) and
transmits the data via the base station controller (BSC) to the mobile service switching center (MSC) . The
access to the network is granted when the MCS has checked the required data. After a successful log-in, the
display of the telephone shows the name of the network (e.g: D1 or O2 etc.).
If the closest MSC is not the one in which the user was entered as a cellular mobile telephone subscriber when
he/she registered his/her cellular phone in the home location register (HLR) , then he/she is listed in the
visitor location register (VLR) that is located there. The MSC mentioned then connects to the MSC of the user
in which he/she is registered as a cellular mobile telephone subscriber in the HLR and access is granted after
checking the required data. The MSC thus automatically obtains information on the location of the subscriber
and can route incoming telephone calls to him/her while he/she is logged into the network. Any change of
location is updated in the MSC.
Cellular mobile telephone subscribers in the public telephone network - GF82.70-P-0005-02S

Fig. 84: Identifying Cellular Mobile Telephone Subscribers In Public Telephone Network
Cellular mobile telephone subscribers in the public telephone network
If the log-in process via the base transceiver station (BTS) , the base station controller (BSC) and the
particular mobile service switching center (MSC) with verification of access authorization through the
authentication center (AC) has been completed, the cellular mobile telephone subscriber can dial the number
of the desired party to be called by entering a telephone number.
If the cellular mobile telephone subscriber is authorized, the MSC feeds the call into the public telephone
network through the public switched telephone network (PSTN) .
Cellular mobile telephone subscriber to cellular mobile telephone subscriber - GF82.70-P-0005-03S

Fig. 85: Identifying Cellular Mobile Telephone Subscriber To Cellular Mobile Telephone Subscriber
Cellular mobile telephone subscriber to cellular mobile telephone subscriber
Cellular mobile telephone subscribers (A) and (B) have logged into the cellular mobile telephone network
outside of the reception range of their (home) mobile switching center (MSC) . They are then logged into the
best located base transceiver station (BTS) and base station controller (BSC) in the closest (external) MSC
and registered in the home location register (HLR) there. The (external) MSC automatically gets in contact
with the responsible (home) MSC (MSC, A is not shown) and provides information on the current location of
the subscriber. The location of the corresponding mobile subscriber is then registered in both MSCs. If cellular
mobile telephone subscriber (A) wants to establish a telephone connection with cellular mobile telephone
subscriber (B), he/she enters his/her number.
This number allows determination of the location of mobile subscriber (B) by his (home) MSC. With the
information on the location, the system then transmits the call from cellular mobile telephone subscriber (A) to
cellular mobile telephone subscriber (B) via the best communication path. During a call the system
automatically continues to search for the best communication possibility to minimize transmission losses.
The communication path is therefore subdivided into the radio telephone network path:
 cellular mobile telephone

 base transceiver station (BTS)
 base station controller (BSC)
 mobile service switching center (MSC)
 mobile service switching center (MSC-B)
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF THE UNIVERSAL PORTABLE CTEL
INTERFACE (UPCI) - GF82.70-P-0996S
Universal Portable CTEL Interface GF82.70-P-0004-

(UPCI), location of components 01S
Universal Portable CTEL Interface GF82.70-P-0004S
(UPCI), function
Switch on/off characteristics of GF82.70-P-2007S
telephone, function
Establishing/terminating a call, GF82.70-P-2008S
telephone, function
Accepting a call, telephone, function GF82.70-P-2009S
Telephone (cellular mobile telephone GF82.70-P-0005S
network), function, scope
Overview of system components of the GF82.70-P-9996S
Universal Portable CTEL Interface
(UPCI), location/task/design/function
CONTENTS FUNCTION DESCRIPTION TELEPHONE (GSM) - GF82.70-P-0998ZZ
network telephone
telephone
cellular telephone (D2B)
MODEL 202.08 /09 /18 with CODE (854) MB portable cellular telephone
MODEL 203 with CODE (853) MB standard telephone with CODE (854) MB portable cellular telephone
Telephone (GSM), function General GF82.70-P-

0003C
Telephone (GSM), function Permanently installed
MODEL 129 with CODES 274, 314a. GF82.70-P-
MODEL 140 with CODES 274, 314a. 0003CE
MODEL 170 with CODE 314a.
MODEL 208 with CODE 274
MODELS 129, 202, 208, 210, 215, GF82.70-P-
220 with CODE 316. 0003CA
MODEL 129, 163, 203, 208, 210, GF82.70-P-
215, 220 with CODE 853. 0003CB
Telephone (GSM), function Portable CTEL
MODELS 129, 140, 202, 210 GF82.70-P-
with CODE (312) D-network portable 0003CF
"portable CTEL".
MODELS 129, 168, 202, 208, 210, GF82.70-P-
215, 220 with CODE (317) D- 0003CC
network portable CTEL (D2B).
MODELS 129, 163, 168, GF82.70-P-
202.08 /09 /18, 203, 208, 210, 215, 0003CD
220 with CODE (854) MB portable
CTEL.
Telephone (D-network), Model 129 up to 31.5.98 with codes GF82.70-P-
Arrangement of components 274, 312, 313, 314a. 0003-01C
Model 202 up to 31.5.98 with codes
312, 313, 314a.
Model 210 up to 31.5.98 with codes
274, 312, 313, 314a.
Model 140 with codes 274, 312, 313,
314a.
316, 317 0003-01D
853, 854. 0003-01DA
Model 163 with codes 853, 854. GF82.70-P-
0003-01Q
Model 168 with code 317 GF82.70-P-
0003-01GC
Model 168 with CODE 854 GF82.70-P-
0003-01GD
0003-01H
Model 202 from 1.6.98 to 31.5.00 GF82.70-P-
with codes 316, 317. 0003-01E
Models 202.08/09/18 as of 1.6.00 GF82.70-P-
with code 854 0003-01EA
853, 854. 0003-01P
MODELS
209.316/342/343/361/365/375/376
with code 853/854
853, 854 0003-01PA
Model 208 from 1.6.98 to 31.5.00 GF82.70-P-
with codes 316, 317. 0003-01K
0003-01KA
Model 210 from 1.6.98 to 31.5.00 GF82.70-P-
with codes 316, 317. 0003-01F
853, 854 0003-01FA
316, 317. 0003-01N
Model 215 as of 1.6.00 up to 31.8.02 GF82.70-P-
with codes 853, 854 0003-01NA
853, 854 0003-01NB
Model 220 with codes 316, 317. GF82.70-P-
0003-01A
853, 854 0003-01AA
853, 854 0003-01AB
Telephone (D-network), Model 129 with codes 274, 312, 313, GF82.70-P-
function schematic 314a. 0003-02C
314a.
Model 170 with codes 312, 313,
314a.
314a.
MODEL 208 with CODE 274
314a.
MODEL 129 with CODE (316) MB GF82.70-P-
D-network 0003-02D
MODEL 168 with CODE (312) MB
D-network
portable CTEL, with CODE (317) D-
D-network
D-network
D-network
D-network
D-network
MODELS 129, 163, 203, 210, 215, GF82.70-P-
220 from 1.6.00 0003-02P
with CODE (853) MB standard
telephone, with CODE (854) MB
portable CTEL
MODELS 168, 202.08 /09 /18 with
CODE (854)
MB portable CTEL, MODELS
209.316/342/343/361/365/375/376
telephone, with CODE (854) MB
Portable CTEL.
Telephone (D-network) log-in GF82.70-P-
0003-03C
Telephone (D-network), mobile GF82.70-P-
subscriber on public switched 0003-04C
telephone network.
Telephone (D-network) mobile GF82.70-P-
subscriber to mobile subscriber 0003-05C
Telephone (D-network), block MODELS 129, 163, 168, GF82.70-P-
diagram 202.08 /09 /18, 203, 210, 215, 220 0003-06A
with CODE (854) MB portable
CTEL.
MODELS 129, 202.08 /09 /18, 203,
210, 215, 220
CTEL, with CODE (813) voice
control system (VCS).
MODELS
209.316/342/343/361/365/375/376
cellular telephone
cellular telephone
MODELS 129, 163, 203, 210, 215, GF82.70-P-
220 with CODE (853) MB standard 0003-06AA
telephone.
MODELS 129, 203, 210, 215, 220
telephone, with CODE (813) voice
Models 215, 220 with code 498 and GF82.70-P-
803. 0003-06M
Start-up/accepting GF82.70-P-
call/completing telephone call 2002C
(D-network), function
Shut down/terminating GF82.70-P-
telephone call (D-network), 2003C
function
Telephone switch-on/off MODELS 129, 170, 202, 208, 210, GF82.70-P-
characteristics (D-network), 215, 220 with CODE (316) MB D- 2005BA
function network telephone (D2B).
MODELS 129, 168, 202, 208, 210, GF82.70-P-
215, 220 with CODE (317) D- 2005AA
MODELS 129, 163, 168, GF82.70-P-
202.08 /09 /18, 203, 208, 210, 215, 2005A
220 with CODE (854) MB portable
CTEL.
MODELS 129, 163, 203, 208, 210, GF82.70-P-
215, 220, 2005B
209.316/342/343/361/365/375/376
cellular telephone
cellular telephone
Survey of system components, GF82.70-P-
telephone (D-network), 9998ZZ
CONTENTS - FUNCTION DESCRIPTION OF VOICE CONTROL SYSTEM (VCS) - GF82.70-P-0999
Contents - function description of voice control system (VCS) - GF82.70-P-0999M
Voice control system (VCS [SBS]), GF82.70-P-0002M

function
Voice control system (VCS), GF82.70-P-0002-
arrangement of components 01M
Voice control system (VCS) function GF82.70-P-0002-
diagram 02M
Activating/accepting call, function GF82.70-P-2000M
Terminating/ending call, function GF82.70-P-2001M
Navigation, function GF82.61-P-2003M
Dialing, function GF82.70-P-3000M
Telephone book, function GF82.70-P-3001M
Station list, function GF82.70-P-3002M
Overview of system components, voice GF82.70-P-9999M
control system (VCS),
Contents - function description of voice control system (VCS) - GF82.70-P-0999ZZ
MODELS 140, 202,203 up to 23.4.04,208.3, 210,215, 220 up to 31.8.03 with CODE (813) Voice control
system (VCS)
Voice control system (VCS), Model 140 GF82.70-P-0002-

arrangement of components Model 210 up to 01B
31.5.98
Model 203 GF82.70-P-0002-
01P
Models 202, 208.3, GF82.70-P-0002-
215, 220 up to 01E
31.5.00
Model 210 as of
1.6.98 up to 31.5.00
Models 202.08/ 09/ GF82.70-P-0002-
18, 208.3 from 01EA
1.6.00
Model 210 as of GF82.70-P-0002-
1.6.00 01EB
Models 215, 220 as GF82.70-P-0002-
of 1.6.00 up to 01EC
31.8.03
Voice control system (VCS) function Model 140 GF82.70-P-0002-
diagram Model 210 up to 02B
31.5.98
Models 202, 208.3, GF82.70-P-0002-
215, 220 up to 02E
31.5.00
Model 210 as of
1.6.98 up to 31.5.00
Model 203 GF82.70-P-0002-
Models 202, 208.3, 02P
210 as of 1.6.00
Models 215, 220, as
of 1.6.00 up to
31.8.03
Voice control system (VCS [SBS]), GF82.70-P-0002B
function
Activating/accepting call, function GF82.70-P-2000B
Terminating/ending call, function GF82.70-P-2001B
with telephone
system
Models 202.08/09/18 GF82.70-P-3000C
as of 1.6.00
Model 203
of 1.6.00
Models 215, 220 as
of 1.6.00 up to
31.8.03
with audio
components (radio,
CD, cassette)
Telephone book, function GF82.70-P-3001B
Station list, function Models 202.08/09/18 GF82.70-P-3002P
as of 1.6.00
Model 203
of 1.6.00
Models 215, 220 as
of 1.6.00 up to
31.8.03
Overview of system components, voice GF82.70-P-9999A
control system (VCS),
ACTIVATING/ACCEPTING CALL, FUNCTION - GF82.70-P-2000
Activating/accepting call, function - GF82.70-P-2000B
MODELS 140, 202, 203 up to 23.4.04, 208.3, 210,215, 220 up to 31.8.03 with CODE (813) Voice control
system (VCS)
Shown on models 202, 203, 208.3, 210, 215, 220 as of 6/1/00
Fig. 86: Identifying Activating/Accepting Call And VCS Switch - Shown On Models 202, 203, 208.3, 210,
215, 220 As Of 6/1/00
Illustrated on model 220 up to 31.5.00

Fig. 87: Identifying VCS Switch - Illustrated On Model 220 Up To 31.5.00
Function
By operating the VCS switch (S93/2) the voice recognition of the voice control system (VCS) is activated. The
following model series dependent control units are used for this purpose:
 In the voice control module (A35/10a1) of the telephone transmitter/receiver/voice control system
(A35/10) (models 140, 210 up to 5/31/98).
 in the voice control system control unit (A35/11) (models 202, 203, 208, 210 as of 1.6.98, 215, 220).
Simultaneously the VCS is actuated, which is signaled to the user by an acoustic signal (beep). Furthermore, the
hands-free system and thus muting of the particular vehicle-specific component of the audio system becomes
active to ensure the greatest possible stability of the user voice input.
The system is then in the Input mode. From this time on, input commands are available to the user, which
permit him/her, via the hands-free system microphone (B25), to connect to the system and control it via the
input commands (spoken input).
If the system does not immediately detect an entry, the sensitivity of the system is increased in step 1. If there
still is no entry, the VCS is deactivated after approx. 15 s.
Accepting call
On models 140, 202, 203, 208.3, 210, 215 and 220 without multifunction steering wheel (MFL) the VCS switch
(S93/2) has to be actuated in order to accept an incoming call, which corresponds to taking the telephone
receiver off the hook when leading a conventional telephone call.
On models 203, 208.3, 210, 215 and 220 with multifunction steering wheel (MFL) an incoming phone call is
accepted via the accept/ terminate phone call button (S111s3).
After activation, the particular vehicle-specific component of the audio system is also muted here to ensure the
greatest possible stability of the user voice input. It is also possible for the user to use the hands-free system
microphone (B25) for the call.
The voice output of the system is accomplished dependent on the model series via one or several hands-free
system speakers.
Models 202.08/09/18 as GF82.70-P-3000C
of 1.6.00
Model 203
Models 208.3, 210 as of
1.6.00
1.6.00 up to 31.8.03
Voice control system switch, GF82.70-P-4100B
location/task
Location / purpose of voice Model 140 GF82.70-P-4101B
control unit Model 210 up to
31.5.98
Hands-free microphone, Models 140, 202, 208, GF82.70-P-4102B
location/task 210
with code (274) MB D-
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with CODE (313) D-
with code (314a)
"Standard" D-network
telephone
Models 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
Hands-free system Models 140, 202, 208, GF82.70-P-4103B
loudspeaker, location/task 210
net telephone
Models 140, 202, 210
with code (312) D-
network portable
"CTEL telephone"
with code (313) D-
network portable
"CTEL telephone"
with code (314a)
telephone
Models 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
CTEL transmitter/receiver, Model 140 GF82.70-P-4104B
location / task Model 210 up to
31.5.98
Voice control system control Models 202, 203, 208.3 GF82.70-P-4113A
unit, location/task Model 210 as of 1.6.98
Models 215, 220 up to
31.8.03
Activating/accepting call, function - GF82.70-P-2000M
Shown on model 211

Fig. 88: Identifying Activating/Accepting Call Function - Shown On Model 211
Function activation
The actuation of the voice control system switch (S93/2) in driver direction is read in by the steering column
module (N80) and the corresponding message is transmitted on the CAN-B (Controller Area Network bus Class
B (interior)) to the audio gateway control unit (N93/1). The audio gateway control unit (N93/1) then transmits
the actuation message via the MOST (Media Oriented System Transport) to the voice control system control
unit (A35/11), which activates the integrated voice recognition of the voice control system. This is announced to
the user through an acoustic signal (beep). At the same time, the hands-free system is activated and the radio
muted to ensure the greatest possible accuracy of the user input. By using the appropriate input commands, the
user can select and operate telephone, radio, CD player, CD changer, cassette deck, and navigation. The spoken
commands are received by the hands-free system microphone group (A67/b1) and forwarded in a conventional
way to the voice control system (A35/11). This system processes the voice input of the user while taking the
ambient noise into account (e.g., wind noise, tire rolling noise). If an entry is not made immediately, the hands-
free system microphone is switched to a more sensitive setting. If there still is no entry, the VCS is deactivated
after approx. 15 s.
Accepting call
An incoming call can be received via the accept/terminate phone call button (S111s3) at the multifunction
steering wheel. As during activation, the radio is also muted here to ensure the greatest possible stability of the
user voice input. The user can immediately hold the phone conversation via the hands-free system microphone
group (A67b1). In this case, the system voice output is accomplished via the handsfree system loudspeakers.
For echo compensation the VCS requires the data from the telephone fixed-line network, which is made
available to the VCS via the MOST. The processed and digitized microphone data are read in by the VCS and
made available on the MOST. They can then be read by the telephone control unit.
In order to achieve a very good hands-free call quality, the telephone has to switch off its own hands-free
call processes (echo compensation, noise compensator, and noise reduction).
Voice control system GF82.70-P-4100M

switch, location/task
control unit, location/task
Hands-free microphone, GF82.70-P-4102M
location/task
Hands-free system GF82.70-P-4103M
loudspeaker, location/task
TERMINATING/ENDING CALL, FUNCTION - GF82.70-P-2001
Terminating/ending call, function - GF82.70-P-2001B
system (VCS)
Fig. 89: Identifying Terminating/Ending Call And VCS Switch - Shown On Models 202, 203, 208.3, 210,
215, 220 As Of 6/1/00
Fig. 90: Identifying VCS Switch - Illustrated On Model 220 Up To 31.5.00
Abort
If the VCS switch (S93/2) is actuated during a phone call, then the voice recognition of the voice control system
(VCS) is deactivated and the existing connection is terminated.
The voice recognition system is located:

 In the voice control module (A35/10a1) of the telephone transmitter/receiver/voice control system
(A35/10) (model 140, 210 up to 5/31/98).
 in the voice control system control unit (A35/11) (models 202, 203, 208, 210 as of 1.6.98, 215, 220).
This is possible at any point during the call. If the user is in the entry mode, they can exit the voice recognition
and deactivate the system via the voice command "End" via the hands-free system microphone (B25). This is
also possible at any point in the input mode.
Ending call
On models 140, 202, 203, 208.3, 210, 215 and 220 without multifunction steering wheel (MFL), the VCS
switch (S93/2) has to be activated (pushed away from the driver) after ending a phone call in order to terminate
the connection.
On models 203, 208.3, 210, 215 and 220 with multifunction steering wheel (MFL), the connection is terminated
via the accept/terminate phone call button (S111s3) and not by operating the VCS switch (S93/2).
If the driver does not end the telephone call, the VCS does not consider the call as terminated. As a result,
the VCS cannot recognize an incoming call.

Models 202.08 /09 /18 GF82.70-P-3000C
as of 1.6.00
Model 203
Models 208.3, 210 as of
1.6.00
1.6.00 up to 31.8.03
location/task
31.5.98
location/task 210
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with CODE (313) D-
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with code (313) D-
network portable
"CTEL telephone"
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
location / task Model 210 up to
31.5.98
31.8.03
Terminating/ending call, function - GF82.70-P-2001M
Shown on model 211
Fig. 91: Identifying Terminating/Ending Call Function - Shown On Model 211
Function cancellation
If during a telephone call, the VCS switch (S93/2) is moved away from the driver, then the voice recognition of
the voice control system is deactivated and an existing connection broken. The voice recognition is located in
the voice control system control unit (A35/11). This is possible at any point during the call. If the device is in
input mode, then the user can command the voice recognizer to deactivate the system via the hands-free system
microphone group (A67b1) using the voice commands "Cancel" or "Canceling". This is possible at any point
during the input mode. Furthermore, the system can be deactivated via closing commands and execution
commands, in other words, the system is deactivated after entering a phone number, for instance at the end of
the execution command "Dial", or after creating a phone book with the execution commands "Accept" or
"Memory". Moreover, the system demands the confirmation command "Yes" when a station or a telephone
number is deleted. If this command is not issued, the systems aborts the deletion process.
Ending call
The call is ended via the accept/terminate phone call button (S111s3) in the multifunction steering wheel or via
the VCS switch (S93/2). If the user fails to press the button or switch (calling party has put phone down) at the
end of the call, then the call is deemed to be still active by the VCS. An incoming call can thus not be
recognized by the VCS, which in turn means that the connection cannot be established.

START-UP/ACCEPTING CALL/COMPLETING TELEPHONE CALL (D-NETWORK), FUNCTION -

GF82.70-P-2002C
network telephone
telephone
Function
Initial operation
Before the telephone is used, it is necessary to log into the telephone network ( digital network ). For this
purpose the SIM ( S ubscriber I dentification M odule) card is required.
After inserting the SIM card (already in telephone transmitter/receiver with permanently installed telephone
depending on system) and then switching on with the ON/OFF switch on the telephone handset (A34) or on the
portable CTEL (A34/6) it is necessary for the user to enter the four to eight-digit PIN code ( P ersonal
Identification N umber) when requested. This number prevents unauthorized use of the card and protects against
misuse Incorrectly entering the code three times in sequence disables the card, which can be re-enabled with the
aid of a personal eight-digit reenable number (PUK, personal unblocking key or also super PIN). This allows
entry of a new PIN number.
If the PUK is entered incorrectly ten times in sequence, the card is rendered unusable and it is necessary to
apply to the provider for a new card.
If the number is entered correctly, the telephone logs into the service provider's network. The telephone is then
ready for use.
Accepting a call
A call can be accepted by the user in a number of ways:
 picking up telephone handset (A34) (fixed installation), Making a call using telephone handset (A34).
 Pressing the appropriate function button, Telephone handset (A34) (permanently installed) or portable
cellular telephone remains in holder, handling call via hands-free system (hands-free system microphone
(B25), model 163/168/170/210/215/220 hands-free system loudspeaker (H4/12), model 129/202/208
double-coil loudspeaker for front right radio and telephone hands-free system (H4/14)).
 On vehicles with voice control system (voice control system (CODE 813b): Actuation of VCS switch
(S93/2))
 On vehicles with multifunction steering wheel (MFL) and multifunction display (A1p13): Actuation of
accept/terminate phone call push-button (S111s3).
Placing a call
Just as with receiving a call, a call can be placed by the user in a number of ways:
 by picking up telephone handset (A34) (fixed installation); after entering the desired subscriber's number
by pressing the transmit button and waiting until the other party answers.
 the telephone handset (A34) (fixed installation) or portable CTEL (A34/6) is left in the cradle; after
entering the desired subscriber's number and then pressing the transmit button, wait until the called
subscriber answers
 On vehicles with voice control system (VCS) (code 813b): Actuate VCS switch (S93/2) (voice control
system (code 813)) and have number dialed using voice entry
 On vehicles with multifunction steering wheel and multifunction display (A1p13): Actuation of
accept/terminate phone call push-button (S111s3). During the call the user can, after actuating the
corresponding function keys, change between the following types of operation: telephone handset (A34)/
portable cellular telephone (A34/6) or hands-free system (hands-free system microphone (B25), model
163/168/170/210/215/220 hands-free system loudspeaker (H4/12), model 129/202/208 double-coil
loudspeaker and right front radio and telephone hands-free system (H4/14)).
When entering the number, it is possible for the user to simplify number entry with the appropriate function
buttons by calling up the desired numbers directly from the memory stored for this purpose. In this case, it is
possible to call numbers stored either on the SIM card or in the telephone memory.
When muted, the word "Phone" appears on the display of the radio/ multifunction display
The information is processed via the vehicle's own bus systems (CAN, D2B or MOST) and discrete lines. In
order to transfer information to the or in the telephone memory.
If the radio is switched on when a call is started, it is muted regardless of whether it is an incoming or outgoing
call.
D2B or MOST) and discrete lines. In order to transfer information to the bus systems, a so-called interface
(adapter) to the bus system in question is required.
More information on the equipment installed is given in the corresponding operating instructions.
Telephone interface, Models 129, 168, 170, GF82.70-P-3107E

location/task/design/ function 202, 208, 210, 215, 220
with code 317 (portable
cellular telephone)
Models 129, 170, 202, GF82.70-P-3107F
208, 210, 215, 220 with
code 316 (permanently
installed telephone)
Models 129, 163, 168, GF82.70-P-3107P
170, 202.08, 202.09,
202.18, 203, 208, 210,
215, 220 with code 854
(portable CTEL)
Hands-free microphone, GF82.70-P-4102B
location/task
Hands-free system loudspeaker, GF82.70-P-4103B
location/task
Telephone handset (D- GF82.70-P-4106C
Telephone transmitter/receiver MODEL 129, 202, 210 GF82.70-P-4107C
(D-network), location/task with code (274) MB D-
network telephone
with code (314a)
Standard D-network
telephone
network telephone
(D2B)
MODEL 140
network telephone
with code (314a)
Standard D-network
telephone
MODEL 170
with code (314a)
Standard D-network
telephone
network telephone
(D2B)
MODEL 208
network telephone
network telephone
(D2B)
MODEL 215, 220 with
code (316) MB D-
network telephone
(D2B)
MODEL 129, 163, GF82.70-P-4107D
202.08 /09 /18, 203,
208, 210, 215, 220 with
code (853) MB
standard telephone
Portable CTEL (D-network), GF82.70-P-4110C
location/task
location/task
SHUT DOWN/TERMINATING TELEPHONE CALL (D-NETWORK), FUNCTION - GF82.70-P-2003C
network telephone
telephone
Function
Terminating a call
If a call has been conducted using the telephone handset (A34) or the portable CTEL (A34/6), there are a
number of ways to terminate the call:
 Hanging the telephone handset (A34) in mount (fixed installation)

 Pressing the End key
If a call has been conducted via the hands-free system there are also a number of possibilities to end the call:
 Pressing the End key

 picking up and putting down the telephone handset (A34) (permanently installed)
 On vehicles with voice control system (VCS) (code 813b): Actuate VCS switch (S93/2)
 On vehicles with multifunction steering wheel: Actuate accept/ terminate phone call button (S111s3)
Shutting off
The unit can be switched off by pressing the OFF button and removing the card.
During this operation ensure that the card is removed only with the unit switched off in order to prevent
destruction of the chip on the SIM card ( S ubscriber I dentification M odule).
Moreover, it may be necessary to end the PIN code ( P ersonal I dentification N umber) again when restarted
(depending on system).
Further information is given in the corresponding operating instructions.
Telephone handset (D- GF82.70-P-4106C

Portable CTEL (D- GF82.70-P-4110C
CELL/TELEPHONE ON/OFF CHARACTERISTICS, FUNTCION - GF82.70-P-2005
Telephone switch-on/off characteristics (D-network), function - GF82.70-P-2005A

MODEL 129, 163, 168, 202.08 /09 /18, 203, 208, 210, 215, 220 with CODE (854) MB portable cellular
telephone
Switch-on/off characteristics of D2B telephone (portable cellular telephone)
The behavior of the D2B telephone in the D2B ring is only subject to the state of circuit 15 (ignition ON/OFF).
Information on the state of c. 15 is transmitted to the CTEL interface (A34/4) by the head unit
(COMAND/radio) via the D2B ring. The CTEL interface (A34/4) does not have an electrical connector to c.
15 and switches the portable cellular telephone on and off by request of the head unit via the D2B ring or an
external wake-up line
When the ignition is switched off the CTEL interface (A34/4) and thereby the telephone remains switched on
for a shut-off delay of t = 10 min. and is then switched off. It is possible to program a different shut-off delay
time (t = 1 - 60 min.)
System characteristics
The CTEL interface (A34/4) has 3 different operating states.
 Power down mode
The interface is switched off except for the external wake-up line.
 Idle mode or shut-off delay mode
The remaining components of the D2B ring are switched off; only the interface remains active for t=10
min (preset) after the D2B ring (ignition OFF) is switched off.
 Active mode
The interface as well as the remaining components of the D2B ring are active and available to the user.
Switch-on procedure
1. Current state: ignition ON, CTEL interface (A34/4) is in inactive state (power down mode), telephone
system is not ready for operation.
The CTEL interface (A34/4) is activated (active mode) when:
 a portable cellular telephone is plugged into the portable cellular telephone mount in the switched-
on state
 a portable cellular telephone plugged into the mount is switched on
 when the portable cellular telephone is plugged in and switched on during a call (incoming and
outgoing)
 a wake-up signal of another D2B ring subscriber is recognized via the external wake-up line
2. Current state: Ignition OFF, CTEL interface (A34/4) is in the shutoff delay phase (idle mode) and D2B
ring is in the inactive state (switched off).
The CTEL interface (A34/4) is activated (switched to active mode) when:
 the portable cellular telephone is plugged in and switched on during a call (incoming and outgoing)
 a wake-up signal from another D2B ring subscriber is recognized via the external wake-up line
Switch-off procedure
The CTEL interface (A34/4) is in the shut-off delay phase (idle mode) and the D2B ring is switched off.
The interface remains switched off as long as the portable cellular telephone is not plugged in or a plugged in
portable cellular telephone is switched off.
The following cases are possible depending on the state of circuit 15:
 Circuit 15 ON
After expiration of the shut-off delay of t = 10 min. (preset) the interface switches off (power down
mode). Thereby the state of the portable cellular telephone plugged in does not change, i.e. a plugged in
or active portable cellular telephone still remains switched on and is not switched off by the interface.
 Circuit 15 OFF
After expiration of the shut-off delay of t = 10 min. (preset) the interface switches off (power down
mode). Thereby the state of the portable cellular telephone plugged in changes, i.e. a plugged in or active
cellular telephone is switched off by the interface.
When the D2B ring is deactivated the CTEL interface (A34/4) switches off when a portable cellular telephone
is not plugged in or a plugged in portable cellular telephone is not switched on. The interface remains active for
the time of the shut-off delay if a switched on portable cellular telephone is plugged in.
Telephone interface, GF82.70-P-3107P

Cellular telephone (GSM 900 MHz) on/off characteristics, function - GF82.70-P-2005AA
MODELS 129, 168, 202, 208, 210, 215, 220 with CODE (317) GSM portable cellular telephone (D2B)
On / off characteristics of D2B telephone (portable CTEL)
The characteristic of the D2B telephone in the D2B ring is solely dependent on the state of terminal 15 (ignition
ON/OFF). Information regarding the state of terminal 15 is sent to the D2B interface portable CTEL (A59/1)
from the Head Unit (COMAND/radio) via the D2B ring. The D2B interface portable CTEL (A59/1) is not
electrically connected to terminal 15 and switches the portable CTEL on or off when commanded by the Head
Unit, via the D2B ring or an external wake-up circuit.
After the ignition is switched off the D2B interface portable CTEL (A59/1) and therefore the telephone
remain switched on for an overshoot period of t=10 min. before being switched off. It is not possible to program
another overshoot period because the interface's overshoot period is preprogrammed and unalterable.
Neither is it possible to influence the on/off characteristic of the D2B telephone by programming the portable
CTEL.
System performance
The portable CTEL D2B interface (A59/1) has three operating states.
 Powerdown mode
The interface is shut down with the exception of the external wake up circuit.
 Idle or overshoot time mode
The remaining components in the D2B ring are switched off, only the interface remains active for t=10
min after switching off the D2B ring (ignition OFF). Each further key operation, during the overshoot
period, extends the overshoot period by t=60 min.
 Active mode
Both the interface and the remaining components in the D2B ring are active and available to the user.
Switch-on operation
1. Current state: ignition ON, portable CTEL D2B interface (A59/1) is in inactive mode (powerdown
mode), the telephone system is not operational.
The portable CTEL D2B interface (A59/1) is activated (active mode) when:
a portable CTEL, in switched-on state, is inserted into the portable CTEL's receptacle

 a portable CTEL in the receptacle is switched on
 a portable CTEL that is in the receptacle and switched on makes a call (incoming/outgoing)
 a wake-up signal of another D2B ring subscriber is recognized via the external wake-up circuit
2. Current state: ignition OFF, the portable CTEL D2B interface (A59/1) is in the overshoot phase (idle
mode) and the D2B ring is in inactive mode (switched off)
The portable CTEL D2B interface (A59/1) is activated (active mode) when:
 a portable CTEL that is in the receptacle and switched on makes a call (incoming/outgoing)
Switching-off process
The portable CTEL D2B interface (A59/1) is in the overshoot phase (idle mode) and the D2B ring is switched
off.
The interface remains switched off for as long as there is no portable CTEL in the receptacle or when one is in
the receptacle but not switched on.
The following cases are possible depending on the status of terminal 15:
 Terminal 15 ON
After expiry of the overshoot period of t=10 min (no further key operations on the portable CTEL during
the overshoot period) the interface is switched off (powerdown mode). This does not alter the state of the
portable CTEL in the receptacle, in other words, a portable CTEL in the receptacle and switched on
remains switched on and is not switched off by the interface .
 Terminal 15 OFF
After expiry of the overshoot period of t=10 min (no further key operations on the portable CTEL during
the overshoot period) the interface is switched off (powerdown mode). This alters the state of the portable
CTEL in the receptacle, in other words, a portable CTEL in the receptacle is switched off by the
interface.
When the D2B ring is deactivated the portable CTEL D2B interface (A59/1) is switched off if a portable
CTEL is not in the receptacle or if a portable CTEL is in the receptacle but not switched on. The interface
remains active for the duration of the overshoot period, when a portable CTEL is inserted into the receptacle
and switched on.
Telephone interface, The D2B GF82.70-P-3107E

position/task/design/function interface and the
CTEL interface are
Telephone switch-on/off characteristics (D-network), function - GF82.70-P-2005B
MODELS 129, 163, 203, 208, 209.3 /4, 210, 215, 220 with CODE (853) MB standard cellular telephone
with CODE (854) MB portable cellular telephone
General
The status of the telephone in the D2B ring depends exclusively on the status of circuit 15 (ignition ON/OFF).
Information on the state of "circuit 15" is sent over the D2B ring to the telephone transmitter/ receiver, D2B
(A35/13), the telephone transmitter / receiver (A35) (for model 163) or the telephone interface (A34/4) from the
radio (A2) or the COMAND operating, display and control unit (A40/3) (except model 129). The telephone
transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) or the telephone
interface (A34/4) do not have any electrical connection to "circuit 15" and they are switched on or off by a Head
Unit command, via the D2B ring or an external wake-up line.
For "circuit 15 OFF" the telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35)
(for model 163) and thus the telephone or the telephone interface (A34/4) is switched on with the portable
CTEL for a run-on time of t = 10min. to t = 60 min. (run-on time is parameterizable) and it is then switched off
again.
System characteristics
The telephone control unit for the telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver
(A35) (for model 163) or the telephone interface (A34/4) have 3 operating conditions.
 Powerdown mode
The telephone control unit is switched off with the exception of the external wake-up line.
 Idle mode or run-on time mode
The remaining components of the D2B ring are switched off; only the telephone transmitter/receiver,
D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) is active during the run-on time,
after the D2B ring "circuit 15 OFF" has been switched off. During the run-on time the telephone can be
used without any PIN inquiry.
 Active mode
The telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35) (for model 163)
or the telephone interface (A34/4), and the remaining components in the D2B ring are active and
available to the user.
Switch-on process
1st state: "Circuit 15 ON", telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35)
(for model 163) or the telephone interface (A34/4) is in inactive state (Powerdown mode), the telephone system
is not operational.
The telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) or the
telephone interface (A34/4) is activated (Active mode) when:
 the portable CTEL (A34/6) or the telephone handset (A34) is switched on.
 a call is made or received with the telephone switched on.
 a wake-up signal from another D2B ring subscriber is recognized via the external wake-up line.
2nd state: "circuit 15 OFF", telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver
(A35) (for model 163) or the telephone interface (A34/4) are in the run-on phase (Idle mode).
The telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) or the
telephone interface (A34/4) is activated (Active mode) when:
 a call is made or received with the telephone switched on.

 a wake-up signal from another D2B ring subscriber is recognized via the external wake-up line.
Switch-off procedure
The telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) is in
the run-on phase (Idle mode) and the D2B ring is switched off.
The following cases are possible:
 For "circuit 15 ON" and expiry of the run-on time of t = 10 min. to t = 60 min. (run-on time is
parameterizable) and no further presses of a button on the telephone during the run-on time the telephone
transmitter/receiver D2B (A35/13), telephone transmitter / receiver (A35) (for model 163) or the
telephone interface (A34/4) is switched off (Powerdown mode). In doing so the state of the telephone is
not altered, in other words, an active telephone remains switched on and is not switched off by the
telephone transmitter/receiver, D2B (A35/13), or telephone transmitter / receiver (A35) (for model 163).
 For "circuit 15 OFF" and expiry of the run-on time and no further presses of a button on the telephone
during the run-on time the telephone transmitter/receiver, D2B (A35/13), telephone transmitter / receiver
(A35) (for model 163) or the telephone interface (A34/4) is switched off (Powerdown mode). In this case,
the status of the telephone changes, meaning, a switched on telephone is switched off.
When the D2B ring is deactivated, the telephone transmitter/receiver, D2B (A35/13), telephone transmitter /
receiver (A35) (for model 163) is switched off, if neither the telephone is switched on nor the receiver is on the
cradle.
CTEL antenna, location / task Model 163 GF82.62-P-4105P

Models 208.3, 215
with code (855)
TELE AID
Models 203, 210 and
220 with code (855)
TELE
AID and code (930)
taxi emergency call
Models 203, 209.3 GF82.62-P-4105PP
Model 209.4 GF82.62-P-4105Q
Compensator, location/task Models 209.3/4 GF82.70-P-3109Q
Hands-free system microphone, Models 203, 208.3, GF82.70-P-4102A
location/task 210, 215, 220 with
code (855) TELE
AID
Models 203, 210,
220 with code (930)
taxi emergency call
Model 210 with code
(348) TELE AID
emergency call
system
Models 129, 208.3,
210, 215, 220 with
code (347) TELE
AID emergency call
system (D2B)
Models 209.3/4 GF82.70-P-4102Q
Hands-free system speaker, Models 163, 203 GF82.70-P-4103B
location/task Models 129, 210
with code (274) MB
D-net telephone,
code (312) D-net
portable CTEL, code
(313) D-net
"portable CTEL",
code (314a) D-net
"Standard"
telephone, code
(316) MB D-net
telephone (D2B),
code (317) D-net
portable CTEL
(D2B)
Models 215, 220
with code (316) MB
D-net telephone
(D2B), code (317)
D-net portable CTEL
(D2B)
Model 208 with code
(274) MB D-net
telephone, code
(316) MB D-net
telephone (D2B),
code (317) D-net
portable CTEL
(D2B)
Model 209.3 with GF82.70-P-4103Q
code (852) portable
CTEL preinstallation
assembly on dome,
code (855) TELE
AID
Model 209.4 with GF82.70-P-4103QA
code (852) portable
CTEL preinstallation
assembly on dome,
code (855) TELE
AID
Telephone transmitter/receiver (D- Models 209.3/4 with GF82.70-P-4107Q
network), location/task CODE (853) MB
Standard telephone
Telephone interface, GF82.70-P-3107Q
Telephone handset (D-network), Models 209.3/4 with GF82.70-P-4106Q
location/task CODE (853) MB
Standard telephone
Models 163, 203 GF82.70-P-4106C
Models 129, 210
with code (274) MB
D-net telephone,
code (314a) D-net
"Standard"
telephone, code
(316) MB D-net
telephone (D2B)
Model 208 with code
(274) MB D-net
telephone, code
(316) MB D-net
telephone (D2B)
Model 215, 220 with
code (316) MB D-
network telephone
(D2B)
Portable cellular telephone (D- Models 209.3/4 with GF82.70-P-4110Q
network), location/task CODE (854) MB
portable CTEL
Cellular telephone (GSM 900 MHz) on/off characteristics, function - GF82.70-P-2005BA
MODELS 129, 170, 202, 208, 210, 215, 220 with CODE (316) MB GSM cellular telephone (D2B)
On / off characteristics of D2B telephone (fixed installation)
The characteristic of the D2B telephone in the D2B ring is solely dependent on the state of terminal 15 (ignition
ON/OFF). Information regarding the state of terminal 15 is sent to the D2B interface fixed installation (A59)
from the Head Unit (COMAND/radio) via the D2B ring. The D2B interface fixed installation (A59) is not
electrically connected to terminal 15 and switches the CTEL transmitter/receiver (A35) on or off when
commanded by the Head Unit, via the D2B ring or an external wake-up circuit. After the ignition is switched
off the D2B interface fixed installation (A59) and therefore the telephone remains switched on for an
overshoot period of t=10 min. before being switched off. It is not possible to reprogram the overshoot period.
System performance
The D2B interface fixed installation (A59) has three operating states.
 Powerdown mode
The D2B interface fixed installation (A59) is switched off with the exception of the external wake-up
circuit.
 Idle or overshoot time mode
The remaining components in the D2B ring are switched off, only the D2B interface fixed installation
(A59) remains active for t=10 min after the D2B ring has been switched off (ignition OFF). Each further
key operation, during the overshoot period, extends the overshoot period by t=60 min.
 Active mode
Both the D2B interface fixed installation (A59) and the other components in the D2B ring remain active
and available to the user.
Switch-on operation
1. Current state: ignition ON, D2B interface fixed installation (A59) is in inactive mode (powerdown
mode), the telephone system is not operational.
The D2B interface fixed installation (A59) is activated (active mode) when:
The telephone is switched on by the handset


 a telephone that is in the receptacle is switched on and makes a call (incoming/outgoing)
2. Current state: ignition OFF, the D2B interface fixed installation (A59) is in the overshoot phase (idle
mode) and the D2B ring is in inactive mode (switched off)
The D2B interface fixed installation (A59) is activated (active mode) when:
 a telephone that is in the receptacle is switched on and makes a call (incoming/outgoing)

Switching-off process
The D2B interface fixed installation (A59) is in the overshoot phase (idle mode) and the D2B ring is switched
off.
The following cases are possible depending on the status of terminal 15:
 Terminal 15 ON
After expiry of the overshoot period of t=10 min (no further telephone key operations during the
overshoot period) the D2B interface fixed installation (A59) switches off (powerdown mode). The
status of the telephone is not altered here, in other words, a switched on telephone remains so and is not
switched of by the D2B interface fixed installation (A59) .
 Terminal 15 OFF
After expiry of the overshoot period of t=10 min (no further telephone key operations during the
overshoot period) the D2B interface fixed installation (A59) switches off (powerdown mode). The
status of the telephone is altered here, in other words, a switched on telephone is switched off by the D2B
interface fixed installation (A59) .
When the D2B ring is deactivated the D2B interface fixed installation (A59) is switched off if the telephone is
not switched on.
Telephone interface, The telephone and GF82.70-P-3107F

position/task/design/function D2B interfaces are
SWITCH ON/OFF CHARACTERISTICS OF TELEPHONE, FUNCTION - GF82.70-P-2007S
ON/off characteristics
The Universal Portable CTEL Interface system (UPC) is activated using the on/off button of the portable CTEL
(A34/6). There is also the option to activate the system automatically through a wake-up pulse via the MOST
bus. It can be started via the status "Circuit 15 ON", or with code (527) COMAND APS (with navigation) via
the COMAND operating, display and control unit (A40/3).
To be able to operate the System Universal Portable CTEL Interface (UPCI), it has to be logged into the
particular telephone network (e.g. D-net or E-net). To do this, the Subscriber Identification Module (SIM) is
required, which is located on the SIM-card. After inserting the SIM card and subsequent activation, the user has
to enter, depending on the request, the 4 to 8-digit Personal Identification Number (PIN).
This PIN number prevents unauthorized use of the card and therefore protects against misuse.
Incorrectly entering the code 3 times in sequence disables the SIM card, which can be re-enabled with the aid of
a personal 8-digit reenable number Personal Unblocking Key (PUK). This allows entry of a new PIN. If the
PUK is entered incorrectly 10 times in sequence, the SIM card is rendered unusable and it is necessary to apply
to the provider for a new SIM card. If the PIN is entered correctly, the portable CTEL (A34/6) logs into the
particular network of the service provider and is ready for use.
Switch off characteristics
The Universal Portable CTEL Interface system (UPCI) is deactivated using the on/off button of the portable
CTEL (A34/6) or automatically based on the run-on time set at the portable CTEL (A34/6).
By actuating the on/off button at the particular portable CTEL (A34/6) and then removing the SIM-card, the
portable CTEL (A34/6) is deactivated.
The SIM-card shall only be removed while the portable CTEL is deactivated (A34/6) to prevent the
memory chip that is located on the SIM-card from being destroyed. When the portable CTEL (A34/6) is
activated again, the PIN has to be re-entered.
Only model 220
It is not possible to use the rear telephone handset (A34/8) to switch the Universal Portable CTEL Interface
(UPCI) system on or off.
UHI Portable CTEL GF82.70-P-5000S

Receiver (Universal
Portable CTEL
Interface), location/task
Universal Portable CTEL GF82.70-P-5100S
Interface (UPCI [UHI])
ESTABLISHING/TERMINATING A CALL, TELEPHONE, FUNCTION - GF82.70-P-2008S
 Voltage supply OK.

 MOST ring active.
 Portable CTEL (A34/6) inserted in the UHI Portable CTEL receiver (Universal Portable CTEL Interface)
(A34/15).
 Enabled SIM card inserted into the portable CTEL (A34/6).
 Correct entry of PIN and successful log-in into the particular network of the service provider.
Placing a call
 After entering the desired telephone number or selecting a stored telephone number using the block of
digits of the portable CTEL (A34/6) and subsequently operating the "Accept telephone call" button, the
telephone call is being established.
 After entering the desired telephone number or selecting a stored telephone number via the block of digits
of the COMAND operating, display and control unit (A40/3) with code (527) COMAND APS (with
navigation) and subsequent operation of the "accept telephone call" button, the telephone call is being
established.
 The multifunction steering wheel (MFL) can be used to select the telephone book via the system selection
button (S110s3), and a stored telephone number can be selected using the scroll forward/back button
(S110s1). The telephone call is then established via the "accept/terminate phone call" button (S111s3).
 After operating the VCS switch (S93/2) the telephone call can be established via voice input with code
(813) voice control system (VCS).
The stored telephone numbers are either located on the SIM-card or in the memory of the telephone.
If an audio source (e.g. CD player with changer (in trunk) (A2/6)) is active at the time a telephone conversation
starts, irrespective whether this is an incoming or outgoing telephone call, it is muted. During muting, the note
"Telephone call" appears each time for instance in the display of the COMAND operating, display and control
unit (A40/3) or in the multifunction display (A1p13) of the instrument cluster (A1).
Terminating a call
The user has several options for ending a telephone call:
 By pressing the "End telephone call" button at the portable CTEL (A34/6).
 By pressing the "End telephone call" button at the COMAND operating, display and control unit (A40/3)
with code (527) COMAND APS (with navigation).
 By pressing the "accept/terminate telephone call" button (S111s3) at the multifunction steering wheel
(MFL).
 With code (813) voice control system (VCS) through voice input, or by operating the VCS [SBS] switch
(S93/2).
Only model 220
The rear telephone handset (A34/8) can be used to establish or terminate a telephone call via the Universal
Portable CTEL Interface (UPCI) control unit (N123/1).
Telephone antenna, GF82.62-P-4105S

location/task
Compensator, location/task GF82.70-P-3109S
Hands-free microphone, GF82.70-P-4102SA
location/task
UHI Portable CTEL Receiver GF82.70-P-5000S
(Universal Portable CTEL
Telephone/portable GF82.70-P-5200S
CTEL/STH radio remote
control antenna splitter,
location/task
ACCEPTING A CALL, TELEPHONE FUNCTION - GF82.70-P-2009S
The user has several options for accepting a telephone call:
 By pressing the "accept telephone call" button at the particular portable CTEL (A34/6).
 By pressing the "accept/terminate telephone call" button (S111s3) at the multifunction steering wheel
(MFL).
 With code (813) voice control system (VCS) through voice input after operating the VCS switch (S93/2).
 By pressing the "accept telephone call" control button at the COMAND operating, display and control
unit (A40/3) with code (527) COMAND APS (with navigation).
Only model 220
By pressing the "accept telephone call" at the rear telephone handset (A24/8) it is possible to accept telephone
calls in "private mode".

location/task
location/task
location/task
DIALING, FUNCTION - GF82.70-P-3000
Dialing, function - GF82.70-P-3000B
system (VCS) Selection and dialogue with the telephone system
Fig. 92: Identifying Activating/Accepting Call And VCS (SBS) Switch - Shown On Models 202, 203,
208.3, 210, 215, 220 As Of 6/1/00
Fig. 93: Identifying VCS (SBS) Switch - Illustrated On Model 220 Up To 31.5.00
Function
After activating the voice control system (VCS) with the VCS switch (S93/2), the user has a number of
possibilities for establishing a desired call. Different commands are available to accomplish this depending on
the state.
No number stored in telephone book
User editing commands:
 Dial telephone number

 Dial number
User final commands:
 Dial
 Memory
After activation has been completed and the user has spoken an editing command, e.g. "Dial number", the user
is requested to enter a telephone number by the voice control system (VCS) by the voice output saying "Please
say number".
The entry can be made in 2 different ways:
 Block of numbers suitable for entering longer numbers (approx. 3 to 5 numbers per number block, in each
case with a speaking pause of approx. 0.5 s between the number blocks)
 Number chains (up to 5 numbers, without speech pause), suitable for entering short numbers.
Depending on the vehicle-specific equipment, the number entered via voice command is shown in the display of
the instrument cluster (A1) or in models 203, 208.3, 210, 215 and 220 in the display of the COMAND
If an error occurs when entering the desired telephone number, e.g., improper recognition of a number by the
VCS or incorrect entry by the user, it is possible for the user to delete or correct the number.
If the number was entered without errors and recognized correctly by the VCS, the final command "Dial" given
by the user is confirmed by the VCS announcement "The number is being dialed" and the connection is
established.
If the user would like to have the desired phone number permanently available after entering it successfully,
then instead of the final command "Dial" the final command "Store" must be entered.
Thereupon the VCS requests the user to enter the associated name through the spoken announcement "Please
say the name". After this has been entered by the user, the VCS requests the user to repeat the name as
confirmation. Then the number and the associated name are stored in the telephone book and acknowledged
with the spoken announcement "Name and number have been stored".
The entry stored in the telephone book can only be called up reliably by the user who stored them.
Numbers with associated names are stored in the telephone book
User editing commands:
 Dial name
 Read telephone book
In this case, the user has 2 options for establishing a telephone connection:
 The user can enter the name with the editing command "Select name".
 He/she can have the VCS read the telephone book with the editing command "Listen to telephone book"
and then actuate the VCS switch (S93/2) (activation) while the desired name is being read and thus
selecting the corresponding name.
The editing command "Read telephone book" can also be used when the VCS is having difficulties in
recognizing a name desired by the user via a spoken input. If it is already in the telephone book, the name can
then be selected and thus the connection established.
With the two listed selection options the termination command "Dial" can be omitted.
After the VCS has repeated the name, the voice output announces to the user: "The number is being dialed". At
the same time, the connection is established. However, if the desired names are not available (e.g., the desired
connection is busy), the user has the option of redialing the last number after dialing has stopped and after
reactivation of the VCS with the VCS switch (S93/2) and the editing command "Redialing".
All functions in the VCS can be deactivated at any time by using the VCS switch (S93/2) (pushed away
from the driver) or in the dialog with the VCS via the command "End".
Deleting or correcting number chains/blocks during number entry
If the VCS system has performed a faulty recognition or the user has made a wrong entry, then this number can
be corrected using 2 methods.
If the number has been entered as a number chain (spoken together without pauses), the number can only be
changed with the following editing commands:
 Delete
 Delete number
 Delete telephone number
This means that all numbers entered previously are deleted and the system outputs a message to the user via
voice output indicating "Number deleted, please say number or command" and asks for the entry of further
numbers or commands.
If the number has been entered as a series of number blocks (3 to 5 numbers per block, speech pause of 0.5 s
between individual blocks), the number can be changed with the following editing commands:
 Correct
 Correction
 Correct telephone number/number
This means that the block of numbers entered last is deleted and the block of numbers entered previously is
repeated by the VCS. Then the VCS requests the user to "Continue" with voice output requesting either more
numbers or a command.
In case of the number entry of number chains, after more than 20 numbers have been entered without a speaking
pause, the VCS reports: "The number is too long" and the user is requested to enter the given number as a
sequence of number blocks. This then makes it possible to enter long telephone numbers as well.
If the user wants to check the numbers already entered by listening to them again, this is possible with the
command "Repeat". The VCS then repeats all of the numbers entered up to that point and requests the user with
voice output "Continue" to enter additional numbers or a command.
However, he/she also has the option of making international calls via the VCS and controlling announcement
services as well as the mailbox.
As of 1.6.00 a help function exists which is intended to make operation of the VCS as easy as possible for the
user.
If the user is in dialog mode with the telephone and says the word "Help", the VCS reads the most important
telephone commands aloud.
If the user is in dialogue mode with the radio component of the particular vehicle-specific audio system, then
they can say "Help phone" whereupon the system is changed and the VCS reads out the most important phone
commands.
Telephone book, function GF82.70-P-3001B

location/task
Location/purpose of voice Model 140 GF82.70-P-4101B
31.5.98
location/task 210
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with CODE (313) D-
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Model 203 with code
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with code (313) D-
network portable
"CTEL telephone"
with code (314a)
telephone
Models 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
location/task Model 210 up to
31.5.98
31.8.03
Dialing, function - GF82.70-P-3000C
MODELS 202.08 /09 /18 as of 1.6.00, 203 up to 23.4.04, 208.3, 210 as of 1.6.00,215, 220 as of 1.6.00 up to
31.8.03 with CODE (813) Voice control system (VCS) Selection and dialogue with the audio components
Fig. 94: Identifying Activating/Accepting Call And VCS (SBS) Switch - Models 202.08 /09 /18 As Of
1.6.00, 203 Up To 23.4.04, 208.3, 210 As Of 1.6.00,215, 220 As Of 1.6.00 Up To 31.8.03 With Code (813)
Control of audio functions
After activating the voice control system (VCS) with the VCS switch (S93/2), the user has (depending on the
equipment) several options for establishing a desired audio connection, provided the radio component of the
particular vehicle-specific audio system is activated.
To request the desired audio function, the following commands can be used.
To activate the radio component:
 Radio
 Radio on
 Turn radio on
 Turn on radio
To activate the CD component (except code (818a) CD changer in luggage compartment (10-disks), except
code (818b) single CD player additional equipment, except code (819) CD changer (6-disk), except code (819a)
CD changer):
 CD
 CD on
 Turn CD on
 Turn on CD
To activate the cassette component:
 Cassette
 Cassette on
 Turn cassette on
 Turn on cassette
To activate the CD component (with code (818a) CD changer in luggage compartment (10-disks), with code
(818b) single CD player additional equipment, with code (819) CD changer (6-disk), with code (819a) CD
changer):
 CD player
 CD player on
 Turn CD player on
 Turn on CD player
 CDC
 CDC on
 Turn CDC on
 Turn on CDC
If the user is then in the dialog mode with the desired audio function, additional commands are available for
control within the system.
If the radio component is activated, the following control commands are available:
 Station search
 Different station
 Next station
 Find different station
 Frequency
 Store station (when station list present)
 Select station (when station list present)
 Read station list (if station list is present)
 Read stations (when station list is present)
 Delete station list (when station list is present)
 Delete station
 Traffic radio on/Switch on traffic radio/Traffic radio off
 FM/Long Wave/Middle Wave/Short Wave
 Help/Help radio
If the cassette component is activated, the following control commands are available:
 Different title
 Next title
 Find different title
 Search
 Other side
 Wind cassette forward
 Wind cassette back
 Fast forward
 Fast reverse
 Return flow
 Help/Help cassette
 Help/Help CD changer/Help CD player
If the CD component is activated, the following control commands are available:
 CD number xx (when changer present)

 Insert CD number xx (when changer present)
 Select CD number xx (when changer present)
 Next CD (when changer present)
 Select next CD/Insert next CD (when changer present)
 Different CD (when changer present)
 Select different CD/Insert different CD (when changer present)
 CD title xx (if changer present)
 CD title number xx (if changer present)
 Select title xx (with single CD radio and/or changer and CD already selected)
 Select title number xx (with single CD radio and/or changer and CD already selected)
 Different title/next title (with single CD radio and/or changer and CD already selected)
 Find different title (with single CD radio and/or changer and CD already selected)
 Help/Help CD changer/Help CD player
A personal station list can be created with the commands listed above. The sequence is the same as for creating
a personal telephone book, however, with the commands listed above.
A help function is available that supports the user in operating the VCS. If the user is in dialogue mode with the
radio component of the particular vehicle-specific audio system and says the word "Help", the VCS reads out
the most important commands of the radio components. If the user is in dialogue mode with the cassette
component, then they can say "Help Radio" whereupon the system is changed and the VCS reads out the most
important radio component commands.
Station list, function GF82.70-P-3002P

Voice control system GF82.70-P-4100B
Hands-free microphone, Models 202, 208, 210 GF82.70-P-4102B
location/task with code (274) MB D-
net telephone
Models 202, 210
with code (312) D-
telephone
with code (313) D-
with code (314a)
telephone
Models 202, 208, 210,
215, 220
network telephone (D2B)
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
Hands-free system Models, 202, 208, 210 GF82.70-P-4103B
loudspeaker, location/task with code (274) MB D-
net telephone
Models 202, 210
with code (312) D-
telephone
with code (313) D-
network portable "CTEL
telephone"
with code (314a)
telephone
Model 202, 208, 210,
215, 220
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
Voice control system GF82.70-P-4113A
Dialing, function - GF82.70-P-3000M
Function
After activating the system, the user has a number of options for establishing a desired connection by using the
following commands for editing.
However, the user has to take into consideration whether the card is inserted, the PIN is entered, the network is
available, and the telephone is ready.
User editing commands for stored or non-stored numbers:
 Dial telephone number

 Dial number
 Dial name
 Read telephone book
User final commands:
 Dial
 Store
After activation has been completed and the user has spoken the editing command, e.g. "Dial number" or "Dial
telephone number", the voice control system (VCS) requests the user to enter a telephone number by the voice
output saying "Please say number".
If an error occurs when entering the desired telephone number, e.g., improper recognition of a number by the
VCS or incorrect entry by the user, it is possible for the user to delete or correct the number. If the number was
entered without errors and recognized correctly by the VCS, the final command "Dial" given by the user is
confirmed by the VCS announcement "The number is being dialed" and the connection is established. If the
user would like to have the desired phone number permanently available after entering it successfully, then
instead of the final command "Dial" the final command "Store" must be spoken. Thereupon the VCS requests
the user to enter the desired name through the spoken announcement "Please say the name". After this has been
entered by the user, the VCS requests the user to repeat the name as confirmation. Then the number and the
associated name are stored in the telephone book, indicated by the spoken announcement "Name and number
have been stored".
The entries stored in the telephone book can only be called up reliably by the users who store them.
"Dialing a name" entry:
 The editing command "dial name" can be used to request a name that is already stored in the telephone
book. To this end, the VCS requests the user to say the desired name
"Listening to the telephone book" entry:
 The editing command "Read telephone book" can be selected to have the telephone book read out by the
VCS, in order to press the VCS switch (S93/2) when the desired name is being read out. With this
command it is therefore possible to "scroll" through the telephone book.
The editing command "Read telephone book" can also be used when the VCS has difficulty in recognizing a
name entered by the user using voice input.
If it is already in the telephone book, the name can then be selected and thus the connection established.
With the two dialing options listed here, the final command "Dial" is not needed.
After the name has been repeated by the VCS, the user is informed by the voice output feature that the "number
is being dialed" and that the call is completed.
If, with the dialing options listed, the desired number is not available (e.g., the desired connection is busy), the
user then has the option of redialing the number dialed last after terminating the dialing procedure and
reactivating the VCS with the editing command "Redial".
During the particular dialing options, it is possible at any time to terminate the dialog with the VCS either by
pressing the VCS switch (S93/2) or spoken input "Terminate" by the user.
Deleting or correcting digits during the number entry
 Delete
 Delete number
This means that all the numbers previously entered are deleted, the system informs the user of this via the
spoken announcement "The number is deleted, please say it" and other numbers or commands are requested for
the entry.
It is also possible to make calls abroad using the VCS. In addition to this, it is also possible to control
announcement services or to operate the mailbox.
The VCS has a help function to make operation as simple as possible. The user is in Dialog mode with the
telephone and says the word "Help", the VCS reads the most important telephone commands aloud.
If the user is in dialog with the COMAND operating, display and control unit (A40/3), then he/she can say
"Help phone" whereupon the system is changed and the VCS reads out the most important phone commands.

location/task
TELEPHONE BOOK, FUNCTION - GF82.70-P-3001
Telephone book, function - GF82.70-P-3001B
MODELS 140, 202, 203 up to 23.4.04, 208.3, 210, 215, 220 up to 31.8.03 with CODE (813) Voice control
system (VCS)
Fig. 95: Identifying Activating/Accepting Call And VCS (SBS) Switch - Shown On Models 202, 203,
208.3, 210, 215, 220 As Of 6/1/00

Creating telephone book
The voice control system (VCS) allows the user to create his/her own telephone book. Telephone numbers
called frequently can be stored here together with freely selectable names.
30 to 50 entries can be stored depending on the length of the names selected.
To create or extend a personal telephone book, the user needs the following editing commands after the VCS
was activated with the VCS switch (S93/2):
 Store name
 Store number
 Store telephone number
After saying the editing command, the user is requested by the VCS to enter a telephone number. This is
accomplished as an entry of:
 Blocks of numbers suitable for entering longer numbers (approx. 3 to 5 numbers per number block, in
each case with a speaking pause of approx. 0.5 s between the number blocks)
 Number chains (up to 5 numbers, without speech pause), suitable for entering short numbers.
If an error occurs when entering the desired telephone number, i.e. improper recognition of a number by the
VCS or incorrect entry by the user, it is possible for the user to delete or correct the number.
If no errors occurred while entering the number, the VCS requests the user to "Please say name" after the
command "Store".
If this name has been entered by the user, the VCS requests the user to say the name again as confirmation.
If a different name is given when the name is entered the second time, the VCS voice output requests the user to
"Please say again".
If the user says the name mentioned first, the VCS requests the user to repeat it.
The system stores the telephone book entry (name and associated number) in the telephone book only when the
associated name and its repetition are identical.
The system voice output indicates "Name and number stored".
Calling up telephone book entries
The VCS user can use the editing command "Read telephone book" to have the complete telephone book read
out. In doing so, the user can select a certain name and thus start the dialing process.
Deleting individual entries in telephone book
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete name" to
delete an individual entry in the telephone book. The VCS then requests the user to say the name to be deleted.
After entry of the name by the user, the user is asked, as confirmation, if the name selected is really to be
deleted. If the use answers "Yes", the name entered is deleted from the telephone book and the VCS voice
output indicates "Name deleted". If the user answers "Yes", the name entered is deleted from the telephone
book and the VCS voice output indicates "Name deleted". If the user answers "No", the name remains stored.
Any other word spoken by the user will end the dialog with the VCS, however without deleting the entry.
Deleting entire telephone book
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete telephone
book" to delete all entries from the telephone book. After entry of this editing command, the VCS voice output
asks the user if he/she really wants to delete the telephone book. If the answer is "Yes", the user is asked again
as a confirmation "Are your sure". If the user answers "Yes" to this question, all entries in the telephone book
are deleted. If he/she answers with "No", the VCS starts reading the telephone book entries aloud again.
While the telephone book is being read aloud, the user can select a name to be deleted by activating the VCS
switch (S93/2). The selected name is then repeated by the VCS. The user is then asked, as confirmation, if
he/she really wants to delete the selected name. If the name to be deleted by activating the VCS switch (S93/2).
The selected name is then repeated by the VCS. The user is then asked, as confirmation, if he/she really wants
to delete the selected name. If the user answers "Yes", the name specified is deleted from the telephone book. If
he/she answers "No", the system continues to read the telephone book entries aloud. Any other word will end
the dialog with the VCS, however without deleting an entry.
Deleting or correcting number chains/blocks during number entry
If the number has been entered as a number chain (spoken together without pauses), the number can only be
changed with the following editing commands:
 Delete
 Delete number
This means that all numbers entered previously are deleted and that the system outputs a message to the user via
voice output indicating "Number deleted, please say number or command" and to enter an additional number or
command.
If the number has been stored as a series of number blocks (3 to 5 numbers per block, speech pause of 0.5 s
between individual blocks), the number can only be changed with the following editing commands:
 Correct
 Correction
 Correct telephone number
 Correct telephone/number
This means that the block of numbers entered last is deleted and the block of numbers entered previously is
repeated by the VCS. Then the VCS requests the user to "Continue" with voice output requesting either more
With both types of number entry, after more than 20 numbers have been entered without a speaking pause, the
VCS reports: "The number is too long", and the user is requested to enter the given number as a sequence of
number blocks.
This then makes it possible to enter long telephone numbers as well. If the user wants to check the numbers
already entered by listening to them again, this is possible with the command "Repeat". The VCS repeats all of
the numbers entered up to that point and then requests the user with voice output "Continue" to enter additional

location/task
31.5.98
location/task 210
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with code (313) D-
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with code (313) D-
network portable
"CTEL telephone"
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
31.5.98
31.8.03
Telephone book, function - GF82.70-P-3001M
Reading the telephone book
Following the command "Read telephone book" the VCS reads out the names that are stored in the address
book. If, while reading out a name, the VCS switch (S93/2) is moved in driver direction, then this name is
selected and a question is asked regarding whether the private, business or the CTEL number should be dialed.
Actions in the address book
The address book can be used in a similar way as the telephone book; it is possible to have the address book
read out and to open or delete individual entries depending on the voice command using the VCS switch
(S93/2) in driver direction. If a voice tag has been assigned to an entry, then this entry can be selected via voice
command. To do this, the speech recognition system is operated in compound word mode; words both from the
speaker dependent and the non speaker dependent part are recognized.
Deleting the address book
The command "Delete address book" enables all or individual address book entries to be deleted.
Dialing a name
With the aid of this command, telephone numbers can be selected from the address book by entering the related
name via a voice command. The entry is speaker-dependent and can only be requested reliably again by the
person who saved the entry.
Deleting a name
With the aid of the command "Delete name" it is possible to delete entries from the address book. In doing so,
there is a distinction between entries having been created by voice input or in writing. The entire entry is only
deleted, if the entry was created via voice operation and was not edited.
Navigate key word (Voicetag)
If in the address book only one geocode is stored per voice command, then this is used to start the navigation
system. Otherwise a question is asked as to whether the business or private address should be selected. It is also
possible, though to directly enter business or private via the "keyword".
Select keyword (Voicetag)
If only one number is stored in the address book, then this number is dialed promptly. Otherwise, the system
asks whether the business, mobile CTEL or private number should be dialed. It is also possible, though to
directly enter business, cellular mobile telephone or private via the "keyword".
Delete keyword (Voicetag)
With the aid of this command it is possible to delete keywords from the address book. In doing so, there is a
distinction whether the entry was created via voice input or whether the entry was created in writing. The entire
entry is deleted, if the entry was created via voice operation and was not edited. Otherwise, only the keyword is
deleted, and the remaining data in the entry are retained.
Displaying and processing an entry
Entries that have already been assigned a keyword can be displayed on the display of the COMAND operating,
display and control unit (A40/3) via voice command.
Entries that have not been assigned a spoken keyword can be selected by spelling out. The spelling feature can
also be started by using the appropriate control button (softkey) in the main address book menu in the operation
field of the COMAND operating, display and control unit (A40/3).
The user can now select an entry from the numbered name list, the "Pick list" (the recognized results that were
entered into the address book) either by typing the number of the desired entry on the telephone keypad of the
COMAND operating, display and control unit (A40/3) or speaking the number of the desired entry.
Example:
"Use 1" or "Accept 1" accepts the first alternative, number 2 accepts the second alternative.
With "Go forward" you can browse through to the next page. With "Back" you return to the previous page.
With "correct" it is possible to exit the current Pick list.
The opened entry can then be processed or used via voice command. To do this, the voice recognition has to be
restarted by using the VCS switch (S93/2).
Store name
Once an entry has been opened, a keyword can be allocated to this entry with the "save name" command.
Store number
Once an entry has been opened, a phone number can be saved for this entry with the "save number" command.
Dial
If only one number is saved in the entry, then it is dialed promptly, otherwise the system asks which numbers
should be dialed. It is however also possible to specify the desired number straight away, by additionally
appending "private", "portable cellular phone" or "business" to the word "Select".
Delete number
If only one number is stored in the address book, then it is deleted by using the "delete number" command,
otherwise the system asks which number should be deleted.
Listening to names
By using the "listen to name" command it is possible to listen to the keyword that has been allocated to the card
of the opened entry.
Deleting a name
By using the "delete name" command it is possible to delete the keyword that has been allocated to the opened
entry.
Navigating
The Geocode that is recorded in the address book can be transmitted to the navigation system. If only one
Geocode is stored navigation is started. Otherwise, the systems asks whether it should guide the user to the
business or private address. It is also possible, though to directly enter "navigation business" or "navigation,
private". If no valid Geocode is stored then the system issues an acoustic response.
Address book help
The VCS reads the help text for the address book. The help text depends on the which help is requested:
 Outside of the address book

 Address book opened, name list displayed
 Entry opened

location/task
STATION LIST, FUNCTION - GF82.70-P-3002
Station list, function - GF82.70-P-3002M
Function
The voice control system (VCS) allows the user to create a list of stations. Stations selected frequently can be
stored here together with freely selectable names or the proper station name. 10 entries can be stored.
To create or expand the personal list of stations after switching on the operating unit and activating the VCS
with the VCS switch (S93/2), the user has to say the editing command "store station".
After saying the editing command, the user is requested by the VCS to enter a station name.
"Please say the name".
If this name has been entered by the user, the VCS requests the user to say the name again as confirmation. If a
different name is given when the name is entered the second time (confirmation), the VCS voice output "Please
say again" can be heard. If the user then says the name mentioned first, the VCS requests the user to repeat it
again. The system stores the station list entry (name and associated station) in the station list only when the
associated name and its repetition are identical.
The system voice output then indicates "Station stored".
Calling up station list entries
The VCS user can use the editing command "Read list of stations" to have the complete list of stations read out.
In doing so, the user can select a certain station name in order to set a new station. Selection is accomplished by
actuating the VCS switch (S93/2).
Selecting station from station list
The user can use the editing command "Select station" to select a station from the list of stations. After this
editing command, the VCS asks the user: "Please say name" for this station. If the user says the name specified
previously while storing the station, then the voice control system VCS switches to the desired station after the
user has repeated the station name.
Deleting individual entries from the station list
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete station"
to delete an individual entry in the list of stations. The VCS then requests that the name of the station to be
deleted is stated. After entry of the station name by the user, he/she is asked, if he/she really wants to delete the
name. If the user answers "Yes", the specified station name is deleted from the station list, the message "Station
deleted" being displayed. If the user answers "No" or if too much time elapses, the deletion process is aborted
and the station name is retained. Any other word spoken by the user terminates the dialog with the VCS.
Delete entire station list
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete station
list" to delete all entries from the list of stations. The editing command is followed by a VCS voice output,
asking whether the list of stations really should be deleted. If the user answers with "Yes", then he/she is asked
by a voice output: "Are you sure?". If the user answers this question with "Yes", all station list entries are
deleted. If the user answers with "No", the VCS starts to read out the station list entries.
While the station list is being read out, the user can select a station to be deleted by activating the VCS switch
(S93/2). The selected station is then repeated by the VCS. The user is then asked, if he/she really wants to delete
the selected station. If the user answers "Yes", the specified station is deleted from the station list. If the user
answers "No", the system continues reading the station list entries aloud. Any other word terminates dialog with
the VCS. The user can interrupt the dialog with the VCS at any time by activating the VCS switch (S93/2).

location/task
control unit, location/
task
Station list, function - GF82.70-P-3002P
MODELS 202.08 /09 /18 as of 1.6.00, 203 up to 23.4.04, 208.3, 210 as of 1.6.00, 215, 220 as of 1.6.00 up to
31.8.03 with CODE (813) Voice control system (VCS)
Fig. 97: Identifying Activating/Accepting Call And VCS (SBS) Switch - Models 202.08 /09 /18 As Of
1.6.00, 203 Up To 23.4.04, 208.3, 210 As Of 1.6.00, 215, 220 As Of 1.6.00 Up To 31.8.03 With Code (813)
Creating station list
The voice control system (VCS) allows the user to create a list of stations. Stations selected frequently can be
stored here together with freely selectable names. 10 entries can be stored.
To create or add to a personal list of stations, the radio component of the particular vehicle-specific audio
system and the VCS have to be activated via the VCS switch (S93/2). To do this, the VCS needs the editing
command "save station".
Next, the VCS asks the user: "Please say name" for this station.
The VCS repeats this to confirm that the name was understood correctly. If the second entry differs from the
first, the system asks: "Please say again". In doing so, the system returns to the name entry loop, in other words
the user has to enter both names again.
The system stores the station list entry (name and associated station) in the station list only when the associated
name and its repetition are identical.
If the name entry loop was completed successfully, the user receives the following acknowledgment:
"Station has been stored".
Calling up station list entries
The VCS user can use the editing command "Read list of stations" to have the complete list of stations read out.
In so doing the user can select a specific name and set a new station. Selection is accomplished by actuating the
VCS switch (S93/2).
Selecting station from station list
The VCS user can use the editing command "Select station" to select a station in the list of stations.
After this editing command, the user is requested by the VCS to "Please say name" for entry of the station
name. If the user enters a station name previously stored in the station list, the VCS confirms the station name
and changes the selected station.
Deleting individual entries from the station list
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete station"
to delete an individual entry in the list of stations. The VCS then requests that the name of the station to be
deleted is entered.
After the user has entered the station name, the VCS repeats the question which station is to be deleted in order
to make sure that the selected station really is to be deleted.
If the user answers "Yes", the specified station name is deleted from the station list and confirmed by the VCS
voice output message "Station deleted". If the user answers "No", the name remains stored.
Any other word spoken by the user will end the dialog with the VCS without deleting the station. Deleted
station names cannot be recovered.
Delete entire station list
After activating the VCS using the VCS switch (S93/2) the user can use the editing command "Delete station
list" to delete all entries from the list of stations. After entry of this editing command, the VCS voice output asks
the user if he/she really wants to delete the station list. If the answer is "Yes", the VCS repeats the request for
confirmation of the clear instruction: "Are you sure".
If the user answers "Yes" to this question, all station list entries are irrevocably deleted. If he/she answers with
"No", the VCS starts reading the station list entries aloud again.
While the station list is being read aloud, the user can select a station to be deleted by activating the VCS switch
(S93/2). The selected station is then repeated by the VCS. The user is then asked, as confirmation, if he/she
really wants to delete the selected station.
If the user answers "Yes", the specified station is deleted from the station list. If the user answers "No", the
system continues reading the station list entries aloud. Any other word terminates dialog with the VCS.
Moreover, the user can continue dialog with the VCS at any time with the VCS switch (S93/2).
Voice control system GF82.70-P-4100B

Hands-free microphone, Models, 202, 208, 210 GF82.70-P-4102B
location/task with code (274) MB D-
net telephone
Models 202, 210
with code (312) D-
telephone
with code (313) D-
with code (314a)
telephone
Model 202, 208, 210,
215, 220
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
Hands-free system Models, 202, 208, 210 GF82.70-P-4103B
loudspeaker, location/task with code (274) MB D-
net telephone
Models 202, 210
with code (312) D-
telephone
with code (313) D-
network portable "CTEL
telephone"
with code (314a)
telephone
Models 202, 208, 210,
215, 220
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
Voice control system GF82.70-P-4113A
OPTICAL WAVEGUIDE INTERFACE, LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-3106
Optical waveguide interface, location/task/design/function - GF82.70-P-3106A
MODELS 215, 220 up to 31.8.02 with CODE (317) GSM portable cellular telephone (D2B)
MODELS 215, 220 up to 31.8.02 with CODE (318) Additional portable for telephone in center console
MODELS 215, 220 up to 31.8.02 with CODE (494a) USA version
Shown on Model 220

Fig. 98: Identifying Optical Waveguide Interface Location - Shown On Model 220
Optical waveguide With code 317, up to 31.8.02 GF82.70-P-3106-01A

interface, position
with code (494a) GF82.70-P-3106-01D
at -Vehicle, D2B
Portable CTEL interface
(A59/1) to be retrofitted by
MB North America (MBNA).
With code 318, up to 31.8.02 GF82.70-P-3106-01B
Optical waveguide The D2B Portable CTEL
interface, task interface (A59/1) is needed
for connecting the portable
CTEL (with code 317, code
318 or code 494a) to the
Digital Data Bus (D2B).
Optical waveguide D2B interface
interface, design
 Input for theD2B wake-
up signal
 Integrated charging unit
for rechargeable battery
for portable cellular
telephone
Optical waveguide with code 316 up to 31.8.02 GF82.70-P-3106-04A
interface, function
Optical waveguide interface, position - GF82.70-P-3106-01A
Shown on Model 220

Fig. 99: Identifying Optical Waveguide Interface Position - Shown On Model 220
Optical waveguide interface, position - GF82.70-P-3106-01B
Shown on Model 220
Fig. 100: Identifying Optical Waveguide Interface Position - Shown On Model 220
Fiber optic cable interface, location - GF82.70-P-3106-01D
Models 215, 220 with code 352a and code 494a

Fig. 101: Identifying Fiber Optic Cable Interface Location - Illustrated On Model 220
Fiber-optic conductor interface, function - GF82.70-P-3106-04A
Models 215, 220 with code 317 or code 318 or code 494a
The portable CTEL D2B interface (A59/1) is switched on or off via a discrete "Wake-up" line. It responds to
the negative edge of the pulse (in rest state the level is at "high") and the duration of the "Wake-up" signal.
Generally, after switching off the D2B the portable CTEL D2B interface (A59/1) remains active for a
further 10 min, insofar as a portable CTEL is inserted into the holder and active.
The COMAND operating, display and control module (A40/3n1) sends control data over the D2B to the
portable CTEL D2B interface (A59/1) . Once there the incoming control data is forwarded to the portable
CTEL with the aid of discrete databus lines.
The portable CTEL D2B interface (A59/1 ) switches the portable CTEL on or off and transmits the functions
to be executed (e.g. dial subscriber's number).
The other way around the portable CTEL data (caller's voice, control data, telephone numbers) is transmitted by
the portable CTEL D2B interface (A59/1) in an appropriate D2B format and forwarded for further processing
to the COMAND operating, display and control module (A40/3n1) .
Charging up the portable CTEL battery
The portable CTEL's battery is charged up until the portable CTEL D2B interface (A59/1) is activated over the
D2B (regardless of whether the portable CTEL is switched on or off).
Optical waveguide interface, location/task/design/function - GF82.70-P-3106B
MODELS 215, 220 up to 31.8.02 with CODE (316) MB GSM cellular telephone (D2B)
Shown on Model 220
Fig. 102: Identifying Optical Waveguide Interface Location - Shown On Model 220
Optical waveguide with code 316, 318 up to

interface, position 31.8.02
Optical waveguide The D2B interface for
interface, task fixed installation CTEL
(A59) is needed for
connecting the CTEL
transmitter / receiver
(A35) to the Digital Data
Bus (D2B). For dynamic
route guidance (code
815):
Passing on the TMC
traffic data received via
the telephone to the
traffic data recorder
(A2/43)
Optical waveguide D2B interface
interface, design
 Interface to the RB
CAN
 Input for the D2B
wake-up signal
Optical waveguide with code 316 up to GF82.70-P-3106-04B
interface, function 31.8.02
Light wave conductor interface, location - GF82.70-P-3106-01C

Model 129
Fig. 103: Identifying Light Wave Conductor Interface Location - Model 129
Model 170
Fig. 104: Identifying Light Wave Conductor Interface Location - Model 170
Model 202 sedan, 208.3

Fig. 105: Identifying Light Wave Conductor Interface Location - Illustrated On Model 202
Model 202 T-model
Fig. 106: Identifying Light Wave Conductor Interface Location - Illustrated On Model 202 T-model
Model 210 sedan
Fig. 107: Identifying Light Wave Conductor Interface Location - Illustrated On Model 210 Sedan
Model 210 T-model
Fig. 108: Identifying Light Wave Conductor Interface Location - Illustrated On Model 210 T-model
Model 220
Fig. 109: Identifying Light Wave Conductor Interface Location - Illustrated On Model 220
Optical waveguide interface, function - GF82.70-P-3106-04B
Models 215, 220 with code 316
The D2B interface for fixed CTEL installation (A59) is switched on or off via a discrete "wake-up" line. It
responds to the negative edge of the pulse (in rest state the level is at "high") and the duration of the "Wake-up"
signal.
The COMAND operating, display and control module (A40/3n1) transmits control data via the D2B to theD2B
interface for fixed CTEL installation (A59). From there the incoming control data are passed on to the CTEL
transmitter/receiver using discrete data lines (A35). The D2B interface for fixed CTEL installation (A59)
switches the CTEL transmitter / receiver (A35) on or off and conveys the functions to be performed (e.g. select
call number).
Vice versa the data (caller's voice, control data) of the CTEL transmitter / receiver (A35) from the D2B
interface for fixed CTEL installation (A59) are transmitted in a corresponding D2B format and passed on for
further processing to the COMAND operating, display and control module (A40/3n1).
Transmission of the traffic news on the Traffic Message Channel (TMC) (with dynamic route guidance only
(code 815)):
The TMC traffic messages are received from the CTEL transmitter / receiver (A35) and transmitted to fixed
CTEL installation D2B interface (A59). The data are converted there and passed on to the traffic data recorder
(A2/43) via the RB-CAN.
TELEPHONE INTERFACE, LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-3107
Telephone interface, location/task/design/function - GF82.70-P-3107C
MODEL 215, 220 up to 31.8.03 with CODE (854) MB portable cellular telephone
Fig. 110: Identifying Telephone Interface Location
Telephone interface, The telephone interface

luggage compartment floor
behind the rear bench seat.
Telephone interface, task  Connecting the
portable telephone
(A34/6) to the D2B
(digital data bus) as
ring participant
 Charging the portable
telephone (A34/6) via
the telephone
interface (A34/4)
 Antenna connection to
the vehicle
Telephone interface,  D2B interface
design
 Signal processing and
conversion
 Input for D2B wake-
up signal
Telephone interface, GF82.70-P-3107-02Q
function
Telephone interface, function - GF82.70-P-3107-02Q
The telephone interface (A34/4) is switched on and off via a discrete wake-up line. It reacts to the voltage drop
(level is max. 5 V in quiescent condition) and the duration of the wake-up signal.
The telephone interface (A34/4) is wired directly to the portable CTEL bracket for power supply and signal
transmission.
Incoming control data from the Digital Data Bus (D2B) are relayed via the telephone interface (A34/4) to the
portable CTEL bracket and therefore the portable CTEL (A34/6) using discrete data lines.
The telephone interface (A34/4) therefore conveys the functions to be carried out (e.g. select phone number,
"ON" or "OFF", etc.) to the portable CTEL (A34/6) upon request from the operating unit.
In the reverse direction, the data (caller's voice, control data) is transmitted from the telephone interface (A34/4)
in an appropriate D2B format and relayed for further processing to the operating unit. The telephone interface
(A34/4) converts electrical pulses into optical pulses.
Telephone interface, location/task/design/function - GF82.70-P-3107CA
MODEL 215, 220 as of 1.9.03 with CODE (854) MB portable cellular telephone

Fig. 111: Identifying Telephone Interface Location

luggage compartment floor
behind the rear bench seat.
Telephone interface, task  Connecting the
portable telephone
(A34/6) to the Media
Oriented System
Transport (MOST) as
a ring participant
 Charging the portable
telephone (A34/6) via
the telephone
interface (A34/4)
 Antenna connection to
the vehicle
Telephone interface,  MOST interface
design
 Signal processing and
conversion
 Input for the MOST
wake-up signal
Telephone interface, GF82.70-P-3107-02QA
function
Telephone interface, function - GF82.70-P-3107-02QA

The telephone interface (A34/4) is switched on and off via a discrete wake-up line. It reacts to the voltage drop
(level is max. 5 V in quiescent condition) and to the duration of the wake-up signal.
The telephone interface (A34/4) is wired directly to the portable telephone holder for power supply and signal
transfer purposes.
Control data coming in from the Media Oriented System Transport (MOST) is passed on via the telephone
interface (A34/4) to the portable telephone holder and therefore to the portable telephone itself (A34/6) using
discrete data lines.
Thus, upon request from the operating unit, the telephone interface (A34/4) conveys the functions to be carried
out (e.g. select phone number, "ON" or "OFF", etc.) to the portable telephone (A34/6). Conversely, the
telephone interface (A34/4) transfers data (caller's voice, control data) in an appropriate MOST format and this
data is passed to the operating unit for further processing. The telephone interface (A34/4) converts electrical
pulses into optical pulses.
CTEL interface, location/task/design/function - GF82.70-P-3107E
MODELS 129, 168, 170, 202, 208, 210, 215, 220 with CODE (317) GSM portable cellular telephone (D2B)
Models 215, 220, (illustration shows model 220)
Fig. 112: Identifying Portable Cellular Telephone D2B Interface
Telephone interface, D2B interface and

location telephone interface are
Model 129 GF82.70-P-3107-01F
Model 168 GF82.70-P-3107-01J
Model 170 GF82.70-P-3107-01I
Model 202 GF82.70-P-3107-01G
Model 208 GF82.70-P-3107-01K
Model 210 GF82.70-P-3107-01H
Telephone interface, The portable CTEL D2B
task interface (A59/1) is required
to connect the mobile phone
to the digital data bus (D2B).
design
 Input for D2B Wake-
Up signal
for mobile phone
rechargeable battery
Telephone interface, GF82.70-P-3107-02C
function
CTEL interface, function - GF82.70-P-3107-02C
Theportable CTEL D2B interface (A59/1) is switched on or off via a discrete "Wake-Up" line. It reacts to the
falling impulse edge (at rest state level is "high") and the duration of the "Wake-Up" signal.
Generally after switching off the D2B, the D2B interface mobile phone (A59/1) remains active for a further 10
minutes, provided a switched-on mobile phone is in the cradle.
Incoming control data from D2B is directed to the mobile phone via the portable CTEL D2B interface
(A59/1) with the aid of discrete data lines; then as requested by the radio (A2) the portable CTEL D2B
interface (A59/1) switches the mobile phone on or off and relays the functions to be carried out (e.g. dial
number). Inversely, the mobile phone data (voice of caller, control data, telephone numbers) is converted into
an appropriate D2B format by the portable CTEL D2B interface (A59/1) and then directed to the radio (A2)
for further processing.
Charging mobile phone rechargeable battery
The mobile phone rechargeable battery remains on charge as long as the portable CTEL D2B interface
(A59/1) is activated via the D2B (regardless of whether the mobile phone is switched on or off).
CTEL interface, location/task/design/function - GF82.70-P-3107F
MODELS 129, 170, 202, 208, 210, 215, 220 with CODE (316) MB GSM cellular telephone (D2B)
Models 215, 220 (illustration shows model 220)

Fig. 113: Identifying CTEL Interface And E-network Compensator
Telephone interface, D2B interface and telephone

location interface are identical
components
Model 129 GF82.70-P-3107-01F
Model 170 GF82.70-P-3107-01I
Model 202 GF82.70-P-3107-01G
Model 208 GF82.70-P-3107-01K
Model 210 GF82.70-P-3107-01H
Telephone interface, The fixed installation CTEL
task D2B interface (A59) is required
to connect the CTEL
transmitter/receiver (A35) to
the digital data bus (D2B).
With dynamic route guidance
(code 815) additional task:
Relay of T raffic-M essage C
hannel (TMC) traffic data to
traffic data memory (A2/43)
received via telephone
design
 Interface to CAN
(telephone)
 Input for D2B Wake-Up
signal
Telephone interface, GF82.70-P-3107-02D
function
Telephone interface, function - GF82.70-P-3107-02D
The fixed installation CTEL D2B interface (A59) is switched on or off via a discrete "Wake-Up" line. It
reacts to the falling impulse edge (at rest state level is "high") and the duration of the "Wake-Up" signal.
Incoming control data from D2B is directed to the CTEL transmitter/receiver (A35) via the fixed installation
CTEL D2B interface (A59) with the aid of discrete data lines; then as requested by the radio (A2) the fixed
installation CTEL D2B interface (A59) switches the CTEL transmitter/receiver (A35) on or off and relays
the functions to be carried out (e.g. dial number).
Inversely, the data (voice of caller, control data) of the CTEL transmitter/receiver (A35) is converted into an
appropriate D2B format by the portable CTEL D2B interface (A59) and then directed to the radio (A2) for
further processing.
Telephone interface, location/purpose/design/function - GF82.70-P-3107P
MODEL 129, 163, 168, 202.08 /09 /18, 203, 208, 210, 215, 220 with CODE (854) MB portable cellular
telephone
Location of components in model series 203, illustrated on model 203.0
Fig. 114: Identifying E-Network Compensator And CTEL Interface - Illustrated On Model 203.0
Telephone interface, Model 129 GF82.70-P-3107-01FA

location
Model 163 GF82.70-P-3107-01P
Model 168 GF82.70-P-3107-01JA
Model 202.08, 202.09, 202.18 GF82.70-P-3107-01GA
Model 208 GF82.70-P-3107-01KA
Model 210 GF82.70-P-3107-01HA
Models 215, 220 GF82.70-P-3107-01O
purpose (A34/4) is required for
connecting the portable
cellular telephone to the
digital data bus (D2B).
design
 Input for D2B wake-up
signal
for rechargeable battery
for portable cellular
telephone
Telephone interface, GF82.70-P-3107-02P
function
CTEL interface, location - GF82.70-P-3107-01O
Models 215, 220
Shown on model 215
Fig. 115: Identifying CTEL Interface Location - Shown On Model 215
Telephone interface, function - GF82.70-P-3107-02P
TheCTEL interface (A34/4) is switched on and off via a discrete wake-up line. It responds to the negative edge
of the pulse (in rest state the level is at "high") and the duration of the "wake-up" signal.
Generally, the CTEL interface (A34/4) remains active for another 10 minutes after the D2B ring is switched
off, when a switched on portable cellular telephone is inserted in the mount.
Control data coming from the D2B ring are transmitted to the portable cellular telephone via the CTEL
interface (A34/4) with the aid of discrete data lines; thereby the
CTEL interface (A34/4) switches the portable cellular telephone on and off by the request of the head unit
(radio or COMAND) and transmits the functions to be performed (e.g. dialing number).
On the other hand the data for the portable cellular telephone (voice of caller, control data, telephone number) is
transferred in a corresponding D2B format by the CTEL interface (A34/4) and transmitted to the head unit
(radio or COMAND) for further processing.
Loading rechargeable battery for portable cellular telephone
The rechargeable battery in the portable cellular telephone is charged as long as the CTEL interface (A34/4) is
activated via the D2B ring (regardless of whether the portable cellular telephone is switched on or off).
COMPENSATOR, LOCATION/PURPOSE - GF82.70-P-3109
Compensator, location/purpose - GF82.70-P-3109P
MODEL 129, 163, 168, 202.08 /09 /18, 203, 208.3, 210, 215, 220 with CODE (854) MB portable cellular
telephone
Location of components in model series 203, illustrated on model 203.0
Fig. 116: Identifying E-Network Compensator - Illustrated On Model 203.0

On vehicle floor below cover plate in trunk
Compensator, location Model 129 GF82.70-P-3109-01A

Model 163 GF82.70-P-3109-01G
Model 168 GF82.70-P-3109-01F
Model 202.08, 202.09, GF82.70-P-3109-01B
202.18, 208.3
Model 208.3 GF82.70-P-3109-01BA
Model 210 GF82.70-P-3109-01C
Model 215 GF82.70-P-3109-01D
Model 220 GF82.70-P-3109-01E
Compensator, purpose  When calling with the
portable cellular
telephone (portable
cellular telephone in
charging station in
vehicle) losses in the
antenna lead can occur
due to higher
transmission frequency
of the E-network. The
compensator has the
purpose to compensate
the losses (amplifier
function).
Compensator, location - GF82.70-P-3109-01D
Model 215
Below right of parcel shelf

Fig. 117: Identifying Compensator Location - Model 215
Compensator, location - GF82.70-P-3109-01E
Model 220
Below right of parcel shelf
Fig. 118: Identifying Compensator Location - Model 220
Compensator, location/task - GF82.70-P-3109S

Shown on model 220
Fig. 119: Identifying Compensator Location - Shown On Model 220
Compensator, location The E-net compensator

(A28/3) is located in the
luggage compartment on
the right behind the side
paneling.
Compensator, purpose The E-net compensator
(A28/3) compensates the
damping of the E-net
telephone signals that
form due to the higher
transmission frequencies
of the E-net.
TELECOMMUNICATIONS CONTROL UNIT, LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-

3114SU
MODEL 215.3, 220.0 /1 with CODE (383a) Tele-Aid fixed installation telephone

Fig. 120: Identifying Telecommunications Control Unit Location - Illustrated On Model 215
Telecommunications control The telecommunications control

unit, location unit (N112) is located under the
right rear seat.
Telecommunications control The telecommunications control
unit, task unit (N112) has the following
purpose:
 Telephone/short message
service/bluetooth
 Emergency call, service
and breakdown assistance
 Position determination
 Traffic services
 Priority control
Telecommunication control GF82.70-P-3114-
unit design 03SU
Telecommunications control GF82.70-P-3114-
unit function 04SU
Telecommunication control unit design - GF82.70-P-3114-03SU

Fig. 121: Identifying Telecommunication Control Unit Function Diagram
VOICE CONTROL SYSTEM SWITCH, LOCATION/TASK - GF82.70-P-4100
Voice control system switch, location/task - GF82.70-P-4100B
system (VCS)
Shown on model 202, 203, 208.3, 210, 215, 220 as of 6/1/00
Fig. 122: Identifying Activating/Accepting Call And VCS (SBS) Switch - Shown On Model 202, 203,
208.3, 210, 215, 220 As Of 6/1/00

Voice control system Model 140 GF82.70-P-0002-01B

(VCS), arrangement of Model 210 up to 31.5.98
components
Model 203 GF82.70-P-0002-01P
Models 202, 208.3, 215, GF82.70-P-0002-01E
220 up to 31.5.00
up to 31.5.00
Model 202.08/09/18, GF82.70-P-0002-01EA
208.3 from 1.6.00
Model 210 as of 1.6.00 GF82.70-P-0002-01EB
Models 215, 220 as of GF82.70-P-0002-01EC
1.6.00 up to 31.8.03
Voice control system GF82.70-P-4100-02B
switch, purpose
Voice control system switch, purpose - GF82.70-P-4100-02B
With multifunction steering wheel (MFL)
 Activation of the voice control system (VCS)

 Deactivation of the voice control system (VCS)
Without multifunction steering wheel (MFL)
 Activation of the voice control system (VCS)

 Deactivation of the voice control system (VCS)
 Accepting an incoming telephone call
 Terminating a telephone call
Voice control system switch, location/task - GF82.70-P-4100M
Shown on model 211

Fig. 124: Identifying Voice Control System Switch - Shown On Model 211
Voice control system The VCS switch (S93/2) is

switch, location installed on the right side of
the steering column module
(N80).
Voice control system The VCS switch (S93/2)
switch, purpose reads in the following driver
requests:
 Activation of the VCS

and the hands-free
system of the telephone
 Deactivation of the
VCS
HANDS-FREE MICROPHONE, LOCATION/TASK - GF82.70-P-4102
Arrangement/purpose of hands-free system microphone - GF82.70-P-4102A
MODEL 140, 210 with CODE (348) TELE AID emergency call system
MODEL 129, 202, 208.3, 210, 215 up to 31.8.03, 220 with CODE (347) TELE AID emergency call system
(D2B)
MODEL 140, 202, 203, 210, 220 up to 31.8.03 with CODE (930) Taxi emergency call
MODEL 203, 208.3, 210, 215, 220 up to 31.8.03 with CODE (855) TELE AID
Fig. 125: Identifying Hands-Free System Microphone - Model 203 Up To 31.8.03 With Code (930) And
Up To 31.8.03 With Code (855)
Hands-free system GF82.70-P-4102-01B

microphone location
Hands-free system  Voice input for TELE
microphone purpose AID emergency call,
TELE AID
telediagnosis,
information call
 Listening to vehicle
interior during a TELE
AID taxi emergency call
(code 930)
Hands-free system microphone position - GF82.70-P-4102-01B
Shown on model 210 sedan
Fig. 126: Identifying Hands-Free System Microphone - Shown On Model 210 Sedan
The hands-free system microphone is near the base of the inside rearview mirror in all vehicles
Hands-free microphone, location/task - GF82.70-P-4102B
network telephone
telephone
telephone with CODE (313) D-network "Portable CTEL" telephone with CODE (314a) "Standard" D-
network telephone with CODE (316) MB D-network telephone (D2B) with CODE (317) D-network
portable CTEL telephone (D2B) with CODE (854) MB portable CTEL
MODEL 203 with CODE (450) Taxi version
MODEL 215 up to 31.8.03 with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM
portable cellular telephone (D2B) with CODE (853) MB standard cellular telephone with CODE (854)
MB portable cellular telephone
MODEL 220 up to 31.8.03 with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM
Fig. 127: Identifying Hands-Free System Microphone - Model 203 With Codes (853) (854) (450)
Hands-free system GF82.70-P-4102-01A

microphone, location
Hands-free system  Voice input for
microphone, purpose making telephone
calls using the hands-
free system
 Voice input for the
operation of the voice
control system (VCS)
(interactive dialog)
Hands-free system microphone, location - GF82.70-P-4102-01A
The hands-free system microphone (B25) of all vehicles is located near the mirror base of the inside
rearview mirror unit (A67).
Fig. 128: Identifying Hands-Free System Microphone - Illustrated On Model 210.0

Hands-free microphone, location/task - GF82.70-P-4102M
MODEL 215.3, 220.0 /1 as of 1.9.03 with CODE (813) Voice control system (VCS)
MODEL 215.3, 220.0 /1 with CODE (359) TELE AID emergency call system
Fig. 129: Identifying Hands-Free Microphone Location
Hands-free system The hands-free system

microphone, location microphone group (A67b1) is
installed on the underside of the
inside rearview mirror unit
(A67).
Handsfree system  Voice input for making
microphone, purpose telephone calls using the
hands-free system
 Voice input for the
operation of the audio,
communication and
navigation components
 Voice input for emergency
call (TELE AID)
Hands-free microphone, location/purpose - GF82.70-P-4102S
Models 215, 220
Location in the overhead control panel

Fig. 130: Identifying Hands-Free System Microphone
Hands-free system The microphone is located in

microphone, location the base of the inside
rearview mirror.
Hands-free system  Voice input for
microphone, purpose telephoning via the
hands-free system
 Voice input for
telephoning via the
voice control system
(VCS) (interactive
dialog with the voice
control system)
 Voice input for an
emergency call (TELE
AID)
Hands-free microphone, location/task - GF82.70-P-4102SA
Shown on model 220

Fig. 131: Identifying Hands-Free System Microphone Location - Shown On Model 220
Hands-free system The hands-free system

microphone, location microphone (B25) is
located in the overhead
control panel (N70)
control unit.
Hands-free system Acoustic signals are
microphone, purpose converted into electric
signals.
HANDS-FREE SYSTEM LOUDSPEAKER, LOCATION/TASK - GF82.70-P-4103
Hands-free system loudspeaker, location/task - GF82.70-P-4103B
MODELS 129 with CODE (274) MB D-network telephone with CODE (312) GSM portable cellular
telephone with CODE (313) D-network "portable CTEL" telephone with CODE (314a) "Standard" D-
network telephone
MODELS 163 with CODE (853) MB standard cellular telephone with CODE (854) MB portable cellular
telephone
MODELS 168 with CODE (312) GSM portable cellular telephone with CODE (317) GSM portable
cellular telephone (D2B) with CODE (854) MB portable cellular telephone
MODELS 170 with CODE (312) GSM portable cellular telephone with CODE (313) D-network "portable
CTEL" telephone with CODE (314a) "Standard" D-network telephone with CODE (316) MB GSM
cellular telephone (D2B) with CODE (317) GSM portable cellular telephone (D2B)
cellular telephone (D2B) with CODE (854) MB portable cellular telephone
MODELS 203 up to 23.4.04 with CODE (853) MB standard cellular telephone with CODE (854) MB
MODELS 208 with CODE (274) MB D-network telephone with CODE (316) MB GSM cellular telephone
MODELS 215 up to 31.8.03 with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM
MODELS 220 up to 31.8.03 with CODE (316) MB GSM cellular telephone (D2B) with CODE (317) GSM
Shown on model 210

Fig. 132: Identifying Hands-Free System Loudspeaker - Shown On Model 210
Hands-free system GF82.70-P-4103-01A

loudspeaker, location
Hands-free system  Hands-free system
loudspeaker, purpose voice output
 Voice output of voice
 Sound reproduction of
audio signals
Hands-free system loudspeaker, location - GF82.70-P-4103-01A
Illustrated on Model 129
Fig. 133: Locating Hands-Free System Loudspeaker - Illustrated On Model 129

Illustrated on Model 163
Fig. 134: Locating Hands-Free System Loudspeaker - Illustrated On Model 163
Shown on Model 170
Fig. 135: Locating Hands-Free System Loudspeaker - Shown On Model 170
Illustrated on Model 210.0
Fig. 136: Locating Hands-Free System Loudspeaker - Illustrated On Model 210.0

As of 1.6.98 loudspeaker output is accomplished via the entire loudspeaker system.
Illustrated on Model 210.2
Fig. 137: Locating Hands-Free System Loudspeaker - Illustrated On Model 210.2
As of 1.6.98 loudspeaker output is accomplished via the entire loudspeaker system.
Shown on Model 220
Fig. 138: Locating Hands-Free System Loudspeaker - Shown On Model 220
Loudspeaker output is accomplished via the entire loudspeaker system.
Model 203 and model 215
All speakers of the speaker system are used for the voice output in the vehicle.
Model 140
The speakers for the hands-free system are located on the left front and right front instrument panel.
All speakers of the speaker system are used for the voice output in the vehicle.
Model 168
The right front hands-free system speaker (H4/12) in the front passenger footwell is actuated to accomplish the
voice output.
Model 202 and Model 208
The speakers for the hands-free system are retrofitted and are located in the center console as well as in the right
front passenger footwell.
Model 202 only
In addition, the radio and telephone hands-free system dual coil speaker (H4/13) is installed on the rear shelf.
Hands-free system loudspeaker, location/task - GF82.70-P-4103M
MODELS 215.3, 220.0 /1 as of 1.9.03 with CODE (813) Voice control system (VCS) with CODE (388)
"Portable CTEL" UPCI telephone system with CODE (810) sound system
Shows model 220
Fig. 139: Identifying Hands-Free System Loudspeaker Location - Shows Model 220
Hands-free system The speakers are installed

loudspeaker, location in the particular doors.
The bass module speaker
(H4/17) is centrally
located below the rear
shelf. The center cockpit
(H4/27) is centrally
located below the
instrument panel.
Hands-free system The speakers are used for
loudspeaker, purpose the acoustic output when
calling in hands-free
mode and for the voice
TELEPHONE HANDSET (D-NETWORK), LOCATION/PURPOSE - GF82.70-P-4106
Telephone handset (D-network), location/purpose - GF82.70-P-4106C
MODEL 129 with CODE (274) MB D-network telephone with CODE (314a) Standard D-network
telephone with CODE (316) MB GSM cellular telephone (D2B) with CODE (853) MB standard cellular
telephone
telephone
MODEL 163 with CODE (853) MB standard cellular telephone
MODEL 170 with CODE (314a) Standard D-network telephone with CODE (316) MB GSM cellular
telephone (D2B)
telephone with CODE (316) MB GSM cellular telephone (D2B)
MODEL 203 with CODE (853) MB standard cellular telephone
(D2B) with CODE (853) MB standard cellular telephone
telephone with CODE (316) MB GSM cellular telephone (D2B) with CODE (853) MB standard cellular
telephone
MODEL 215 with CODE (316) MB GSM cellular telephone (D2B) with CODE (853) MB standard
cellular telephone
cellular telephone
Fig. 140: Identifying CTEL Handset - Model 203 With Code (853)
Telephone handset (D- GF82.70-P-4106-01A

network), location
Telephone handset (D-  Interface between user
network), purpose and system
 Mount for control and
display elements of
telephone
 Holder for SIM card S
ubscriber I
dentification M odule)
 Memory for storing
names, numbers, short
messages, etc.
 Includes microphone
and loudspeaker
Telephone handset (D-network), location - GF82.70-P-4106-01A
Shown on model 202
Fig. 141: Identifying Telephone Handset (D-Network) Location - Shown On Model 202
On model 163 the handset is only located on the center console and not in the armrest depending on the
equipment
Telephone handset (D-network), location/task - GF82.70-P-4106S
MODELS 220 as of 1.6.04 with CODE (388) "Portable CTEL" UPCI telephone system
Fig. 142: Identifying Rear Telephone Handset Location
Telephone handset (D- The rear telephone

network), location handset (A34/8) is
located in the rear area on
the cardan shaft tunnel.
Telephone handset (D- The rear telephone
network), purpose handset (A34/8) is
Bluetooth-capable. It can
be used to call in "private
mode".
TELEPHONE TRANSMITTER/RECEIVER (D-NETWORK), LOCATION/TASK - GF82.70-P-4107
Telephone transmitter/receiver (D-network), location/task - GF82.70-P-4107C
MODEL 129 with CODE (274) MB D-network telephone with CODE (314a) "Standard" D-network
telephone
MODEL 170 with CODE (314a) "Standard" D-network telephone with CODE (316) MB GSM cellular
telephone (D2B)
(D2B)
cellular telephone
cellular telephone
Shows model 220
Fig. 143: Identifying D2B Telephone Transmitter Receiver Location (Model 220)
Telephone In model 215 and 220 the D2B

transmitter/receiver (D- telephone transmitter/receiver
network), location (A35/13) is installed underneath the
rear seat.
Model 129 GF82.70-P-4107-
01A
Model 140 GF82.70-P-4107-
01B
Model 170 GF82.70-P-4107-
01C
Model 202 GF82.70-P-4107-
01D
Model 208 GF82.70-P-4107-
01F
Model 210 GF82.70-P-4107-
01E
Telephone  Transmitter/receiver for the
transmitter/receiver (D- telephone system
network), task
 Speaker switchover for
hands-free system and
muting the radio (A2)
 Signal processing,
digital/analog conversion and
analog/digital conversion
Telephone transmitter/receiver (D-network), location/purpose - GF82.70-P-4107D
MODEL 129, 163, 203, 208, 210, 215, 220 with CODE (853) MB standard cellular telephone
Fig. 144: Identifying CTEL D2B Transceiver Unit
Telephone Model 129 GF82.70-P-4107-

transmitter/receiver (D- 01AA
network), location
Model 163 GF82.70-P-4107-01H
Model 203 GF82.70-P-4107-01P
Model 208.3 GF82.70-P-4107-
01FA
Model 210 GF82.70-P-4107-
01EA
Models 215, 220 GF82.70-P-4107-
01GA
Telephone  Switch center for
transmitter/receiver (D- telephone system
network), purpose
 Switches over
loudspeaker of hands-
free system and sets
radio to mute
 Signal processing,
digital/analog and
analog/digital
conversion
 Memory for telephone
numbers
GSM cellular telephone transmitter/receiver, location - GF82.70-P-4107-01GA
Models 215, 220
Shown on model 220
Fig. 145: Identifying GSM Cellular Telephone Transmitter/Receiver Unit Location - Shown On Model
220
VEHICLE INTERFACE (CELLULAR TELEPHONE), LOCATION/PURPOSE - GF82.70-P-4108C
MODEL 129 with CODE (312) GSM cellular telephone with CODE (313) D-network cellular telephone
with CODE (317) GSM cellular telephone (D2B)
MODEL 168 with CODE (312) GSM cellular telephone with CODE (317) GSM cellular telephone (D2B)
MODEL 208.3 with CODE (317) GSM cellular telephone (D2B)
MODEL 220 with CODE (317) GSM cellular telephone (D2B)
On vehicles with code 317 A34/4 (CTEL interface) is replaced by A59/1 (D2B interface for cellular
telephone)
Fig. 146: Identifying CTEL Interface
Location GF82.70-P-4108-01A
Purpose  Interface between
vehicle equipment and
cellular telephone
 Switches speaker over
to hands-free system
and mutes radio
 Connection between
antenna and cellular
telephone
Vehicle interface (cellular telephone), location - GF82.70-P-4108-01A
Sedans
Codes 312, 313
telephone).
1. Models 129, 140, 168, 170, 202, 208, 210 sedan up to 31.5.98
2. Model 210 sedan as of 1.6.98
3. Model 220
Fig. 147: Identifying Vehicle Interface (Cellular Telephone) Location - Sedans
T-model
telephone).
1. Models 202, 210 T-model up to 31.5.98

2. Model 210 T-model as of 1.6.98
Fig. 148: Identifying Vehicle Interface (Cellular Telephone) Location - T-model
(GSM) ANTENNA SPLITTER, LOCATION/TASK - GF82.70-P-4109D
MODELS 215, 220 with CODE (853) MB standard cellular telephone with CODE (854) MB portable
cellular telephone only in conjunction with Telestart
Fig. 149: Identifying Antenna Splitter
Antenna splitter (GSM Model 215 GF82.70-P-4109-01D

900), location
Model 220 GF82.70-P-4109-01C
Antenna splitter (GSM  enables simultaneous
900), task operation of a telephone
and the Telestart system
via one antenna
 enables simultaneous
operation of a D-net and
C-net telephone and the
radio via one antenna
when using a multiple
range antenna
Antenna splitter (GSM), location - GF82.70-P-4109-01C
Model 220
Fig. 150: Identifying Antenna Splitter (GSM) Location
Antenna splitter (GSM), location - GF82.70-P-4109-01D
Model 215
Fig. 151: Identifying Antenna Splitter (GSM) Location
PORTABLE CELLULAR TELEPHONE (D-NETWORK), LOCATION/PURPOSE - GF82.70-P-4110C

cellular telephone with CODE (317) GSM portable cellular telephone (D2B) with CODE (854) MB
cellular telephone
MODEL 163 with CODE (854) MB portable cellular telephone
cellular telephone with CODE (317) GSM portable cellular telephone (D2B)
cellular telephone with CODE (317) GSM portable cellular telephone (D2B)
MODEL 203 with CODE (854) MB portable cellular telephone
MODEL 208 with CODE (317) GSM portable cellular telephone (D2B) with CODE (854) MB portable
cellular telephone
cellular telephone with CODE (317) GSM portable cellular telephone (D2B) with CODE (854) MB
cellular telephone
cellular telephone
Fig. 152: Identifying Portable CTEL - Model 203 With Code (854)
Portable cellular GF82.70-P-4110-
telephone (D- 01A
network), location
Portable cellular  Interface between user and
telephone (D- system
network), purpose
 Transmitter/receiver for system
 Mount for control and display
elements of telephone
 Mount for SIM card (S
ubscriber I dentification M
odule (system dependent)
 Memory for storing names,
numbers, short messages, etc.
 Microphone and loudspeaker
integrated
Portable cellular telephone (D-network), location - GF82.70-P-4110-01A
Shown on model 202
Fig. 153: Identifying Portable Cellular Telephone (D-Network), Location - Shown On Model 202
On model 163 the portable cellular telephone is only located on the center console and not in the armrest
depending on the equipment.
GPS/TELEPHONE ROOF ANTENNA, LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-4111
GPS/telephone roof antenna, location/task/design/function - GF82.70-P-4111A
MODELS 140, 210 up to 31.5.98 with CODE (348) TELE AID emergency call system
MODELS 129, 202, 208.3, 210 as of 6/198, 220 with CODE (347) TELE AID emergency call system (D2B)
MODEL 140 as of 1.1.98, 168, 202, 208.3, 210.0 as of 1.1.98, 210.2 with CODE (351) Auto pilot system
(APS)
MODELS 163,168, 208.3, 210 with CODE (353) Audio 30 APS
MODELS 163, 208.3, 210, 220 with CODE (352a) COMAND operating and display system with CODE
(353) Audio 30 APS with CODE (853) MB standard CTEL telephone with CODE (854) MB portable
CTEL telephone with CODE (855) TELE AID
MODEL 163 with CODE (522) Modular control system (MCS) Radio USA
Location shown on model 210
Fig. 154: Identifying Telephone And GPS Roof Antenna
The telephone antenna (A2/49a1) and the GPS antenna (A2/49a2) are integrated in an antenna housing.
GPS/telephone roof Models 129, 140, 168, GF82.70-P-4111-01A

antenna, location 202, 208.3, 210
Model 220 GF82.70-P-4111-01B
Model 163 GF82.70-P-4111-01GH
GPS/telephone roof Receiving and amplifying
antenna, purpose the global positioning
system (GPS) satellite
signals as well as
transmitting and receiving
the mobile radio signals
(GSM 900 MHz).
GPS/telephone roof The GPS/telephone roof
antenna, design antenna (A2/49) consists
of two components:
CTEL antenna

(A2/49a1)
 GPS antenna
(A2/49a2)
Model 163 as of 01.09.01 GF82.70-P-4111-03GH
GPS/CTEL roof antenna, Code 351 or code 353, GF82.70-P-4111-04A
function except models
129 /163 /220
Code 353 for model 163 GF82.70-P-4111-04D
Code 347 or 348 or 352 GF82.70-P-4111-04B
except models 168/163
Model 163 as of 01.09.01 GF82.70-P-4111-04GH
Telephone/GPS roof antenna, location - GF82.70-P-4111-01B
Model 220 with code 352 or 347
Fig. 155: Identifying Telephone/GPS Roof Antenna Location
GPS/telephone roof antenna location/task/design/function - GF82.70-P-4111SX
MODEL 220.0 /1 with CODE (383a) Tele-Aid fixed installation telephone
MODEL 220.0 /1 with CODE (359) TELE AID emergency call system
Fig. 156: Identifying GPS/Telephone Roof Antenna
GPS/telephone roof The telephone and GPS

antenna, location roof antenna (A2/49) is
installed in the center of
the rear window.
GPS/telephone roof Receiving and amplifying
antenna, purpose global positioning system
(GPS) satellite signals as
well as transmitting and
receiving mobile radio
signals (telephone
network).
GPS/telephone roof The telephone and GPS
antenna, design roof antenna (A2/49)
consists of a telephone
call transmission and
reception unit and a
Global Positioning
System (GPS) antenna.
Furthermore, the
telephone and GPS roof
antenna (A2/49) features
a coaxial connection.
GPS/telephone roof GF82.70-P-4111-04SX
antenna, function
GPS/telephone roof antenna, function - GF82.70-P-4111-04SX
telephone antenna (A2/49a1)
The received telephone signals are amplified by the integrated antenna amplifier. The antenna amplifier is
supplied with power by the coaxial antenna cable (phantom feed). The amplified signals are forwarded to the
telecommunications control unit (N112) (with code (383a) fixed installation telephone Tele-Aid) or the
emergency call system control unit (N123/4) (with code (359) TELE AID emergency call system) via the
coaxial antenna cable.
GPS antenna (A2/49a2)

The received satellite signals are amplified by the integrated antenna amplifier. The antenna amplifier is
supplied with power by the coaxial antenna cable (phantom feed). The amplified signals are forwarded to the
antenna splitter (A2/5) via the coaxial antenna cable. The antenna splitter (A2/5) distributes the Global
Positioning System (GPS) signal to the navigation processor control units (N41/1) and telecommunications
control unit (N112) (with code (383a) fixed installation telephone Tele-Aid) or emergency call system control
unit (N123/4) (with code (359) TELE AID emergency call system).
GPS/TELEPHONE/TWO-WAY RADIO ROOF ANTENNA, FUNCTION - GF82.70-P-4112-04A
Models 140 except 140.063/07, 202, 210, 220
CTEL antenna (A2/49a1)
The received signals are transmitted to the emergency call system control module (TELE AID) (A35/8) via a
coaxial antenna cable; transmitting is accomplished vice versa.
GPS antenna (A2/49a2)
The received satellite signals are amplified by the integrated antenna amplifier. The antenna amplifier is
supplied with power by the coaxial antenna cable (phantom supply).
The amplified signals are transmitted to the emergency call system control module (TELE AID) (A35/8) via
a coaxial antenna cable.
The antenna serves only for reception of GPS signals, no signals are transmitted.
Two-way radio antenna (A2/49a3)
The received signals are transmitted to the two-way radio (A49) via a coaxial cable, transmitting is
accomplished vice versa.
VOICE CONTROL SYSTEM CONTROL UNIT, LOCATION/TASK - GF82.70-P-4113
Voice control system control unit, location/task - GF82.70-P-4113A
MODEL 202, 203 up to 23.4.04, 208.3, 210 as of 1.6.98, 215, 220 up to 31.8.03 with CODE (813) Voice
Fig. 157: Identifying Voice Control System Control Unit - Model 202, 203 Up To 23.4.04, 208.3
Voice control system Model 202 GF82.70-P-4113-01A

control unit, location
Model 203 GF82.70-P-4113-01P
Model 208.3 GF82.70-P-4113-01B
Model 210 GF82.70-P-4113-01C
Models 215, 220 GF82.70-P-4113-01D
Voice control system GF82.70-P-4113-02A
control unit, purpose
Voice control system control unit, location - GF82.70-P-4113-01D
Illustrated on model 220, location with a portable CTEL or fixed installation up to 31.5.00
Fig. 158: Identifying Voice Control System Control Unit Location - Portable CTEL
Illustrated on model 220, location with fixed installation as of 1.6.00
Fig. 159: Identifying Voice Control System Control Unit Location - Fixed Installation As Of 1.6.00
Voice control system control unit, purpose - GF82.70-P-4113-02A
The voice control system control unit (A35/11) has the following tasks:
 Control with the aid of the interactive dialogue for models 203, 208.3, 210, 215 and 220 of the functions
of the COMAND operating, display and control unit (A40/3) and for model 202 of the functions of the
radio and navigation operating unit (A2/29) and the systems involved.
 Display of the selected number at the telephone handset
 On model 203 the display of the telephone number in the instrument cluster (A1) and on the COMAND
 Muting the particular vehicle-specific component of the audio system and speaker switchover in order to
make the voice output possible via the hands-free system
 Ambient noise-dependent volume control for voice output in 3 stages.
 External interface for hands-free system microphone (B25).
Voice control system control unit, location/task - GF82.70-P-4113M
Shows model 220
Fig. 160: Identifying Voice Control System Control Unit Location - Shows Model 220
Voice control system The voice control system

control unit, location control unit (A53/11) is
installed in the rear,
passenger-side under the
seat.
Voice control system GF82.70-P-4113-02M
control unit, purpose
Voice control system control unit, purpose - GF82.70-P-4113-02M
As part of the integrated communication and audio systems in the vehicle, the voice control system control unit
(A35/11) is designed for audio and communication components and navigation systems in the vehicle.
The goal of the voice control is to take the strain off the user during a journey, to give him/her access to a series
of functions, without diverting the driver's attention from the road and to enable him/her to have intuitive
control of the voice control functions.
LIGHT WAVE CONDUCTOR INTERFACE, LOCATION/PURPOSE - GF82.70-P-4114A
MODEL 129, 170, 202, 208.3, 210, 220 with CODE (316) MB D-network telephone (D2B)
MODEL 129, 168, 170, 202, 208.3, 210, 220 with CODE (317) MB D-network cellular telephone (D2B)
Fig. 161: Identifying Light Wave Conductor Interface
Location Code 316 GF82.70-P-3106-01C

Code 317 GF82.70-P-4108-01A
Purpose Code 316
 Adapter function: Adaptation

of CTEL transmitter/receiver
to vehicle bus system (D2B)
Code 317
 Adapter function: Adaptation

of cellular telephone to vehicle
bus system (D2B)
 Interface between vehicle
system and cellular telephone
 Switches loudspeaker system
over to hands-free operation
and mutes radio
 Adapter function between
antenna system and cellular
telephone
UHI PORTABLE CTEL RECEIVER (UNIVERSAL PORTABLE CTEL INTERFACE),

LOCATION/TASK - GF82.70-P-5000S
Shown on model 220

Fig. 162: Identifying UHI Portable CTEL Holder Location - Shown On Model 220
UHI Portable CTEL The UHI portable CTEL

receiver (Universal receiver (Universal
Portable CTEL Portable CTEL Interface)
Interface), location (A34/15) is located below
the armrest in the center
console.
UHI Portable CTEL The UHI portable CTEL
receiver (Universal receiver (Universal
Portable CTEL Portable CTEL Interface)
Interface), task (A34/15) is the interface
between the portable
CTEL (A34/6) and the
Universal Portable CTEL
Interface (UPCI) control
unit (N123/1).
UNIVERSAL PORTABLE CTEL INTERFACE (UPCI [UHI]) CONTROL UNIT, LOCATION/TASK -

GF82.70-P-5100S
Shown on model 220

Fig. 163: Identifying Universal Portable CTEL Interface Control Unit Location - Shown On Model 220
Universal Portable CTEL The Universal Portable

Interface (UPCI) control CTEL Interface (UPCI)
unit, location control unit (N123/1) is
located below the rear
bench seat.
Universal Portable CTEL The Universal Portable
Interface (UPCI) control CTEL Interface (UPCI)
unit, task control unit (N123/1) is
used to convert electric
signals into optical
signals and vice versa.
Furthermore, it is used as
a transmitter and receiver
for Bluetooth-capable
devices (e.g. rear
telephone handset
(A34/8)). This function is
not available in the USA
TELEPHONE/PORTABLE CTEL/STH RADIO REMOTE CONTROL ANTENNA SPLITTER,

LOCATION/TASK - GF82.70-P-5200S
Shown on model 220

Fig. 164: Identifying Telephone/Portable CTEL/STH Radio Remote Control Antenna Splitter Location -
Shown On Model 220
Telephone/portable The telephone/portable

CTEL/STH radio remote CTEL/STH radio remote
control antenna splitter, control antenna splitter
location (A2/53) is located in the
luggage compartment on
the right behind the side
paneling.
Telephone/portable The telephone/portable
CTEL/STH radio remote CTEL/STH radio remote
control antenna splitter, task control antenna splitter
(A2/53) separates the
signals for the portable
CTEL (A34/6) and the
telestart signal for the STH
heater unit (A6) with code
(228) stationary heater.
OVERVIEW OF SYSTEM COMPONENTS OF THE UNIVERSAL PORTABLE CTEL INTERFACE

(UPCI), LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-9996S

location/task
location/task
location/task
Telephone handset (D- only model 220 GF82.70-P-4106S
Table of contents for function GF82.70-P-0996S
description of the Universal
Portable CTEL Interface
(UPCI)
SURVEY OF SYSTEM COMPONENTS, TELEPHONE (D-NETWORK),

LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-9998ZZ
network telephone
telephone
cellular telephone (D2B)
MODEL 203 with CODE (853) MB standard telephone with CODE (854) MB portable cellular telephone
Telephone interface, Models 129, 170, GF82.70-P-3107F

location/task/design/function 202, 208, 210, 215,
220 with MB
network D cellular
telephone (D2B)
CODE 316
Models 129, 168, GF82.70-P-3107E
170, 202, 208, 210,
215, 220 with D-
network portable
CTEL (D2B) CODE
317
MODELS 129, 163, GF82.70-P-3107P
168, 202.08 /09 /18,
203, 208, 210, 215,
220 with MB
portable CTEL 854
MODELS 215, 220 GF82.70-P-3107D
up to 31.10.02 with
CODE (352a)
COMAND operating
and display system
with CODE (498)
Japanese version
MODELS 215, 220 GF82.70-P-3107M
as of 1.11.02 with
CODE (498)
Japanese version
with CODE (803)
model year 2003
Compensator, location/task MODELS 129, 163, GF82.70-P-3109P
168, 202.08 /09 /18,
203, 208.3, 210, 215,
220 with CODE
(854) MB portable
CTEL
Hands-free microphone, location/task GF82.70-P-4102B
Hands-free system loudspeaker, GF82.70-P-4103B
location/task
Telephone antenna, location/task MODEL Series 163 GF82.62-P-4105P
with CODE (853)
MB standard
telephone
with CODE (854)
MB portable cellular
telephone
MODELS 203, 210,
220
with CODE (853)
MB standard
telephone
with CODE (854)
telephone
with CODE (855)
TELE AID
with CODE (930)
taxi emergency call
MODEL 208.3, 215
with CODE (853)
MB standard
telephone
with CODE (854)
telephone
with CODE (855)
TELE AID
Telephone handset (D-network), Models 129, 140, GF82.70-P-4106C
location/task 163, 170, 202, 203,
208, 210, 215, 220
Telephone transmitter/receiver Model 129, 140, GF82.70-P-4107C
(D-network), location/task 170, 202, 208, 210,
215, 220
MODELS 129, 163, GF82.70-P-4107D
203, 208, 210, 215,
220 with CODE
(853) MB standard
CTEL
Antenna splitter (D-network), MODELS 129, 140, GF82.70-P-4109C
location/task 202, 208.4
Model 210 up to
31.12.96
Model 215, 220 GF82.70-P-4109D
with CODE (853)
MB standard
telephone
with CODE (854)
telephone
Portable cellular telephone (D- GF82.70-P-4110C
Contents function description telephone GF82.70-P-0998ZZ
(GSM)
OVERVIEW OF SYSTEM COMPONENTS, VOICE CONTROL SYSTEM (VCS),

LOCATION/TASK/DESIGN/FUNCTION - GF82.70-P-9999
Overview of system components, voice control system (VCS), location/task/design/function - GF82.70-P-9999A
system (VCS)

location/task
31.5.98
location/task 210
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with CODE (313) D-
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Model 203 with CODE
(450) taxi version
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
net telephone
Models 140, 202, 210
with code (312) D-
telephone
with code (313) D-
telephone
with code (314a)
telephone
Model 202, 208, 210,
215, 220
network telephone
(D2B)
with code (317) D-
telephone (D2B)
Models 203, 208, 210,
215, 220
with code (853) MB
standard telephone
Models 202, 203, 208,
210, 215, 220
with code (854) MB
portable CTEL
telephone
31.5.98
31.8.03
Contents - function description GF82.70-P-0999ZZ
of voice control system (VCS)
Overview of system components, voice control system (VCS), location/task/design/function - GF82.70-P-9999M

location/task
Contents - function GF82.70-P-0999M
description of voice
COCKPIT MANAGEMENT AND DATA SYSTEM (COMAND), FUNCTION - GF82.85-P-0003
Cockpit management and data system (COMAND), function - GF82.85-P-0003B
MODEL 215, 220 up to 31.8.03 with CODE (352a) COMAND operating and display system with CODE
(494a) USA version
Fig. 165: Cockpit Management And Data System Function Diagram
Block diagram of overall COMAND system, illustrated with following equipment: CD changer (code
819), sound system (code 810), voice control system (SBS) (code 813)
The COMAND operating, display and control unit (A40/3) is the central component in the COMAND system.
It contains a video-capable LCD color display for showing information such as operating menus and map data
for the navigation system. The following systems are operated centrally and operation is menu-guided on the
display:
 Radio
 CD (audio MP3)
 CD player with changer (optional)
 Sound system (optional)
 Navigation system
 Portable telephone (optional)
 SDARS (optional)
 Telematics services (e.g. emergency call)
Several functions can also be activated with the aid of the multifunction steering wheel switches. It should be
noted here that all button actuations on the multifunction steering wheel, which affect the COMAND operating,
display and control unit (A40/3), are sent first of all from the steering column module (N80) as a CAN message
to the instrument cluster(A1).
A point to note in this connection is that the instrument cluster (A1) links the incoming button operations with
the current menu setting in the multifunction display (A1p13) and then transmits a corresponding CAN message
to the COMAND operating, display and control unit (A40/3).
The vehicle can be equipped as an optional extra with an infrared remote control for issuing commands from the
passenger compartment as well as a voice control system (SBS) (code 813). These two features increase level
the operating convenience even further.
COMAND bus system
The digital components in the COMAND operating, display and control unit (A40/3) are interlinked by a bus
system.
The bus system is used to transmit data (control commands and useful information) between the various system
components.
Various bus systems have been installed (refer to block diagram) because the individual components sometimes
operate with different data formats or different transmission speeds and levels of reliability are required:
 Interior CAN (CAN-B)

 Engine compartment CAN (CAN-C)
 Digital data bus (D2B)
The digital data bus (D2B) is used to transmit data between the external audio components, the telephone
system and if present the voice control system. Control data as well as the actual audio signals (e.g. music from
CD changer) can be transferred.
The interior CAN (CAN-B) is used to make the link up to further control units in the vehicle (e.g.instrument
cluster (A1), steering column module (N80) etc.).
In this way, e.g. the instrument cluster (A1) receives via the COMAND operating, display and control unit
(A40/3), the audio, telephone and navigation data as well as the time over the bus.
Radio mode, function GF82.60-P-2001D

CD-player mode, with code 819, 819a GF82.60-P-2002AB
function
Volume and tone settings, GF82.60-P-2003AB
function
Switch on/off behavior, GF82.85-P-2006AB
function
Telephone mode, GF82.85-P-2007C
function
Cassette mode, function GF82.85-P-2010AB
Navigation mode, Except code 498 GF82.85-P-2012A
function
Starguide, function as of 1.9.00 GF82.85-P-2014A
Information service, as of 1.9.00 GF82.85-P-3016A
function
Data transmission for as of 1.9.00 GF82.85-P-3017A
Starguide, function
Data transfer between GF82.85-P-3008AB
COMAND and
instrument cluster,
function
Cockpit management and data system (COMAND), function - GF82.85-P-0003BA
MODEL 215, 220 as of 1.9.03 with CODE (352) COMAND operating and display system with CODE
(494) USA version
Fig. 166: Cockpit Management And Data System Function Diagram - Shown On Model 220
Block diagram of overall COMAND system, shown on model 220 with the following equipment:
 Code (810) Sound system

 Code (813) Voice control system (VCS)
 Code (819) CD changer (6-disk)
The COMAND operating, display and control unit (A40/3) is the central component in the system. It has a color
Liquid Crystal Display (LCD) with video capability for displaying information such as operating menus and
map data for navigation. The following systems are operated centrally and menu-assisted on the display:
 Radio
 CD (audio MP3)
 CD player with changer (optional)
 Sound system (optional)
 Navigation system
 Portable CTEL telephone (optional)
 SDARS (optional)
 Telematics services (e.g. emergency call)
Several functions can also be activated with the aid of the multifunction steering wheel switches. It should be
noted here that all button actuations on the multifunction steering wheel, which affect the COMAND operating,
display and control unit (A40/3n1), are sent first of all from the steering column module (N80) as a Controller
Area Network (data bus /CAN bus) (CAN) message to the instrument cluster (A1).
The instrument cluster (A1) links the incoming button actuations with the current menu setting in the
multifunction display (A1p13) and then transmits a corresponding CAN message to the COMAND operating,
display and control unit (A40/3n1).
The vehicle can be equipped optionally with an infrared remote control for issuing commands from the
passenger compartment and with a code (813) Voice control system (VCS), whereby the operator convenience
level can be yet again improved.
COMAND operating, display and control unit (A40/3) bus system
The digital components in the COMAND operating, display and control unit (A40/3n1) are networked through
a bus system.
The bus system is used to transmit data (control commands and useful information) between the various system
components.
As to some extent the individual components operate with various data formats, or different requirements on bit
rate and safety are made, various bus systems are installed:
 Controller Area Network bus class B (interior) (CAN-B)

 Controller Area Network Bus Class C (engine compartment) (CAN-C)
 Media Oriented System Transport (MOST)
Data are exchanged between the external audio components, the telephone system and the voice control system
with code (813) Voice control system (VCS) via the MOST. Control data as well as the actual audio signals
(e.g. music from CD changer) can be transferred.
The CAN-B is used to connect to further control units in the vehicle (e.g. instrument cluster (A1), steering
column module (N80)).
E.g., the instrument cluster (A1) receives via the COMAND operating, display and control unit (A40/3) the
audio, telephone and navigation data as well as the time over this bus.
The CAN-C is also networked with the control units that are connected to the CAN-B at the same time. This
helps to exchange data that have a direct influence on engine management.

CD-player mode, GF82.60-P-2002AB
function
Volume/tone GF82.60-P-2003AB
adjustments, function
Switch on/off behavior, GF82.85-P-2006AB
function
Telephone mode, GF82.85-P-2007C
function
Cassette mode, function up to 31.8.02 GF82.85-P-2010AB
Navigation mode, GF82.85-P-2012A
function
Starguide, function GF82.85-P-2014A
Information service, GF82.85-P-3016A
function
Data transmission for GF82.85-P-3017A
Starguide, function
Data transfer between GF82.85-P-3008AB
COMAND and
instrument cluster
function
CONTENTS, FUNCTION DESCRIPTION OF COCKPIT MANAGEMENT AND DATA SYSTEM

(COMAND) - GF82.85-P-0997BZ
version
CD-player mode, function with codes 819, 819a GF82.60-P-2002AB
Volume/tone adjustments, function GF82.60-P-2003AB
Continuous position finding, function GF82.61-P-2002CA
Basic position finding, function GF82.61-P-3006CA
Global positioning system (GPS) GF82.61-P-3007BA
position finding, function
Map-based position finding, function GF82.61-P-3008BA
Route calculation, function GF82.61-P-3011DA
Navigation, function GF82.61-P-3012CA
Navigation in digitalized map area, GF82.61-P-4000BA
function
Navigation in non-digitalized map area, GF82.61-P-4001BA
function
Cockpit management and data system up to 31.8.03 GF82.85-P-0003B
(COMAND), function
as of 1.9.03 GF82.85-P-0003BA
Switch on/off behavior, function GF82.85-P-2006AB
Telephone mode, function GF82.85-P-2007C
Cassette mode, function GF82.85-P-2010AB
Navigation mode, function except code 498 GF82.85-P-2012A
Starguide, function as of 1.09.00 GF82.85-P-2014A
Information service, function as of 1.09.00 GF82.85-P-3016A
Data transmission for Starguide, as of 1.09.00 GF82.85-P-3017A
function
Voice output, function GF82.85-P-3001AB
Data exchange between COMAND and GF82.85-P-3008AB
instrument cluster, function
Overview of system components for GF82.85-P-9997BZ
cockpit management and data system
(COMAND),
SWITCH ON/OFF BEHAVIOR, FUNCTION - GF82.85-P-2006AB
version
Switch on characteristics
Navigation system activation
When the driver's door is opened, navigation is activated via the interior CAN (CAN-B). This process lasts for
approximately 2 seconds and may be accompanied by faintly audible noises from the DVD drive integrated in
the navigation processor. The display of the COMAND operating, display and control unit (A40/3) remains
switched off.
When the status of the ignition/starter switch then changes (e.g. Circuit 15R ON), the navigation system
remains active for 30 min.
Activation of overall system
The display is switched on when the transmitter key (A8/1) is turned to position 1 ("Circuit 15R ON") provided
that the COMAND system was switched on when the transmitter key (A8/1) was last removed. The COMAND
is now operational. The system which was active before the COMAND system was last switched off (e.g. radio)
is switched on and the corresponding basic menu is displayed. If the COMAND system was switched off for
longer than 30 minutes, a warning menu appears with general instructions on how to use the system.
All other subsystems are activated when the ignition/starter switch is turned to position 2 ("Circuit 15C ON").
Conduct when pushing the "ON" button
COMAND can also be switched on when the transmitter key (A8/1) has been removed, by pressing the "ON"
button. All COMAND functions are then available for 30 minutes. The COMAND system switches off
automatically once this time has elapsed.
If the system switches off automatically after 30 minutes it can be switched back on again by pressing the "ON"
button. The 30 minutes cycle then starts from the beginning.
COMAND is deactivated when the transmitter key (8/1) (Circuit 15C OFF") is removed of the ignition. Then
the navigation system run-on time of 30 minutes starts (standby mode). During this period all the important
locating parameters are stored.
Furthermore, the COMAND operating, display and control unit (A40/3) is in principle always active, when the
interior CAN (CAN-B) is active. During this period COMAND can, however, only be operated if the above-
mentioned switch-on conditions are met with.
Pressing the "Monitor ON/OFF" button only switches off the display.
Automatic switch off
The COMAND central computer constantly monitors the battery voltage. Depending on the voltage value the
system will act as follows:
 Battery voltage is between 11.5 and 9.5 V (battery warning area)

If the battery voltage drops below 11.5 V a message appears on the display requesting that the driver
switch on the engine. If the engine is not started, another warning appears after 3 minutes that 10 seconds
remains to start the engine before the system switches off. In this case switching on the engine prevents
the system from being automatically shut down. If the system has been switched off and the voltage
reading rises again above 11.5 V, COMAND will not be automatically activated.
If a system has been shut down it can be switched back on again manually. The warning procedure recurs
each time until the fault has been rectified.
 Battery voltage less than 9.5 V (low voltage)
The COMAND system is automatically switched to a defined waiting state in which only the battery
voltage is monitored.
The current operating status is stored. In this condition COMAND cannot be operated or made to respond via
STAR DIAGNOSIS. Communication with external components does not take place.
As of 1.9.02 the map is displayed again after the last driving direction has been given by the navigation
system (arrival at destination). COMAND is switched off completely after a run-on time of 1 minute.
Exceptions to switch on/off behavior (run-on mode) if destination is not reached (as of 1.9.02):
 The navigation system remains active for up to 30 minutes (when fueling, when the driver is taking a
break, etc.). The navigation is continued as soon as the engine is restarted.
 After 30 minutes up to a maximum of 2 hours the COMAND remains in the "sleep mode". The route is
recalculated when the driver restarts the engine and navigation continues.
 When the driver starts the engine after an interval of 2 hours the system asks the driver if the route should
be recalculated.
YES = The route is recalculated.
NO = Navigation ends.
Volume/tone GF82.60-P-2003AB
adjustments, function
TELEPHONE MODE, FUNCTION - GF82.85-P-2007C
MODEL 215, 220 with CODE (352) COMAND operating and display system with CODE (494) USA
version
Fig. 167: Telephone Mode Function Diagram
Valid up to 31.8.02
Block diagram for COMAND telephone system, shown on model 220 with the following equipment:

 Code (813) Voice control system (VCS)
On vehicles as of 1.9.03, all audio signals of the audio components, voice signals as well as the signals of
the navigation processor (N41/1) are transmitted via the Media Oriented System Transport (MOST).
On vehicles as of 1.9.03, the navigation processor (N41/1) is installed as a separate control unit in the left of
the engine compartment.
On vehicles as of 1.9.03, the audio gateway control unit (N93/1) is also installed as an interface between the
Controller Area Network bus class B (interior) (CAN-B) and the MOST. The audio signals are then sent to the
audio gateway control unit (N93/1) and output via the vehicle speakers.
The telephone system can be operated directly at the COMAND operating, display and control unit (A40/3n1)
on the multifunction steering wheel (MFL) in combination with the multifunction display (A1p13) of the
instrument cluster (A1) or via voice command (optional).
Making a call, function
The data telegrams (e.g. dial telephone number) for operating the telephone system are forwarded from the
COMAND operating, display and control unit (A40/3n1) over the Digital Data Bus (D2B) to the portable CTEL
D2B interface (A59/1).
The portable CTEL D2B interface (A59/1) transmits the data telegrams via a separate interface to the portable
CTEL (A34/6). The actual telephone connection is made over the portable CTEL (A34/6) and the telephone
antenna (A2/49a1) (on model 220) or the telephone antenna (A2/22) (on model 215).
The telephone antenna (A2/49a1) (on model 220) and the telephone antenna (A2/22) (on model 215) are each
connected to the E-call control unit (A35/8).
If required, a high frequency relay integrated in the E-call control unit (A35/8) connects the telephone antenna
(A2/49a1) (on model 220) or the telephone antenna (A2/22) (on model 215) to the portable CTEL (A34/6).
Handsfree conversation, function
The driver's voice is converted by the handsfree system microphone (B25) into a digital signal and sent by the
portable CTEL D2B interface (A59/1) to the portable CTEL (A34/6).
The voice signals of the party called are forwarded by the portable CTEL D2B interface (A59/1) to the Digital
Data Bus (D2B) and received by the audio component of the COMAND operating, display and control unit
(A40/3). There the signals are amplified and output via the vehicle speakers.
The US vehicles are prepared for installation of Motorola TDMA, CDMA (V60) or GSM portable CTELs
(V60i).
During a telephone call the audio signal is automatically muted.
If the vehicle is equipped with code (810) Sound system, the voice signals are picked up by the sound
amplifier (A2/13), amplified and then output via the vehicle speakers.
The COMAND operating, display and control unit (A40/3) has the following telephone functions:
 Direct dialing of a telephone number via the rotary switch or the numerical keypad, display of the name
of the person called (provided that the entered number is known).
 Speed dialing takes place by dialing the first 10 memory locations with only one key, dialing all further
memory locations takes place by entering the 3-digit memory location number.
 Locking the telephone system
 Ability to sort the memory locations according to:
Memory location number
 Names
 The 10 numbers last dialed
With code (348)
EMERGENCY
CALL emergency
call system
GPS/telephone roof antenna Model 220 GF82.70-P-4111A
location/task/design/function With code (347)
TELE AID
emergency call
system (D2B)
With code (352)
COMAND operating
and display system
with code (353)
Audio 30 APS
with code (853) MB
standard telephone
with code (854) MB
portable CTEL
telephone
With code (855)
TELE AID
CASSETTE MODE, FUNCTION - GF82.85-P-2010AB
MODEL 215, 220 up to 31.8.02 with CODE (352) COMAND operating and display system with CODE
(494) USA version
Fig. 168: Cassette Mode Function Diagram
Block diagram for COMAND cassette operation, illustrated with the following equipment installed :
On vehicles as of 1.9.03, all audio signals of the audio components, voice signals as well as the signals of
the navigation processor (N41/1) are transmitted via the Media Oriented System Transport (MOST).
Function
The Compact Cassette (CC) player is integrated in the COMAND operating, display and control unit
(A40/3n1). It is activated after inserting a cassette by pressing the "TAPE" button. The audio signals are
amplified by the COMAND operating, display and control unit (A40/3) and directly output via the vehicle
speakers.
If the vehicle is also equipped with a code (810) Sound system, the audio signals are transferred to the Digital
Data Bus (D2B), amplified by the sound amplifier (A2/13) and output via the vehicle speakers.
The COMAND cassette system has:
 Autoreverse drive
 Fast forward and reverse
 Dolby B/C
Noise suppression system for cassettes that have been recorded with Dolby B/C.
 CPS
Track skipping and repeat function (music track search facility MTL). If the repeat function is active,
"WDH" appears in the display.
 SCAN
Play track for approx. 8 sec. and automatic fast forward to next track. If no more tracks are detected, tape
is wound to end.
 BLANK-SKIP
If the drive does not detect a sound signal on the cassette for more than 15 sec., it automatically fast
forwards to the next track. If no more tracks are detected, the tape is wound to the end.
The CPS, SCAN and Blank-SKIP functions require:
 Sufficiently long breaks between the tracks (Break > approx. 3 s)

 low noise level during breaks
 Clearly recognizable track starts and ends
Cassettes with a playing time of 120 min. cannot be used.
As of 1.9.02, the Compact Cassette (CC) player in the COMAND operating, display and control unit
(A40/3) is omitted. However, an additional jack socket for an AUX connection, the Walkman separation point
(X39/45), is provided.
Operating, display and control unit, GF82.85-P-3114D

TV-MODE, FUNCTION - GF82.85-P-2011A
MODEL 215, 220 with CODE (352) COMAND operating and display system with CODE (860) TV tuner
Fig. 169: TV-Mode Function Diagram - Without Code (810) Sound System Up To 31.8.03
COMAND TV system block diagram, without Code (810) Sound system up to 31.8.03
Fig. 170: TV-Mode Function Diagram - Without Code (810) Sound System As Of 1.9.03
Block diagram of COMAND TV system, without sound system code (810) as of 1.9.03
On vehicles as of 1.9.03, the TV tuner (MOST) (A2/10) is integrated in the Media Oriented System
Transport (MOST). Thus, the data exchange (audio and video signals) with the other TV components takes
place via this fiber optical cable.
Controller Area Network bus class B (interior) (CAN-B) and the MOST. The audio signals are then sent to the
TV system control
The TV tuner (A2/42) is controlled via the COMAND operating, display and control unit (A40/3). The
communication between the COMAND operating, display and control unit (A40/3) and the TV tuner (A2/42)
takes place via the Robert Bosch CAN (RB-CAN).
The COMAND TV system has the following features:
 4-way TV antenna diversity

 Multistandard capability, i.e. Color decoder for NTSC, PAL and SECAM standard with automatic
detection
 Videotext decoder
 10 memory locations for the station list sorted by reception field strength and 10 further memory
locations for freely selectable stations
 SCAN function (the stations are played in succession)
 On Screen Display (OSD) function (text displays on the screen)
The COMAND TV system provides a facility for connecting other video sources such as a video recorder
or Camcorder. The relevant connectors are provided on the TV tuner (A2/42).
TV reception
The 4 TV antennas in the rear window receive the TV high-frequency signals completely independent from one
another. The video and sound signals are modulated upon these high-frequency signals. The rear window
antenna amplifier module (A2/12) filters the frequencies of the TV frequency bands from the high frequency
signals and amplifies them. The amplified signals are led to the TV tuner (A2/42) via 4 separate coaxial cables.
The TV tuner (A2/42) selects the strongest of the incoming antenna signals (antenna diversity), selects the
required transmitter and then demodulates the TV sound and TV video signals in accordance with the relevant
transmission standard (e.g. NTSC). The video and sound signals prepared in this way are transferred as red-
green-blue synchronous video signals (RGBS) as well as low-frequency signals (LF) for the audio signals (TV
sound) to the COMAND operating, display and control unit (A40/3) and the operating and display unit rear
monitor (A40/2).
TV picture display
up to 31.8.02
The TV picture is only shown on the display of the COMAND operating, display and control unit (A40/3)
under the following prerequisites:
 The parking brake has to be actuated and the selector lever has to be in the "P" or "N" position (both
pieces of information come via the CAN-B).
as of 1.9.02
The display in the COMAND operating, display and control unit (A40/3) switches off automatically at a speed
of v > 8 km/h. In contrast to this, the pictures are also displayed on the rear monitor operating and display unit
(A40/2) while driving. The TV system can then also be operated from the rear by remote control.
TV sound playback (up to 31.8.03)
The TV tuner (A2/42) forwards the TV audio signal to the COMAND operating, display and control unit
(A40/3) via separate lines.
The signals are then amplified and converted into acoustic signals by the vehicle speakers. 2 sets of headphones
can be connected to the operating and display unit rear monitor(A40/2). Only the TV sound can be heard on
these headphones, regardless of the audio source that is being played on the vehicle speakers.
With code (810) Sound system, the TV audio signals are sent from the COMAND operating, display and
control unit (A40/3) via the Digital Data Bus (D2B) to the sound amplifier (A2/13), where they are received,
amplified and then converted into acoustic signals via the vehicle speakers.
TV mute function (as of 1.6.01)
The mute status of the audio sources (muting) is maintained if it was activated before switching off.
Displaying mute status in the TV screen
If audio sources are muted, a symbol appears in the top right of the display.
To be able to display on the TV screen that the mute function is active, the corresponding message has to be
transmitted to the TV tuner (A2/42).
The setting which was performed last before switching off the ignition, is adopted when the ignition is switched
on again.

Rear monitor, Model 220 up to GF82.60-P-3101A
location/task/design/function 31.8.02
With code (861)
Rear TV screen
except CODE (498)
Japanese version
except CODE (494)
USA version
Model 220 as of GF82.60-P-3101AS
1.9.02
With code (861)
Rear TV screen
except CODE (498)
Japanese version
except CODE (494)
USA version
TV tuner, location/task/design/function up to 31.8.03 GF82.60-P-3109C
except CODE (498)
Japanese version
except CODE (494)
USA version
as of 1.9.03 GF82.60-P-3109CA
except CODE (498)
Japanese version
except CODE (494)
USA version
Rear window antenna, GF82.62-P-3106A
Audio gateway control unit, as of 1.9.03 GF82.62-P-3116SZ
location/task/design
NAVIGATION MODE, FUNCTION - GF82.85-P-2012A
MODEL 215, 220 with CODE (352) COMAND operating and display system except CODE (498) Japan
version
Fig. 171: Navigation Mode Function Diagram - With Code (810) Sound System Up To 31.8.03
Block diagram for COMAND navigation system, shown on model 220 with code (810) Sound system and
code (854) MB standard CTEL up to 31.8.03
Fig. 172: Navigation Mode Function Diagram - Shown On Model 220 With Code (810) Sound System As
Of 1.9.03
Block diagram for COMAND navigation system, shown on model 220 with code (810) Sound system as of
1.9.03
On vehicles as of 1.9.03, the navigation processor (N41/1) is installed externally in the luggage
compartment as a separate control unit and integrated into the Media Oriented System Transport (MOST).
Thus, all optical and acoustic information is transmitted via this fiber optical cable.
Controller Area Network bus class B (interior) (CAN-B) and the Media MOST. The audio signals are then sent
to the audio gateway control unit (N93/1) output via the vehicle speakers.
With the aid of the COMAND navigation system, the location and the orientation of the vehicle, the direction of
travel and the distance to the destination (with specified destination) are determined. Subsequently, the
measures that are required to reach the destination (navigation) are initiated.
The navigation system is activated by pressing the "NAVI" button on the control unit.
A navigation processor with CD drive for the digital map data is integrated in the COMAND operating, display
and control unit (A40/3).
After activation of the navigation system, the following note appears on the display:
 Up to 31.5.01: "Please insert Navi CD"
 As of 1.6.01: "Please insert Navi CD, type DX"
 As of 1.9.03: "Please insert Navi DVD"
As of 1.9.02 it is possible to playback audio CDs in the navigation CD drive after the loading process and
during navigation.
Destination entry
The destination is entered menu-assisted on the COMAND operating, display and control unit (A40/3) and is
processed by the navigation processor.
The destination is entered menu-assisted on the display of the COMAND operating, display and control unit
(A40/3) and is processed by the navigation processor. The COMAND system offers the following possibilities
for destination entry:
 Address
 Destination memory
 Destination with map
 Special destinations (e.g. railway station, airport etc.)
 Travel guide (as of 1.6.01)
 Last destinations
It is also possible to enter an intermediate destination (e.g. from Hanover to Stuttgart via Cologne).
The entry is made menu-assisted on the display of the COMAND operating, display and control unit (A40/3).
Parts of the route can also be excluded from the calculation. This may be useful for avoiding heavily-used or
toll roads.
Dynamic supplementation
This function is realized with the manual entry of the destination. During entry, the letters for the destination to
be entered are supplemented using an existing list during dynamic supplementation. The supplemented
characters have a black background. Deleting can be accomplished character by character.
Predictive text input (as of 1.6.01)
During entry, the letters for the destination to be entered are supplemented using an existing list during dynamic
supplementation.
The predictive text input feature refers to the entry of the destination and street during navigation.
Position finding
COMAND continuously calculates the position of the vehicle using the following methods:
 Basic position finding (dead reckoning)

 Map-supported map matching
 GPS position finding
The navigation processor calculates the most probable position by continuously comparing the results returned
by these 3 methods.
Route calculation
The route is calculated in the navigation processor in accordance with the specified destination. If the vehicle
deviates from the route a new calculation is made. There are the following options to calculate the route:
 The fasted route

 The shortest route
 A dynamic route
 A user-defined route
If the vehicle is equipped with a dynamic navigation system (standard as of 1.6.00), the current traffic situation
(e.g. road works, traffic jam) also influences the route calculation. The calculated route is stored in the
navigation processor.
Route guidance
After the navigation processor has calculated the route, navigation is started.
The following 3 types of display can be selected for graphic navigation:
 Symbolic depiction (system of navigation symbols)

 Map display
 Mixture of map and symbol display
It is possible to change arbitrarily between the 3 types of presentation. The destination-finding system is also
supported by voice output from the vehicle loudspeakers.
Continuous position except CODE (494) USA GF82.61-P-2002C

finding, function version
Voice output, function except CODE (494) USA GF82.85-P-3001A
version
STARGUIDE, FUNCTION - GF82.85-P-2014A
MODEL 203.0 /2 /7 up to 23.4.04, 208, 210, 215, 220 with CODE (352a) COMAND operating and display
system with CODE (491) U.S. version
The Starguide system exploits the availability of existing telecommunication technology in the USA. This is
used to provide a personal information service.
Technical requirements:

 The latest navigation CD (it contains the latest software for implementing the respective system services;
the navigation system is updated.)
 the requirements for using the systems concerned have been met.
System requirements:
 GPS: Global Positioning System The GPS is available for performing precise positioning and navigation.
At this time, several satellites orbiting the earth are used for this system; these satellites travel in different
orbits.
 AMPS: Advanced Mobile Phone System. The AMPS network is now available in the densely populated
areas of the USA for 98% of the population.
 SOC: Service Operating Center. The SOC accepts all individual requests from the driver and transmits
the relevant information to the vehicle.
Personal information service concept:
 Provision of individual information and news in accordance with a personal interest profile (stock market,
weather, sports, etc.).
 Using a button to send a request to the Service Operating Center.
 The service center (Service Operating Center (SOC)) sends individual information and news in
accordance with customer profile.
 The data transmitted are shown on the display of the COMAND operating, display and control unit
(A40/3) and can be read there.
Information service, GF82.85-P-3016A

function
VOICE OUTPUT, FUNCTION - GF82.85-P-3001AB
MODELS 215, 220 with CODE (352) COMAND operating and display system with CODE (494) USA
version
Illustrated with following equipment specification:
 Code (810) Sound system up to 31.8.03

Fig. 173: Voice Output Function Diagram
In vehicles as of 01.09.03, all audio signals, voice signals and navigation processor (N41/1) signals are
transferred via the Media Oriented System Transport (MOST).
As of 1.9.03 the navigation processor (N41/1) is installed as a separate control unit in the left of the engine
compartment.
When using the navigation system, the user is much supported by voice output:
 Direction information
 Road numbers of national roads and highways
As of 01.06.01, specification of "compass direction" (north, south, east and west). No compass direction is
specified in the case of streets (e.g. in towns) which are designated by a name.
The voice data is originally stored on the CD as individual word segments. This data record is transferred
automatically from the CD to the navigation processor where it is stored in a non-volatile memory. The
navigation processor links these segments to complete instructions or information and produces appropriate low
frequency (LF) signals.
When required, the low frequency (LF) signals generated in this way are relayed via external cables to the
COMAND audio signal processing system in analog format, amplified and output via the vehicle speakers.
If the vehicle is equipped with a code (810) sound system (see block diagram), the voice signals are placed
on the Digital Data Bus (D2B) by the COMAND audio signal processing system, received and amplified by the
sound amplifier (A2/13) and then output via the vehicle speakers.
Several driving recommendations in quick succession are combined into a single voice output.
Manual language loading
Status as of 01.06.01; COMAND features various languages:
 English
 English
 Italian
 French
 Spanish
 Dutch
These can be selected using the "System settings" menu. The data for voice output is transferred from the CD to
the navigation processor where it is stored in a non-volatile memory. Language loading only takes a few
seconds and modifies both the voice output and the menu texts on the display.
Voice loading takes place again automatically after a power disconnection.
Severe vibration (e.g. bad roads) must be avoided while a language is being loaded from the CD. Otherwise
voice output might be fragmentary. If this is the case, the language must be reloaded.
Volume of voice output
The voice output volume can be adjusted during voice output. A difference of at least 12.5 dB is maintained
between the volume of the current audio source and the voice output volume.
If the volume is turned down during voice output, for example, and the 12.5 dB difference to the audio signal
becomes smaller, COMAND automatically reduces the level of the audio signal until the 12.5 dB difference is
reached again.
After voice output has taken place the volume of the audio signal is increased to match that of the voice output.
The volume of the voice output cannot be reduced to below a certain minimum level.
Superimposition of voice output and an audio source.
If an audio source (e.g. CD, radio) is active at the same time as voice output, the two signal sources are
superimposed.
Voice output mute circuit
The navigation voice output can be muted during voice output by pressing the mute button (button marked with
struck-out speaker). The mute feature applies only for the current voice output.
Route calculation, GF82.61-P-3011DA
function
DATA TRANSFER BETWEEN COMAND AND INSTRUMENT CLUSTER, FUNCTION - GF82.85-P-

3008AB
version
Multifunction steering wheel controls shown on model 220 up to 31.5.00
Fig. 174: Identifying Multifunction Steering Wheel Controls - Shown On Model 220 Up To 31.5.00
Multifunction steering wheel controls shown on model 215 and 220 as of 1.6.00
Fig. 175: Identifying Multifunction Steering Wheel Controls - Shown On Model 215 And 220 As Of 1.6.00
COMAND operation on multifunction steering wheel
Using the multifunction display (A1p13) on the instrument cluster (A1) and the switch on the multifunction
steering wheel the following COMAND-controlled systems can be operated and information concerning the
relevant systems displayed:
 Audio radio, CD changer (optional), cassette drive

 Navigation
 Telephone
All data exchange between the instrument cluster (A1) and the COMAND operating, display and control unit
(A40/3) takes place via the interior CAN (CAN-B)
All button presses on the multifunction steering wheel are read in by the steering column module (N80) (voltage
coded). The steering column module (N80) sends the relevant messages over the interior CAN (CAN-B). The
instrument cluster (A1) interprets the data using the system currently displayed on the multifunction display
(A1p13) (audio, navigation, telephone). This interpretation is necessary because the operation of the buttons
depends on the content of the multifunction display (A1p13). The interpreted CAN data from the instrument
cluster (A1) is not valid for the COMAND operating, display and control unit (A40/3).
Operating and display options on the multifunction display (A1p13)
Radio
Display:
 Set frequency band and where applicable memory location number (e.g. FM1)
 Information whether station search was accomplished with frequency or stored station list ("SP")
Operation:
 Volume
 Station search with station list or frequency
CD changer (optional)
Display:
 Number of CD currently playing

 CD track number
Operation:
 Volume
 Selection of track
Cassette drive
Display:
 Cassette side currently playing
Operation:
 Volume
 Rewind to start of current track
 Wind forward to next track
Navigation
Display:
 Street vehicle is currently on

 Next street to turn off into
 Distance to next turn-off
 Turnoff arrow
Operation:
 Volume of voice output
Telephone
Display:
 Name of provider
 Vehicle outside transmit or receive range of telephone network
 Telephone number (if stored) or name of caller (if transmitted via radio)
Operation:
 Volume
 Selection of name from stored phone directory, display of phone number and memory location number of
party being called.
 Accepting a call
 Dial repeat
Instrument cluster (IC), GF54.30-P-3039S

location/task
INFORMATION SERVICE, FUNCTION - GF82.85-P-3016A
MODELS 203.0 /2 /7 up to 23.4.04, 208, 210, 215, 220 with CODE (352a) COMAND operating and
display system with CODE (491) U.S. version
Service request procedure
Press the "SVC" button on the COMAND operating, display and control unit (A40/3) to switch to service mode.
In the "SVC" start screen you can choose whether to send a new "Send New Request for Info Service" request
or select the option "View Info Service of..." in order to view a previous information data record.
The rotary push-button on the COMAND operating, display and control unit (A40/3) is used to make the
selection and confirm it by pressing the button.
If "Send New Request for Info Service" is selected, the COMAND operating, display and control unit (A40/3)
sends this request to the E-Call control unit (A35/8) via the digital data bus (D2B). The E-call control unit sends
the request to the service provider via the existing telephone network.
The request is processed on the Internet on the basis of the personal information profile and sent to the vehicle
via the telephone network. The user is informed that the request has been received by a confirmation tone and
the message "New Info Received!" The security prompt "Read Later When Stopped?" with the reply "Yes" or
"No" is intended as a traffic safety measure.
If "Yes" is selected, the system jumps back to the previous menu, such as for radio, CD, navigation. If "No" is
selected, the messages are listed in accordance with the personal information profile.
The messages can be read in sequence. You can jump to the next message by pressing the rotary push-button on
the COMAND operating, display and control unit (A40/3). You can scroll through the message by turning the
rotary push-button.
The "BACK" button can be used to return to the previous menu at any time.
The information that is received can be scrolled through and read page by page. It is not possible to jump
straight to a particular page. The user can also modify the formatting.
Data transmission for GF82.85-P-3017A

Starguide, function
DATA TRANSMISSION FOR STARGUIDE, FUNCTION - GF82.85-P-3017A
MODELS 203.0 /2 /7 up to 23.4.04, 208, 210, 215, 220 with CODE (352a) COMAND operating and
display system with CODE (491) U.S. version
Fig. 176: Identifying Data Transmission For Starguide, Function - Models 203.0 /2 /7 Up To 23.4.04, 208,
210, 215, 220 With Code (352A) And (491)
System concept for the information service
The user determines his own interest profile for service information (such as world news, stock exchange
information, etc.) and transmits this information request to the Mercedes-Benz customer service department.
This profile is sent to the service center (Service Operating Center (SOC)).
By pressing the "SVC" button (on the COMAND operating, display and control unit (A40/3)), the customer can
transmit a request for updated service information to the service center (Service Operating Center (SOC)).
At the service center (Service Operating Center (SOC)) the customer profile is used as a set of criteria for
selecting information. The requested information is put together by the information provider and sent to the
vehicle via the service center (Service Operation Center (SOC)). The data transmitted appear on the display of
the COMAND operating, display and control unit (A40/3).
Operating, display and control MODEL 203 GF82.85-P-3114R

unit, location/
task/design/function
NAVIGATION PROCESSOR, LOCATION/TASK/DESIGN/FUNCTION - GF82.85-P-3103BA
MODEL 215, 220 as of 1.9.03 with CODE (352a) COMAND operating and display system
Fig. 177: Identifying Navigation Processor Location
Navigation processor, The navigation processor

location (N41/1) is installed on the
left-hand side of the trunk.
Navigation processor, The navigation processor
task (N41/1) is responsible for
providing navigation
information in the vehicle.
Navigation processor,  GPS receiver
design
 Navigation processor
 DVD drive and
control electronics
 Integrated yaw rate
sensor
 MOST interface
Navigation processor, GF82.85-P-3103-07B
function
Navigation processor, function - GF82.85-P-3103-07B
Navigation processor and GPS control unit.
The navigation processor (N41/1) is the central component of the navigation system. It uses the incoming
signals to calculate the location of the vehicle and also calculates the vehicle's route after the destination has
been entered. The GPS control unit is part of the navigation processor (N41/1). It evaluates the satellite signals
received from the GPS antenna (A2/49a2) (with model 220), GPS antenna (A2/23) (with model 215) and uses
these signals to calculate the position of the vehicle. At least 4 satellites are required for dead reckoning, 3
satellites are sufficient for other calculations. If these requirements for dead reckoning do not exist, only the
number of satellites appears in the display.
All optical information is passed to the COMAND operating, display and control unit (A40/3) via the Media
Oriented System Transport (MOST). The acoustic driving directions are also transferred directly to the audio
gateway control unit (N93/1) via the MOST bus.
Below is a list of the basic functions:
 Receive operating unit commands

 Control the DVD drive
 Determine the position of the vehicle
 Evaluate wheel pulses
 Route planning, route calculation and navigation
 Optical driving directions
 Communication with other system components via the optical MOST bus
 Display maps of various scales
Yaw rate sensor
The yaw rate sensor determines the direction changes of the vehicle. The yaw rate sensor is build into the
navigation processor (N41/1). Calibration is not required.
When navigation begins the message "Please insert DX navigation CD" appears on the display of the
operating unit.
This message is intended to ensure that the customer procures the right navigation DVD.
The DVD contains the following data:
 Program data for execution in navigation processor

 Voice data for voice output
 Map data.
The digitized map area on the DVD contains villages, towns, cities, streets, intersections and their attributes
(e.g.: one-way streets, turn prohibitions, etc.). It does not contain information about company and private land,
farms, small housing estates and paths.
ANTENNA, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.85-P-3107
Antenna splitter, location/purpose/design/function - GF82.85-P-3107A
MODEL 208, 210, 215, 220 with CODE (352a) COMAND operating and display system with CODE (347)
TELE AID emergency call system (D2B)
MODEL 208, 210, 215, 220 with CODE (352b) Information and communication system (ICS) with CODE
(498) Japanese version with CODE (347a) EMERGENCY CALL system
Antenna splitter, Model 208: Right bottom trunk floor

location Model 210: Below headliner in left
C-pillar
Models 215, 220 GF82.85-P-3107-
01A
Antenna splitter, Distribution of GPS signal
purpose The antenna splitter (A2/5) is
required when the vehicle is equipped
with:
 TELE AID/EMERGENCY
CALL (code 347) and with
 COMAND (code 352)
simultaneously.
Antenna splitter,  Active frequency splitter with
design power supply via coaxial cable
(phantom power supply)
 3 coaxial connection sockets
Antenna splitter, The antenna splitter (A2/5) receives

function the signals from the GPS antenna
(A2/49a2, A2/23) and distributes
them to the TELE AID control
module (A35/8) and the navigation
processor (A40/3n2) integrated into
the COMAND operating, display
and control module (A35/8) .
Antenna splitter, location - GF82.85-P-3107-01A
Models 215, 220 with code 352 and 347

Fig. 179: Identifying Antenna Splitter Location - Illustrated On Model 220
Antenna, location/purpose/design/function - GF82.85-P-3107SZ
Antenna splitter, GF82.85-P-3107-01SZ

location
Antenna splitter, The antenna splitter (A2/5)
purpose distributes the Global
Positioning System (GPS)
signal to the navigation
processor control units (N41/1)
and telecommunications
control unit (N112) (up to
31.5.04) or emergency call
system control unit (N123/4)
(as of 1.6.04).
Antenna splitter, design The antenna splitter (A2/5)
consists of the diplexer with
voltage supply via coaxial
cable (phantom voltage) and of
3 coaxial sockets.
Antenna splitter, GF82.85-P-3107-04SZ
function
Antenna splitter, location - GF82.85-P-3107-01SZ
Shown on MODEL 220
Fig. 181: Identifying Antenna Splitter Location - Shown On Model 220
Antenna splitter, function - GF82.85-P-3107-04SZ
The antenna splitter (A2/5) splits the Global Positioning System (GPS) signal from the GPS antenna (A2/49a2)
(model 220) or GPS antenna (A2/23) (model 215) for the navigation processor control units (N41/1) and
telecommunications control unit (N112) (with code (383a) fixed installation telephone Tele-Aid) or emergency
call system control unit (N123/4) (with code (359) TELE AID emergency call system).
SATELLITE RADIO, LOCATION/TASK - GF82.85-P-3113B
(494a) USA version
Shown on model 220

Fig. 182: Identifying Satellite Radio Location - Shown On Model 220
Satellite radio, location The SDAR control unit

(N87/5) is installed as a
dealer optional extra on a
bracket above the
navigation processor
(N41/1) at the
wheelhouse on the left-
Satellite radio, task GF82.85-P-3113-01B
Satellite radio, task - GF82.85-P-3113-01B
The SDAR antenna (A2/82) receives S band signals from satellites and is able, with a special antenna on the
floor, to also receive these signals from satellite transmitters near to the earth (mostly in towns). The signals
received from the SDAR antenna (A2/82) are passed on to the SDAR control unit (N87/5) via a coaxial cable.
The SDAR control unit (N87/5) receives and decodes the signals. These are then transmitted to the operating
unit via Media Oriented Systems Transport (MOST).
In the USA version, the Sirius satellite radio receiver can be installed as an optional extra. The complete
wiring is already pre-installed in the vehicle.
OPERATING, DISPLAY UNIT WITH CONTROL UNIT, LOCATION/TASK/DESIGN/FUNCTION -

GF82.85-P-3114
Operating, display unit with control unit, location/task/design/function - GF82.85-P-3114D
MODEL 215, 220 up to 31.8.02 with CODE (352a) COMAND operating and display system with CODE
(494a) USA version
Fig. 183: Identifying COMAND Operating Display And Control Unit
Fig. 184: Identifying COMAND Operating Display And Control Unit - Front View (Version As Of 1.9.00)
Version as of 1.9.00
Fig. 185: Identifying COMAND Operating Display And Control Unit - Rear View
Operating, display unit The COMAND operating,

with control unit, display and control unit
location (A40/3) is installed in the
center console between the
operating module for the
interior air conditioning and
the upper control panel.
Operating, display unit Central control of the
with control unit, task following systems:
Radio, cassette drive

 6-disk CD changer
(optional)
 Sound system
(optional)
 Navigation
 Telephone
Operating, display unit Except code 498 GF82.85-P-3114-07D

with control unit, design
Operating, display unit GF82.85-P-3114-08BA
with control unit,
function
Operating, display unit with control unit, design - GF82.85-P-3114-07D
The following components are integrated in the COMAND operating, display and control unit (A40/3):
 Graphic compatible LCD color display

 Radio
 Multi-standard disk drive
The following interfaces are integrated in the COMAND operating, display and control unit (A40/3):
 Digital data bus (D2B)

 Interior CAN (CAN-B)
 K line (diagnostic interface)
Operating, display unit with control unit, function - GF82.85-P-3114-08BA
In vehicles from 01.09.03 onwards, the audio gateway control unit (N93/1) is also installed as interface
between the class B (interior) Controller Area Network Bus (CAN-B) and the Media Oriented System Transport
(MOST). The audio signals are then sent to the audio gateway control unit (N93/1) and output via the vehicle
speakers.
Processing button and switch operations
The controls on the function keypad in the COMAND operating, display and control unit (A40/3) are read in
via microcontroller I/O ports and made available to the central computer.
Depending on the system function, the control actuations are processed in the central computer and transferred
to the other system components via the digital data bus (D2B) and CAN-B in the form of a data telegram.
Graphic editing and image output
The graphic subsystem edits and outputs the operating displays. The operating screens are internally output to
the display by the graphics system via the RGB output.
The RGB signal contains the information and amplitudes for the three primary colors of red, green and blue,
and a synchronization signal. The actuation electronics in the display unit evaluate the RGB signal and actuate
the color and intensity of the individual pixels line by line.
A horizontal synchronization pulse occurs at the end of each line.
The electronic circuitry of the display unit then starts the next line. When the last line of the display has been
reached, a vertical synchronization pulse occurs, and the electronics actuate the first line again.
Audio signal output
The audio signals from the various sources (Radio, CD, navigation system voice output etc.) are prepared by the
COMAND operating, display and control unit (A40/3n1) and amplified before being output via the vehicle
speakers. In vehicles with code (810) sound system, the final amplification of the audio signals is carried out by
the sound amplifier (A2/13). The audio source data are transmitted to the sound amplifier (A2/13) via the digital
data bus (D2B) for this purpose.
Info menu as of 1.6.01
The Info menu is accessed directly using the "i button" or the "INF button". This functionality can be selected
independently of source (e.g. from the telephone or radio menu).
You can return to the screen from which "Info" was selected by pressing the Back key. If the Mode item was
selected in the Info menu, the system switches to the screen that was accessed prior to the Info menu when the
Back key is pressed.
On-board diagnosis, shown in display
The following information is incorporated in the Info menu: up to 31.05.01
 Warm start (operating condition)

 Battery voltage (e.g. 13.21V)
Added as of 01.06.01
 GPS, item number (number and position of available satellites)

 Direction of travel
 Speed (mph)
At least 4 satellites are required for dead reckoning, 3 satellites are sufficient for other calculations.
If these conditions for position calculation are not met, only the number of satellites appears in the display.
Diagnosis interface (K-line) and D2B component fault management
During COMAND operation the system stored all faults that have occurred in non-volatile memory. These can
be read out via the diagnostic interface (K-line) using STAR DIAGNOSIS. Output of the errors on the display
unit is not possible. The COMAND fault management also includes the connected components (e.g.
communication with D2B equipment). Each D2B component has its own fault memory. The faults are
transferred via the D2B bus to the COMAND operating, display and control unit (A40/3) upon request by
STAR DIAGNOSIS and can then be read out via the diagnostic interface.
Navigation and GPS control unit
The navigation processor is the central component of the COMAND navigation system.
It is integrated in the COMAND operating, display and control unit (A40/3) and calculates the location of the
vehicle from the incoming signals. It also calculates the vehicle's route after the destination has been entered.
The GPS control unit is part of the navigation processor.

In model 220 it analyses the satellite signals received by the GPS antenna (A2/49a2) or in model 215 by the
GPS antenna (A2/23) and uses them to calculate the vehicle position.
Yaw rate sensor
The yaw rate sensor determines the direction changes of the vehicle. It is installed in the navigation processor.
Calibration is not required.
In vehicles from 01.06.00 onwards, the traffic data recorder (A2/43) is also integrated in the COMAND
In vehicles from 01.09.03 onwards, the navigation processor (N41/1) is installed as a separate control unit
in the left of the trunk.
The CD drive of the COMAND operating, display and control unit (A40/3n1) reads data from the CD that has
been inserted and makes it available to the navigation processor via the internal data bus.
After the activation of the navigation system, the following instruction appears on the display:
 Up to 31.8.03: "Please insert Navi CD type DX"

 As of 01.09.03: "Please insert Navi DVD"
In vehicles from 31.8.03 onwards it is possible to play audio CDs after loading and during navigation.
The navigation CD contains the following information:
 Program data for execution in navigation processor

 Voice data for voice output
 Map data.
The digitized map area on the CD contains towns, streets, intersections and their attributes (e.g.: one-way
streets, turn prohibitions etc.).
It does not contain information about company and private land, farms, housing estates and paths.
Cassette player (up to 31.08.02)
The cassette flap is moved in and out, opened and closed by a motor.
When the cassette tape is being played it is led past the reading head of the cassette player at a constant speed.
In order to reduce noise during cassette playback, noise suppression measures (e.g. DOLBY B or DOLBY C)
are required.
The audio signal voltage that is generated is amplified in the cassette player and relayed to the audio
components of the COMAND operating, display and control unit (A40/3).
DOLBY B reduces tape hiss in the high frequency range. Signals that are weak and in the upper sound
range are amplified during recording. Using DOLBY B during playback of a cassette, the signals that were
amplified during recording are reduced to the original level. This measure reduces the noise level. DOLBY C is
a further development of DOLBY B.
Operating, display unit with control unit, location/task/design/function - GF82.85-P-3114DA
(494a) USA version
Shown on model 220
Fig. 186: Identifying COMAND Operating Display And Control Unit Location - Shown On Model 220
Operating, display unit The COMAND operating,

with control unit, display and control unit
location (A40/3) is installed in the
center console between the
operating module for the
interior air conditioning and
the upper control panel.
Operating, display unit Central control of the
with control unit, task following systems:
 Radio and CD player

 Cassette drive
(optional)
 Sound system
(optional)
 Navigation
 Telephone
Operating, display unit Except code 498 GF82.85-P-3114-07DA

with control unit, design
Operating, display unit GF82.85-P-3114-08BA
with control unit,
function
Operating, display unit with control unit, design - GF82.85-P-3114-07DA
The following components are integrated in the COMAND operating, display and control unit (A40/3):
 Color liquid crystal display (LCD) with graphics capability

 Radio tuner
 CD drive
In vehicles from 01.09.03 onwards, the navigation processor (N41/1) is installed as a separate control unit
in the left of the trunk.
The COMAND operating, display and control unit (A40/3) has the following interfaces:
 Digital databus (D2B)

 Class B (interior) Controller Area Network Bus (CAN-B)
 K bus (diagnostic interface)
In vehicles from 01.09.03 onwards, the audio gateway control unit (N93/1) is also installed as interface
between the CAN-B and the Media Oriented System Transport (MOST). The audio signals are then sent to the
OVERVIEW OF SYSTEM COMPONENTS FOR COCKPIT MANAGEMENT AND DATA SYSTEM

(COMAND), LOCATION/TASK/DESIGN/FUNCTION - GF82.85-P-9997BZ
version
Instrument cluster (IC), location / task GF54.30-P-3039S

location / task / design / function
Sound amplifier, with Code (810) GF82.62-P-3100A
location/task/design/function Sound system up to
31.08.03
with Code (810) GF82.62-P-3100AB
Sound system as of
01.09.03
with Code (348)
EMERGENCY
CALL system
Radio satellite antenna, location/task as of 1.9.03 GF82.62-P-4109B
CD player with changer, up to 31.8.03 GF82.64-P-3114B
location/task/design with code (819) CD
changer with 6 CDs
CD player with changer, as of 1.9.03 GF82.64-P-3113BA
location/task/design/function with code (819) CD
changer with 6 CDs
GPS/telephone roof antenna Model 220 GF82.70-P-4111A
location/task/design/function with Code (347)
TELE AID
emergency call
system (D2B).
with CODE (353)
Audio 30 APS
with CODE (853)
MB standard
telephone
with CODE (854)
MB portable CTEL
telephone
with Code (855)
TELE AID
as of 1.9.02 GF82.85-P-3114DA
Navigation processor, as of 1.9.03 GF82.85-P-3103BA
Radio satellites, location/task as of 1.9.03 GF82.85-P-3113B
Contents, function description of GF82.85-P-0997BZ
cockpit management and data system
(COMAND)
MULTIFUNCTION STEERING WHEEL, FUNCTION - GF82.90-P-0001
Multifunction steering wheel, function - GF82.90-P-0001A
MODEL 220 up to 31.8.03 with CODE (494) USA version with CODE (498) Japan version
Multifunction steering wheel shown
Fig. 187: Identifying Multifunction Steering Wheel
General information
The multifunction steering wheel serves to increase active driving safety in road traffic in combination with the
instrument cluster (A1). This allows the driver to concentrate on the traffic without distraction when controlling
and operating various vehicle components (for example: CD changer, telephone).
The multifunction steering wheel allows the driver to control and call up the following systems without taking
his hands off the steering wheel:
 COMAND
 CD changer
 Cassette player
 Telephone/voice control system
 Navigation
 Trip computer
 Settings (setting time, shutoff delay for interior lighting, ...)
The main system selected by the driver is displayed in the multifunction display (A1p13) on the instrument
cluster (A1). The fanfare horns can also be actuated via the steering wheel impact plate (1).
Keypad
Each of the systems can be actuated using the system selection button (S110s3). Each press of the button opens
the next system screen in the multifunction display (A1p13). It is not possible to move backwards.
If necessary, the system selection button must be pressed repeatedly until the desired system reappears in the
multifunction display (A1p13).
It is possible to "scroll" in a system with the scroll forward/back button (S110s1) to open additional submenus.
The voice control system (VCS) can also be switched on and off using the system selection and voice control
system button (S110s3).
With the buttons:
 For accepting or terminating a call (S111s3) it is possible to accept (answer) or terminate (hang up) a call.
 "+" and "a" for setting specific functions and for volume control (S111s1), the volume of a currently
active system can be changed.
It is also possible to adjust the interior light OFF delay time, for example, using the "+" (increase) and
"a" (decrease) buttons.
The control signals are transmitted from the keypad on the steering wheel via the clock spring contact to the
control unit located in the steering column module (N80).
The signals are transmitted from the steering column module (N80) via the vehicle's own bus system (interior
CAN) to the instrument cluster (A1). Depending on the system shown in the display, a CAN signal for the
required component (CD changer, telephone...) is generated and transmitted from here. In the COMAND
operating, display and control unit (A40/3), the CAN signal is converted in such a way that the Digital Data Bus
system (D2B) can relay the signals to the required device (CD changer, telephone...).
Multifunction steering GF82.90-P-0001-01I

wheel, networking of
components
Table of contents for GF54.30-P-0997S
instrument cluster (IC)
Table of contents for GF54.50-P-0999SZ
trip computer
Table of contents for GF54.35-P-0999SZ
fanfare horn system
Cockpit management and Code 494 with code 352 GF82.85-P-0003B
data system (COMAND),
function
Digital Data Bus (D2B) GF82.00-P-0001A
function
CAN data bus, general GF54.00-P-0005A
information, function
Multifunction steering wheel, networking of components - GF82.90-P-0001-01I
Fig. 188: Multifunction Steering Wheel Component Networking Diagram - Shown In Model 220 With
COMAND
Shown in model 220 with COMAND
In model 215, the switch for voice operation is not located on the multifunction steering wheel, but on the
steering column switch module.
Fig. 189: Multifunction Steering Wheel Component Networking Diagram - Shown In Model 220 With
Radio (Audio 30)
Shown in model 220 with radio (Audio 30)
In model 215, the switch for voice operation is not located on the multifunction operation is not located on
the multifunction steering wheel, but on the steering column switch module.
Multifunction steering wheel, function - GF82.90-P-0001SM
MODEL 220.0 /1, 215.3 as of 1.9.03
The multifunction steering wheel (MFL) serves to increase active driving safety in road traffic in combination
with the instrument cluster (A1). The driver can concentrate on the traffic without distraction when controlling
and operating various vehicle components. The MFL allows the driver to operate and call up the following
systems and information:
 Radio (RD) and navigation (NAVI)

 Fault and warning messages
 Interior lights (IBL) (e.g. OFF delay times)
 Exterior lights (ABL) (e.g. OFF delay times, daytime running lamps)
 Trip computer (ART)
 Active service system (ASSYST)
 Distronic (autonomous intelligent cruise control) (ART) (only in active state, no operation)
 Roadside assistance and MB information call
 Telematic Alarm Identification on Demand (emergency call system) (TELE AID) (only )
 Telephone (TEL) (e.g. read SMS messages)
 Tire pressure monitor (TPM)
 Basic settings (e.g. mirror fold-in facility, switching key-dependent convenience functions on and off)
 Circuit 15R ON
 No undervoltage or overvoltage
Only systems and functions with which the vehicle is equipped are displayed. If a system is not installed, it
is "skipped" when the system selection button (S110s3) on the left multifunction steering wheel button group
(S110) is pressed.
The system selected by the driver is displayed in the multifunction display (A1p13) on the instrument cluster
(A1). The fanfares (H2) can also be operated using the fanfare horn system button (S110s5) and the fanfare
horn system button (S111s5) beneath the impact plate on the MFL.
If the vehicle has a TRIP, there is also a "last mode" function. When you switch to this system, the last
selected submenu is displayed; in the other systems, the user is guided to a defined entry level.
Left multifunction steering wheel button group (S110)
In system selection button (S110s3) and Scroll forward and backward buttons (S110s1) are included in the left
multifunction steering wheel button group (S110). Each of the systems can be called with the system selection
button (S110s3). It is possible to "scroll" forward and backward in the systems.
Other submenus can be called up in the NAVI system by scrolling forwards and backwards (S110s1).
Right multifunction steering wheel button group (S111)
The right multifunction steering wheel button group (S111) contains the accept/terminate phone call button
(S111s3), and the + and button, setting of specific functions and volume control (S111s1). A telephone call can
be accepted or terminated with the accept/terminate phone call button (S111s3).
The volume for the system currently active can be adjusted with the + and -button, setting of specific functions
and volume control (S111s1). In the System settings menu, settings such as increasing or decreasing the OFF
delay time for the external lights and setting the time can also be made using this button.
Multifunction steering Model 220.0 (except GF82.90-P-0001-01SM

wheel, networking of 220.074)
components Model 220.1 (except
220.174/179)
Model 215.3 (except
215.374/379)
Model 220.074/174/179 GF82.90-P-0001-01SN
Model 215.374/379
Scanning of switch Model 220.0 (except GF82.90-P-3001SM
positions, function 220.074)
Model 220.1 (except
220.174/179)
Model 215.3 (except
215.374/379)
Model 220.074/174/179 GF82.90-P-3001SN
Model 215.374/379
Multifunction steering wheel, networking of components - GF82.90-P-0001-01A
Fig. 190: Multifunction Steering Wheel Component Networking Diagram
Component networking
Multifunction steering wheel networking of components - GF82.90-P-0001-01SM

Multifunction steering wheel networking of components - GF82.90-P-0001-01SN

MULTIFUNCTION STEERING WHEEL FUNCTION DESCRIPTION CONTENTS - GF82.90-P-0999
Multifunction steering wheel function description contents - GF82.90-P-0999A
MODEL 220 up to 31.8.03 with CODE (494) USA version with CODE (498) Japan version
Multifunction steering GF82.90-P-0001A

wheel function
Multifunction steering GF82.90-P-0001-01A
wheel networking of
components
Table of contents, GF54.30-P-0997S
description of instrument
cluster functions(IC)
Table of contents, GF54.50-P-0999SZ
trip computer
Table of contents, GF54.35-P-0999SZ
function description,
fanfare horn system
Cockpit management and Code 494 with code 352 GF82.85-P-0003B
data system (COMAND),
function
Digital Data Bus (D2B) GF82.00-P-0001A
function
CAN data bus, function GF54.00-P-0005A
Multifunction steering wheel, function description contents - GF82.90-P-0999SM
MODEL 220.0 /1, 215.3 as of 1.9.03
Multifunction steering wheel, function GF82.90-P-0001SM

Multifunction steering wheel, Model 220.0 (except GF82.90-P-0001-
networking of components 220.074) 01SM
Model 220.1 (except
220.174/179)
Model 215.3 (except
215.374/379)
Model GF82.90-P-0001-
220.074/174/179 01SN
Model 215.374/379
Scanning of switch positions, function Model 220.0 (except GF82.90-P-3001SM
220.074)
Model 220.1 (except
220.174/179)
Model 215.3 (except
215.374/379)
Model GF82.90-P-3001SN
220.074/174/179
Model 215.374/379
Survey of multifunction steering wheel GF82.90-P-9999SM
system components
SCANNING OF SWITCH POSITIONS, FUNCTION - GF82.90-P-3001
Scanning of switch positions, function - GF82.90-P-3001SM
MODEL 220.0 /1, 215.3 (except 220.074 /174 /179, 215.374 /379) as of 1.9.03
The button presses on the multifunction steering wheel (MFL) are read in by the steering column module (N80)
(voltage coded). Different resistors are connected in series upstream and downstream of the individual buttons.
Pressing the buttons relays different voltages to the steering column module (N80). The steering column module
(N80) interprets the button-related request from these voltages and can then generate and transmit an
appropriate Class B (interior) Controller Area Network Bus (CAN-B) message.
Priorities
If, within the left multifunction steering wheel button group (S110) or the right multifunction steering wheel
button group (S111) several buttons are pressed simultaneously, the instrument cluster (A1) will always only
activate one function. As a result, the different functions have different priority ranks.
Below, the buttons within the right multifunction steering wheel button group(S111) are arranged in descending
priority order:
 Fanfare horn button (S111s5)

 Buttons + and -for setting specific functions and volume control (S111s1)
The buttons within the left multifunction steering wheel button group (S111) are arranged in descending priority
order:

 System select button (S110s3)
 Scroll forward/back button (S110s1)
Multifunction steering GF82.90-P-4000SM

wheel location/task
Scanning of switch positions, function - GF82.90-P-3001SN

MODEL 220.074 /174 /179, 215.374 /379 as of 1.9.03
The button presses on the multifunction steering wheel (MFL) are read in by the steering column module (N80)
(voltage coded). Different resistors are connected in series upstream and downstream of the individual buttons.
Pressing the buttons relays different voltages to the steering column module (N80). The steering column module
(N80) interprets the button-related request from these voltages and can then generate and transmit an
appropriate Class B (interior) Controller Area Network Bus (CAN-B) message. The requests from the steering
wheel gear shifter PLUS switch (S111/1) and the steering wheel gear shifter MINUS switch (S110/1) are also
read in voltage-coded. The steering column module (N80) receives the requests from the steering wheel gear
shifter PLUS switch (S111/1) and the steering wheel gear shifter MINUS switch (S110/1) and relays them to
the electronic selector lever module control unit (N15/5) via discrete cabling.
Priorities
If, within the left multifunction steering wheel button group (S110) or the right multifunction steering wheel
button group (S111) several buttons are pressed simultaneously, the instrument cluster (A1) will always only
activate one function. As a result, the different functions have different priority ranks.
Below, the buttons within the right multifunction steering wheel button group(S111) are listed in descending
priority order:

 Steering wheel gear shifter PLUS (S111/1)
 Buttons + and -for setting specific functions and volume control (S111s1)
Below, the buttons within the left multifunction steering wheel button group (S111) are listed in descending
priority order:

 Steering wheel gear shifter MINUS (S110/1)
 System select button (S110s3)
Multifunction steering wheel GF82.90-P-4000SM

location/task
Steering wheel gear shifter, GF27.19-P-5137RM
MULTIFUNCTION STEERING WHEEL LOCATION/TASK - GF82.90-P-4000SM
MODEL 220.0 /1, 215.3 as of 1.9.03

Fig. 193: Identifying Multifunction Steering Wheel Location
Multifunction steering GF82.90-P-4000-01SM

wheel button group,
location
Multifunction steering Accepting and relaying
wheel button group, task commands that
correspond to the
individual button presses.
Multifunction steering wheel button group, location - GF82.90-P-4000-01SM
The left multifunction steering wheel button group (S110) is located on the left next to the impact plate of the
multifunction steering wheel (MFL), in a location that is easy for the driver to see and access. The left
multifunction steering wheel button group (S110) consists of the scroll forward/back button (S110s1) at the top
and the system selection button (S110s3) at the bottom.
The right multifunction steering wheel button group (S111) is located on the right next to the impact plate of the
MFL, in a location that is easy for the driver to see and access. The right multifunction steering wheel button
group (S111) consists of the + and a button, setting of specific functions and volume control (S111s1) at the top
and the accept/terminate phone call button (S111s3) at the bottom.
SURVEY OF MULTIFUNCTION STEERING WHEEL SYSTEM COMPONENTS

LOCATION/TASK/DESIGN/FUNCTION - GF82.90-P-9999SM
MODEL 220.0 /1, 215.3 as of 1.9.03
Multifunction steering wheel GF82.90-P-4000SM

location/task
Steering wheel gear shifter, Model 220.074/174/179 GF27.19-P-5137RM
location/task/function Model 215.374/379
Multifunction steering wheel, GF82.90-P-0999SM
function description contents
TELE AID, FUNCTION - GF82.95-P-0001
TELE AID, function - GF82.95-P-0001A
MODEL 129, 202, 208.3, 210 as of 1.6.98, 215, 220 with CODE (347) TELE AID emergency call system
(D2B)
MODEL 140, 210 up to 31.5.98 with CODE (348) TELE AID emergency call system
MODEL 140, 202, 210, 220 with CODE (930) Taxi emergency call
TELE AID, general
TELE AID is an automatic emergency call system using the availability of new technologies such as vehicle
location finding via satellite and mobile telephone network for reducing accident causes. The name TELE AID
stands for TELE MATIC A LARM IDENTIFICATION ON DEMAND.
Emergency calls and precise location description are automated by TELE AID and therefore do not depend on
incorrect human behavior in stress situations.
Information processing of systems connected with TELE AID is accomplished with conventional wiring and via
vehicle's own bus systems (models 140, 210 up to 31.5.98 via CAN data bus and models 129, 202, 208.3, 210,
215, 220 as of 1.6.98 via CAN and D2B.(Digital data bus or fiber optic cable).
Operational sequence
A TELE AID emergency call can be actuated automatically or manually. The following actuation procedures
should be distinguished:
 Automatically,
 by the emergency tensioning retractor control module with airbag (AB, N2/2, except Models
215, 220)
 by the restraint system control module ( N2/7, models 215, 220)
or
by the emergency call system control module (TELE AID, A35/8)
with integrated roll-over sensor.
 Manually,
actuating the emergency call pushbutton switch (TELE AID, S93/3) and a taxi emergency call in
addition:
 by actuating the emergency alarm actuation button (S62/6).
If an alarm is triggered the emergency call control module (TELE AID, A35/8) sets up an emergency call
telegram containing information on the accident severity, vehicle identification, vehicle position and type of
alarm actuation. The emergency call telegram is transmitted via the vehicle telephone equipment (D-network).
The telephone antenna depends on the model
Model 129: Rod antenna (A28)
Models 202, 208.3, 210, 220: Telephone antenna (A2/49a1)
Model 215: Telephone antenna (A2/22)
If the telephone antenna is defective the system switches automatically over to the TELE AID substitute
antenna (A2/50) .
The emergency call telegram is received by the service provider. There the position specifications are converted
to location and street names with a road data bank and transmitted to the responsible rescue service (in general
the police) together with the information from the emergency call telegram.
The decoded emergency call telegram is transmitted to the rescue service by the service provider as follows:
 Either via electronic data transmission or

 via fax or
 via a telephone voice connection.
A voice connection is accomplished from the vehicle (via telephone D-network) to the rescue service. Then the
required rescue measures are started there.
The emergency call system is initially available only in the Federal Republic of Germany.
When initially started the system performs an authorization. For this purpose it is necessary to insert a SIM ( S
ubscriber I dentification M odule) card into the CTEL transmitter and receiver (A35) and make a service
contract. Without authorization it is not possible to operate a TELE AID service.
When authorization is not accomplished the indicator lamp in the TELE AID emergency call pushbutton
switch (S93/3) comes on.
The type of transmission depends on the technical equipment of the rescue service.
Fig. 194: Locating TELE AID Function
The following structogram indicates, strongly simplified, the sequence of a TELE AID emergency call.
The abbreviations used have the following meaning:
Fig. 195: Identifying TELE AID Emergency Call Block Diagram
TELE AID, location of components Model 129 GF82.95-P-0001-

01E
Model 140.063/07 GF82.95-P-0001-
01C
Model 140 except GF82.95-P-0001-
140.063/07 01A
Models 202, 208.3 GF82.95-P-0001-
01F
210.2 01B
Model 210.2 GF82.95-P-0001-
01D
Model 215 GF82.95-P-0001-
01N
Model 220 GF82.95-P-0001-
01G
TELE AID block diagram Models 129, 140 GF82.95-P-0001-
except 140.063/07, 02A
202, 208.3, 210,
215, 220 with code
347/348, Model 140
with code 930
Models 202, 210, GF82.95-P-0001-
220 with code 930 02B
Taxi emergency call, function Models 202, 210, GF82.95-P-0002A
220 with code 930
TELE AID switch-on/switch-off GF82.95-P-2000A
characteristics, function
Authorization, function GF82.95-P-2001A
Status indicator (indicator lamp), function GF82.95-P-2002A
Emergency call actuation, function GF82.95-P-2003A
Emergency call telegram generation, GF82.95-P-2004A
function
Emergency call telegram transmission, GF82.95-P-2005A
function
Voice connection to vehicle, function GF82.95-P-2006A
Location finding, function GF82.95-P-3000A
Selecting telephone antenna, function GF82.95-P-3001A
PIN check with TELE AID emergency GF82.95-P-3002A
call, function
Data from airbag control module, function GF82.95-P-3003A
TELE AID control module, GF82.95-P-4100A
TELE AID emergency call pushbutton GF82.95-P-4101A
switch, location/purpose/design/function
Emergency alarm system actuation button, Model 140 except GF82.25-P-4100A
location/purpose/design/function 140.063/07, 202,
210, 220 with code
930
Rod antenna, location/purpose Model 129 GF82.62-P-4115B
Global positioning system antenna (GPS), Model 129 GF82.85-P-3105C
Telephone antenna, location/purpose Model 215 GF82.62-P-4105B
Global positioning system antenna, Model 215 GF82.61-P-4106D
GPS/telephone/radio roof antenna, Models 140, 202, GF82.70-P-4111A
location/purpose/design/function 208.3, 210, 220
with code 351, 815,
347, 348
GPS/telephone/radio roof antenna, Model 140 except GF82.70-P-4112A
location/ purpose/design/function 140.063/07, 202,
210, 220 with code
930
TELE AID substitute antenna, GF82.95-P-4102A
location/purpose/ design/function
Hands-free microphone, location/purpose GF82.70-P-4102A
CAN databus, function GF54.00-P-0005A
Digital data bus (D2B), general function GF82.00-P-0001A
TELE AID, location of components - GF82.95-P-0001-01G
Fig. 196: Identifying TELE AID Components Location

TELE AID, location of components - GF82.95-P-0001-01N
TELE AID block diagram - GF82.95-P-0001-02A
Instead of N2/2 the following are integrated in models 215, 220:

Fig. 198: Identifying TELE AID Block Diagram (1 Of 3)
TELE AID block diagram - GF82.95-P-0001-02B
instead of N2/2 model 220 is equipped with

Fig. 199: Identifying TELE AID Block Diagram (2 Of 3)
TELE AID function - GF82.95-P-0001P
MODELS 203, 210, 220 up to 31.8.03 with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODELS 208.3, 215 up to 31.8.03 with CODE (855) TELE AID
TELE AID, general
The name TELE AID stands for TELE MATIC A LARM I DENTIFICATION ON D EMAND. TELE AID is
an automatic emergency call system using the availability of new technologies such as vehicle location finding
via satellite and wide distribution of mobile telephone network for reducing accident causes (rescue time
reduction).
Emergency calls and precise location description are automated by TELE AID and therefore do not depend on
incorrect human behavior in stress situations.
Information processing of systems associated with TELE AID is performed via conventional wiring and
vehicle's own bus systems (CAN and D2B).
TELE AID includes three services:
 TELE AID emergency call

 TELE AID telediagnosis
 MB information
TELE AID emergency call is supplemented by TELE AID telediagnosis and the MB information service
TELE AID telediagnosis allows assistance to be obtained quickly in the case of a vehicle defect.
The prerequisites and function sequence of TELE AID telediagnosis are almost identical to the function
sequence of TELE AID
emergency call.
If vehicle operational problems occur, the driver can reach the responsible Mercedes-Benz service points via
MB-Info.
Function sequence for a TELE AID emergency call
A TELE AID emergency call can be actuated automatically or manually. The following actuation procedures
should be distinguished:
 Automatically,
 by the restraint system control unit (N2/7)
or
by the external tilting cone sensor (B66).

 Manually:
 by pressing the SOS push-button (S93/3) and also for taxi assistance call (code 930)
 by pressing the emergency alarm actuation button (S62/6)
If an alarm is triggered, the D2B telephone and TELE AID transmitter/ receiver (A35/17) sets up an emergency
call telegram containing information on the accident severity, vehicle identification, vehicle positioning and
type of alarm actuation.
If the telephone antenna (A2/22) is defective (model 215), (A2/49a1) (models 203, 208, 210, 220) the vehicle
automatically switches to the TELE AID backup antenna (A2/50).
The emergency call telegram is transmitted via the vehicle telephone equipment (digital network).
The service provider number to be dialed is stored on the SIM card (TELE AID SIM) that is installed in the
D2B telephone and TELE AID transmitter/receiver (A35/17) and dialed automatically by the system. The
numbers dialed by the system vary according to the requested service. While the Tegoron company is
responsible for the TELE AID emergency call, the CAC is responsible for the TELE AID telediagnosis and MB
information (MB customer assistance center). If the power supply is interrupted (e.g. battery failure) the system
is able to switch automatically over to an additional battery (G1/1).
When the vehicle battery is disconnected for repair purposes, for example, the system switches
automatically over to the additional battery (G1/1) when the telephone system is not set to the service mode.
The emergency call telegram is received and decoded by the service provider. When this is done, the position
data contained in the message are converted by means of a street database into location and street name and
forwarded together with further information from the emergency call message, to the rescue center responsible
(as a general rule the police).
The decoded emergency call telegram is transmitted to the rescue service by the service provider as follows:
 Either via electronic data transmission or

 via a telephone voice connection.
With a TELE AID service (emergency call, telediagnosis, MB information) a voice connection (via mobile
telephone network) is accomplished from the vehicle to the associated service point. Then the required rescue
measures are started there.
When initially started the system performs an authorization . For this purpose a valid SIM S ubscriber I
dentification M odule) card (for TELE AID) must be installed in the D2B telephone and TELE AID
transmitter/receiver (A35/17) and a service contract made with the corresponding service provider.
For the TELE AID service (code 855) it is possible to install a SIM card for the D1 or D2 network, whereas
for the TELE AID service (code 855) with taxi emergency call (code 930) the installation of a SIM card for the
D1 network is required. The TELE AID service cannot be used without authorization . If no authorization
has been obtained or the TELE AID emergency call system is malfunctioning, the SOS push-button switch
(S93/3) indicator lamp comes on and an error message appears in the instrument cluster (A1) display.
Pictorial representation of procedure in case of an accident
Fig. 200: Pictorial Representation Of Procedure In Case Of An Accident

If no authorization has been obtained or the TELE AID telediagnosis/MB information service is
malfunctioning, an error message appears also in the instrument cluster (A1) display.
The following structogram indicates, strongly simplified, the sequence of a TELE AID emergency call.
The abbreviations used have the following meaning:
Fig. 201: TELE AID Emergency Call Flow Chart
Emergency call message is shown (TELE AID emergency call)

Fig. 202: Emergency Call Message Is Shown (TELE AID Emergency Call)
This is a TELE AID emergency call, test purposes only for has been triggered.
Emergency Call Card Is Shown (TELE AID Emergency Call)
Fig. 203: Emergency Call Card Is Shown (TELE AID Emergency Call)
This is a TELE AID emergency call, for test purposes only has been triggered.

01P
Model 208.3 GF82.95-P-0001-
01FA
Model 210 GF82.95-P-0001-
01DA
Model 215 GF82.95-P-0001-
01NA
Model 220 GF82.95-P-0001-
01GA
TELE AID block diagram GF82.95-P-0001-
02P
Telediagnosis, function GF82.95-P-2008P
MB information, function GF82.95-P-2010P
Taxi emergency call function Model 203 GF82.95-P-0002P
Model 210, 220 GF82.95-P-0002PA
TELE AID switch-on/switch-off GF82.95-P-2000P
Authorization, function GF82.95-P-2001P
Status indicator, location/function in emergency GF82.95-P-2002P
call system push-
button
Emergency call actuation, function TELE AID GF82.95-P-2003P
emergency call
TELE AID GF82.95-P-2003PA
telediagnosis
Emergency call telegram generation, TELE AID GF82.95-P-2004P
function emergency call
telediagnosis
Emergency call telegram transmission, TELE AID GF82.95-P-2005P
telediagnosis
Voice connection to vehicle, function GF82.95-P-2006P
Position finding, function GF82.95-P-3000P
Selecting telephone antenna, function GF82.95-P-3001P
PIN check with TELE AID emergency GF82.95-P-3002P
call, function
Restraint system control unit data, GF82.95-P-3005P
function
Transmitter/receiver unit, for telephone and GF82.95-P-4300A
TELE AID emergency call push-button, TELE AID GF82.95-P-4101A
TELE AID GF82.95-P-4101P
telediagnosis
Telephone antenna, location/task GF82.62-P-4105P
Emergency alarm system trigger button, Model 203 GF82.25-P-4100P
Model 210, 220 GF82.25-P-4100PA
Global positioning system antenna GF82.61-P-4106P
location/task/design/Function
TELE AID substitute antennas, GF82.95-P-4102P
Hands-free microphone, location/task GF82.70-P-4102A
Additional battery, location/task GF82.95-P-4204P
Rollover sensor, location/task GF82.95-P-4206P
CAN databus, function GF54.00-P-0005A
Digital data bus (D2B), general function GF82.00-P-0001A
TELE AID, location of components - GF82.95-P-0001-01GA
TELE AID, location of components - GF82.95-P-0001-01NA

TELE AID block diagram - GF82.95-P-0001-02P
Shown on model 203

Fig. 206: Identifying Tele Aid Block Diagram - Shown On Model 203
Code 930, taxi emergency call, is omitted in models 209 and 215.
TELE AID function - GF82.95-P-0001SX
MODEL 215.3, 220.0 /1 with CODE (359) TELE AID emergency call system with CODE (494a) USA
version
Current and also future vehicle-based services are implemented using the emergency call system control unit
(N123/4).
The vehicle-based services currently supported in the USA are:
 Telematic Alarm Identification on Demand (emergency call system) (TELE AID) (incl. police emergency
call number "911") manual/automatic
 MB-Info call
 Roadside assistance call (telediagnosis, Roadside Assistance)
 Tracking (dynamic assignment)
 Remote Door Unlock (vehicle unlocking in an emergency)
 Authorization
The emergency call system control unit (N123/4) is not used for normal phone calls.
All telematics services are integrated into the emergency call system control unit (N123/4) and run completely
automatically. They are displayed in the display of the COMAND operating, display and control unit (A40/3)
and in the multifunction display (A1p13) of the instrument cluster (A1). Because position finding is necessary
for the services, the navigation part inside the emergency call system control unit (N123/4) is also used. The
navigation part is a Global Positioning System (GPS) receiver in the emergency call system control unit
(N123/4), which makes it possible to determine the exact location. The vehicle's position and direction of travel
are determined automatically and kept available in a history. The navigation part receives GPS data from the
GPS antenna (A2/23) (model 215) or from the GPS antenna (A2/49a2) (model 220).
The communication part is a cellular phone adapted to the American cellular mobile telephone network and this
phone is only used for telematics functions. The communication part sends and receives data via the telephone
antenna (A2/22) (model 215) or the telephone antenna (A2/49a1) (model 220).
A prerequisite for using the services, however, is a communication module of the emergency call system control
unit (N123/4) authorized for the corresponding service. In other words, the communication module of the
emergency call system control unit (N123/4) must have been factory-configured with the phone number of the
corresponding service provider. In a second step, the user must authorize himself in the Service Center using
this phone number. Authorization also takes place to some extent in the factory. The telematics services are
activated by pressing the corresponding button in the MB-Info and breakdown assistance button group (S93/6)
or for a manual emergency call by pressing the SOS switch (S93/3s1) in the overhead control panel control unit
(N70).
After activation, an SMS is sent to the Service Center by the emergency call system control unit (N123/4). At
the same time as the SMS is sent, a voice connection to the Service Center is established immediately.
Each telematics service must be authorized separately. In the event of a defect or without proper authorization,
an error message is displayed in the multifunction display (A1p13) of the instrument cluster (A1) and in the
display of the COMAND operating, display and control unit (A40/3). The system is operational as soon as
circuit 30 is active.
Self-test
With active circuit 15R, the emergency call system control unit (N123/4) executes a self-test (approx. 3.5 s). If
the test is successful, the system is operational.
Basic functions
 Performing self-diagnoses cyclically

 Make vehicle data ready and if necessary transmit them safely
 Sending data messages (via SMS)
 Setting up telephone connections in handsfree mode
Emergency call system
In the event that a driver gets into an emergency situation in a remote location, a service employee can get an
overview of the situation inside the vehicle using the data transmitted by the emergency call system control unit
(N123/4) and initiate corresponding remedial measures (automatic emergency call). It is also possible to make a
manual emergency call at any time by pressing the SOS switch (S93/3s1) in the overhead control panel control
unit (N70).
The emergency call system is activated in the following two ways:
 Automatically in the event of a crash (by the crash data from the supplemental restraint system (SRS))
 Manually by pressing the SOS switch (S93/3s1) in the overhead control panel control unit (N70)
In both cases, an emergency call is automatically transmitted to the nearest emergency call center. Contents of
the emergency message are:
 Vehicle position, direction of travel and history

 Vehicle data and crash information (severity of accident)
 Customer data of emergency call service
 Status data
 Fault codes
Ending an emergency call
A call is normally ended by the emergency call headquarters.
The making of an emergency call is canceled after the emergency call system control unit (N123/4) has
attempted to dial 5 times without success.
TELE AID block diagram GF82.95-P-0001-02SX

TELE AID switch- GF82.95-P-2000SX
on/switch-off
Authorization, function GF82.95-P-2001SX
Status indicator, GF82.95-P-2002SX
location/function
Emergency call actuation, TELE AID emergency GF82.95-P-2003SX
function call
TELE AID telediagnosis GF82.95-P-2003SXA
Emergency call telegram TELE AID emergency GF82.95-P-2004SX
generation, function call
Emergency call telegram TELE AID emergency GF82.95-P-2005SX
transmission, function call
Voice connection to GF82.95-P-2006SX
vehicle, function
Telediagnosis, function GF82.95-P-2008SX
MB information, function GF82.95-P-2010SX
Position finding, function GF82.95-P-3000SX
Selecting telephone GF82.95-P-3001SX
antenna, function
Restraint system control GF82.95-P-3005SX
unit data, function
TELE AID block diagram - GF82.95-P-0001-02SX
Fig. 207: TELE AID Block Diagram - Shown On Model 220
Shown on model 220

Shown on model 215
TELE AID function - GF82.95-P-0001SZ
MODEL 215.3, 220.0 /1 with CODE (383a) Tele-Aid fixed installation telephone with CODE (494a) USA
version
Current and also future vehicle-based services are implemented using the telecommunications control unit
(N112).
The vehicle-based services currently supported in the USA are:
 Telematic Alarm Identification on Demand (emergency call system) (TELE AID) (incl. police emergency
call number "911") manual/automatic
 MB-Info call
 Roadside assistance call (telediagnosis, Roadside Assistance)
 Tracking (dynamic assignment)
 Remote Door Unlock (vehicle unlocking in an emergency)
 Authorization
All telematics services are integrated into the telecommunications control unit (N112) and run completely
automatically. They are displayed in the display of the COMAND operating, display and control unit (A40/3)
and in the multifunction display (A1p13) of the instrument cluster (A1). Because position finding is necessary
for the services, the navigation part inside the telecommunications control unit (N112) is also used. The
navigation part is a Global Positioning System (GPS) receiver in the telecommunications control unit (N112),
which makes it possible to determine the exact location. The vehicle's position and direction of travel are
determined automatically and kept available in a history. The navigation part receives GPS data from the GPS
antenna (A2/23) (model 215) or from the GPS antenna (A2/49a2) (model 220).
The communication part is a cellular phone adapted to the American cellular mobile telephone network and this
phone is only used for telematics functions. The communication part sends and receives data via the telephone
antenna (A2/22) (model 215) or the telephone antenna (A2/49a1) (model 220).
A prerequisite for using the services, however, is a communication module of the telecommunications control
unit (N112) authorized for the corresponding service. In other words, the communication module of the
telecommunications control unit (N112) must have been factory-configured with the phone number of the
corresponding service provider. In a second step, the user must authorize himself in the Service Center using
this phone number. Authorization also takes place to some extent in the factory. The telematics services are
activated by pressing the corresponding button in the MB-Info and breakdown assistance button group (S93/6)
or for a manual emergency call by pressing the SOS switch (S93/3s1) in the overhead control panel control unit
(N70).
After activation, an SMS is sent to the Service Center by the telecommunications control unit (N112). At the
same time as the SMS is sent, a voice connection to the Service Center is established immediately.
Self-test
With active circuit 15R, the telecommunications control unit (N112) executes a self-test (approx. 3.5 s). If the
test is successful, the system is operational.
Basic functions
 Performing self-diagnoses cyclically

 Make vehicle data ready and if necessary transmit them safely
 Sending data messages (via SMS)
 Setting up telephone connections in handsfree mode
Emergency call system

overview of the situation inside the vehicle using the data transmitted by the telecommunications control unit
(N112) and initiate corresponding remedial measures (automatic emergency call). It is also possible to make a
manual emergency call at any time by pressing the SOS switch (S93/3s1) in the overhead control panel control
unit (N70).
The emergency call system is activated in the following two ways:
 Automatically in the event of a crash (by the crash data from the supplemental restraint system (SRS))
 Manually by pressing the SOS switch (S93/3s1) in the overhead control panel control unit (N70)
In both cases, an emergency call is automatically transmitted to the nearest emergency call center. Contents of
the emergency message are:
 Vehicle position, direction of travel and history

 Vehicle data and crash information (severity of accident)
 Customer data of emergency call service
 Status data
 Fault codes
The making of an emergency call is canceled after the telecommunications control unit (N112) has
TELE AID block diagram GF82.95-P-0001-02SZ

TELE AID switch- GF82.95-P-2000SZ
on/switch-off
Authorization, function GF82.95-P-2001SZ
Status indicator, GF82.95-P-2002SZ
location/function
Emergency call actuation, TELE AID emergency GF82.95-P-2003SZ
function call
TELE AID telediagnosis GF82.95-P-2003SZA
Emergency call telegram TELE AID emergency GF82.95-P-2004SZ
generation, function call
Emergency call telegram TELE AID emergency GF82.95-P-2005SZ
transmission, function call
Voice connection to GF82.95-P-2006SZ
vehicle, function
Telediagnosis, function GF82.95-P-2008SZ
MB information, function GF82.95-P-2010SZ
Position finding, function GF82.95-P-3000SZ
Selecting telephone GF82.95-P-3001SZ
antenna, function
Restraint system control GF82.95-P-3005SZ
unit data, function
TELE AID block diagram - GF82.95-P-0001-02SZ
Shown on model 220

Shown on model 215
CONTENTS, FUNCTION DESCRIPTION OF TELE AID - GF82.95-P-0999
Contents, function description of TELE AID - GF82.95-P-0999SX
version
TELE AID function GF82.95-P-0001SX

02SX
TELE AID switch-on/switch-off GF82.95-P-2000SX
Authorization, function GF82.95-P-2001SX
Status indicator, location/function GF82.95-P-2002SX
Emergency call actuation, function TELE AID GF82.95-P-2003SX
emergency call
TELE AID GF82.95-P-
telediagnosis 2003SXA
Emergency call telegram generation, TELE AID GF82.95-P-2004SX
TELE AID GF82.95-P-
Emergency call telegram transmission, TELE AID GF82.95-P-2005SX
TELE AID GF82.95-P-
Voice connection to vehicle, function GF82.95-P-2006SX
Telediagnosis, function GF82.95-P-2008SX
MB information, function GF82.95-P-2010SX
Position finding, function GF82.95-P-3000SX
Selecting telephone antenna, function GF82.95-P-3001SX
Restraint system control unit data, GF82.95-P-3005SX
function
Overview of system components, GF82.95-P-9999SX
TELE AID emergency call system,
Contents, function description of TELE AID - GF82.95-P-0999SZ
version
TELE AID function GF82.95-P-0001SZ

02SZ
TELE AID switch-on/switch-off GF82.95-P-2000SZ
Authorization, function GF82.95-P-2001SZ
Status indicator, location/function GF82.95-P-2002SZ
Emergency call actuation, function TELE AID GF82.95-P-2003SZ
emergency call
TELE AID GF82.95-P-
telediagnosis 2003SZA
Emergency call telegram generation, TELE AID GF82.95-P-2004SZ
TELE AID GF82.95-P-
Emergency call telegram transmission, TELE AID GF82.95-P-2005SZ
TELE AID GF82.95-P-
Voice connection to vehicle, function GF82.95-P-2006SZ
Telediagnosis, function GF82.95-P-2008SZ
MB information, function GF82.95-P-2010SZ
Position finding, function GF82.95-P-3000SZ
Selecting telephone antenna, function GF82.95-P-3001SZ
Restraint system control unit data, GF82.95-P-3005SZ
function
Overview of system components, GF82.95-P-9999SZ
TELE AID emergency call system,
Contents, function description of TELE AID - GF82.95-P-0999ZZ
(D2B)
TELE AID, function GF82.95-P-0001A

TELE AID introduction, general Model 140 as of GF82.95-P-9611A
6/97
Taxi emergency call, function Model 140 except GF82.95-P-0002A
140.063/07, 202,
210, 220
01E
140.063/07 01A
Model 140.063/07 GF82.95-P-0001-
01C
Models 202, 208.3 GF82.95-P-0001-
01F
Model 210.2 GF82.95-P-0001-
01D
210.2 01B
Model 215 GF82.95-P-0001-
01N
Model 220 GF82.95-P-0001-
01G
except 140.063/07 02A
202, 208.3, 210,
215, 220 with code
347/348, Model 140
with code 930
Models 202, 210, GF82.95-P-0001-
function
function
Selecting telephone antenna, function GF82.95-P-3001A
call, function
Data from TELE AID airbag control GF82.95-P-3003A
module, function
210, 220 with code
930
Global positioning system antenna, Model 215 GF82.61-P-4106D
GPS/telephone roof antenna, Models 140, 202, GF82.70-P-4111A
with code 351, 815,
347, 348
210, 220 with code
930
TELE AID SWITCH-ON/SWITCH-OFF CHARACTERISTICS, FUNCTION - GF82.95-P-2000
TELE AID switch-on/switch-off characteristics, function - GF82.95-P-2000A
(D2B)
Switch-on characteristics
The TELE AID system is switched on by turning the starter switch (S2) to circuit 15R. The switch-on
procedure is indicated by the indicator lamp (4 s) coming on in the TELE AID pushbutton switch (S93/3) .
Then the system is ready for operation.
After switch-on the emergency call system control module (TELE AID, A35/8) activates the CTEL
transmitter and receiver (A35) and waits for readiness confirmation of the
 emergency tensioning retractor control module (ETR) with airbag (AB) (N2/2)
or depending on vehicle model the
 restraint system control module (N2/7).
 TELE AID is switched off when circuit 15R of the starter switch (S2) is switched off, an emergency call
is not activated and the telephone is set to shut-off delay.
The telephone system can be set to shut-off delay so that it is possible to continue a call for a certain
time even with circuit 15R: OFF .
 For control of the telephone system TELE AID remains also active during the telephone shut-off
delay, however, it is not possible to trigger an emergency call.
 During an emergency call TELE AID is not switched off before the emergency call is
terminated.
 If an authorization is accomplished while switching off circuit 15R it is interrupted and TELE AID then
switched off.

except 140.063/07 02A
202, 208.3, 210,
220 with code
347/348, Model 140
with code 930
Models 202, 210, GF82.95-P-0001-
TELE AID switch-on/switch-off characteristics, function - GF82.95-P-2000P
TELE AID switch-on characteristics emergency call
The TELE AID emergency call system is switched on by turning the key in the starter switch to position 1 or 2.
The switch-on procedure is indicated by the indicator lamp flashing (4 sec.) in the SOS push-button switch
(S93/3). Moreover, the D2B telephone and TELE AID transmitter/receiver (A35/17) waits for a ready
confirmation from the restraint system control unit (N2/7). The system is operational as soon as the ready
confirmation is received. If the system is not authorized an error message appears in the instrument cluster (A1),
the system is not operational and the indicator lamp in the SOS push-button (S93/3) illuminates.
TELE AID switch-on characteristics telediagnosis
The TELE AID telediagnosis system is always ready for operation, even when the key in the starter switch is in
the 0 position, and the telediagnosis push-button switch on the telephone handset (A34) has been pressed
correspondingly. The telephone must be switched on (stand-by mode) and the TELE AID telediagnosis system
must be authorized.
If the system is not authorized an error message appears in the instrument cluster (A1) and the system is not
operational.
TELE AID switch-off characteristics emergency call
 The TELE AID emergency call is switched off when the starter switch is in position 0, no emergency call
is active and the telephone is not set to shut-off delay.
 For control of the telephone system TELE AID remains also active during the telephone shut-off delay,
however, it is not possible to trigger an emergency call.
 During a call TELE AID is only then switched off when the emergency call is terminated.
 If an authorization is in progress while switching off, the authorization is interrupted and TELE AID
switched off.
The telephone system can be set to power-down in order to continue a telephone conversation for a certain
time in spite of " Circuit 15R: OFF ".
TELE AID switch-off characteristics telediagnosis
When the telephone is switched off TELE AID telediagnosis is deactivated.

02P
Status indicator (indicator lamp), for TELE AID GF82.95-P-2002P
TELE AID push-button, for TELE AID GF82.95-P-4101A
for TELE AID GF82.95-P-4101P
telediagnosis
TELE AID switch-on/switch-off characteristics, function - GF82.95-P-2000SX
version
Self-test
With active circuit 15R, the emergency call system control unit (N123/4) executes a self-test (approx. 3.5 s). If
the test is successful, the system is operational.
The making of an emergency call is canceled after the emergency call system control unit (N123/4) has
TELE AID control GF82.95-P-4100SX
unit/task/design/function
TELE AID switch-on/switch-off characteristics, function - GF82.95-P-2000SZ
version
Self-test
With active circuit 15R, the telecommunications control unit (N112) executes a self-test (approx. 3.5 s). If the
test is successful, the system is operational.
The making of an emergency call is canceled after the telecommunications control unit (N112) has
Telecommunications control unit, GF82.70-P-3114SU

AUTHORIZATION, FUNCTION - GF82.95-P-2001
Authorization, function - GF82.95-P-2001A
(D2B)
With the authorization the service provider authorizes to trigger a TELE AID emergency call. The authorization
is vehicle and not person related.
Authorization is required in the following cases:

 When the system is initially started up.
 With new SIM card (subscriber identification module)
 When the vehicle owner changes
 After expiration of 6 months since last authorization
During authorization a check is accomplished via mobile telephone:
 of the validity of the SIM card installed in the CTEL transmitter and receiver (A35)
 of the vehicle identification number (VIN)
If the system is not authorized a TELE AID emergency call is not possible. In this case a 112 emergency
call, if required) (without emergency call telegram) is transmitted because it does not require authorization.
When authorization is not accomplished the indicator lamp in the TELE AID emergency call pushbutton
switch (S93/3) comes on.
Authorization when TELE AID is initially started or when a SIM card is initially operated:
Before starting authorization always store PIN (personal identification number) in the emergency call system
control module (TELE AID, A35/8) , otherwise a TELE AID emergency call is not possible. For this purpose
call up menu " PIN code required " of the CTEL handset (A34) . After entering the PIN select menu point "
Change PIN code " (also when first PIN is maintained). After entering and confirmation of the new PIN the
message "Store export PIN " appears automatically on the display. Confirm with " OKAY ". The PIN is now
stored in the emergency call system control module (TELE AID, A35/8) .
Always when changing the PIN also store via "Store export PIN" .
Authorization sequence
The Mercedes-Benz service station informs the service provider about the deadline of the start-up. There the
transmission of the authorization message for the corresponding vehicle is prepared.
For authorization circuit 15R and the telephone should be switched on. The actual authorization is accomplished
automatically and takes approx. 5 minutes.
The TELE AID system is authorized as soon as the indicator lamp in the TELE AID emergency call
pushbutton switch (S93/3) goes out. If the authorization is not granted within 10 minutes inform service
provider.
In order to ensure a malfunction-free procedure the following should be avoided during an authorization:
 An emergency alarm actuation or

 switching off circuit 15R with the starter switch (S2) or
 switching off the telephone or
 setting TELE AID to diagnostic mode (via hand-held tester).
Deauthorization
When the vehicle owner changes the TELE AID system must be deauthorized before handing over the vehicle
to avoid misuse. Inform service provider for deauthorization.
Following deauthorization the indicator lamp in the emergency call pushbutton switch (S93/3) comes on. This
illumination can be prevented by correspondingly coding the hand-held tester
For authorization or deauthorization a malfunction-free telephone reception is required (observe display on

CTEL handset (A34), if necessary park vehicle outdoors).

call, function
Authorization, function - GF82.95-P-2001P
authorization for TELE AID emergency call and TELE AID telediagnosis
MODELS 208.3, 215 up to 31.8.03 with CODE (855) TELE AID authorization for TELE AID emergency
call and TELE AID telediagnosis
Authorizing TELE AID emergency call
With the authorization the service provider authorizes the actuation of a TELE AID emergency call. The
authorization is vehicle and not person-related.

 With a new SIM card (S ubscriber I dentification M odule) for TELE AID
 After expiration of a period of 6 months following last authorization (this procedure is accomplished
automatically in the background).
 The validity of the SIM card (for TELE AID) installed in the D2B telephone and TELE AID
transmitter/receiver (A35/17).
 The vehicle identification number (VIN)
If the system is not authorized a TELE AID emergency call is not possible. In this case "only" a 112 emergency
call (without emergency call telegram) is transmitted, which does not require authorization. If the system is not
authorized, the indicator lamp in the SOS push-button switch (S93/3) illuminates and an error message appears
on the display in the instrument cluster/COMAND.
To ensure trouble-free operation the following should be avoided during authorization:
 Actuating an emergency alarm/telediagnosis or

 switching off the ignition or
 switching off the telephone or
 Setting TELE AID to diagnosis mode (via STAR diagnosis).
Misuse of emergency call alarm is subject to punishment!
Procedure when alarm is triggered erroneously
If an emergency call is triggered erroneously in the workshop it is not possible to interrupt it even disconnecting
the battery. In this case always wait until voice contact is made with police. Then inform police of unintentional
actuation to prevent rescue vehicles from starting their rescue service.
Authorization TELE AID telediagnosis
With the authorization the service provider (Mercedes-Benz Customer Assistance Center (CAC)) authorizes to
trigger a TELE AID telediagnosis call (roadside assistance call) and a TELE AID information call. The
authorization is vehicle and not person-related.

 With a new SIM card (subscriber identification module) for TELE AID
 The validity of the SIM card (for TELE AID) installed in the D2B telephone and TELE AID
 The vehicle identification number (VIN)
For questions concerning authorization, deauthorization and diagnosis contact CAC Maastricht :
Telephone: 0031-433 56 2312
Fax: 0031-433 56 2313
For all questions concerning applications contact the relevant network provider:
Authorization procedure for TELE AID emergency call, TELE AID telediagnosis
Ancillary work
 The salesperson must submit the application together with the user and complete the transfer process to
the user.
 The authorization process must be performed by the mechanic, i.e. they must ensure that a vehicle with
functioning telematic services is handed over to the user.
Application and application shipping for TELE AID
The salesperson must complete two application forms together with the user and send them to the network
provider.
When filling out the applications ensure that the data (vehicle chassis number, vehicle license plate, GSM
number) is completely and correctly entered, otherwise it is not possible to perform the authorization. It is
particularly important to enter the authorization date (access authorization date).
After filling out the applications, send them to the Customer Assistance Center (CAC) by fax.
Checking delivery date
Authorization of TELE AID is performed on the day entered in the application for access authorization.
This deadline depends on the delivery date of the vehicle from the Mercedes-Benz plant. The salesman
coordinates the transfer date with the user and plans the date for the access authorization.
The dealer picks up the confirmation for the delivery date from Mercedes-Benz and then plans the date for
access authorization.
The authorization only works on this particular day (a GSM network must be available), the activation date
(keyword: authorization accurate to the day). On this date the service centers transmit authorization messages to
the D2B telephone and TELE AID transmitter/receiver (A35/17) via the GSM network.
Modifying access authorization date
If the day of the authorization is postponed, inform CAC about the new deadline (telephone fax).
For precise identification of the vehicle to be authorized the CAC requires the data of the telematic application.
If the CAC is not informed about the modification of the access authorization date the dealer is not able to
perform an authorization (changing form for access authorization date).
Before starting the actual authorization check the following list.
Refer to the checklist to ensure that the authorization is prepared in full.

1. The TELE AID SIM card is installed in the D2B telephone and TELE AID transmitter/receiver (A35/17)
2. The D2B telephone and TELE AID transmitter/receiver (A35/17) is programmed.
If the D2B telephone and TELE AID transmitter/receiver (A35/17) is installed in the factory, it is already
programmed at the factory.
If the D2B telephone and TELE AID transmitter/receiver (A35/17) is a replacement unit, it should be
programmed on site.
3. TELE AID is applied for (telematic application sent to network provider)

4. No SIM card has been inserted in the telephone handset (A34)
5. The authorization corresponds to the access authorization day on the telematic application
6. PIN for TELE AID SIM card is known
The PIN is stored in the letter of the telephone card, which can only be opened when the customer is
present.
Authorization sequence
1. Switch on c. 15 R (ignition)
2. Display on telephone handset (A34) informs that no telematic services (error message in instrument
cluster) are available
3. Display on telephone handset (A34) informs that service mode* is currently active; quit this mode.
4. Display on telephone handset (A34) requests PIN of TELE AID SIM, which must be entered on the
telephone handset (A34) (entered numbers are not shown, only placeholders (asterisks)
5. Display on handset requests further processing steps for entered PIN code, which must be stored, which is
absolutely necessary for using TELE AID
6. Automatic authorization is now started and completed after 15 minutes. Circuit 15 R must be left
switched on during this time (service mode*).
The service mode on the D2B telephone and TELE AID transmitter/ receiver (A35/17) deactivates the
automatic switchover of the system to the additional battery, when the main power supply is interrupted. The
service mode is switched on by STAR diagnosis. It is also switched off by STAR diagnosis or via the handset.
After successful authorization, the error messages in the instrument cluster (A1) are erased. If the error
messages have not been erased after the authorization phase lasting 15 minutes then there is a fault.
Switch ignition on and off after authorization time.
Error limitation
If both error messages are still active both services could not be authorized. If only one error message is active
this service could not be authorized. Read out fault codes The fault codes of the D2B telephone and TELE
AID transmitter/receiver (A35/17) must be read out using STAR Diagnosis. Compare chassis number stored in
the D2B telephone and TELE AID transmitter/receiver (A35/17) with chassis number in vehicle papers.
If no faults have been found on the vehicle or the D2B telephone and TELE AID transmitter/receiver (A35/17),
please contact CAC.
The CAC helps authorizing TELE AID. Chassis number and fault codes are required for this purpose.
Moreover, they check whether the access authorization date coincide with the date specified by CAC.
The CAC clarifies together with dealer the error cause for the services (TELE AID emergency
call/telediagnosis).
Then authorization is performed again.
Handing over vehicle
Following authorization the vehicle can be handed over to the user.
Coordinating later authorization date
TELE AID could not be authorized until the time specified, however, the user insists on handing over the
vehicle.
A new TELE AID authorization date should be agreed upon with user.
On this specific day the vehicle should be present in the workshop. The CAC is informed about the new access
authorization date in due time. Inform the user that the TELE AID is not operative and have them sign a
confirmation form ('Shut-down confirmation' form).
TELE AID should not be authorized
The vehicle is, however, equipped with a TELE AID system, the TELE AID service should not be authorized
(no telematic application present). The user is informed, that the system does not work and signs a form for
confirmation (preprinted form).
The error messages indicated in the instrument cluster (A1) are deactivated by STAR diagnosis. Affix sticker
(out of order) on cover of SOS push-button (S93/3).
glued. Ensure that the D2B telephone and TELE AID transmitter/ receiver (A35/17) is no longer in the
production mode* (via STAR diagnosis).
Production mode*
The production mode deactivates all TELE AID services. The production mode is used in the Mercedes-Benz
plant and is switched off at the end of the line. The production mode is also switched off when the TELE AID
service is authorized.
If the D2B telephone and TELE AID transmitter/receiver (A35/17) is not authorized, because the user does not
want the authorization, it is essential to exit from the production mode with the STAR Diagnosis.
Deauthorization
Written notice by the user
If the TELE AID is no longer used a notice should be signed by the user (form 'Notice of TELE AID service').
The dealer sends the notice to the CAC. The notification for the TELE AID services should have the following
specifications:
 Vehicle chassis number (VIN)

 SA code for D2B telephone and TELE AID transmitter/receiver (A35/17)
 GSM number for TELE AID SIM card
 Desired deauthorization date
 Name of customer
 Signature of customer
 Stamp of dealer
 Signature of dealer
Deauthorizing TELE AID by the dealer
Deauthorization of TELE AID system is performed by the dealer. This is accomplished on the day entered on
the notice as deauthorization date. For deauthorization of the TELE AID services check the following list.
1. Check whether TELE AID services are still active

2. Send TELE AID notice to CAC
3. Ensure that the TELE AID SIM card is still installed in the D2B telephone and TELE AID
transmitter/receiver (A35/17)
4. Ensure that there is no SIM card in the telephone handset (A34)
Deauthorization sequence
1. Switch on circuit 15 R on the deauthorization date (ignition).

2. Enter PIN for TELE AID SIM card
3. Now the deauthorization is performed automatically.
4. The deauthorization is terminated after 15 minutes. The error messages (authorize SOS/authorize
telediagnosis) and the indicator lamp in the SOS push-button switch (S93/3)are active.
5. If this is not the case the dealer can request the deauthorization from the CAC by telephone.
Changing owner of a TELE AID vehicle
If the TELE AID vehicle owner changes the procedure differs depending on the TELE AID status
(authorized/not authorized) before and after the owner change.
Four different cases are to be distinguished:
1. Previous and subsequent owner use TELE AID

2. Previous and subsequent owner do not use TELE AID
3. Previous owner uses TELE AID and subsequent owner does not use TELE AID
4. Previous owner does not use TELE AID and subsequent owner uses TELE AID
TELE AID is only allowed to be operated with a regular police license plate (legal prescription) and not
with another one (for example red license plate).
Previous and subsequent owner use TELE AID
The TELE AID service of the previous owner should be given notice and deauthorized. The TELE AID services
of the subsequent owner should be applied for and deauthorized.
Previous and subsequent owner do not use TELE AID
The subsequent owner confirms in written form (form) that he is informed by that the TELE AID does not work
Previous owner uses TELE AID and subsequent owner does not use TELE AID
The TELE AID service of the previous owner should be given notice and deauthorized.
An application for the TELE AID services must not be performed for the subsequent owner. However, the error
messages for TELE AID emergency call and telediagnosis are to be deactivated via STAR diagnosis. The
subsequent owner confirms in written form (form) that he is informed by that the TELE AID does not work
Previous owner does not use TELE AID and subsequent owner uses TELE AID
When the vehicle is handed over by the previous owner the error messages for authorization of TELE AID
emergency call and telediagnosis are to be activated via STAR diagnosis. An application is to be made for the
TELE AID service for the subsequent owner as well as authorization.
TELE AID control unit replacement (applies not when vehicle owner changes)
The D2B telephone and TELE AID transmitter/receiver (A35/17) must be replaced, since an error in the TELE
AID emergency call, TELE AID telediagnosis or on the telephone function is present.
Before replacing the D2B telephone and TELE AID transmitter/receiver (A35/17) check the previous TELE
AID status (authorized/not authorized).
Control unit replacement with authorized TELE AID
Perform the following steps:

1. Preprinted form 'Modification application for control unit replacement' should be filled out by the dealer
and user and sent to the CAC.
2. Remove defective D2B telephone and TELE AID transmitter/ receiver (A35/17)
3. Remove TELE AID SIM card from D2B telephone and TELE AID transmitter/receiver (A35/17)
4. Install TELE AID SIM card into new D2B telephone and TELE AID transmitter/receiver (A35/17)
5. Install new D2B telephone and TELE AID transmitter/receiver (A35/17) into vehicle
6. Program new D2B telephone and TELE AID transmitter/receiver (A35/17)for TELE AID
7. Authorize TELE AID (without new authorization TELE AID service is not possible with the new control
unit).
Control unit replacement with non-authorized TELE AID
Perform the following steps:
1. Remove defective D2B telephone and TELE AID transmitter/ receiver (A35/17)
2. Install new D2B telephone and TELE AID transmitter/receiver (A35/17) into vehicle
3. Deactivate error messages for TELE AID emergency call and telediagnosis.
Replace TELE AID SIM card
TELE AID SIM card replacement with authorized TELE AID
1. Preprinted form 'Modification application for SIM card replacement' should be filled out by the dealer
and user and sent to the CAC.
2. Deauthorization date for old and card authorization date for new card are filled out in the modification
application.
3. Dealer sends application filled out to the CAC.
4. TELE AID is deauthorized at the specified deauthorization date with the old card
5. TELE AID is authorized at the specified deauthorization date with the new card
TELE AID SIM card replacement with authorized TELE AID
The SIM card installed in the D2B telephone and TELE AID transmitter/ receiver (A35/17) is not used for
TELE AID but for normal telephone calls. When replacing the card TELE AID related measures are not
required.
Confirmation on shutdown/non- OF82.95-P-3000-

operative status of TELE AID system, 02A
form
Notice for TELE AID service, form OF82.95-P-3000-
03A
Modification application for replacing OF82.95-P-3000-
control units for TELE AID, form 04A
Modification application for SIM card OF82.95-P-3000-
replacement for TELE AID, form 05A
Changing access authorization date OF82.95-P-3000-
(authorization deadline) for TELE AID, 06A
form
Status indicator, location/function GF82.95-P-2002P
call, function
location/task/design/ function TELE AID
TELE AID push-button, GF82.95-P-4101P
Authorization, function - GF82.95-P-2001SX
version
A prerequisite for using the services is a communication module of the emergency call system control unit
(N123/4) authorized for the corresponding service. In other words, the communication module of the
emergency call system control unit (N123/4) must have been factory-configured with the phone number of the
corresponding service provider. In the subsequent step, the user must authorize himself in the Service Center
using this phone number. Authorization also takes place to some extent in the factory.
The telematics services are activated by pressing the corresponding button in the MB-Info and breakdown
assistance button group (S93/6) or for a manual emergency call by pressing the SOS switch (S93/3s1) in the
overhead control panel control unit (N70). After activation, an SMS is sent to the Service Center by the
emergency call system control unit (N123/4). At the same time as the SMS is sent, a voice connection to the
Service Center is established immediately.
Telediagnosis pushbutton switch(es), GF82.95-P-4105SX

location/ task
SOS switch, GF82.95-P-4107SX
Authorization, function - GF82.95-P-2001SZ
version
A prerequisite for using the services is a communication module of the telecommunications control unit (N112)
authorized for the corresponding service. In other words, the communication module of the telecommunications
control unit (N112) must have been factory-configured with the phone number of the corresponding service
provider. In the subsequent step, the user must authorize himself in the Service Center using this phone number.
Authorization also takes place to some extent in the factory.
The telematics services are activated by pressing the corresponding button in the MB-Info and breakdown
assistance button group (S93/6) or for a manual emergency call by pressing the SOS switch (S93/3s1) in the
overhead control panel control unit (N70). After activation, an SMS is sent to the Service Center by the
telecommunications control unit (N112). At the same time as the SMS is sent, a voice connection to the Service
Center is established immediately.

location/task
STATUS INDICATOR, LOCATION/FUNCTION - GF82.95-P-2002
Status indicator, location/function - GF82.95-P-2002A
(D2B)
The status indicator in the TELE AID pushbutton switch (S93/3) serves for checking the function of the
TELE AID system.
Every time the TELE AID system is switched on the status indicator comes on for approx. 4 s and signals the
readiness of TELE AID for an emergency call. Then the status indicator goes out.
If a TELE AID emergency call (not with taxi emergency call) is triggered the status indicator starts flashing (0.5
s on, 0.5 s off, ...). If it was not possible to transmit a TELE AID emergency call (data and voice) nor a 112
emergency call the status indicator comes on. If a voice connection is completed the status indicator returns to
the same status as before the emergency call actuation.
If the TELE AID system is in the diagnosis mode the status indicator also starts flashing.
A TELE AID system error is present when the status indicator does not go out 5 s after switching on or when it
comes on at a later time.
Fig. 211: Identifying TELE AID Pushbutton Switch Graph (1 Of 2)
Permanent illumination of the status indicator can have the following causes:
External error
 Power supply too low

 No or incorrect SIM card installed
 Communication with emergency tensioning retractor control module with airbag (AB) (N2/2, except
models 215, 220) or restraint system control module (N2/7, models 215, 220) interrupted
 Communication with traction system control module (N47) interfered
 Malfunction of emergency call pushbutton switch (S93/3)
 Error of emergency alarm actuation switch (S62/6) (only with code 930, taxi emergency call)
 Error of GPS reception (antenna system)
Model 129: rod antenna (A28)
Models 202, 208.3, 210, 220: telephone antenna (A2/49a1)
Model 215: telephone antenna (A2/22)
 No reception over TELE AID substitute antenna (A2/50) or telephone antenna (A2/49a1)
 CTEL transmitter and receiver (A35) or connection to emergency call system control module
(TELE AID, A35/8) erroneous
Internal error
 Vehicle is not authorized or is in the progress of authorization

 Memory defect on emergency call system control module (TELE AID, A35/8)
 Rollover sensor (B66) defective
 GPS reception erroneous
 The PIN (P ersonal I dentification N umber) has not been stored in the emergency call system control
module (TELE AID, A35/8) by the user (e.g. after changing PIN number)
The emergency call system control module (TELE AID, A35/8) can be coded with the hand-held tester so
that the status indicator does not come on even when the system is not authorized (however, all further system
errors are indicated).

call, function
Data from airbag control module for TELE GF82.95-P-3003A
AID, function
with code 351, 815,
347, 348
210, 220 with code
930
Status display position/function - GF82.95-P-2002P
MODEL 203, 210, 220 with CODE (855) TELE AID with CODE (930) Taxi emergency call for TELE
AID emergency call
MODEL 208.3, 215 with CODE (855) TELE AID for TELE AID emergency call
The status indicator in the TELE AID push-button switch (S93/3) serves for checking the function of the
TELE AID system.
Every time the TELE AID system is switched on the status indicator comes on for approx. 4 s and signals the
readiness for TELE AID for an emergency call. Then the status indicator goes out.
If an TELE AID emergency call (not on taxi emergency call code 930) is triggered the status indicator starts
flashing (0.5 s on, 0.5 s off, ...) and a message appears in the instrument cluster. If it was not possible to transmit
a TELE AID emergency call (data and voice) and no 112 emergency call the status indicator comes on and a
message appears on the display of the instrument cluster. If a voice connection is completed the status indicator
returns the same status as before the emergency call actuation and a message appears on the instrument cluster
display.
If the TELE AID system is in the diagnosis mode the status indicator also starts flashing.
A TELE AID system error is present when the status indicator does not go out 5 s after switching on or when it
comes on at a later time. A message then appears in the instrument cluster display.
Fig. 212: Identifying TELE AID Push-Button Switch Graph
Permanent illumination of the status indicator can have the following causes:
External error
 Rollover sensor (B66) defective

 Power supply too low
 No or incorrect SIM card installed
 Communication with restraint system control module (N2/7) interrupted
 Communication with traction system control module (N47) interfered
 Error on TELE AID push-button switch (S93/3)
 Error on emergency alarm actuation switch (S62/6) (only with code 930, taxi emergency call)
 Error on GPS reception (antenna system)
 No reception over TELE AID substitute antenna (A2/50) or telephone antenna (A2/22, A2/49a1
Internal error
 GPS reception erroneous

 Vehicle is not authorized or is in the progress of authorization
 Memory defect on telephone transmitter/receiver and TELE AID, D2B (A35/17)
 The PIN (P ersonal I dentification N umber) is not stored in the telephone transmitter/receiver and
TELE AID, D2B (A35/17) by the user (e.g. after changing PIN number)
 Telephone transmitter/receiver unit integrated in telephone transmitter/receiver and TELE AID, D2B
(A35/17) erroneous
The telephone transmitter/receiver and TELE AID, D2B (A35/17) can be coded with STAR diagnosis so
that the status indicator does not come on even when the system is not authorized (all other system errors are
indicated).
The dealer should have the customer confirm deactivation the status indicator using a preprinted form.

Emergency call actuation function GF82.95-P-2003P
call, function
Restraint system control module data, GF82.95-P-3005P
function
location/purpose/ design/function TELE AID
TELE AID push-button switch, GF82.95-P-4101A
Telephone antenna, location/purpose GF82.62-P-4105P
TELE AID substitute antenna, GF82.95-P-4102P
Rollover sensor, location/purpose GF82.95-P-4206P
Status indicator, location/function - GF82.95-P-2002SX

version
The system operates automatically in the event of a crash! The system is activated manually by pressing the
SOS switch (S93/3s1). This may be the case for emergency situations or when an accident is spotted. The
activated emergency call system is indicated by a flashing red LED in the SOS switch (S93/3s1). If a recall to
the vehicle by the emergency call center is not be replied to, a search and rescue operation will be initiated in
due course by the local rescue teams. If the emergency call system is unable to establish a connection to the
emergency call center or the subscriber identification module (SIM) card has not been authorized, the system
automatically calls the police emergency call number "911" and tries to establish a connection via the hands-
free system. In this case, no data are transferred by SMS.
SOS switch (S93/3s1)
The SOS switch (S93/3s1) is covered with a safety flap bearing red lettering. The flap is labeled "SOS". By
tipping on the safety flap, it is released and opens independently with the help of a spring mechanism. Pressing
the SOS switch (S93/3s1) for longer than 0.5 sec. activates the system.
MB-Info and breakdown assistance button group (S93/6)
The MB-Info and breakdown assistance button group (S93/6) is located on the left of the center console at the
right front. Pressing a button in the MB-Info and breakdown assistance button group (S93/6) for longer than 0.5
s activates the system. The activated system is indicated by a flashing red LED in the buttons.
On pressing a button in the MB-Info and breakdown assistance button group (S93/6), an SMS is automatically
sent. At the same time as the SMS is sent, a voice connection to the Service Center is established immediately.
Status reports
The status messages are output in the display of the following components:

 Multifunction display (A1p13) of instrument cluster (A1)

location/task
Status indicator, location/function - GF82.95-P-2002SZ
version
The system operates automatically in the event of a crash! The system is activated manually by pressing the
SOS switch (S93/3s1). This may be the case for emergency situations or when an accident is spotted. The
activated emergency call system is indicated by a flashing red LED in the SOS switch (S93/3s1). If a recall to
the vehicle by the emergency call center is not be replied to, a search and rescue operation will be initiated in
due course by the local rescue teams. If the emergency call system is unable to establish a connection to the
emergency call center or the subscriber identification module (SIM) card has not been authorized, the system
automatically calls the police emergency call number "911" and tries to establish a connection via the hands-
free system. In this case, no data are transferred by SMS.
SOS switch (S93/3s1)
The SOS switch (S93/3s1) is covered with a safety flap bearing red lettering. The flap is labeled "SOS". By
tipping on the safety flap, it is released and opens independently with the help of a spring mechanism. Pressing
the SOS switch (S93/3s1) for longer than 0.5 sec. activates the system.
MB-Info and breakdown assistance button group (S93/6)
The MB-Info and breakdown assistance button group (S93/6) is located on the left of the center console at the
right front. Pressing a button in the MB-Info and breakdown assistance button group (S93/6) for longer than 0.5
s activates the system. The activated system is indicated by a flashing red LED in the buttons. On pressing a
button in the MB-Info and breakdown assistance button group (S93/6), an SMS is automatically sent.
At the same time as the SMS is sent, a voice connection to the Service Center is established immediately.
Status reports
The status messages are output in the display of the following components:

 Multifunction display (A1p13) of instrument cluster (A1)

location/task
EMERGENCY CALL ACTUATION, FUNCTION - GF82.95-P-2003
Emergency call actuation, function - GF82.95-P-2003A
MODELS 129, 202, 208.3, 210 as of 1.6.98, 215, 220 with CODE (347) TELE AID emergency call system
(D2B)
MODELS 140, 210 up to 31.5.98 with CODE (348) TELE AID emergency call system
MODELS 140, 202, 210, 220 with CODE (930) Taxi emergency call
A TELE AID emergency call can be triggered automatically or manually:
Manually,
 with the aid of the emergency call system pushbutton switch (TELE AID S93/3), if the vehicle is not
involved itself in an accident or the driver requires assistance.
 with the aid of the emergency alarm actuation switch (S62/6) (only with code 930, taxi emergency
call).
For diagnosis purposes : manually using the hand-held tester (has not been available since TELE AID
introduced!).
Automatically,
 using the emergency tensioning retractor control module (GUS) with airbag (AB) (N2/2, except
models 215, 220) or the restraint systems control module (N2/7, only models 215, 220) , if an airbag is
triggered or a heavy rear end collision occurs.
 if the roll-over sensor in the emergency call system control module (TELE AID, A35/8) registers a
roll-over or
 the external tilting cone sensor (B66) recognizes a rollover and transmits it to the telephone
transmitter/receiver and TELE AID, D2B (A35/17) .
A TELE AID emergency call is completed when the service center terminates the voice connection.
Emergency call priority
The information on how an emergency call is triggered is entered into the emergency call telegram generated
by the TELE AID, D2B emergency call system control module (A35/8) . The types of actuation have various
priorities:
Highest priority:
1. Automatic emergency call

2. Manual taxi emergency call with S62/6 (only with code 930, taxi emergency call)
Lowest priority
3. Manual emergency call with S93/3
If an emergency call is already active when an emergency is actuated this active call is terminated. The
emergency call with the lower priority is not started.
If an emergency call with lower priority is already active when triggering, this call is interrupted and the
emergency call with the higher priority is started.
Special features of taxi emergency call (Code 930)
A taxi emergency call should not be noticed by the person(s) posing the threat. For this purpose the emergency
alarm actuation button (S62/6) is concealed in the driver's footwell. An indicator lamp confirming when the
triggering button is pressed can be optionally installed. It illuminates for 2 minutes after a taxi emergency call
has been triggered. The indicator lamp is installed so that the driver can recognize when it flashes. Moreover, it
is ensured that in the event of a taxi emergency call:
 no dialing or ringing tones can be heard,

 the dialing procedure is carried out silently,
 the state display is not activated in the TELE AID emergency call system pushbutton switch (S93/3) ,
 the volume of the radio cannot be decreased or the radio cannot be set to mute.
 no confirmation messages can be received from the service provider or the police.
The police monitors the passenger compartment via the hands-free system on a taxi emergency call and decides
if a voice connection should be completed.
The taxi emergency call is terminated:
 by the police or
 automatic (after 90 min) by emergency call system control module (TELE AID, A35/8) or
 when an automatic TELE AID emergency call is triggered.
A TELE AID emergency call or taxi call for assistance must only be triggered in emergencies. The
telephone system cannot be used for any other purpose during an emergency call.

function
function
State display (indicator lamp), function GF82.95-P-2002A
Data from airbag control module for GF82.95-P-3003A
TELE AID, function
TELE AID control module GF82.95-P-4100A
TELE AID emergency call pushbutton, GF82.95-P-4101A
Emergency alarm system actuation Models 140 except GF82.25-P-4100A
button, location/task/design/function 140.063/07, 202,
210, 220 with code
930
Emergency call actuation, function - GF82.95-P-2003P

for a TELE AID emergency call
MODELS 208.3, 215 up to 31.8.03 with CODE (855) TELE AID for a TELE AID emergency call
A TELE AID emergency call can be triggered automatically or manually:
Manually:
 With the aid of the SOS push-button switch (S93/3s1), if the vehicle is not involved itself in an accident
or the driver requires help.
 with the aid of the emergency alarm actuation switch (S62/6) (only with code 930, taxi emergency call).
For diagnostic purposes, manually with Star Diagnosis.
Automatically:
 via the restraint system control unit (N2/7) when an airbag/ sidebag is actuated or in the event of severe
rear-end collision.
 When the external tilting cone sensor (B66) recognizes a rollover and transmits it to the D2B telephone
and TELE AID transmitter/ receiver (A35/17) or
 if the rollover sensor in the TELE AID control unit (A35/8) (models 208, 210, 215, 220) registers a
rollover.
A TELE AID emergency call is completed when the service center terminates the voice connection.
The information how an emergency call is triggered is entered into the emergency call telegram generated by
the D2B telephone and TELE AID transmitter/receiver (A35/17). The types of actuation have various priorities.
Highest priority:

2. Manual taxi emergency call with (S62/6 (only with code 930, taxi emergency call)
3. Manual emergency call with SOS push-button (S93/3)
4. Telediagnosis call with corresponding button on telephone handset (A34)
Lowest priority
5. MB Info via relevant menu on telephone handset (A34) (see owner's manual)
If an emergency call is already active when an emergency is actuated this active call is terminated. The
emergency call with the lower priority is not started.
If an emergency call with lower priority is already active when triggering, this call is interrupted and the
emergency call with the higher priority is started.
Peculiarities on taxi emergency call (only with code 930)
A taxi emergency call should not be noticed by the person(s) posing the threat. For this purpose the emergency
alarm actuation button (S62/6) is concealed in the driver's footwell. An indicator lamp, which confirms that the
emergency alarm system activate button (S62/6) has been pressed, may be installed as an option. It illuminates
for 2 minutes after a taxi emergency call is triggered. The indicator lamp is installed so that only the driver can
recognize when it flashes. Moreover, it is ensured that in the event of a taxi emergency call:
 When no dial or ring tone can be heard,

 the dialing procedure is carried out silently,
 the status indicator is not activated in the SOS push-button switch (S93/3)
 the volume of the radio cannot be decreased or the radio cannot be set to mute.
 no confirmation messages can be received from the service provider or the police.
The police monitors the passenger compartment via the hands-free system on a taxi emergency call and decides
if a voice connection should be completed.
The taxi emergency call can be terminated:
 by the police
 automatically by the D2B telephone and TELE AID transmitter/ receiver (A35/17) after approximately 90
minutes
 when an automatic TELE AID emergency call is triggered.
A TELE AID emergency call or taxi emergency call can only be triggered in emergencies. The telephone
system cannot be used during an emergency call.
Emergency alarm system actuation Model 203 GF82.25-P-4100P

button, location/task/design/function
Model 210, 220 GF82.25-P-4100PA
Emergency call telegram generation, GF82.95-P-2004P
function
Emergency call telegram transmission, GF82.95-P-2005P
function
function
TELE AID push-button, for TELE AID GF82.95-P-4101A
Emergency call actuation, function - GF82.95-P-2003PA
A telediagnosis call only be triggered manually
 using the SOS push-button (S93/3) on the telephone handset (A34) if it is pressed for more than 2
seconds.
An emergency telegram is then generated in the D2B telephone and TELE AID transmitter/receiver (A35/17)
and is transmitted via radio to the Mercedes-Benz Customer Assistance Center (CAC).
If an emergency call with a higher priority is already active when an emergency call is triggered, this call is
terminated. The emergency call with the lower priority is not started.
If an emergency call with a lower priority is already active when triggering takes place, this is aborted and the
emergency call with higher priority placed instead.
Highest priority:

2. Manual taxi emergency call with S62/6 (only with code 930, taxi emergency call)
3. Manual emergency call with SOS push-button (S93/3)
4. Telediagnosis call with corresponding button on telephone handset (A34)
Lowest priority
5. Information call via relevant menu on Telephone handset (A34)

Emergency call telegram generation, GF82.95-P-2004PA
function
Emergency call telegram transmission, GF82.95-P-2005PA
function
Emergency call actuation, function - GF82.95-P-2003SX
version
TELE AID emergency call
overview of the situation inside the vehicle using the data transmitted by the emergency call system control unit
(N123/4) and initiate corresponding remedial measures. A Telematic Alarm Identification on Demand
(emergency call system) (TELE AID) emergency call can be initiated automatically or manually.
Manual emergency call
It is possible to make a manual emergency call at any time. A manual emergency call is made by pressing the
SOS switch (S93/3s1) labeled "SOS". It is integrated into the overhead control panel control unit (N70). The
SOS switch (S93/3s1) is read in via a discrete line from the emergency call system control unit (N123/4). To
trigger manually, the switch must be pressed for longer than 0.5 s.
The red LED flashes on and off for the duration of the emergency call. Then, an emergency call message is
immediately transmitted to the nearest emergency call center.
automatic alarm call
An automatic emergency call is possible after "circuit 15R ON". The crash is automatically detected by the
restraint systems control unit (N2/7). The emergency call system control unit (N123/4) receives the crash
information twice, as a digital crash signal from the restraint systems control unit (N2/7) via a discrete line, and
also (redundantly) via the Controller Area Network bus class B (interior) (CAN-B). In the event of an accident,
an automatic emergency call is made immediately. This occurs no matter how severe the detected accident
actually is. With crash deployments, the red LED flashes on and off for the duration of the emergency call.
The following data are automatically transmitted in an emergency call SMS:
 Subscriber identification module (SIM) data

 Phone number
 Vehicle data (e.g. circuit status)
 Crash information (severity of accident), only for an automatic emergency call
 Position data
 Vehicle direction and speed
The user is now able to connect by telephone to the emergency call center. The call is ended by the emergency
call center. The emergency call system control unit (N123/4) deactivates the emergency call request both for a
manual and an automatic emergency call after 5 unsuccessful attempts.
It is only permissible to trigger a TELE AID emergency call in emergencies, noncompliance is a punishable
offense.
Emergency call actuation, function - GF82.95-P-2003SXA
version
TELE AID telediagnosis
Using the MB-Info and breakdown assistance button group (S93/6) either the roadside assistance call (symbol is
a wrench) or the MB-Info call (symbol is the letter "i") is initiated by pressing in the corresponding direction.
Pressing the MB-Info and breakdown assistance button group (S93/6) for longer than 0.5 s activates the system.
The activated system is indicated by a corresponding flashing LED in the MB-Info and breakdown assistance
button group (S93/6).
Irrespective of the request, the MB-Info and breakdown assistance button group (S93/6) is input by the
emergency call system control unit (N123/4) via a discrete line. An SMS is sent automatically by the emergency
call system control unit (N123/4). At the same time as the SMS is sent, a voice connection to the Service Center
is established immediately.

Telediagnosis pushbutton switch GF82.95-P-4105SX
(es), location/task
Emergency call actuation, function - GF82.95-P-2003SZ
version
overview of the situation inside the vehicle using the data transmitted by the telecommunications control unit
(N112) and initiate corresponding remedial measures. A Telematic Alarm Identification on Demand
(emergency call system) (TELE AID) emergency call can be initiated automatically or manually.
Manual emergency call
It is possible to make a manual emergency call at any time. A manual emergency call is made by pressing the
SOS switch (S93/3s1) labeled "SOS". It is integrated into the overhead control panel control unit (N70). The
SOS switch (S93/3s1) is read in via a discrete line from the telecommunications control unit (N112). To trigger
manually, the switch must be pressed for longer than 0.5 s.
The red LED flashes on and off for the duration of the emergency call. Then, an emergency call message is
immediately transmitted to the nearest emergency call center.
automatic alarm call
An automatic emergency call is possible after "circuit 15R ON". The crash is automatically detected by the
restraint systems control unit (N2/7). The telecommunications control unit (N112) receives the crash
information twice, as a digital crash signal from the restraint systems control unit (N2/7) via a discrete line, and
also (redundantly) from the Media Oriented System Transport (MOST) via the audio gateway control unit
(N93/1). In the event of an accident, an automatic emergency call is made immediately. This occurs no matter
how severe the detected accident actually is. With crash deployments, the red LED flashes on and off for the
duration of the emergency call.
The following data are automatically transmitted in an emergency call SMS:

 Phone number
 Position data
The user is now able to connect by telephone to the emergency call center. The call is ended by the emergency
call center. The telecommunications control unit (N112) deactivates the emergency call request both for a
manual and an automatic emergency call after 5 unsuccessful attempts.
It is only permissible to trigger a TELE AID emergency call in emergencies, noncompliance is a punishable
offense.

Emergency call actuation, function - GF82.95-P-2003SZA
version
Using the MB-Info and breakdown assistance button group (S93/6) either the roadside assistance call (symbol is
a wrench) or the MB-Info call (symbol is the letter "i") is initiated by pressing in the corresponding direction.
Pressing the MB-Info and breakdown assistance button group (S93/6) for longer than 0.5 s activates the system.
The activated system is indicated by a corresponding flashing LED in the MB-Info and breakdown assistance
button group (S93/6).
Irrespective of the request, the MB-Info and breakdown assistance button group (S93/6) is input by the
telecommunications control unit (N112) via a discrete line. An SMS is sent automatically by the
telecommunications control unit (N112). At the same time as the SMS is sent, a voice connection to the Service
Center is established immediately.

location/task
EMERGENCY CALL TELEGRAM GENERATION, FUNCTION - GF82.95-P-2004
Emergency call telegram generation, function - GF82.95-P-2004A
(D2B)
After an emergency call is triggered the emergency call system control module (TELE AID, A35/8)
automatically generates an emergency call telegram. It includes the following information:
 Vehicle location: Longitude and latitude

 Type of emergency call actuation Automatically or manually with the TELE AID pushbutton switch
(S93/3) or the emergency call actuation button (S62/6) (only with taxi emergency call)
 Crash parameter from emergency tensioning retractor control module with airbag (AB, N2/2, except
models 215, 220) or restraint system control module (N2/7, only models 215, 220) and from roll-over
sensor
 Identification number for identifying vehicle,
 Time of emergency call.
The emergency call telegram is transmitted to the service provider via mobile telephone (D-network) and is
automatically decoded there.
In the emergency call system control module (TELE AID, A35/8) up to three generated emergency call
telegrams are stored. If already more than three emergency call telegrams are stored the oldest telegram is
written over. During a taxi emergency call the current vehicle position is stored every 10 minutes in addition.

function
Data from airbag control module, function GF82.95-P-3003A
210, 220 with code
930
Emergency call telegram generation, function - GF82.95-P-2004P
After an emergency call is triggered the D2B telephone and TELE AID transmitter/receiver (A35/17)
automatically generates an emergency call telegram.
It includes the following information:
 Location of the vehicle: degrees longitude and latitude

 Type of emergency call activation: automatically or manually with the TELE AID push-button switch
(S93/3) or the emergency call actuation button (S62/6) (taxi emergency call only)
 Crash parameter from restraint system control unit (N2/7) and from external tilting cone sensor (B66),
 Identification number for identifying vehicle,
 Time of emergency call.
The emergency call telegram is relayed to the service provider via mobile telephone (digital network) and is
automatically decoded there.
Up to three emergency call telegrams are stored in the D2B telephone and TELE AID transmitter/receiver
(A35/17). If already more than three emergency call telegrams are stored the oldest telegram is written over.
During a taxi emergency call the current vehicle position is stored every 10 minutes in addition.
Emergency alarm system trigger Model 203 GF82.25-P-4100P

button, location/task/design/function
Model 210, 220 GF82.25-P-4100PA
TELE AID push-button, GF82.95-P-4101A
Emergency call actuation, function GF82.95-P-2003P
Emergency call telegram transmission, GF82.95-P-2005P
function
function
Emergency call telegram generation, function - GF82.95-P-2004PA
After a TELE AID telediagnosis is activated, the D2B telephone and TELE AID transmitter/receiver (A35/17)
automatically generates an emergency call message. It includes the following information:
 Location of the vehicle: degrees longitude and latitude

 Data for vehicle identification
 Model, model year, type of engine
 Information on current vehicle status

 Engine temperature
 Mileage
 Battery voltage
 Displayed malfunction and warning messages
The emergency call telegram is transmitted to the Mercedes Benz Customers Assistance Center (CAC) via
mobile telephone (digital network) and is automatically decoded there to start corresponding help measures.
TELE AID telediagnosis does only operate when the system is authorized.
Emergency call actuation, function GF82.95-P-2003PA

Emergency call telegram transmission, GF82.95-P-2005PA
function
Emergency call telegram generation, function - GF82.95-P-2004SX
version
In the event of an emergency call, all the data for an emergency call telegram are compiled by the emergency
call system control unit (N123/4). The following data are automatically transmitted in an emergency call
telegram as an SMS:

 Phone number
 Type of deployment (manual or automatic emergency call)
 Position data

Emergency call telegram generation, function - GF82.95-P-2004SXA
version
Telediagnosis call (roadside assistance call)
An SMS is automatically transmitted to the service center when the MB-Info and breakdown assistance button
group (S93/6) is actuated. The following data are automatically transmitted in a roadside assistance call:
 Vehicle position
 Vehicle identification data
 Status data
 Fault code
MB information call
The service is activated by the user by actuating the MB-Info and breakdown assistance button group (S93/6). If
the service is authorized and no service with a higher priority is active, the emergency call system control unit
(N123/4) transmits an SMS to the service center. For this purpose, the following data are transmitted:
Telediagnosis pushbutton switch GF82.95-P-4105SX

(es), location/ task
Emergency call telegram generation, function - GF82.95-P-2004SZ
version
In the event of an emergency call, all the data for an emergency call telegram are compiled by the
telecommunications control unit (N112). The following data are automatically transmitted in an emergency call
telegram as an SMS:

 Phone number
 Type of deployment (manual or automatic emergency call)
 Position data

Emergency call telegram generation, function - GF82.95-P-2004SZA
version
Telediagnosis call (roadside assistance call)
group (S93/6) is actuated. The following data are automatically transmitted in a roadside assistance call:
 Status data
 Fault code
MB information call
The service is activated by the user by actuating the MB-Info and breakdown assistance button group (S93/6). If
the service is authorized and no service with a higher priority is active, the telecommunications control unit
(N112/) transmits an SMS to the service center. For this purpose, the following data are transmitted:

location/task
EMERGENCY CALL TELEGRAM TRANSMISSION, FUNCTION - GF82.95-P-2005
Emergency call telegram transmission, function - GF82.95-P-2005A
(D2B)
After a TELE AID emergency call is triggered (automatically or manually) the emergency call system control
module (TELE AID, A35/8) generates an emergency call telegram and transmits it to the service provider
(Debis Telematic Services) via mobile telephone (D-network).
The emergency call system control module (TELE AID, A35/8) takes over the sole control of the telephone
system in the case of an emergency call to ensure the following:
 If the telephone is switched off before an emergency alarm is triggered, it must be activated.
 a possibly existing telephone connection is interrupted,
 operation of the telephone with the aid of the CTEL handset (A34) is no longer possible.
The radio connection is completed with the aid of the telephone antenna via the CTEL transmitter and
receiver (A35)

If the telephone antenna is no longer functioning after an accident, the emergency call control module
(TELE AID (A35/8) switches automatically over to the TELE AID substitute antenna (A2/ 50) .
The service provider receives the emergency call. For this purpose the service provider has a graphic capable
workstation with road data base. Among others, there the vehicle location is determined with the information
from the emergency call telegram. The service provider transmits the decoded emergency call telegram to the
responsible service center (police, fire brigade, German Red Cross, ...).
Peculiarities in the case of a taxi emergency call (code 930):
TELE AID transmits each minute its current position to the emergency call center when the taxi emergency call
is active.
The emergency call system must be authorized to transmit an emergency call telegram.

with code 351, 815,
347, 348
210, 220 with code
930
Emergency call telegram transmission, function - GF82.95-P-2005P
After a TELE AID emergency call has been triggered (automatically or manually) the D2B telephone and TELE
AID transmitter/receiver (A35/17) generates an emergency call telegram and the transmits it to the service
provider via mobile telephone (D-network).
In the case of an emergency the D2B telephone and TELE AID transmitter/receiver (A35/17) take over the sole
control of the telephone system to ensure the following:
 If the telephone is switched off before an emergency alarm is triggered, it is activated

 a possible present telephone connection is interrupted,
 the telephone can no longer be operated using the telephone handset (A34).
The radio connection is made via the telephone system with the aid of the telephone antenna (A2/22) (model
215), (A2/49a1) (models 203, 208, 210, 220).
If the telephone antenna (A2/22) (model 215), (A2/49a1) (models 203, 208, 210, 220) is not longer working as a
result of an accident, the D2B telephone and TELE AID transmitter/receiver (A35/17) automatically switches to
the TELE AID backup antenna (A2/50). If the power supply is interrupted (for example battery interruption) the
D2B telephone and TELE AID transmitter/receiver (A35/17) switches automatically over to the additional
battery (G1/1).
The service provider receives the emergency call. He has a graphic capable workstation with road data base.
There, among others, the location of the vehicle is determined from the information of the emergency call
telegram. The service provider transmits the decoded emergency call telegram to the responsible service center
(police, fire brigade, German Red Cross, ....).
Peculiarities on taxi emergency call (code 930):
TELE AID transmits its current position to the emergency call center every 45 seconds during a taxi emergency
call.

Emergency call telegram transmission, function - GF82.95-P-2005PA
After a TELE AID telediagnosis has been triggered, the D2B telephone and TELE AID transmitter/receiver
(A35/17) generates an emergency call telegram and then relays it to the Mercedes-Benz Customer Assistance
Center (CAC) via mobile telephone (digital network). Then a radio connection (voice connection) is completed
to the vehicle.
In the case of an emergency the D2B telephone and TELE AID transmitter/receiver (A35/17) take over the sole
control of the telephone system to ensure the following:
 If the telephone is switched off before the actuation, it must be activated

 any existing telephone connection is interrupted
 the telephone can no longer be operated using the telephone handset (A34).
The radio connection is made via the telephone system with the aid of the telephone antenna (A2/22) (model
215), (A2/49a1) (models 203, 208, 210, 220).
If the telephone antenna (A2/22) (model 215), (A2/49a1) (models 203, 208, 210, 220) is no longer working as a
result of a fault, the D2B telephone and TELE AID transmitter/receiver (A35/17) automatically switches to the
TELE AID backup antenna (A2/50). If the power supply is interrupted (for example battery interruption) the
D2B telephone and TELE AID transmitter/receiver (A35/17) switches automatically over to the additional
battery (G1/1).
The Mercedes-Benz Customer Assistance Center (CAC) has a graphic-capable workstation with street data
base.
Here the emergency call telegram information about the location and status of the vehicle and the necessary
action to take can be clarified with the Mercedes-Benz experts by telephone.

Voice connection to vehicle, function GF82.95-P-2006PA
Emergency call telegram transmission, function - GF82.95-P-2005SX
version
In the event of an emergency call, in addition to active telephone connections, active service calls (MB-Info or
roadside assistance call) are also interrupted. The emergency call system control unit (N123/4) sends the
emergency call telegram to the nearest emergency call center and at the same time always establishes a
telephone connection to the emergency call center. If the emergency call was started automatically and the
connection to the emergency call center was not possible, a telephone connection is automatically established to
the police emergency phone number "911". In such case, no emergency call data are transmitted. The
emergency call must then be made verbally. With a manual emergency call, this procedure may be configured.
The emergency call system must be authorized for transferring an emergency call telegram.
Usually, the telephone connection is established via the telephone antenna (A2/49a1) (model 220) that is located
at the rear window, or via the telephone antenna (A2/22) (model 215) at the tailgate. If the telephone antenna
(A2/49a1) (model 220) or the telephone antenna (A2/22) (model 215) is defective, e.g., in the event of a
rollover, 2 emergency antennas are available in the rear bumper of the vehicle, which basically consist of the
emergency call system antenna splitter (A2/25) and the emergency call system left backup antenna (A2/54) and
emergency call system right backup antenna (A2/55). The emergency call system control unit (N123/4)
recognizes the failure of the antenna and subsequently actuates the emergency call system left backup antenna
(A2/54) and the emergency call system right backup antenna (A2/55) automatically.
GPS/telephone roof antenna Model 220 GF82.70-P-4111SX

Telephone antenna, location/task Model 215 GF82.62-P-4105SZ
TELE AID substitute antennas, GF82.95-P-4102SX
Emergency call telegram transmission, function - GF82.95-P-2005SXA
version
In the event of a service call (MB-Info or roadside assistance call), active telephone connections are interrupted.
The emergency call system control unit (N123/4) sends an SMS to the nearest service center and at the same
time always establishes a telephone connection to the service center.
emergency call system right backup antenna (A2/55). The emergency call system control unit (N123/4)
recognizes the failure of the antenna and subsequently actuates the emergency call system left backup antenna
(A2/54) and the emergency call system right backup antenna (A2/55) automatically.

Emergency call telegram transmission, function - GF82.95-P-2005SZ
version
In the event of an emergency call, in addition to active telephone connections, active service calls (MB-Info or
roadside assistance call) are also interrupted. The telecommunications control unit (N112) sends the emergency
call telegram to the nearest emergency call center and at the same time always establishes a telephone
connection to the emergency call center. If the emergency call was started automatically and the connection to
the emergency call center was not possible, a telephone connection is automatically established to the police
emergency phone number "911". In such case, no emergency call data are transmitted. The emergency call must
then be made verbally. With a manual emergency call, this procedure may be configured.
The emergency call system must be authorized for transferring an emergency call telegram.
emergency call system right backup antenna (A2/55). The telecommunications control unit (N112/) recognizes
the failure of the antenna and subsequently actuates the emergency call system left backup antenna (A2/54) and
the emergency call system right backup antenna (A2/55) automatically.

Emergency call telegram transmission, function - GF82.95-P-2005SZA

version
In the event of a service call (MB-Info or roadside assistance call), active telephone connections are interrupted.
The telecommunications control unit (N123/) sends an SMS to the nearest service center and at the same time
always establishes a telephone connection to the service center.
emergency call system right backup antenna (A2/55). The telecommunications control unit (N112/) recognizes
the failure of the antenna and subsequently actuates the emergency call system left backup antenna (A2/54) and
the emergency call system right backup antenna (A2/55) automatically.

VOICE CONNECTION TO VEHICLE, FUNCTION - GF82.95-P-2006
Voice connection to vehicle, function - GF82.95-P-2006A
(D2B)
After the service center (police, fire brigade, German Red Cross, ...) has received a TELE AID emergency call
telegram a radio connection is completed to the vehicle to interview passengers or persons involved. This
allows rescue measures to be started depending on the actual severity of the accident.
The radio communication between the vehicle and the responsible service center is accomplished via the
telephone antenna and the CTEL transmitter and receiver (A35) . If the telephone antenna does not
operate due to an accident it is automatically switched over to the TELE AID substitute antenna (A2/50) .

In general the voice connection is accomplished with the hands-free system of the telephone. The hands-free
system consists of the hands-free system microphone (B25), the hands-free system loudspeaker (H4/12)
and the CTEL transmitter and receiver (A35) .
Depending on the vehicle model it is possible, however, to combine the hands-free system loudspeaker with
other output systems, e.g. as double-coil loudspeaker (radio/telephone) in model 202 (H4/13) or as system
loudspeakers in model 220 (H4/9, H4/10) .
When the voice connection is completed TELE AID is also terminated.
Peculiarities in the case of a taxi emergency call (code 930):
The voice connection is normally limited to monitoring the passenger compartment via the hands-free system
microphone (B25) , since otherwise the person threatening would be warned or could be caused to panic. The
service center only attempts to obtain further information in special cases.

with code 351, 815,
347, 348
210, 220 with code
930
Voice connection to vehicle, function - GF82.95-P-2006P
After the service center (police, fire brigade, German Red Cross, ...) has received a TELE AID emergency call
telegram a radio connection is completed to the vehicle to interview passengers or persons involved. This
allows rescue measures to be started depending on the actual severity of the accident.
The radio connection between the vehicle and the responsible service center is completed in the vehicle via the
telephone system. If the telephone antenna (A2/22) (model 215), (A2/49a1) (models 203, 208, 210, 220) is no
longer working due to an accident, the vehicle automatically switches over to the TELE AID backup antenna
(A2/50). If the power supply has collapsed (battery sheared off), the system switches over automatically to the
backup battery (G1/1).
The voice connection is completed over the hands-free system microphone (B25) and the emergency call
system loudspeakers or the hands-free system (model-dependent).
The voice connection is normally limited to listening to the vehicle passenger compartment via the hands-free
system microphone (B25), otherwise the threatening person may be warned or panicked. The service center
only attempts to obtain additional information in special cases by asking questions.

Emergency call system loudspeaker, GF82.95-P-4203A
location/task
Voice connection to vehicle, function - GF82.95-P-2006PA
After the Mercedes-Benz Customer Assistance Center (CAC) has received a TELE AID telediagnosis a radio
connection is completed to the vehicle to check with the driver the defect occurred. This allows to start rescue
measures corresponding to the vehicle defect.
The radio connection between the vehicle and the responsible service center is completed in the vehicle via the
telephone system.
If the telephone antenna (A2/22) (model 215), (A2/49a1) (models 203, 208, 210, 220) is no longer working due
to a fault, the vehicle automatically switches over to the TELE AID backup antenna (A2/50). If the power
supply is completely interrupted it is automatically switched over to the additional battery (G1/1).
The voice connection is made via the hands-free system microphone (B25) and the emergency call system
loudspeakers or the hands-free system (model-dependent).
The voice connection is normally limited to listening to the vehicle passenger compartment via the hands-free
system microphone (B25), otherwise the threatening person may be warned or panicked. The service center
only attempts to obtain additional information in special cases by asking questions.

Emergency call system loudspeaker, GF82.95-P-4203A
location/task
Voice connection to vehicle, function - GF82.95-P-2006SX
version
Irrespective of the type of emergency call, a voice connection is established to the service center immediately in
parallel to transmitting the SMS and the user can talk to a service receptionist. If the service center is unable to
establish a connection to the vehicle, the emergency call system control unit (N123/4) itself tries to establish a
connection between the vehicle and the service center. Both, the emergency call and the information service are
free services provided by Mercedes-Benz customer support.
The hands-free system microphone group (A67b1) is used for the voice input. The voice output occurs
exclusively via the left front speaker (H4/9) and the right front speaker (H4/10). Both speakers are actuated
discretely by the emergency call system control unit (N123/4). Usually, the telephone connection is established
via the telephone antenna (A2/49a1) (model 220) that is located at the rear window, or via the telephone
antenna (A2/22) (model 215) at the tailgate. If the telephone antenna (A2/22) (model 215) or the telephone
antenna (A2/49a1) (model 220) is defective, e.g., in the event of a rollover, 2 emergency antennas are available
in the rear bumper of the vehicle, which are called emergency call system left backup antenna (A2/54) and
emergency call system right backup antenna (A2/55). The emergency call system control unit (N123/4) detects
the antenna failure and consequently actuates the emergency antennas automatically.

Emergency call system loudspeaker, GF82.95-P-4203SX
location/purpose
Hands-free microphone, location/task GF82.70-P-4102M
Voice connection to vehicle, function - GF82.95-P-2006SZ
version
Irrespective of the type of emergency call, a voice connection is established to the service center immediately in
parallel to transmitting the SMS and the user can talk to a service receptionist. If the service center is unable to
establish a connection to the vehicle, the telecommunications control unit (N112) itself tries to establish a
connection between the vehicle and the service center. Both, the emergency call and the information service are
free services provided by Mercedes-Benz customer support.
The hands-free system microphone group (A67b1) is used for the voice input. The voice output occurs
exclusively via the left front speaker (H4/9) and the right front speaker (H4/10). Both speakers are actuated
discretely by the telecommunications control unit (N112). Usually, the telephone connection is established via
the telephone antenna (A2/49a1) (model 220) that is located at the rear window, or via the telephone antenna
(A2/22) (model 215) at the tailgate. If the telephone antenna (A2/22) (model 215) or the telephone antenna
(A2/49a1) (model 220) is defective, e.g., in the event of a rollover, 2 emergency antennas are available in the
rear bumper of the vehicle, which are called emergency call system left backup antenna (A2/54) and emergency
call system right backup antenna (A2/55). The telecommunications control unit (N112) detects the antenna
failure and consequently actuates the emergency antennas automatically.

Emergency call system loudspeaker, GF82.95-P-4203SX
location/purpose
TELEDIAGNOSIS, FUNCTION - GF82.95-P-2008
Telediagnosis, function - GF82.95-P-2008P
MODELS 208, 215 up to 31.8.03 with CODE (855) TELE AID
Telediagnosis is a supplemented of the TELE AID emergency call The objective of the telediagnosis service is
quick and aimed support of the "24 h service".
The telediagnosis is triggered manually by the driver in the event of technical problems. When the TELE AID
push-button switch is actuated (min. 2 seconds) on the telephone handset (A34) an emergency call telegram is
generated automatically in the D2B telephone and TELE AID transmitter/receiver (A35/17) and transmitted to
the Mercedes-Benz Customer Assistance Center (CAC).
It includes vehicle position data and data for quick and reliable handling of a breakdown. The emergency call
telegram is transmitted via mobile telephone (digital network). if the telephone antenna (A2/22) is defective
(model 215), (A2/49a1) (models 203, 208, 210, 220) the vehicle automatically switches to the TELE AID
backup antenna (A2/50)
A short time after the telediagnosis is triggered an automatic voice connection is completed to the Mercedes-
Benz Customer Assistance Center (CAC) and to the diagnosis experts there.
Further procedure are clarified with the driver.
If the power supply is interrupted (for example battery interruption) the D2B telephone and TELE AID
transmitter/receiver (A35/17) switches automatically over to the additional battery (G1/1).
If the error can be eliminated with the aid of the diagnosis experts the telediagnosis is completed.
If the error is not eliminated the Mercedes-Benz Customer Assistance Center (CAC) starts additional help
measures.
If local help is required, position data are taken over into a mapping program with an electronic card. This
serves for determining the vehicle location and the next MB service center. The service center is notified and
receives the required vehicle data from the Mercedes-Benz Customer Assistance Center (CAC) to start effective
help measures.
Telediagnosis can only operate when the system is authorized.
Emergency call actuation, function for TELE AID GF82.95-P-2003PA

telediagnosis
Emergency call telegram generation, for TELE AID GF82.95-P-2004PA
function telediagnosis
Emergency call telegram transmission, for TELE AID GF82.95-P-2005PA
function telediagnosis
TELE AID push-button, for TELE AID GF82.95-P-4101P
location/task/design/function telediagnosis
Telediagnosis, function - GF82.95-P-2008SX
version
The vehicle is equipped with the following MB telematics services:
 Roadside assistance call (telediagnosis, roadside assistance)

 MB information call
Roadside assistance call (telediagnosis, roadside assistance)
The telediagnosis service provides the user with the opportunity to establish contact with a service center, for
instance in the event of a vehicle defect. The service center is now able to conduct a remote diagnosis of the
facts and initiate the appropriate effective remedial actions while considering additional vehicle-specific data.
group (S93/6) is actuated.
The following data are automatically transmitted in a roadside assistance call:
 Status data
 Fault code
The service center can request additional status data and fault codes from the emergency call system control
unit (N123/4) by means of an SMS. The service center calls the vehicle after the data have been evaluated. The
exact situation and additional service measures can then be coordinated between the driver and the service
center.
Status reports
Status reports are issued in the display of the following components:

 Multifunction display (A1p13) of the instrument cluster (A1)

location/task
Telediagnosis, function - GF82.95-P-2008SZ
version

Roadside assistance call (telediagnosis, roadside assistance)
The telediagnosis service provides the user with the opportunity to establish contact with a service center, for
instance in the event of a vehicle defect. The service center is now able to conduct a remote diagnosis of the
facts and initiate the appropriate effective remedial actions while considering additional vehicle-specific data.
group (S93/6) is actuated.
The following data are automatically transmitted in a roadside assistance call:
 Status data
 Fault code
The service center can request additional status data and fault codes from the telecommunications control unit
(N112) by means of an SMS. The service center calls the vehicle after the data have been evaluated. The exact
situation and additional service measures can then be coordinated between the driver and the service center.
Status reports


location/task
INFOCALL FUNCTION - GF82.95-P-2009P
MODELS 203, 210, 220 with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODELS 208.3, 215 with CODE (855) TELE AID

The Infocall is manually triggered by the driver. Selecting the appropriate menu (Info service) on the CTEL
handset automatically causes the CTEL and TELE AID, D2B transmitter/receiver unit (A35/17) to
automatically call the Mercedes Customers Assistance Center (CAC) via the GSM CTEL network. This free
voice-only connection can be used to obtain any information that is available about the vehicle.
For example, it can be used to ask questions about:
 Operating the vehicle.

 Mercedes-BenzCard services
 Information about DaimlerChrysler
 Technical and service inquiries
 Leasing and financing services
 Accessory information brochures
Transmitter/receiver unit for CTEL and GF82.95-P-4300A

location/purpose/design/function TELE AID
MB INFORMATION, FUNCTION - GF82.95-P-2010
MB information, function - GF82.95-P-2010P
The objective the information call service is to offer the user a quick and convenient way to contact the
Mercedes Customers Assistance Center (CAC).
The information call is triggered manually by the driver. By selecting the corresponding menu (information
service) on the telephone handset (A34) a connection is automatically established with the CAC by the D2B
telephone and TELE AID transmitter/receiver (A35/17) via mobile telephone (digital network). The pure voice
connection can be used without any costs to check all available information in context wit the vehicle.
These could be questions about:
 operating the vehicle

 Mercedes-Benz Card services
 Information on DaimlerChrysler
 Questions on technical and service subjects
 Leasing or financing offers
 Information brochures for accessories
The information call service is only available when the system is authorized.
MB information, function - GF82.95-P-2010SX
version

MB information call
The "MB-Info" service provides the customer with the opportunity to establish contact to a DaimlerChrysler
service center. This information service provides the user with current information (e.g., traffic situation,
possible alternative routes) or additional DC-specific information. This service is mainly available as a voice
service and is completed via the emergency call system control unit (N123/4). The service is activated by the
user by actuating the MB-Info and breakdown assistance button group (S93/6).
If the service is authorized and no service with a higher priority is active, the emergency call system control unit
(N123/4) transmits an SMS to the service center.
For this purpose, the following data are transmitted:
In parallel to transmitting the SMS, a voice connection is immediately established to the service center and the
user can talk to a service receptionist. If the service center is unable to establish a connection to the vehicle, the
emergency call system control unit (N123/4) itself tries to establish a connection between the vehicle and the
service center. The information service is a free service provided by Mercedes-Benz customer support.
The following information can be requested:
 Current traffic situation

 Technical questions
 Services
 Mercedes-Benz products
 Complaints
 Mercedes card
 Leasing and financing offers
Status reports

The following conditions are issued during an MB information call:
 MB-Info, Call in Progress

 MB-Info, Call Active
 MB-Info, Call Failed

location/task
MB information, function - GF82.95-P-2010SZ
version

MB information call
The "MB-Info" service provides the customer with the opportunity to establish contact to a DaimlerChrysler
service center. This information service provides the user with current information (e.g., traffic situation,
possible alternative routes) or additional DC-specific information. This service is mainly available as a voice
service and is completed via the telecommunications control unit (N112). The service is activated by the user by
actuating the MB-Info and breakdown assistance button group (S93/6).
If the service is authorized and no service with a higher priority is active, the telecommunications control unit
(N112/) transmits an SMS to the service center.
For this purpose, the following data are transmitted:
In parallel to transmitting the SMS, a voice connection is immediately established to the service center and the
user can talk to a service receptionist. If the service center is unable to establish a connection to the vehicle, the
telecommunications control unit (N112) itself tries to establish a connection between the vehicle and the service
center. The information service is a free service provided by Mercedes-Benz customer support.
The following information can be requested:
 Current traffic situation

 Technical questions
 Services
 Mercedes-Benz products
 Complaints
 Mercedes card
 Leasing and financing offers
Status reports


location/task
LOCATION FINDING, FUNCTION - GF82.95-P-3000
Location finding, function - GF82.95-P-3000A
(D2B)
Location finding with GPS

Illustration deviating from TELE AID system: Location of GPS/telephone roof antenna (A2/49) on trunk lid
or at rear end of vehicle roof (varies according to model).
Fig. 213: Identifying Location Finding With GPS
Location finding with dead reckoning
Illustration deviates from TELE AID system: Location of GPS/telephone roof antenna (A2/49) on trunk lid or
at rear end of vehicle roof (varies according to model).
Fig. 214: Identifying Location Finding With Dead Reckoning
With TELE AID the vehicle location is calculated by two methods which check each other. The methods are
called GPS location finding and dead reckoning.
GPS location finding:
GPS antenna depends on model:
Models 129, 215 GPS antenna (A2/23)
Models 202, 208.3, 210, 220 GPS/telephone roof antenna (A2/49)
The vehicle position (location precision approx. 100 m) is calculated in the global position system (GPS)
control module by the signals received by the GPS antenna from min. 3 satellites. The GPS control module is
integrated into the emergency call system control module (TELE AID, A35/8) .
Dead reckoning:
For dead reckoning of the vehicle the emergency call system control module (TELE AID, A35/8) requires
the following information:
 The signals edited by the traction system control module (N47) for the left front speed sensor (L6/1)
and the right front speed sensor (L6/2)
 the reversing signal
 the signal from the stop lamp switch (S9/1)
The dead reckoning is permanently accomplished by the emergency call system control module (TELE AID,
A35/8) with circuit 15R on: The momentary vehicle position is calculated from the path traveled considering
the vehicle alignment and direction of motion.
Mileage covered
The number of impulses from the front wheel speed sensors (L6/1 and L6/2) is a measure for the distance
traveled.
Vehicle alignment
From the speed difference of the front speed sensors (L6/1 and L6/2) the emergency call system control
module (TELE AID, A35/8) calculates the vehicle alignment.
Direction of motion
The reverse lamp signal indicates whether the vehicle moves forward or backward.
The stop lamp switch signal is only used for plausibility checks when calculating the location.
Positioning errors and corrections
Rolling backwards without the reverse gear being engaged is evaluated as forward motion, and may lead to an
error in map matching. Rolling with the ignition switched off or vehicle transportation also falsify map
matching.
The location finding errors are automatically corrected when receiving the GPS data.
The vehicle should be (for correct dead reckoning) equipped with permissible tires and the TELE AID
should be coded correspondingly with the aid of the hand-held tester. The same applies for changes on the
chassis. Prerequisite for GPS location finding is a free view to the sky.
When initially started up or after interruption of the power supply the vehicle should be parked outdoors for
approx. 30 minutes so that the GPS system can recalibrate. Otherwise it is not ensured with a TELE AID
emergency call or a taxi emergency call that the correct vehicle position is entered into the emergency call
telegram.
function
function
Global positioning system antenna Model 215 GF82.61-P-4106D
Location/purpose/design/function
location/purpose/design/function 208, 210, 220 with
code 351, 815, 347,
348
210, 220 with code
930
Position finding, function - GF82.95-P-3000P
The global positioning system (GPS) is a satellite-supported location finding system set up by the US
Department of Defense. It is a toll-free service available throughout the world. 26 satellites are currently
orbiting the earth on 6 different trajectories. The GPS satellites continuously transmit time and position data
(longitude/latitude).
Position finding
The vehicle location is determined parallel with two methods supplementing each other. The methods are called
GPS location finding and basic location finding (dead reckoning).
GPS location finding:
GPS localizing is irreplaceable, especially in the case of journeys outside of the digitalized map area and after
vehicle transportation (e.g. by train, ferry or towing).
A repeated GPS location finding (following satellite reception interruption) can take several minutes (up to 20
minutes when the unit is initially started up).
The computer and the GPS receiver unit are integrated in the D2B telephone and TELE AID
transmitter/receiver (A35/17). If signals from at least 3 satellites have been received by the GPS antenna
(A2/23) (model 203, 215), (A2/49a2) (models 208, 210, 220), the position and accuracy of the receiver location
(vehicle) can be calculated.
Moreover, the direction of motion is determined with the aid of the sequence of the locations calculated with
GPS.
Parallel to the GPS location finding, the basic location finding takes place .
For the basic location finding of the vehicle, the D2B CTEL and TELE AID transmitter-receiver (A35/17)
requires the following information:
 the signals from the left (L6/1) and right (L6/2) wheel speed sensors that have been prepared by the
traction system control unit (N47). The number of impulses from the left front wheel speed sensor (L6/1)
is a measure for the distance traveled.
 the data in the yaw rate sensor (gyro sensor) integrated in the D2B telephone and TELE AID
The D2B telephone and TELE AID transmitter/receiver (A35/17) calculates the vehicle alignment
(compass point) from the gyro sensor data.
 The data on the direction of travel
The reverse lamp signal indicates whether the vehicle is moving forward or backward.
Basic position finding is constantly carried out by the D2B telephone and TELE AID transmitter/receiver
(A35/17) with "circuit 15R: ON" (once per second). The momentary vehicle position (longitude/latitude) is
calculated from the path traveled under consideration of the vehicle alignment and direction of motion.
If the computer calculates that the basic location finding is less precise than the GPS location finding, the
currently calculated position is corrected with the aid of the GPS data.
In case of an accident the D2B telephone and TELE AID transmitter/ receiver (A35/17) automatically generates
an emergency call telegram containing the vehicle's position data and transmits it via the vehicle's mobile
telephone system (D-network).
The emergency call signal reaches the service provider. With the available equipment (graphic-capable
workstation and electronic road database), it is possible to determine the precise location of the vehicle with the
aid of the position data.
Rolling backwards without the reverse gear engaged is evaluated as forwards motion, and may lead to a
temporary error in map matching. Rolling with ignition switched off or vehicle transportation also falsify the
position finding. In both cases the deviation is corrected automatically by the computer in the D2B telephone
and TELE AID transmitter/receiver (A35/17) when GPS data are received.
Emergency call telegram generation, TELE AID GF82.95-P-2004P

telediagnosis
telediagnosis
Global positioning system (GPS) GF82.61-P-4106P
antenna location/task/design/Function
Position finding, function - GF82.95-P-3000SX
version
The global positioning system (GPS) is a satellite-supported localizing system set up by the American
Department of Defense. It is a toll-free service available throughout the world. The GPS satellites continuously
transmit time and position data (longitude and latitude).
Position finding
The vehicle location is determined parallel with 2 methods supplementing each other. The methods are called
GPS position finding and basic position finding.
GPS position finding
GPS position finding is irreplaceable for journeys outside the digitized map area and after vehicle transport
(e.g., train or ferry journeys and towing). A new GPS position (after interruption of the satellite reception) can
take several minutes (up to 20 minutes when the equipment is first set up). The navigation processor and the
receiver unit of the GPS are integrated in the emergency call system control unit (N123/4). If signals are
received from at least 3 satellites via the GPS antenna (A2/23) (model 215) or the GPS antenna (A2/49a2)
(model 220), it is possible to calculate the position and accuracy of the location finding of the receiver (vehicle).
In addition, the vehicle's direction of travel is determined with the aid of the sequence of the locations
calculated with GPS.
Basic location finding
To find the basic position, which takes place in parallel to the GPS position finding, the emergency call system
control unit (N123/4) requires the following information:
 The signals processed by the ESP, SPS [PML] and BAS control unit (N47-5) of the left front rpm sensor
(L6/1), right front rpm sensor (L6/2), left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4), which
get to the central gateway control unit (N93) via the Controller Area Network Bus Class C (engine
compartment) (CAN-C). The central gateway control unit (N93) receives the message and transmits it
over the Controller Area Network (databus/CAN bus) (CAN) diagnosis to the emergency call system
control unit (N123/4).
 The data of the yaw rate sensor (gyrosensor) integrated in the emergency call system control unit
(N123/4) (the emergency call system control unit (N123/4) uses the data of the integrated gyrosensor to
calculate the vehicle orientation (direction)).
 The data about vehicle direction (forward or reverse)
The basic position finding is performed continuously by the emergency call system control unit (N123/4) with
"circuit 15R ON". The current vehicle position (longitude and latitude) is calculated from the travel distance in
consideration of the vehicle alignment and direction of travel. If the navigation processor determines that the
basic location finding is less accurate than the GPS location finding, the position currently calculated is
corrected using GPS data. If an accident occurs, the emergency call system control unit (N123/4) automatically
generates an emergency telegram that contains the position data of the vehicle and transmits it over the vehicle's
cellphone system. The emergency call signal reaches the service provider. With the equipment there, the exact
position of the vehicle is determined using the position data.
Rolling backward with the ignition switched off or vehicle transportation also falsify position finding. The
deviation is automatically corrected by the integrated navigation processor in the emergency call system control
unit (N123/4) in both cases when the GPS data are received.
TELE AID control GF82.95-P-

unit/task/design/function 4100SX
GPS/telephone roof antenna Model 220 GF82.70-P-
location/task/design/function 4111SX
GPS antenna, location/task Model 215 GF82.62-P-4107SZ
Antenna, location/purpose/design/function GF82.85-P-3107SZ
Position finding, function - GF82.95-P-3000SZ
version
The global positioning system (GPS) is a satellite-supported localizing system set up by the American
Department of Defense. It is a toll-free service available throughout the world. The GPS satellites continuously
transmit time and position data (longitude and latitude).
Position finding
The vehicle location is determined parallel with 2 methods supplementing each other. The methods are called
GPS position finding and basic position finding.
GPS position finding
GPS position finding is irreplaceable for journeys outside the digitized map area and after vehicle transport
(e.g., train or ferry journeys and towing). A new GPS position (after interruption of the satellite reception) can
take several minutes (up to 20 minutes when the equipment is first set up). The navigation processor and the
receiver unit of the GPS are integrated in the telecommunications control unit (N112). If signals are received
from at least 3 satellites via the GPS antenna (A2/23) (model 215) or the GPS antenna (A2/49a2) (model 220),
it is possible to calculate the position and accuracy of the location finding of the receiver (vehicle). In addition,
the vehicle's direction of travel is determined with the aid of the sequence of the locations calculated with GPS.
Basic location finding
To find the basic position, which takes place in parallel to the GPS position finding, the telecommunications
control unit (N112) requires the following information:
 The signals processed by the ESP, SPS [PML] and BAS control unit (N47-5) of the left front rpm sensor
(L6/1), right front rpm sensor (L6/2), left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4), which
get to the central gateway control unit (N93) via the Controller Area Network Bus Class C (engine
compartment) (CAN-C). The central gateway control unit (N93) receives the message and transmits it to
the audio gateway control unit (N93/1) via the Controller Area Network Bus Class B (interior) (CAN-B).
From there, the data are transmitted to the telecommunications control unit (N112) via the Media
Oriented System Transport (MOST).
 The data about vehicle direction (forward or reverse)
The basic position finding is performed continuously by the telecommunications control unit (N112) with
"circuit 15R ON". The current vehicle position (longitude and latitude) is calculated from the travel distance in
consideration of the vehicle alignment and direction of travel. If the navigation processor determines that the
basic location finding is less accurate than the GPS location finding, the position currently calculated is
corrected using GPS data. If an accident occurs, the telecommunications control unit (N123/) automatically
generates an emergency telegram that contains the position data of the vehicle and transmits it over the vehicle's
cellphone system. The emergency call signal reaches the service provider. With the equipment there, the exact
position of the vehicle is determined using the position data.
Rolling backward with the ignition switched off or vehicle transportation also falsify position finding. The
deviation is automatically corrected by the integrated navigation processor in the telecommunications control
unit (N112) in both cases when the GPS data are received.
Telecommunications control unit, GF82.70-P-

location/task/design/function 3114SU
SELECTING TELEPHONE ANTENNA, FUNCTION - GF82.95-P-3001
Selecting telephone antenna, function - GF82.95-P-3001A

(D2B)
An antenna is required for transmitting a TELE AID emergency call telegram, for completing a voice
connection or for simply making a phone call (global system for mobile communication)
When making normal telephone calls the telephone antenna is used for this purpose.
This antenna can be damaged in the case of an accident (e.g. rollover). TELE AID emergency call is no longer
possible then. To prevent this in any case the TELE AID substitute antenna (A2/50) is installed in addition to
the telephone antenna. . This antenna is located at a crash-safe location and is only used if required. For this
purpose the emergency call system control module (TELE AID, A35/8) has two GMS antenna inputs and one
output; the corresponding active antenna is switched through to the telephone transmitter/receiver (A35) via this
output.
Fig. 215: Identifying TELE AID Emergency Call System Control Module Diagram (1 of 2)
As long as no emergency call is triggered the telephone antenna is always active. In the event of an emergency
call the emergency call system control module (TELE AID, A35/8) checks the signal level of the telephone
antenna . If it is not sufficient it checks the level of the TELE AID substitute antenna (A2/50) The antenna
with the higher signal level is used for radio connection (see structogram).
The telephone antenna inputs on the emergency call system control module (TELE AID, A35/8) are
equipped with identical sockets. Always ensure that the antennas are installed correctly (color marking).

function
with code 351, 815,
347, 348
210, 220 with code
930
Selecting telephone antenna, function - GF82.95-P-3001P
A GSM (global system for mobile communication) is required for transmitting a TELE AID emergency call
telegram (TELE AID emergency call or telediagnosis), for completing a voice connection or for simply making
a phone call.
For normal telephone calls this is (model 215) the telephone antenna (A2/22), (model 203, 208, 210, 220) or
telephone antenna (A2/49a1). In case of an accident (e.g. rollover) the telephone antenna (A2/22), (A2/49a1)
can be destroyed. The antenna could also have another defect. TELE AID emergency call/telediagnosis is no
longer possible then. In order to be sure that this is prevented, the TELE AID backup antenna (A2/50) is
installed as well as the telephone antenna (A2/22), (A2/49a1). These antennas are located at a crash-safe
location and should only be used if required. For this purpose the D2B telephone and TELE AID
transmitter/receiver (A35/17) has two GSM antenna inputs via which the corresponding active antenna is
switched through.
Fig. 216: Identifying Tele Aid Emergency Call System Control Module Diagram - Models 203 With
Codes (855) And (930)
The telephone antenna (A2/22) (model 215), (A2/49a1) (models 203, 208, 210, 220) is continuously active until
an emergency call is triggered. If an emergency call is triggered the D2B telephone and TELE AID
transmitter/receiver (A35/17) checks the signal level of the telephone antenna (A2/22) (model 215), (A2/49a1)
(models 203, 208, 210, 220). If this is too low the level of the TELE AID backup antenna (A2/50) is checked
The antenna with the higher signal level is used for connection (see structogram).

telediagnosis
Selecting telephone antenna, function - GF82.95-P-3001SX
version
at the top of the rear window, or via the telephone antenna (A2/22) (model 215) at the tailgate. If the telephone
antenna (A2/22) (model 215) or the telephone antenna (A2/49a1) (model 220) is defective, e.g., in the event of a
emergency call system right backup antenna (A2/55).
The emergency call system control unit (N123/4) recognizes the failure of the antenna and actuates the
emergency call system left backup antenna (A2/54) and the emergency call system right backup antenna
(A2/55) automatically via a discrete line.

Selecting telephone antenna, function - GF82.95-P-3001SZ
version
at the top of the rear window, or via the telephone antenna (A2/22) (model 215) at the tailgate. If the telephone
antenna (A2/22) (model 215) or the telephone antenna (A2/49a1) (model 220) is defective, e.g., in the event of a
emergency call system right backup antenna (A2/55).
The telecommunications control unit (N112) recognizes the failure of the antenna and actuates the emergency
call system left backup antenna (A2/54) and the emergency call system right backup antenna (A2/55)
automatically via a discrete line.

PIN CHECK WITH TELE AID EMERGENCY CALL, FUNCTION - GF82.95-P-3002
PIN check with TELE AID emergency call, function - GF82.95-P-3002A
(D2B)
The abbreviation for PIN stands for P ersonal I dentification N umber. The PIN is a 4-digit code serving as pass
word for making calls with the telephone system. It should be entered by the user after switching on the
telephone system (with D1-network entering is optional).
Since the PIN cannot be entered manually in the event of a TELE AID emergency call (or taxi emergency call)
special prerequisites are provided:
The user can store the PIN number in the emergency call system control module (TELE AID, A35/8) via the
CTEL handset (A34).Then TELE AID can automatically transmit the PIN to the CTEL transmitter and
receiver (A35) in the event of an emergency call.
It is always possible to change the PIN with the CTEL handset (A34) or erase it in the EPROM of the
emergency call system control module (TELE AID, A35/8) .
Always observe that no TELE AID emergency call is transmitted when the PIN is erased or not stored. The
indicator lamp in the TELE AID emergency call pushbutton switch (S93/3) comes on as a signal.
Authorization function, store PIN GF82.95-P-2001A

function
PIN check with TELE AID emergency call, function - GF82.95-P-3002P
The abbreviation PIN means P ersonal I dentification N umber. The PIN is a 4-digit code which acts as a
password for telephoning with the telephone system. It has to be entered by the operator after the telephone
system is switched on.
Since it is not possible to enter the PIN manually when making a TELE AID emergency call or with a taxi
emergency call, certain measures have been taken to automate this process:
The user can store the PIN number in the D2B telephone and TELE AID transmitter/receiver (A35/17) using
the telephone handset (A34). If an accident occurs (signal from restraint systems control unit (N2/7)) the D2B
telephone and TELE AID transmitter/receiver (A35/17) falls back on the stored PIN. This is the same as manual
entry of the PIN and automatically activates the telephone system to allow an emergency call to be placed over
the telephone system.
The PIN can be changed at any time using the telephone handset (A34), or deleted from the D2B telephone and
TELE AID transmitter/ receiver (A35/17) EPROM.
Do not forget that it is not possible to place a TELE AID emergency call if the PIN has been erased or
not stored. As a signal, the indicator lamp in the SOS push-button switch (S93/3) then lights up .

DATA FROM AIRBAG CONTROL MODULE FOR TELE AID, FUNCTION - GF82.95-P-3003A
(D2B)
The emergency call system control module (TELE AID, A35/8) receives the following messages from the
emergency tensioning retractor control module with airbag (AB) (N2/2, not in models 215, 220) or from
the restraint system control module (N2/7, Models 215, 220) :
B1: Readiness
B2: Test signal for function check
B3: Front end collision, emergency tensioning retractor activated
B4: Rear end collision, emergency tensioning retractor activated.
B5: Front end collision, airbag triggered
B6: Side collision, side airbag triggered
After TELE AID is switched on, the emergency call system control module (TELE AID, A35/8) waits for a
readiness message from the emergency tensioning retractor control module with airbag (AB) (N2/2, not in
models 215, 220) or from the restraint system control module (N2/7, models 215, 220) If this message is not
received within 30 s the indicator lamp in the TELE AID emergency call pushbutton switch (S93/3) comes
on and the error is stored in the DTC memory. Ready messages coming in later are still accepted, the status
indicator lamp goes also out.
After the ready message is received the emergency call system control module (TELE AID, A35/8) expects
further ready messages every 500 ms. If this is not accomplished for more than 3 s, the status indicator lamp in
the TELE AID emergency call pushbutton switch (S93/3) comes on and the error is stored in the DTC
memory of the emergency call control module (TELE AID, A35/8) . Later incoming messages are still
received.
A TELE AID emergency call is automatically actuated when a crash message is received twice within one
second in the emergency call system control module (TELE AID, A35/8) .
When a crash message is received once the status indicator lamp in the TELE AID pushbutton switch (S93/3)
comes on. This is entered into the DTC memory of the emergency call control module (TELE AID, A35/8) ,
later incoming messages are, however, still received.

function
RESTRAINT SYSTEM CONTROL UNIT DATA, FUNCTION - GF82.95-P-3005
Restraint system control unit data, function - GF82.95-P-3005P
The D2B telephone and TELE AID transmitter/receiver (A35/17) receives the following messages from the
restraint systems control unit (N2/7)
B1: Ready
B2: Test signal for operational check
B3: Front end collision, emergency tensioning retractor control unit activated
B4: Rear end collision, ETR activated
B5: Front end collision, airbag triggered
B6: Side collision, sidebag deployed

B7: Side collision, windowbag deployed
After TELE AID has been switched on, the D2B telephone and TELE AID transmitter/receiver (A35/17) awaits
a ready message. If this has not been received even after 30 s, the status display in the SOS push-button switch
(S93/3) lights up and the fault is entered in the fault memory. Messages of readiness arriving later are
nevertheless accepted, the status display then goes out again.
After the ready message has been received, the CTEL and D2B telephone and TELE AID transmitter/receiver
(A35/17) awaits a further ready confirmation every 500 ms. If this is not received for longer than 3 seconds the
status display illuminates in the SOS push-button switch (S93/3) and the error is stored in the fault memory of
the D2B telephone and TELE AID transmitter/receiver (A35/17). Later incoming messages are still received
A TELE AID emergency call is automatically triggered by the D2B telephone and TELE AID
transmitter/receiver (A35/17) if a crash message is received twice within one second.
With a single crash message, the state display in the SOS push-button (S93/3) lights up. An entry is made in the
fault memory of the D2B telephone and TELE AID transmitter/receiver (A35/17), and subsequent messages
continue to be received.

Emergency call actuation, function GF82.95-P-2003P
Restraint system control unit data, function - GF82.95-P-3005SX
version
The emergency call system control unit (N123/4) receives the messages listed in the following as a digital crash
signal from the restraint systems control unit (N2/7) via a discrete line and additionally (redundantly) via the
Controller Area Network (databus/CAN bus) (CAN) diagnosis from the central gateway control unit (N93). The
central gateway control unit (N93) receives the message via the Controller Area Network Bus Class B (interior)
(CAN-B) from the restraint systems control unit (N2/7).
Crash data on CAN diagnosis
CRASH DATA ON CAN DIAGNOSIS - BYTE NO.1

Bit No. Crash level Type of accident
Bit 0 CRASH_A Head-on collision 1
Bit 1 CRASH_B Rear end collision 1
Bit 2 CRASH_C Head-on collision 5
Bit 3 CRASH_D Side collision 1
Bit 4 CRASH_E Rear end collision 2
Bit 5 CRASH_F Head-on collision 2
Bit 6 CRASH_G Rollover 1
Bit 7 CONF_CRASH Confirmation bit (from byte 1, 2)
CRASH DATA ON CAN DIAGNOSIS - BYTE NO.2

Bit 0 CRASH_H Rollover 2
Bit 1 CRASH_I Rollover 3
Bit 2 CRASH_K Rear end collision 3
Bit 3 CRASH_L Side collision 2
Bit 4 CRASH_M Not assigned
Bit 5 CRASH_N Not assigned
Bit 6 CRASH_G Not assigned
CRASH_O Not assigned
Bit 7 CRASH_P Not assigned
An automatic emergency call is made in the event of an accident. This occurs no matter how severe the detected
accident actually is.
Error messages
The restraint systems control unit (N2/7) sends a signal every 500 ms. This is done to indicate to the emergency
call system control unit (N123/4) that the crash detection function is working properly.
The restraint systems control unit (N2/7) cyclically carries out a self-test. An error in the system during normal
operation is indicated, if the red LED in the SOS switch (S93/3s1) lights up. The corresponding error message is
displayed in the COMAND operating, display and control unit (A40/3) and in the multifunction display
(A1p13) of the instrument cluster (A1). The red LED remains on until circuit 15 is switched off or the fault is
rectified. The SOS switch (S93/3s1) is monitored. The system detects when an SOS switch (S93/3s1) is stuck.
False signals are ignored and the system remains operational.

Emergency tensioning retractor with GF91.60-P-4006B
airbag control unit,
Restraint system control unit data, function - GF82.95-P-3005SZ
version
The telecommunications control unit (N112) receives the messages listed in the following as a digital crash
signal from the restraint systems control unit (N2/7) via a discrete line and additionally (redundantly) via the
Media Oriented System Transport (MOST) from the audio gateway control unit (N93/1). The audio gateway
control unit (N93/1) receives the message via the Controller Area Network Bus Class B (interior) (CAN-B)
from the restraint systems control unit (N2/7).
Crash data
BYTE NO.1
Bit 0 CRASH_A Head-on collision 1
Bit 1 CRASH_B Rear end collision 1
Bit 2 CRASH_C Head-on collision 5
Bit 3 CRASH_D Side collision 1
Bit 4 CRASH_E Rear end collision 2
Bit 5 CRASH_F Head-on collision 2
Bit 6 CRASH_G Rollover 1
Bit 7 CONF_CRASH Confirmation bit (from byte 1, 2)
BYTE NO. 2
Bit 0 CRASH_H Rollover 2
Bit 1 CRASH_I Rollover 3
Bit 2 CRASH_K Rear end collision 3
Bit 3 CRASH_L Side collision 2
Bit 4 CRASH_M Not assigned
Bit 5 CRASH_N Not assigned
Bit 6 CRASH_G Not assigned
CRASH_O Not assigned
Bit 7 CRASH_P Not assigned
An automatic emergency call is made in the event of an accident. This occurs no matter how severe the detected
accident actually is.
Error messages
The restraint systems control unit (N2/7) sends a signal every 500 ms. This is done to indicate to the
telecommunications control unit (N112) that the crash detection function is working properly.
The restraint systems control unit (N2/7) cyclically carries out a self-test. An error in the system during normal
operation is indicated, if the red LED in the SOS switch (S93/3s1) lights up. The corresponding error message is
displayed in the COMAND operating, display and control unit (A40/3) and in the multifunction display
(A1p13) of the instrument cluster (A1). The red LED remains on until circuit 15 is switched off or the fault is
rectified. The SOS switch (S93/3s1) is monitored. The system detects when an SOS switch (S93/3s1) is stuck.
False signals are ignored and the system remains operational.
TELE AID CONTROL MODULE, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.95-P-4100
TELE AID control module, location/purpose/design/function - GF82.95-P-4100A
(D2B)
TELE AID, location of Model 129 GF82.95-P-0001-01E

components
Model 140 except GF82.95-P-0001-01A
140.063/07
Model 140.063/07 GF82.95-P-0001-01C
Models 202, 208.3 GF82.95-P-0001-01F
Model 210 except 210.2 GF82.95-P-0001-01B
Model 210.2 GF82.95-P-0001-01D
Model 215 GF82.95-P-0001-01N
Model 220 GF82.95-P-0001-01G
TELE AID control  Central control of
module, purpose TELE AID emergency
call and taxi
emergency call (only
with code 930)
 Calculation of vehicle
location
 Recognition of vehicle
rollover
TELE AID control  Stable metal housing
module, design with 4-hole mount
(except models 215,
220)
 Stable metal housing
with 2-hole mount
(models 215, 220)
 6 connection sockets
with code 348
 7 connection sockets
with code 347
 Integrated roll-over
sensor
 Integrated GPS control
module
TELE AID control GF82.95-P-4100-04A
module, function
TELE AID control module, function - GF82.95-P-4100-04A
In the emergency call system control module (TELE AID, A35/8) all data important for a TELE AID
emergency call are processed centrally (with code 930 also data of taxi emergency call). It calculates the vehicle
position with the aid of the installed GPS control module and generates an emergency call telegram in the event
of an emergency call. An installed roll-over sensor recognizes when the vehicle rolls over.
The data from the emergency tensioning retractor control module with airbag (AB, N2/2) (not models 215,
220) are received via serial interface. On models 215, 220 the emergency tensioning retractor control
module with airbag (AB, N2/2) is replaced by the restraint system control module (N2/7) .
The CTEL transmitter and receiver (A35) and the CTEL handset (A34) are connected directly to the
emergency call system control module (TELE AID, A35/8) . Both units can be actuated by the emergency
call system control module (TELE AID, A35/8) directly via the serial TELE AID interface (DSC uplink, DSC
downlink).
The emergency call system control module (TELE AID, A35/8) is capable of HHT diagnosis
The emergency call system control module (TELE AID, A35/8) should not be turned around the longitudinal
or lateral axis when circuit 15R is "ON". The installed rollover sensor would in this case recognize a
rollover and trigger a TELE AID emergency call. For this purpose always lay the emergency call system
control module (TELE AID, A35/8) down in installation position when removed and when leads are
connected and secure against falling down.
TELE AID control unit/task/design/function - GF82.95-P-4100SX
Shown on model 215

Fig. 217: Identifying Emergency Call System Control Unit
TELE AID control unit, The emergency call system

location control unit (N123/4) is
installed on the right under
the rear bench seat.
TELE AID control unit, GF82.95-P-4100-02SX
task
TELE AID control unit,  Integrated telephone
design module
 Integrated navigation
module
 Integrated additional
battery
 Memory for vehicle-
specific data
 Screened metal
housing
TELE AID control unit, GF82.95-P-4100-04SX
function
TELE AID control unit, task - GF82.95-P-4100-02SX
The emergency call system control unit (N123/4) has the following tasks:
 Integral telephone module for emergency call, service and telediagnosis

 Independent position sensing
 Acquiring and storing vehicle-specific data (e.g. circuit status)
 Actuation of the telephone antenna (A2/22) (model 215) or the telephone antenna (A2/49a1) (model 220).
Actuation of the emergency call system left backup antenna (A2/54) and the emergency call system right
backup antenna (A2/55) in the event of a rollover.
 Voice output via left front speaker (H4/9) and right front speaker (H4/10)
 Input of crash data from the restraint systems control unit (N2/7) via a discrete line
 Unlocking the vehicle in an emergency
 Reading in the SOS switch (S93/3s1) and the MB-Info and breakdown assistance button group (S93/6)
via 2 separate and discrete lines
 Satellite data via the GPS antenna (A2/23) (model 215) or the GPS antenna (A2/49a2) (model 220)
 Generating and keeping an SMS ready
 Muting other audio signals (e.g. radio, navigation)
TELE AID control unit, function - GF82.95-P-4100-04SX
The emergency call system control unit (N123/4) operates with its own microprocessor. In doing so, a
differentiation is made between the 2 sections of the telephone module and the navigation module. All data that
are important for an Telematic Alarm Identification on Demand (emergency call system) (TELE AID)
emergency call are centrally processed in the emergency call system control unit (N123/4). It calculates the
vehicle's position with the aid of the installed navigation module and generates the emergency telegram in the
form of an SMS in the event of an emergency call.
The crash data are received from the restraint systems control unit (N2/7) via a serial interface.
The emergency call system control unit (N123/4) is diagnosis capable with STAR DIAGNOSIS via the
Controller Area Network (databus/CAN bus) (CAN) diagnosis and the central gateway control unit (N93).
TELE AID PUSH-BUTTON, LOCATION/TASK/DESIGN/FUNCTION - GF82.95-P-4101
TELE AID push-button switch, position/task/design/function - GF82.95-P-4101A
MODELS 129, 202, 208.3, 210, 215, 220 with CODE (347) TELE AID emergency call system (D2B)
MODELS 140, 210 with CODE (348) TELE AID emergency call system
MODELS 140, 202, 203, 210, 220 with CODE (930) Taxi emergency call
MODELS 203, 210, 220 with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODELS 203, 208.3, 210, 215, 220 with CODE (855) TELE AID
Location of TELE AID push-button (S93/3)
Shown on model 210

Fig. 218: Identifying TELE AID Push-button - Shown On Model 210
TELE AID push-button, In area of mirror base for all

position models
TELE AID push-button,  To trigger a manual
task TELE AID
emergency call
 To signal the TELE
AID operating state
TELE AID push-button,  Integrated LED for
design night lighting
(terminal 58d)
 Two integrated LEDs
as operating status
display
 Cover cap to protect
against inadvertent
actuation
 "Sense" resistor
connected in parallel
to the switch contact
TELE AID push-button, GF82.95-P-4101-04A
function
TELE AID push-button, function - GF82.95-P-4101-04A
An electric current flows in park position through the control resistor that is installed in the SOS push-button
switch (S93/3) (parallel to the switch contact). This indicates to the D2B telephone and TELE AID
transmitter/receiver (A35/17) that the feed line and the ground line are OK.
When pressing the SOS push-button switch (S93/3), the control resistor is bridged by a switch contact. This is
detected by the CTEL and TELE AID transmitter/receiver, D2B (A35/17) and a TELE AID emergency call is
then activated.
TELE AID push-button, location/task/design/function - GF82.95-P-4101P
for telediagnosis
Fig. 219: Identifying Telediagnosis Push-button Switch And Telephone Handset - Models 203 Up To
31.8.03 With Code (855) TELE AID With Code (930)
TELE AID push-button,  Activating a manual

task telediagnosis call
TELE AID push-button,  The push-button switch
design for activating a
telediagnosis call is
integrated in the
handset of the fixed
installation cellular
phone
TELE AID SUBSTITUTE ANTENNA, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.95-P-4102
TELE AID substitute antenna, location/purpose/design/function - GF82.95-P-4102A
(D2B)
TELE AID, location of Model 129 GF82.95-P-0001-01E

components
Model 140 except 140.063/07 GF82.95-P-0001-01A
Model 140.063/07 GF82.95-P-0001-01C
Models 202, 208.3 GF82.95-P-0001-01F
Model 210.2 GF82.95-P-0001-01D
Model 215 GF82.95-P-0001-01N
Model 220 GF82.95-P-0001-01G
TELE AID substitute  Transmission and
antenna, purpose reception of TELE AID
emergency signals if
reception via the
telephone antenna is
defective.
TELE AID substitute  Antenna tuned to upper
antenna, design MHz range
 Attached coaxial cable
TELE AID substitute  The signals received

antenna, function from the TELE AID
substitute antenna
(A2/50) are transmitted
to the emergency call
system control module
(TELE AID, A35/8) via
the co-axial cable.
TELE AID substitute antennas, location/task/design/function - GF82.95-P-4102P
MODEL 203
Fig. 220: Identifying Bumper (Model 203)
TELE AID substitute Models 208.3, 210 GF82.95-P-4102-01B

antennas, location
Model 215, 220 GF82.95-P-4102-01C
TELE AID substitute Transmission/reception of TELE
antennas, task AID emergency call signals
(emergency call/telediagnosis) if
reception of telephone antenna is
poor.
TELE AID substitute  Antenna tuned to upper
antennas, design MHz range
 Attached coaxial cable
TELE AID substitute The signals received by the TELE

antennas, function AID backup antenna (A2/50) are
relayed to the D2B telephone and
TELE AID transmitter/receiver
(A35/17) via the coaxial cable.
Spare TELE AID antenna location - GF82.95-P-4102-01C
Shown on model 215

Fig. 221: Identifying Bumper And Spare TELE AID Antenna
TELE AID substitute antennas, function - GF82.95-P-4102-04SX
In the event of condition restriction or destruction of telephone antenna (A2/22) (model 215) or telephone
antenna (A2/49a1) (model 220), the system uses the emergency call system left backup antenna (A2/54) and the
emergency call system right backup antenna (A2/55). The telecommunications control unit (N112) (with code
(383a) fixed installation telephone Tele-Aid) or the emergency call system control unit (N123/4) (with code
(359) TELE AID emergency call system) chooses and decides whether and which antenna is to be used for the
emergency call.
The signals received by the emergency call system left backup antenna (A2/54) and the emergency call system
right backup antenna (A2/55) are forwarded discretely via a coaxial cable to the telecommunications control
unit (N112) (with code (383a) fixed installation telephone Tele-Aid) or the emergency call system control unit
(N123/4) (with code (359) TELE AID emergency call system) and vice versa.
TELE AID substitute antennas, location/task/design/function - GF82.95-P-4102SX
Shown on model 215

Fig. 222: Identifying Emergency Call System Antenna Splitter And Emergency Call System Left Backup
Antenna
TELE AID substitute The emergency call

antennas, location system left backup
antenna (A2/54) and the
right backup antenna
(A2/55) are integrated in
the area of the vents in
the rear bumper.
TELE AID substitute Taking over the task of
antennas, task transmitting and
receiving for the
Telematic Alarm
Identification on Demand
(emergency call system)
(TELE AID) function in
the event of a failure (e.g.
rollover) of the telephone
antenna.
TELE AID substitute  Antenna tuned to
antennas, design upper MHz range
 Attached coaxial
cable
TELE AID substitute GF82.95-P-4102-04S
antennas, function
TELEDIAGNOSIS PUSHBUTTON SWITCH(ES), LOCATION/TASK - GF82.95-P-4105SX

Fig. 223: Identifying MB-Info And Breakdown Assistance Button Group (Model 215)
Telediagnosis pushbutton The MB-Info and

switch(es), location breakdown assistance
button group (S93/6) is
positioned in the left
stowage compartment of
the right front center
console.
Telediagnosis pushbutton The MB-Info and
switch(es), task breakdown assistance
button group (S93/6) can
be used to trigger the
roadside assistance call or
the MB information call
dependent upon the
operation direction.
Moreover, it indicates the
particular operating
condition to the driver via
the 2 light emitting
diodes (LED).
SOS SWITCH, LOCATION/TASK/DESIGN/FUNCTION - GF82.95-P-4107SX

Fig. 224: Identifying SOS Switch (Model 215)
SOS switch, location The SOS switch (S93/3s1) is

integrated into the overhead
control panel control unit
(N70).
SOS switch, task  Triggering a manual
TELE AID emergency
call
 Visual feedback signal
for the TELE AID
operating conditions
SOS switch, design  Integrated light emitting
diodes for night
illumination (circuit
58d) and to indicate the
operating condition
 Cap for protecting
against unintentional
actuation
 Control resistance that
is parallel to the switch
contact
SOS switch, function GF82.95-P-4107-04SX
SOS switch, function - GF82.95-P-4107-04SX
In park position, an electric current flows via the control resistance (parallel to the switch contact) installed in
the SOS switch (S93/3s1). This helps the emergency call system control unit (N123/4) (with code (359) TELE
AID emergency call system) or the telecommunications control unit (N112) (with code (383a) fixed installation
telephone Tele-Aid) to detect that the feed line and the ground line are OK. When pressing the SOS switch
(S93/3s1) the control resistance is bridged by a switch contact.
The SOS switch (S93/3s1) is read in by the emergency call system control unit (N123/4) (with code (359)
TELE AID emergency call system) or by the telecommunications control unit (N112) (with code (383a) fixed
installation telephone Tele-Aid) via a discrete line. The emergency call system control unit (N123/4) (with code
(359) TELE AID emergency call system) or the telecommunications control unit (N112) (with code (383a)
fixed installation telephone Tele-Aid) recognizes a manual emergency call when the SOS switch (S93/3s1) is
pressed and then transmits the call.
EMERGENCY CALL SYSTEM LOUDSPEAKER, LOCATION/TASK - GF82.95-P-4203
Emergency call system loudspeaker, location/task - GF82.95-P-4203A
MODEL 129, 202, 208.3, 210, 215, 220 up to 31.8.03 with CODE (347) TELE AID emergency call system
(D2B)
MODEL 210 with CODE (348) TELE AID emergency call system
MODEL 203, 208.3, 210, 215, 220 up to 31.8.03 with CODE (855) TELE AID
MODEL 202, 203, 210, 220 up to 31.8.03 with CODE (930) Taxi emergency call
MODEL 209.3 /4 with CODE (855) TELE AID
Location, shown on model 209

Fig. 225: Identifying Left/Right Front Emergency Call Speaker - Location, Shown On Model 209
Emergency call system Models 209.3/4

loudspeaker, location The emergency call
speakers are located in the
driver footwell next to the
foot-operated parking
brake covering and in the
front passenger footwell to
the right below the knee
bolster.
Model 129 GF82.95-P-4203-01A
Model 202 GF82.95-P-4203-01B
Model 208.3 GF82.95-P-4203-01C
Model 210 GF82.95-P-4203-01D
Models 203, 215, 220 GF82.95-P-4203-01E
Emergency call system Communication during a
loudspeaker, purpose TELE AID call
(emergency call,
telediagnosis call,
information call) takes
place via the speakers that
are allocated to the
system. The emergency
call system speakers are
necessary to guarantee the
voice output in cases of
emergency.
Emergency call system speaker, position - GF82.95-P-4203-01E
Shown on model 220

On model 203 the designation for the speaker is changed to
Fig. 226: Identifying Left/Right Emergency Call System Speaker - Shown On Model 220
Driver/front-passenger footwell
Emergency call system loudspeaker, location/purpose - GF82.95-P-4203SX
Fig. 227: Identifying Left Front Speaker And Right Front Speaker (Model 215.3)
Emergency call system The left front speaker

loudspeaker, location (H4/9) is located in the
footwell of the driver at
the lower branch-off to
the A-pillar. The right
front speaker (H4/10) is
located in the footwell of
the front passenger at the
lower branch-off to the
A-pillar.
Emergency call system The communication in
loudspeaker, purpose the event of a TELE AID
call (emergency call,
telediagnosis, MB
information call) takes
place via the left front
speaker (H4/9) and the
right front speaker
(H4/10). This is necessary
to ensure the voice output
in case of emergency.
ADDITIONAL BATTERY, LOCATION/TASK - GF82.95-P-4204P
MODEL 203, 210, 220 up to 31.8.03 with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODEL 208.3, 215 up to 31.8.03 with CODE (855) TELE AID
Location on Model 203
Fig. 228: Identifying D2B Telephone And TELE AID Transmitter/Receiver (Model 203) - Location On
Model 203
Additional battery, For models 203, 209.3/4 the

location additional battery is integrated
in the D2B telephone and
TELE AID
Model 208.3 GF82.95-P-4204-01A
Model 210 GF82.95-P-4204-01B
Model 215, 220 GF82.95-P-4204-01C
Additional battery, Maintaining the voltage
purpose supply. If the power supply to
the vehicle battery is
interrupted because of an
accident, the power supply is
maintained for a limited
period of time by the
additional battery.
Additional battery position - GF82.95-P-4204-01C
Fig. 229: Identifying CTEL And TELE AID Transmitter/Receiver Unit, D2B
Below right rear seat.
ROLLOVER SENSOR, LOCATION/TASK - GF82.95-P-4206P
MODEL 203, 210, 220 up to 31.8.03 with CODE (855) TELE AID with CODE (930) Taxi emergency call
MODEL 208.3, 215 up to 31.8.03 with CODE (855) TELE AID
Location on model 203

Fig. 230: Identifying D2B Telephone And TELE AID Transmitter/Receiver - Location On Model 203
Overturning sensor location - GF82.95-P-4206-01C
Fig. 231: Identifying CTEL And TELE AID Transmitter/Receiver Unit, D2B And Overturning Sensor
TRANSMITTER/RECEIVER UNIT, LOCATION/TASK/DESIGN/FUNCTION - GF82.95-P-4300A
MODEL 203.0 /2, 210, 220 up to 31.8.03 with CODE (853) MB standard cellular telephone with CODE
(855) TELE AID with CODE (930) Taxi emergency call
MODEL 203.7, 208.3, 215 up to 31.8.03, 209.3 /4 with CODE (853) MB standard cellular telephone with
CODE (855) TELE AID
Shown on model 203

Fig. 232: Identifying D2B Telephone And TELE AID Transmitter/Receiver - Shown On Model 203
Transmitter/receiver, Model 203

location The telephone transmitter/receiver
and TELE AID, D2B (A35/17) is
located under a cover on the
luggage compartment floor.
Models 208.3, 209.3/4 with code GF82.95-P-4300-
853, 855 01A
Model 210 with codes 855, 930 GF82.95-P-4300-
01B
Models 215, 220 GF82.95-P-4300-
01C
Transmitter/receiver unit,  Control unit of fixed
purpose installation telephone
 Central control of TELE
AID emergency call and
taxi call for help (with code
930 only)
 Control of TELE AID
telediagnosis and an
information call
 Acceptance of SIM card
Transmitter/receiver, design  Integral telephone
transmitter/receiver unit
 Integrated GPS components
 Integrated additional battery
Integrated interface (D2B
bus)
Transmitter/receiver, Central processing of all the data
function required for a TELE AID
emergency call (with code 930 in
addition the data of a taxi call for
help). Preparation of data required
to calculate the vehicle position
and to generate an emergency call
telegram.
Transmitter/receiver unit location - GF82.95-P-4300-01C
Fig. 233: Identifying CTEL And TELE AID Transmitter/Receiver Unit, D2B
Below right rear seat
OVERVIEW OF SYSTEM COMPONENTS, TELE AID EMERGENCY CALL SYSTEM,

LOCATION/TASK/DESIGN/FUNCTION - GF82.95-P-9999
Overview of system components, TELE AID emergency call system, location/task/design/function - GF82.95-P-9999SX
version
TELE AID control GF82.95-P-

unit/task/design/function 4100SX
SOS switch, location/task/design/function GF82.95-P-
4107SX
Telediagnosis pushbutton switch(es), GF82.95-P-
location/task 4105SX
ELE AID substitute antennas, GF82.95-P-
Emergency call system loudspeaker, GF82.95-P-
location/purpose 4203SX
Contents, function description of TELE GF82.95-P-
AID 0999SX
Overview of system components, TELE AID emergency call system, location/task/design/function - GF82.95-P-9999SZ
version
SOS switch, location/task/design/function GF82.95-P-

4107SX
Telediagnosis pushbutton switch(es), GF82.95-P-
location/task 4105SX
TELE AID substitute antennas, GF82.95-P-
Emergency call system loudspeaker, GF82.95-P-
location/purpose 4203SX
Telecommunications control unit, GF82.70-P-
location/task/design/function 3114SU
Contents, function description of TELE GF82.95-P-0999SZ
AID
Electrical System - Testing & Repair - Body - 215 & 220 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM BODY - AR82.00-Z-
9215AA
MODEL 215
Remove/install front axle level MODEL 215 MODEL AR82.10-P-0004I

sensors 220
Remove/install rear axle level MODEL 215 MODEL AR82.10-P-0005N
sensor 220 with CODE (487)
Active Body Control
(ABC)
Removing and installing fog MODEL 129 as of AR82.10-P-1821C
lamp lens 1.9.95, 170, 208, 215
Remove/install daylight sensor Models 215, 220 AR82.10-P-2400I
headlamp range control CODE (612b) Xenon
module headlamps
Remove/install xenon MODEL 215, 220 with AR82.10-P-4632N
headlamp control unit CODE (612) Xenon
headlamp unit
Remove/install lamp unit MODEL 215 AR82.10-P-4730N
Adjust headlamps MODEL 164, 169, 171, AR82.10-P-4735A
203, 209, 211, 215, 216,
219, 220, 221, 230, 245,
251 ...
Removing and installing MODEL 215, 220 AR82.10-P-4905M
taillamp
Removing and installing fog MODEL 215 AR82.10-P-5103N
lamp
Remove/install license plate Models 215, 220 AR82.10-P-5161M
lamp
Removing and installing MODEL 215 with AR82.15-P-6100N
telescoping nozzle for CODE (600a)
headlamp cleaning system Headlamp cleaning
system
overhead control panel control
module
auxiliary turn signal lamp
Check wiper arms and adjust MODELS 211, 215, AR82.30-P-6000T
220, 230, 240
Removing and installing wiper MODEL 220, 215 AR82.30-P-6100M
arm
system
motor
Remove/install rain sensor MODELS 220, 215 AR82.30-P-7700M
washing water reservoir
windshield washer nozzles
Removing and installing radio MODEL 215 ... AR82.60-P-7502N
Remove/install audio gateway MODELS AR82.60-P-7606M
control unit 220.0## /1##, 215.3##
1# as of 1.9.03 Vehicles
with MOST fiber
optical cable
Removing and installing rear MODEL 215, 220 AR82.62-P-7385I
window noise suppression
capacitor
Removing and installing MODEL 215, 220 with AR82.62-P-7700I
microphone CODE (810) Sound
system Interior
microphone for sound
amplifier
Removing and installing MODELS 215, 220 AR82.62-P-7720I
amplifier (left/right speakers) with CODE (810)
control module Sound system
Removing and installing MODEL 215 AR82.62-P-7833N
loudspeakers in instrument
panel
loudspeakers in the rear shelf
loudspeakers in front doors
Removing and installing MODEL 215, 220 ... AR82.62-P-7853M
speaker in front footwell
Removing and installing MODEL 215, 220 with AR82.62-P-8000MA
Keyless Go antenna CODE (889) Keyless
Go in front door
Removing and installing MODEL 215, 220 with AR82.62-P-8000MC
Go in bumper
Removing and installing MODEL 215, 220 with AR82.62-P-8000MD
Go in trunk
Remove/install antenna MODEL 215, 220 AR82.62-P-8300I
amplifier module
Remove/install CD player MODELS 215.3, AR82.64-P-7507I
with changer 220.0 /1 up to 31.8.02
with CODE (819) 6-
disc CD changer
Remove/install CD player MODEL 215, 220 ... AR82.64-P-7507MN
with changer
Removing and installing voice MODEL 215, 220 ... AR82.70-P-0003I
control system control module
Removing and installing voice MODEL 215, 220 ... AR82.70-P-0003M
control system control module
Removing and installing fiber MODEL 215, 220 AR82.70-P-0004MA
optic cable Between COMAND or
radio/left side of trunk
Removing and installing fiber MODEL 215, 220 AR82.70-P-0004MB
optic cable Between left side of
trunk/right rear seat
Removing and installing fiber MODEL 215, 220 AR82.70-P-0004MC
optic cable Between COMAND or
radio/right rear seat
Removing and installing fiber MODEL 215, 220 AR82.70-P-0004MD
optic cable Between trunk control
modules
Removing and installing fiber MODEL 215, 220 AR82.70-P-0004ME
optic cable Between control
modules right rear seat
Removing and installing GSM MODEL 215 as of AR82.70-P-0010AD
1800 MHz network 1.7.00 with CODE
compensator (854) MB cellular
telephone
Removing and installing MODEL 215, 220 up to AR82.70-P-7379I
cellular telephone interface 30.6.00 with CODE
(316) MB GSM cellular
telephone (D2B)
transmitter/receiver unit 30.6.00 with CODE
telephone (D2B)
Removing and installing MODEL 215, 220 as of AR82.70-P-8911M
transmitter/receiver unit 1.7.00 with CODE
(853) MB standard
cellular telephone
Removing and installing MODEL 215, 220 up to AR82.70-P-8912M
handset 30.6.00 with CODE
telephone (D2B) in
center arm rest
Remove and install bracket for MODEL 215, 220 ... AR82.70-P-8918M
portable CTEL
Removing and installing MODEL 215, 220 ... AR82.70-P-8920I
vehicle interface (cellular
telephone)
Remove/install antenna MODEL 215, 220 with AR82.70-P-8951N
CODE (348) TELE
AID emergency call
system TELE AID
backup antenna in
bumper
Remove/install antenna MODEL 215 Telephone AR82.70-P-8951N
or GPS antenna in trunk
lid
hands-free system microphone
Removing and installing MODEL 215 with AR82.85-P-7472N
COMAND operating, display CODE (352a)
and control module COMAND operating
and display system
TELE AID emergency call CODE (348) TELE
system pushbutton switch AID emergency call
system
TELE AID emergency call CODE (347) TELE
system control module AID emergency call
system (D2B)
Removing and installing MODEL 215, 220 as of AR82.95-P-0005MA
TELE AID emergency call 1.7.00 with CODE
system control module (855) TELE AID
Removing and installing MODEL 215, 220 as of AR82.95-P-0013A
tilting cone sensor 1.7.00 with CODE
(855) TELE AID
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM BODY - AR82.00-Z-
9220AA
MODEL 220
Remove/install front axle MODEL 215 MODEL 220 AR82.10-P-0004I

level sensors
Remove/install rear axle MODEL 220 except CODE AR82.10-P-0005I
level sensor (487) Active Body Control
(ABC)
Remove/install rear axle MODEL 215 MODEL 220 AR82.10-P-0005N
level sensor with CODE (487) Active
Body Control (ABC)
Remove/install lamp lens MODEL 220 AR82.10-P-1820M
Remove/install daylight Models 215, 220 AR82.10-P-2400I
sensor
headlamp range control CODE (612b) Xenon
module headlamps
Remove/install xenon MODEL 215, 220 with AR82.10-P-4632N
headlamp control unit CODE (612) Xenon
headlamp unit
Remove/install headlamp MODEL 220 except CODE AR82.10-P-4730M
unit (612b) Xenon headlamp unit
except CODE (614) Bi-
xenon headlamp unit
Remove/install lamp unit MODEL 220 with CODE AR82.10-P-4730MA
(612) Xenon headlamp unit
with CODE (614) Bi-xenon
headlamp unit
Adjust headlamps MODEL 164, 169, 171, AR82.10-P-4735A
203, 209, 211, 215, 216,
219, 220, 221, 230, 245,
251 ...
taillamp
Remove/install license plate Models 215, 220 AR82.10-P-5161M
lamp
Remove/install center high- MODEL 220 AR82.10-P-5375M
mounted stop lamp
Remove, install telescopic MODEL 220 with CODE AR82.15-P-6100M
nozzle of headlamp cleaning (600a) Headlamp cleaning
system system
Removing and installing rear MODEL 220 AR82.20-P-0113M
dome lamp
Remove/install rear dome MODEL 220 ... AR82.20-P-0113MC
lamp
overhead control panel
control module
auxiliary turn signal lamp
Check wiper arms and adjust MODELS 211, 215, 220, AR82.30-P-6000T
230, 240
wiper arm
wiper system
wiper motor
Remove/install rain sensor MODELS 220, 215 AR82.30-P-7700M
windshield washer nozzles
Remove/install radio MODEL 220 ... AR82.60-P-7502I
Remove/install media MODEL 220.875 /878 with AR82.60-P-7511M
console CODE(P002) media console
Remove/install monitor MODEL 220.875 /878 with AR82.60-P-7512MP
CODE(P003) Video system
Remove/install carrier plate MODEL 220.875 /878 with AR82.60-P-7601MP
for Audio components CODE(P005) Audio system
(High End)
Remove/install carrier plate MODEL 220.875 /878 with AR82.60-P-7602MP
for TV components CODE(P005) Audio system
(High End)
Remove/install audio MODELS 220.0## /1##, AR82.60-P-7606M
gateway control unit 215.3## 1# as of 1.9.03
Vehicles with MOST fiber
optical cable
Removing and installing MODEL 220.875 /878 with AR82.60-P-7710MP
equalizer code (P005) Audio system
(High End)
Removing and installing rear MODEL 215, 220 AR82.62-P-7385I
window noise suppression
capacitor
microphone CODE (810) Sound system
Interior microphone for
sound amplifier
Removing and installing MODEL 220.875 /878 AR82.62-P-7700MP
microphone Intercom microphone/sound
amplifier
microphone/hands-free
system microphone
Removing and installing MODELS 215, 220 with AR82.62-P-7720I
amplifier (left/right CODE (810) Sound system
speakers) control module
loudspeaker amplifier code (P005) Audio system
control module (High End)
Removing and installing MODEL 220.875 /878 with AR82.62-P-7720MQ
loudspeaker amplifier code 810 (front sound
control module system)
Removing and installing MODEL 220.875 /878 with AR82.62-P-7720MR
loudspeaker amplifier standard equipment and
control module code P001 (High-End radio
in rear)
Removing and installing MODEL 220 AR82.62-P-7833I
loudspeakers in instrument
panel
loudspeakers in the rear
shelf
Removing and installing MODELS 220.875 /878 AR82.62-P-7840MP
loudspeaker in rear center
loudspeakers in front doors
speaker in front footwell
Removing and installing MODELS 220.875 /878 AR82.62-P-7854MP
loudspeaker in rear footwell
Remove/install loudspeakers MODEL 220 AR82.62-P-7874I
in rear doors
Removing and installing MODEL 215, 220 with AR82.62-P-8000MA
Keyless Go antenna CODE (889) Keyless Go in
front door
Removing and installing MODEL 220 ... AR82.62-P-8000MB
keyless go antenna
Removing and installing MODEL 215, 220 with AR82.62-P-8000MC
bumper
Removing and installing MODEL 215, 220 with AR82.62-P-8000MD
trunk
keyless go antenna CODE (889) Keyless go to
center door
Removing and installing MODEL 220.875 /878 TV AR82.62-P-8106MP
bumper antenna antenna in front bumper,
with code P004 (TV tuner
package)
Removing and installing MODEL 220 ... AR82.62-P-8106MPA
bumper antenna
Remove/install antenna MODEL 215, 220 AR82.62-P-8300I
amplifier module
Remove/install CD player MODELS 215.3, 220.0 /1 AR82.64-P-7507I
with changer up to 31.8.02 with CODE
(819) 6-disc CD changer
Remove/install CD player MODEL 215, 220 ... AR82.64-P-7507MN
with changer
Removing and installing CD MODEL 220.875 /878 with AR82.64-P-7507MP
player with changer CODE (819) CD changer
with 6 CD's
voice control system control
module
voice control system control
module
Removing and installing MODEL 215, 220 Between AR82.70-P-0004MA
fiber optic cable COMAND or radio/left side
of trunk
Removing and installing MODEL 215, 220 Between AR82.70-P-0004MB
fiber optic cable left side of trunk/right rear
seat
Removing and installing MODEL 215, 220 Between AR82.70-P-0004MC
fiber optic cable COMAND or radio/right
rear seat
Removing and installing MODEL 215, 220 Between AR82.70-P-0004MD
fiber optic cable trunk control modules
Removing and installing MODEL 215, 220 Between AR82.70-P-0004ME
fiber optic cable control modules right rear
seat
Removing and installing MODEL 220 as of 1.7.00 AR82.70-P-0010AE
GSM 1800 MHz network with CODE (854) MB
compensator cellular telephone
cellular telephone interface 30.6.00 with CODE (316)
MB GSM cellular telephone
(D2B)
transmitter/receiver unit 30.6.00 with CODE (316)
(D2B)
Removing and installing MODEL 215, 220 as of AR82.70-P-8911M
transmitter/receiver unit 1.7.00 with CODE (853)
MB standard cellular
telephone
Removing and installing MODEL 220 ... AR82.70-P-8911MP
Removing and installing MODEL 215, 220 up to AR82.70-P-8912M
handset 30.6.00 with CODE (316)
(D2B) in center arm rest
Removing and installing MODEL 220 as of 1.7.00 AR82.70-P-8915M
handset in stowage with CODE (853) MB
compartment armrest or standard cellular telephone
stowage compartment
Remove and install bracket MODEL 215, 220 ... AR82.70-P-8918M
for portable CTEL
vehicle interface (cellular
telephone)
Remove/install antenna MODEL 220 AR82.70-P-8951I
Telephone/GPS antenna on
rear window
Remove/install antenna MODEL 215, 220 with AR82.70-P-8951N
CODE (348) TELE AID
TELE AID backup antenna
in bumper
hands-free system
microphone
Remove and install MODEL 220 as of 1.9.02 AR82.85-P-1000M
COMAND operating,
display and control module
Removing and installing TV MODEL 220 ... AR82.85-P-7366MP
tuner
Removing and installing TV MODEL 220.875 /878 with AR82.85-P-7366MPA
tuner CODE (352a) COMAND
operating and display
system TV tuner for
COMAND
Remove/install operating / MODEL 220 up to 31.8.02 AR82.85-P-7472I
display unit with control unit with CODE (352a)
COMAND operating and
display system
intercom control module code P010 (intercom)
TELE AID emergency call CODE (348) TELE AID
system pushbutton switch emergency call system
TELE AID emergency call CODE (347) TELE AID
system control module emergency call system
(D2B)
Removing and installing MODEL 215, 220 as of AR82.95-P-0005MA
TELE AID emergency call 1.7.00 with CODE (855)
system control module TELE AID
Removing and installing MODEL 202, 210, 220 ... AR82.95-P-0006A
service and breakdown
assistance, emergency call
pushbutton group
Authorization for TELE AID MODEL 129, 140, 170, AR82.95-P-0011A
202, 208, 210, 220 with
SIM card from debitel for
D1 GSM network
Carry out authorization for MODELS 129, 140, 170, AR82.95-P-0011B
TELE AID 202, 208, 210, 220 with
SIM card for the D2 GSM
network
Authorization for taxi MODEL 140, 202, 210, AR82.95-P-0012A
emergency call 220 ...
Removing and installing MODEL 215, 220 as of AR82.95-P-0013A
tilting cone sensor 1.7.00 with CODE (855)
TELE AID
REMOVE/INSTALL FRONT AXLE LEVEL SENSORS - AR82.10-P-0004I
MODEL 215
MODEL 220
Shown on model 220 AIRmatic

Fig. 1: Identifying Front Axle Level Sensors Remove/Install Components (Model 220 AIRmatic)
Remove/Install
Replace self-locking nuts
and bolts
1.1 Remove front wheels Vehicles with AIRmatic AP40.10-P-4050Z
(Code 489a)
2 Disconnect connectors at
front left and right level
sensors (B22/8, B22/9)
3 Unscrew nut (86c) on *BA82.10-P-1002-01A
connecting rod (86) from
front left and right level
sensors (B22/8, B22/9)
4.1 Unscrew nut (86b) on Vehicles with AIRmatic
connecting rod (86) from (Code 489a)
upper wishbone (6) and Installation: Attach
remove connecting rod connecting rod (86) to
(86) the outermost hole (f) on
the upper wishbone (6)
*BA82.10-P-1001-01A
5 Unscrew bolts (86d) on *BA82.10-P-1003-01A
retaining plate (86a) and
remove front left and right
level sensors (B22/8,
B22/9)
7 After replacing the level
sensors, calibrate vehicle
level with Star Diagnosis
(level calibration)
FRONT AXLE LEVEL SENSOR

BA82.10-P-1001- Nut, level sensor Nm 10 10
01A connecting rod to
upper wishbone
BA82.10-P-1002- Nut, connecting rod Nm 5 5
01A to level sensor
BA82.10-P-1003- Bolt/nut of level Nm 4 4
01A sensor to retaining
plate
REMOVE/INSTALL REAR AXLE LEVEL SENSOR - AR82.10-P-0005
Remove/install rear axle level sensor - AR82.10-P-0005I
MODEL 220 except CODE (487) Active Body Control (ABC)
Fig. 2: Identifying Rear Axle Level Sensor Remove/Install Components (Model 220)
Remove/install
and bolts
1 Disconnect plug from rear
axle level sensor (B22/3)
2 Unscrew nut (85e) of *BA82.10-P-1001-02A
control rod (85) from
stabilizer bar intermediate
lever (81)
3 Unscrew nut (85d) of Do not separate
control rod (85) at level control rod (85) or
sensor (B22/3) and change the adjustment
remove control rod (85)
*BA82.10-P-1002-02A
4 Unscrew bolts (85c) of *BA82.10-P-1003-02A
retaining plate (85a) at
level sensor (B22/3) and
remove level sensor
(B22/3)
6 Calibrate vehicle level
using Star Diagnosis after
replacing the level sensor
REAR AXLE LEVEL SENSOR

Number Designation Model 220 except model
220 with code 487
BA82.10-P-1001-02A Nut, lever sensor control Nm 10
rod to torsion bar link
BA82.10-P-1002-02A Nut, control rod to level Nm 5
sensor
BA82.10-P-1003-02A Bolt, level sensor to Nm 4
retaining plate
BA82.10-P-1004-02A Nut, retaining plate to Nm 8
frame floor
Remove/install rear axle level sensor - AR82.10-P-0005N
MODEL 215
MODEL 220 with CODE (487) Active Body Control (ABC)

Fig. 3: Identifying Rear Level Sensor, Spring Control Arm And Bracket
Remove/install
and bolts
1 Disconnect connector
(arrow) on left, right rear
level sensor (B22/7,
B22/10)
2 Unscrew nut (85e) of link
rod at left, right rear level
sensor (B22/7, B22/10)
3 Unscrew bolts (85c) and Installation: Note
remove level sensor installation position of
link rod!
*BA82.10-P-1003-02A
5 Calibrate vehicle level
using Star Diagnosis
(level calibration) after
replacing level sensors
REAR AXLE LEVEL SENSOR

code 487 code 487
BA82.10-P-1003- Bolt, level sensor to Nm 44
02A retaining plate
REMOVE/INSTALL LAMP LENS - AR82.10-P-1820M
MODEL 220
Fig. 4: Identifying Lamp Lens Remove/Install Components
Remove, Install
1 Remove/install headlamp AR82.10-P-4730M
unit
2 Lift catch (2) on Installation: Check
headlamp assembly left, seal (3). Lens (1) must be
right (E1, E2) and heard to latch into all
remove lens (1) catches
order
REMOVING AND INSTALLING FOG LAMP LENS - AR82.10-P-1821C
MODEL 129 as of 1.9.95, 170, 208, 215

Fig. 5: Identifying Fog Lamp Lens Remove/Install Components
Fig. item, etc. Procedure

Removing and installing Model 129 AR82.10-P-5103G
fog lamp
Model 170 AR82.10-P-5103C
Model 208 AR82.10-P-5103D
Model 215 AR82.10-P-5103N
1 Retaining clips
2 Lens
3 Gasket Check for damage,
replace, if necessary.
Ensure that gasket is
seated properly.
REMOVE/INSTALL DAYLIGHT SENSOR - AR82.10-P-2400I
Models 215, 220
Shown on model 220

Fig. 6: Identifying Daylight Sensor Remove/Install Components (Shown On Model 220)
MODIFICATION NOTES
11.4.03 Disconnecting ground Step 1
lead from battery newly
included
Remove/Install
1 Disconnect ground cable AR54.10-P-0003I
of battery
2 Remove overhead control AR82.20-P-1000M
panel control unit
3 Unclip covering (1)
4 Unclip covering (2)
5 Release clips (4) on left
and right
6 Remove automatic light Lens of automatic
switch daylight sensor light switch daylight
(B32/1) sensor (B32/1) is bonded
to the windshield.
Do not replace
7 Unplug electrical
connector (3) from
automatic light switch
daylight sensor (B32/1)
REMOVING AND INSTALLING HEADLAMP RANGE CONTROL MODULE - AR82.10-P-4081M
MODEL 215, 220 with CODE (612b) Xenon headlamps
Fig. 7: Identifying Headlamp Range Control Module Remove/Install Components (Model 220)
retention unit
from battery
3 Fold back floor covering
in passenger footwell and
remove Styrofoam panel
4 Remove mounting plate Grip mounting plate at
(1) in passenger footwell top and fold down into
and fold down into footwell
footwell
5 Release catch and
disconnect connector (2)
remove headlamp range
adjustment control
module (N71) from
mounting plate
REMOVE/INSTALL XENON HEADLAMP CONTROL UNIT - AR82.10-P-4632N
MODEL 215, 220 with CODE (612) Xenon headlamp unit
Shows model 215
Fig. 8: Identifying Xenon Headlamp Control Unit Remove/Install Components (Shows Model 215)
Remove/install
Risk of death caused by Do not come into contact AS15.10-Z-0001-01A
touching parts which with parts that are under
conduct high voltages high voltage. Persons
who have electronic
implants (e.g.
pacemakers) must not
perform any work on the
ignition system.
Risk of death caused by Do not come into contact AS82.10-Z-0001-01A
high voltage levels with parts that are under
present at xenon high voltage. Persons
headlamps. with active electronic
Risk of explosion/fire implants (e.g. heart
hazard through highly pacemakers) must never
flammable material in the work on xenon
area of damaged xenon headlamps. Switch off
bulbs. complete lighting system.
Risk of injury through Wear insulating safety
UV light, hot components shoes, safety glasses and
on xenon headlamps and protective gloves.
glass splinters when Remove highly
xenon bulbs burst. inflammable materials
Risk of poisoning from the hazard area.
through inhalation of Ensure that the
mercury vapor and workplace is sufficiently
swallowing of or skin ventilated.
contact with toxic salts
and mercury compounds.
1 Remove/install lamp unit Model 215 AR82.10-P-4730N
Model 220 AR82.10-P-4730MA
2 Remove screws (1) and
bracket (2)
3 Unclip xenon headlamp
control unit (E1n1, E2n1)
from headlamp
5 Perform a function test
REMOVE/INSTALL LAMP UNIT - AR82.10-P-4730
Remove/install headlamp unit - AR82.10-P-4730M
MODEL 220 except CODE (612b) Xenon headlamp unit except CODE (614) Bi-xenon headlamp unit
Fig. 9: Identifying Headlamp Unit Remove/Install Components
Remove/Install
1 Open engine hood and AR88.40-P-1000M
move to upright position
3 Unclip electrical
connection (3) and remove
4 Remove left front lamp Protect against paint
unit (E1), right front lamp damage on bumper and
unit (E2) fender.
Fold fastening shackle
(4) of bumper forward
slightly (arrow) and
remove left front lamp
unit (E1), right front
lamp unit (E2) towards
vehicle center.
that the ball head (5) on
the housing of the left
front lamp unit (E1),
right front lamp unit (E2)
is seated in its mount.
Check
6 Check settings of
headlamps, correct if
necessary
Check and correct AP82.10-P-8260M
headlamp setting
Remove/install lamp unit - AR82.10-P-4730MA
MODEL 220 with CODE (612) Xenon headlamp unit with CODE (614) Bi-xenon headlamp unit
Fig. 10: Identifying Lamp Unit Remove/Install Components (Model 220)
Remove/install
Risk of death Do not come into contact with parts that are under high voltage. Persons who have
caused by touching electronic implants (e.g. pacemakers) must not perform any work on the ignition
parts which system.
conduct high
voltages
Risk of death Do not come into contact with parts that are under high voltage. Persons with active
caused by high electronic implants (e.g. heart pacemakers) must never work on xenon headlamps.
voltage levels Switch off entire lighting system. Wear insulating safety shoes, safety glasses, and
present at xenon protective gloves. Remove highly inflammable materials from the hazard area. Ensu
headlamps. that the working area is sufficiently ventilated.
Risk of
explosion/fire due
to highly
flammable
materials in the
area of damaged
xenon bulbs
Risk of injury
caused by UV
light, hot
components on
xenon headlamps
and glass splinters
when xenon bulbs
are bursting
Risk of poisoning
due to inhaling
mercury vapors
and when
swallowing/coming
in contact with
toxic salts and
mercury
compounds
1 Open engine hood
and move to
vertical position
2 Remove front
bumper
Model 220 except model
220.025/026/028/063/065/070/073/075/125/128/165/170/173/175/176/178/179/875
Model
220.025/026/028/063/065/070/073/075/125/128/165/170/173/175/176/178/179/875
3 Remove bolts (1,
2)
4 Remove left front Installation: Ensure that the ball head at the housing of the left front lamp unit (
lamp unit (E1) and and right front lamp unit (E2) is seated in its mount
right front lamp
unit (E2) in
direction of the
vehicle center
5 Unclip electrical
connections
(illumination and
headlamp range
adjustment) and
remove
6 Install in the
reverse order
Checking
7 Adjust the zero
position of the
xenon headlamps
Connect STAR
DIAGNOSIS
STAR DIAGNOSIS diagnosis system
8 Check the setting

of the headlamps
and adjust if
necessary
Check and correct
headlamp
adjustment

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS Compact 6511 1801 00
diagnosis system for passenger
cars
Remove/install lamp unit - AR82.10-P-4730N
MODEL 215
Fig. 11: Identifying Lamp Unit Remove/Install Components (Model 215)
Remove/install
Risk of death caused by Do not come into AS15.10-Z-0001-01A
touching parts which conduct contact with parts that
high voltages are under high voltage.
Persons who have
electronic implants (e.g.
pacemakers) must not
perform any work on
the ignition system.
Risk of death caused by high Do not come into AS82.10-Z-0001-01A
voltage levels present at xenon contact with parts that
headlamps. are under high voltage.
Risk of explosion/fire due to Persons with active
highly flammable materials in electronic implants
the area of damaged xenon (e.g. heart pacemakers)
bulbs must never work on
Risk of injury caused by UV xenon headlamps.
light, hot components on Switch off entire
xenon headlamps and glass lighting system. Wear
splinters when xenon bulbs are insulating safety shoes,
bursting safety glasses, and
Risk of poisoning due to protective gloves.
inhaling mercury vapors and Remove highly
when swallowing/coming in inflammable materials
contact with toxic salts and from the hazard area.
mercury compounds Ensure that the working
area is sufficiently
ventilated.
1 Open engine hood and move AR88.40-P-1000M
to vertical position
2 Remove front bumper AR88.20-P-2000M
4 Remove left lamp unit (E1) in Installation: Ensure
direction of vehicle center that the ball head (4) on
the lamp unit's housing
is seated in its mount
5 Unclip electrical connections Connection (3c) to front
(3a, 3b) and remove fog lamp does not have
to be removed
Checking
7 Check and correct headlamp AP82.10-P-8260M
adjustment
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 high Do not come into AS82.10-Z-0001-01A
voltage levels present at xenon contact with parts that
headlamps. are under high voltage.
Risk of explosion/fire due to Persons with active
highly flammable materials in electronic implants
the area of damaged xenon (e.g. heart pacemakers)
bulbs must never work on
Risk of injury caused by UV xenon headlamps.
light, hot components on Switch off entire
xenon headlamps and glass lighting system. Wear
splinters when xenon bulbs are insulating safety shoes,
bursting safety glasses, and
Risk of poisoning due to protective gloves.
inhaling mercury vapors and Remove highly
when swallowing/coming in inflammable materials
contact with toxic salts and from the hazard area.
mercury compounds Ensure that the working
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-4905M
MODEL 215, 220
Fig. 12: Identifying Taillamp Remove/Install Components (Model 215, 220)
1 Open flap (1) to change
bulb
2 Unclip connector (2) and
pull off
3 Unscrew nuts (3) Carefully open flap (1)
and unscrew nut (3a)
4 Remove left/right Installation: Check
taillamp (E3/E4) gasket on taillamp for
damage. Ensure that
gasket is properly seated
REMOVING AND INSTALLING FOG LAMP - AR82.10-P-5103N
MODEL 215
Fig. 13: Identifying Fog Lamp Remove/Install Components (Model 215)
1 Remove engine AR61.20-P-1105M
connector (3) and remove
4 Remove fog lamp (E5/1,
E5/2)
6 Adjust fog lamp and AP82.10-P-8260-04A
check
REMOVE/INSTALL LICENSE PLATE LAMP - AR82.10-P-5161M
Models 215, 220

Fig. 14: Identifying License Plate Lamp Remove/Install Components (Models 215, 220)
Remove, Install
1 Remove inner paneling See ?
(1) on trunk lid
Remove/install trunk lid AR88.50-P-5000M
2 Remove license plate
3 Remove cover (2) on
trunk lid
4 Remove screws (3) and Installation: ensure
pull lens out of license that the seals are seated
plate lamp (E19/1, E19/2) correctly.
on the trunk lid
5 Unplug electrical
connector on license plate
lamp (E19/1, E19/2)
6 Remove license plate
lamp (E19/1, E19/2)
order
REMOVE/INSTALL CENTER HIGH-MOUNTED STOP LAMP - AR82.10-P-5375M
MODEL 220
Fig. 15: Identifying Center High-Mounted Stop Lamp Remove/Install Components
Remove, Install
1 Use a plastic wedge to Pay attention to
lever out cover (2) on cleanliness
rear shelf (1)
1 Fig. 16
2 Detach connector for
center high-mounted stop
lamp (X20/1)
3 Push out center high-
mounted stop lamp (E21)
from covering (2) in
direction of arrow
order
Fig. 16: Identifying Assembly Wedge(110 589 03 59 00)

REMOVE, INSTALL TELESCOPIC NOZZLE OF HEADLAMP CLEANING SYSTEM - AR82.15-P-
6100
Remove, install telescopic nozzle of headlamp cleaning system - AR82.15-P-6100M
MODEL 220 with CODE (600a) Headlamp cleaning system
Fig. 17: Identifying Telescopic Nozzle Of Headlamp Cleaning System Remove/Install Components
MODIFICATION NOTES
29.11.00 Removing headlamp Step 1
deleted
30.11.00 Operation sequence
changed
Remove/install
compartment lining
2 Clamp off washing water Fig. 18
hose (6) with clamp
3 Pivot telescoping nozzle
cover (1) toward front
4 Pull out nozzle (2) until
stop is reached
5 Slightly lift retaining lug Do not lift retaining
(2a) on nozzle (2) with lug too far upward,
suitable tool and remove danger of breaking.
nozzle (2) from
telescoping unit (3)
6 Unscrew nut (4) from Fig. 19
telescoping unit (3)
7 Remove retaining clips
(6) and remove washing
water hose (5) from pop-
up mechanism (3)
8 Unscrew the bolts (7).
9 Pull out pop-up
mechanism (3) downward
11 Check fluid level of
windshield washer system
and correct if necessary
AP82.35-P-8210Z
12 Carry out operational
check
Fig. 18: Identifying Clamp(000 589 40 37 00)
Fig. 19: Identifying Puller(220 589 00 07 00)
Removing and installing telescoping nozzle for headlamp cleaning system - AR82.15-P-6100N

Fig. 20: Identifying Telescoping Nozzle For Headlamp Cleaning System Remove/Install Components
(Model 215)
1 Fold telescoping nozzle
(1) cover toward front
2 Unscrew screws (2) from
telescoping element
mount (3)
3 Remove engine AR61.20-P-1105M
4 Disconnect washing Fig. 18
water hose (4) with clamp
5 Pull off retaining clamp
(5) and remove washing
water hose (4) from
telescoping element
mount (3)
6 Unscrew screw (7) For removing left
telescoping nozzle: ?
Remove fog lamp AR82.10-P-5103N
7 Pull telescoping unit (6)
downward and out
9 Check water level in AP82.35-P-8210Z
headlamp cleaning
system, correct
Fig. 21: Identifying Clamp(000 589 40 37 00)
REMOVE/INSTALL REAR DOME LAMP - AR82.20-P-0113
Removing and installing rear dome lamp - AR82.20-P-0113M
MODEL 220
Fig. 22: Identifying Rear Dome Lamp Remove/Install Components
1 Remove lens (1) on Pay attention to
left/right rear dome lamp cleanliness
(E15/10, E15/11)
2 Pry left/right rear dome Use clean plastic wedge
lamp (E15/10, E15/11) to pry out
out of metal frame (3) in Ensure that plastic
area of clips (2) with wedge is inserted
plastic wedge and swing between left/right rear
downward in direction of dome lamp (E15/10,
arrow. E15/11) and metal frame
(3) and not between sheet
metal frame (3) and
headliner
Fig. 16
3 Disconnect dome lamp
connector (E15/10x1,
E15/11x1)
Remove/install rear dome lamp - AR82.20-P-0113MC
MODELS 220.175 /178 with CODE (Z04) Light armoring with CODE (Z07) Top protection with gimbal-
mounted lamp
Fig. 24: Identifying Gimbal-Mounted Lamp, Dome Lamp And Lens
Remove, Install
1 Unclip gimbal-mounted
lamp (2) and disconnect
connector
2 Unclip lens (1)
3 Unscrew screw (4)
4 Release clamps (arrows),
remove dome lamp (3)
and disconnect connector
order
REMOVING AND INSTALLING OVERHEAD CONTROL PANEL CONTROL MODULE - AR82.20-

P-1000M
MODEL 215, 220
Fig. 25: Identifying Overhead Control Panel Control Module Remove/Install Components - Illustrated
On Model 220
1 Remove light lenses (1) Pay attention to
cleanliness
2 Press clips (arrows) in
swing overhead control
(N70) down
connectors (2) and
connections (2) on
overhead control panel
control module (N70)
REMOVING AND INSTALLING AUXILIARY TURN SIGNAL LAMP - AR82.25-P-4726M

MODEL 215, 220
Fig. 26: Identifying Exterior Mirror Turn Signal Lamp, Cover, Screws And Guides
1 Remove covering on AR88.70-P-9040M
exterior rearview mirror
3 Remove cover (2) with Installation: Ensure
guides (3) from covering that guides (3) are
correctly seated in cover
4 Remove left/right exterior
mirror turn signal lamp
(E6/5, E6/6) from
covering
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. 27: 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. 31
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. 31
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. 16
Fig. 29
Fig. 31
Model 215, 220 AR82.30-P-6400-01M
*BA82.30-P-1005-01A
Fig. 31
Model 230 AR82.30-P-6400-01R
*BA82.30-P-1005-01A
Fig. 31
Model 240 AR82.30-P-6400-01H
*BA82.30-P-1007-01A
Fig. 16
Fig. 31
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
WIPER ARM TEST AND ADJUSTMENT VALUES

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
wiper arm on
front passenger
side in parked
position

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
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

Fig. 30: Identifying Adjustment Tool Set (211 589 02 21 00)
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. 32: 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. 33: 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. 34: Checking Driver-Side Wiper Arm In Parked Position
REMOVING AND INSTALLING WIPER ARM - AR82.30-P-6100M
MODEL 220, 215

Fig. 35: Identifying Wiper Arm, Nuts And Clip
Risk of injury by Always remove the AS82.30-Z-0001-01A
trapping or crushing, or ignition key when
in extreme cases severing working on the wiper
of limbs when accessing mechanism.
the wiper mechanism
1 Move wiper system to AR82.30-P-6800-01E
park position
2 Open hood, place in
vertical position
3 Unscrew nuts (2) *BA82.30-P-1004-01A
4 Remove wiper arm (1) Installation : The
wiper blade must lie
directly on the marking
(arrow) in the screen
printing of the windshield
In models 215, 220 after
aerowiper started to be
used, the clip (3) must be
removed when using new
wiper blades.
6 Check operation of
windshield wipers
WINDSHIELD WIPER
BA82.30-P-1004- Nut for wiper arm Nm 33 33
01A
Adjust wiper arms - AR82.30-P-6100-01T

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

wiper arm on
driver-side in
parked position
wiper arm on
front passenger
side in parked
position

BE82.30-P- Angle of Angle ° 2,0...6,0 2,0...6,0 3,0...5,0
wiper arm on
driver-side in
parked position
BE82.30-P- Angle of Angle ° 2,0...6,0 2,0...6,0 3,0...5,0
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. 37: 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. 38: 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. 39: Identifying Measuring Angle Device
REMOVING AND INSTALLING WIPER SYSTEM - AR82.30-P-6400M

MODEL 220, 215
Fig. 40: Identifying Spreading Rivet And Water Deflector
Fig. 41: Identifying Wiper System, Knurled Nut And Wiper Motor Connector
Removal
Injury hazard! Always remove ignition AS82.30-Z-0001-01A
Windshield wiper key when working on
mechanism can pinch, windshield wiper
crush or, in extreme mechanism.
cases, even sever
extremities.
2 Remove four spreading
rivets (1)
3 Pull water deflector (2)
upward out of channel
(arrow)
4 Unscrew four nuts (3) Do not turn knurled
nut (5), otherwise
inclination angle of wiper
system will be changed
(M6/1x1) from wiper
motor
6 Remove wiper system (4)
Installation
7 Position wiper system (4)
8 Screw in 4 nuts (3) *BA82.30-P-1005-01A
9 Move wiper motor to AR82.30-P-6800-01E
park position
10 Install water deflector (2)
11 Install wiper arms AR82.30-P-6100M
12 Check windshield wiper
for proper function
WINDSHIELD WIPER
BA82.30-P-1005- Nut for wiper Nm 20 20
01A system
Adjusting wiper system - AR82.30-P-6400-01M
Model 215, 220

01E of wiper arm on
driver-side in
parked position
WINDSHIELD WIPER
BA82.30-P-1005- Nut, wiper system Nm 20 20
01A
The wiper system may only be adjusted if the test values of wiper arms 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
corresponding sign has to be changed.
Shown on model 215
1. Install choke angle gauge (A) to driver-side wiper arm (1).

2. Open hood.
See Operating Instructions
3. Remove spreader clip (2) and push back water collector (3) until jam nut (4) is accessible.
4. Loosen jam nut (4) and turn adjusting nut (5) until the correct adjustment value is shown on the dial of the
choke angle gauge (A).
5. Tighten counternuts (4)
6. Install spreader clip (2).
Replace damaged spreader clip (2).
7. Close hood and remove choke angle gauge (A) from driver-side wiper arm (1).
Fig. 43: Identifying Angle Gauge And Driver-Side Wiper Arm
REMOVING AND INSTALLING WIPER MOTOR - AR82.30-P-6800M
MODEL 220, 215
Shows model 220
Fig. 44: Identifying Wiper Motor Remove/Install Components (Shows Model 220)
Remove
Injury Hazard! Always remove ignition AS82.30-Z-0001-01A
Windshield wiper key when working on
mechanism can pinch, windshield wiper
crush or, in extreme cases mechanism.
even sever extremities.
3 Unscrew nut of wiper
motor shaft (1)
4 Pull off crank (2) with
wiper linkage
5 Unclip plug (4) from
fixture
wiper motor
7 Remove wiper motor
(M6/1)
Install
8 Move wiper motor AR82.30-P-6800-01E
(M6/1) to parking
position
9 Insert wiper motor
(M6/1)
10 Screw in wiper motor *BA82.30-P-1001-01A
bolts (3)
11 Clip plug (4) into fixture
12 Align crank (2) at angle *BE82.30-P-1001-01C
(A) to upper rib of wiper
motor fixture
13 Screw nut onto wiper *BA82.30-P-1002-01A
motor shaft (1)
14 Install wiper system AR82.30-P-6400M
15 Close engine hood AR88.40-P-1000M
16 Inspect operation of
windshield wipers
TEST AND ADJUSTMENT VALUES FOR WINDSHIELD WIPER

Number Designation Models 215, 220
BE82.30-P-1001- Dim. Angle "A" between Angle 74
01C crank and rib
Fig. see AR82.30-P-6800M
WINDSHIELD WIPER
BA82.30-P-1001- Bolt to wiper motor Nm 9 9
01A fixing.
BA82.30-P-1002- Nut on wiper motor Nm 19 19
01A shaft
Move wiper motor to parking position - AR82.30-P-6800-01E
Fig. 45: Identifying Wiper Motor Connector And Wiper Motor
Fig. 46: Identifying Wiper Motor Connector

Fig. 47: Identifying Wiper Motor
1. Connect wiper motor (M6/1) to wiper motor connector (1).

2. Hold wiper motor (M6/1) using the left hand.
4. Set combination switch to "stage 1".
5. Turn combination switch back to "level 0".
6. If the wiper motor (M6/1) is in the park position, switch off the ignition.
7. Detach wiper motor connector (1) from wiper motor (M6/1).
REMOVE/INSTALL RAIN SENSOR - AR82.30-P-7700M
MODELS 220, 215
Shows model 220
Fig. 48: Identifying Rain Sensor Remove/Install Components (Shows Model 220)
MODIFICATION NOTES
11.4.03 Disconnecting ground Step 1
lead from battery newly
included
Remove/Install
of battery
2 Remove inside rearview AR68.40-P-0001M
mirror unit (A67) with
cover
3 Detach electrical
connector (1) at rain
sensor (B38)
4 Release retaining clamps
(2) on rain sensor (B38) to
left and right
5 Remove rain sensor (B38) The lens (3) of the
rain sensor (B38) is
bonded to the windshield
and must not be
removed, otherwise the
lens (3) will be damaged.
8 Read coding of the
windshield adaptation for
rain sensor and of
adaptation of the light
sensor booster factor using
STAR DIAGNOSIS and
replace if necessary, select
windshield variant
DIAGNOSIS, read out
fault memory
Diagnosis system STAR *WH58.30-Z-1048-13A
DIAGNOSIS

Number Designation
REMOVING AND INSTALLING WASHING WATER RESERVOIR - AR82.35-P-6000M

MODEL 215, 220
Fig. 49: Identifying Washing Water Reservoir Remove/Install Components (Model 220)
2 Remove washing water
heater hoses (1) on
(4)
3 Unscrew nuts (2) and lift
coolant expansion
reservoir (3) up and lay
down to side
Danger of severe burns Open cooling system AS20.00-Z-0001-01A
to skin and eyes from hot only when coolant
coolant spewing out. temperature is below 90°
Coolant is toxic when C
swallowed Open cover slowly and
reduce pressure
Do not fill beverage
containers with coolant
protective goggles
4 Unclip electrical
connector (5) from
coolant expansion
reservoir (3) and place
coolant expansion
reservoir (3) to side
5 Unclip electrical
connector (6) from
(4)
6 Pull windshield washer Catch washing water
pump (M5/1) and
headlamp washer pump
(M5/2) up completely out
of washing water
reservoir (4) together
with outlet hoses and
electrical connections
7 Remove washing water
reservoir (4) upward
9 Fill windshield washer For mixing ration see
reservoir table on package MB
windshield washer
concentrate according to
service product
specifications sheet 371.
10 Check pumps for proper
function
REMOVING AND INSTALLING WINDSHIELD WASHER NOZZLES - AR82.35-P-6970M
MODEL 220, 215

Fig. 50: Identifying Windshield Washer Nozzles Remove/Install Components (Model 220, 215)
2 Unscrew screws (1) on
cover (2)
3 Hold back overlapping
part of insulating mat (3),
unclip cover (2) from
engine hood and remove
cover (2)
4 Pull washing water hose
(4) off of windshield
washer nozzle (5)
5 Disconnect heated washer
nozzle connector (2-pin,
X88/11) from windshield
washer nozzle (5)
6 Press clip (A) in direction
of arrow and remove
windshield washer nozzle
(5)
8 Check fluid level in AP82.35-P-8210Z
windshield washer
system, correct
9 Check windshield washer AP82.35-P-8252BA
and wiper for proper
function
REMOVE/INSTALL RADIO - AR82.60-P-7502
Remove/install radio - AR82.60-P-7502I
MODEL 220 up to 31.8.02 with CODE (750a) MB radio Audio 30 RDS with CODE (753) MB radio
Audio 30 RDS with CODE (756a) MB radio Audio 10 RDS with CD compartment
Fig. 51: Identifying Center Console Cover, Bolts And Radio
Remove/Install
1 Connect no load AR54.10-P-1030-
current retention unit 07I
CMP 12.2 quiescent current retention *WH58.30-Z-1012-
unit 09A
Risk of explosion No fire, sparks, open flames or smoking. AS54.10-Z-0001-
caused by explosive Wear protective gloves, acid-resistant 01A
gas. Risk of clothing and safety glasses. Pour battery
poisoning and electrolyte only into suitable and
caustic burns caused appropriately marked containers.
by swallowing
battery electrolyte.
Risk of injury
caused by burns to
skin and eyes from
battery acid or when
handling damaged
lead-acid batteries
2 Disconnect ground AR54.10-P-0003I
cable of battery
Notes on battery AH54.10-P-0001-
01A
Notes on AGM Model 220.028 with CODE (450) Taxi AH54.10-P-0002-
battery version. 01A
Models 220.070/075/175/178/875/878
as of 1.1.01.
3 Remove center AR68.20-P-2350M
console cover (1)
4 Undo screws (2) and
remove radio (A2)
from the center
console covering
order
6 Test for proper
operation

Number Designation
Removing and installing radio - AR82.60-P-7502N
MODEL 215 with CODE (750a) MB radio Audio 30 RDS with CODE (753) MB radio Audio 30 RDS
with CODE (756a) MB radio Audio 10 RDS with CD compartment
Fig. 52: Identifying Center Console Cover, Screws And Radio (Model 215)
retention unit
from battery
3 Remove center console AR68.20-P-2350N
cover (1)
remove radio (A2) from
center console cover
REMOVE/INSTALL AUDIO GATEWAY CONTROL UNIT - AR82.60-P-7606M
MODELS 220.0## /1##, 215.3## 1# as of 1.9.03 Vehicles with MOST fiber optical cable
Fig. 53: Identifying Audio Gateway Control Unit Remove/Install Components (Shown On Model 220)
Shown on model 220 with sound system (code 810)
Remove/install
1 Connect no load *WH58.30-Z-1012-
current retention unit 09A
caustic burns appropriately marked containers.
caused by
swallowing battery
electrolyte. Risk of
injury caused by
burns to skin and
eyes from battery
acid or when
handling damaged
lead-acid batteries
2 Disconnect battery AR54.10-P-0003I
ground line
Notes on battery All models AH54.10-P-0001-
01A
Notes on AGM Model 215 as of 1.1.01. AH54.10-P-0002-
battery Model 220.028 with code (450) Taxi 01A
version.
Models 220.070/075/175/178/875/878
as of 1.1.01.
3 Remove coverings in Left side paneling. AR68.30-P-4600M
trunk
4.1 Remove Only models 220.0/1 as of 1.9.02 with AR91.25-P-
overpressure code (433) left dynamic seat, incl. 1570MB
reservoir for multicontour seat or with code (434)
dynamic seat control right dynamic seat, incl. multicontour
seat.
5.1 Remove CD changer Only vehicles with CD changer (6-disc) AR82.64-P-
(code 819). 7507MN
Remove only CD changer bracket; do
not remove CD changer from the
bracket.
CD changer and navigation processor
have a common bracket.
6.1 Remove bracket for Only vehicles with COMAND APS
navigation processor (with navigation) code (527a).?
Remove CD player with changer. AR82.64-P-
CD changer and navigation processor 7507MN
have a common bracket.
Only remove the bracket of the
navigation processor; do not remove
navigation processor from the bracket.
7.1 Unscrew bolts (2) Only for vehicles without CD
from bracket (6) changer (6-disc) (code 819) and without
COMAND APS (with navigation) code
(527a).
8 Unscrew bolts In model 215 the bracket (6) is
(16,17) from bracket attached using a bolt and the nut (17)
(6) instead of the nut (16).
9 Take bracket (6) Do not buckle or extend fiber
with audio gateway optical cable, routing radii must be
control unit (N93/1) greater than 25 mm! Do not damage
and Sound amplifier standard wiring harness (23).
(A2/13) (for vehicles
with sound system
(code 810)) out of
wheelhouse recess
10 Remove black
antenna connector
(8) and yellow
antenna connector
(9) from the rear face
of the audio gateway
11 Detach MOST fiber
optical cable
coupling (10) from
the rear face of the
audio gateway
12 Detach black, 4-pin
coupling (11) from
the front face of the
audio gateway
13.1 Detach black, 14-pin Only for vehicles without sound
coupling (12a) from system (code 810).
the front face of the
audio gateway
14 Unscrew the two
collar nuts (22)
(magnifiers)
15 Push out audio CAUTION:
gateway control unit For model 215 with Sound amplifier
(N93/1) from bracket (A2/13), for sound system (code 810).
(6) to front in Do not damage standard wiring
direction of arrow harness (23).
order
Check
17 Perform function See owner's manual.
check

Number Designation
REMOVING AND INSTALLING REAR WINDOW NOISE SUPPRESSION CAPACITOR - AR82.62-

P-7385I
MODEL 215, 220

Fig. 54: Identifying Electrolytic Capacitor, Electrical Connectors, Screws And Nuts
1 Remove paneling on C- Model 215 AR68.30-P-4490N
pillar
Model 220 AR68.30-P-4490M
disconnect electrical
connections (2) from
electrolytic capacitor
(rear window noise
suppresser, (C3)
3 Unscrew nut (3) and
remove rear window
noise suppresser
capacitor from C-pillar
REMOVING AND INSTALLING MICROPHONE - AR82.62-P-7700I
MODEL 215, 220 with CODE (810) Sound system
Interior microphone for sound amplifier

Fig. 55: Identifying Cover And Sound Amplifier Microphone
2 Unclip cover (1)
3 Unclip sound amplifier
microphone (B25/6)
REMOVING AND INSTALLING AMPLIFIER (LEFT/RIGHT SPEAKERS) CONTROL MODULE -

AR82.62-P-7720I
MODELS 215, 220 with CODE (810) Sound system
Shown on model 220

Fig. 56: Identifying Amplifier (Left/Right Speakers) Control Module Remove/Install Components
retention unit
of battery
3 Remove paneling in trunk Floor covering, rear AR68.30-P-4600M
end center assembly
paneling and side
paneling on left-hand
side.
4 Unscrew nuts (2) and
bolts (1), remove
mounting bracket
upwards
5 Disconnect couplings Do not bend D2B
wires.
If the sound amplifier
(A2/13) is removed for a
longer period of time, an
adapter must be installed
to close off the D2B ring.
6 Detach sound amplifier
(A2/13) from mounting
bracket
order
REMOVING AND INSTALLING LOUDSPEAKERS IN INSTRUMENT PANEL - AR82.62-P-7833
Removing and installing loudspeakers in instrument panel - AR82.62-P-7833I
MODEL 220
Fig. 57: Identifying Center Cockpit Speaker And Connector
1 Remove instrument panel AR68.10-P-1000M
2 Remove center cockpit
(H2/27)
(H4/27x1)
Removing and installing loudspeakers in instrument panel - AR82.62-P-7833N
MODEL 215
Fig. 58: Identifying Loudspeakers In Instrument Panel Remove/Install Components
1 Unclip vent cover (1) Installation: Ensure
from instrument panel that vent cover first
with suitable tool and moves into guides (b) and
remove catches in the retaining
lugs (a)
remove center cockpit
(H4/27)
3 Disconnect loudspeaker
connector (H4/27x1)
REMOVING AND INSTALLING LOUDSPEAKERS IN THE REAR SHELF - AR82.62-P-7836I
MODEL 215, 220

Fig. 59: Identifying Loudspeakers In Rear Shelf Remove/Install Components
1 Remove rear shelf AR68.30-P-4580M
(H4/17x1, H4/17x2)
3 Press retaining clips (A,
B) on speaker housing (1)
for bass speaker (H4/17)
together from passenger
compartment side and lift
speaker housing.
4 Move speaker housing
toward trunk until guide
(C) is free and remove
speaker housing
REMOVING AND INSTALLING LOUDSPEAKERS IN FRONT DOORS - AR82.62-P-7845I
MODEL 215, 220
Models 215, 220

Fig. 60: Identifying Loudspeakers In Front Doors Remove/Install Components (Model 220)
Model 215 only
Fig. 61: Identifying Loudspeakers In Front Doors Remove/Install Components (Model 215)
1 Remove door liner on Model 215 AR72.10-P-1000N
front doors
Model 220 AR72.10-P-1000M
2 Unclip left front door
speaker group connector
(H4/1x1) and pull out
3 Remove paneling (2) on
rearview mirror triangle
4 Unclip tweeter speaker
(H4/1h1) from paneling
5 Unscrew screws (1) on
woofer speaker (H4/1h2)
and remove speaker
6.1 Unscrew screws (3) from Model 215
speaker 3 (H4/1h3) and
remove speaker
7.1 Remove connector (4) Model 215
from speaker 3 (H4/1h3)
and remove speaker
REMOVING AND INSTALLING SPEAKER IN FRONT FOOTWELL - AR82.62-P-7853M
MODEL 215, 220 with CODE (347) TELE AID emergency call system (D2B)
Emergency call system loudspeaker
Fig. 62: Identifying Speaker In Front Footwell Remove/Install Components
Figure item, etc. Working notes

1 Screw unscrew
2 Covering remove
H4/9 Left front loudspeaker
H4/10 Right front loudspeaker
REMOVE/INSTALL LOUDSPEAKERS IN REAR DOORS - AR82.62-P-7874I

MODEL 220
Fig. 63: Identifying Loudspeakers In Rear Doors Remove/Install Components
Remove/install
1 Remove door control Speakers are always AR72.12-P-1010M
module (1). changed in pairs
2 Unclip tweeter speaker
(H4/1h1) from door
control module covering
3 Remove door liner from AR72.29-P-1000M
rear door
4 Unclip left rear door
tweeter speaker (H4/3x1)
and detach
5 Undo screws (1) on
woofer speaker (H4/4h2)
and remove speaker
REMOVING AND INSTALLING KEYLESS GO ANTENNA - AR82.62-P-8000
Removing and installing Keyless Go antenna - AR82.62-P-8000MA
MODEL 215, 220 with CODE (889) Keyless Go in front door

Fig. 64: Identifying Keyless Go Antenna Remove/Install Components
1 Remove door liner on Model 215 AR72.10-P-1000N
front door
Model 220 AR72.10-P-1000M
4 Unclip Keyless Go
right/left front door
antenna (A2/38, A2/40)
and remove
Removing and installing keyless go antenna - AR82.62-P-8000MB
MODEL 220.026 /028 /063 /065 /070 /075 /128 /165 /170 /175 /178 /875 /878 with CODE (889) Keyless go
in rear door
Illustrated on model, Series 220.026

Fig. 65: Identifying Keyless Go Antenna Remove/Install Components (Model Series 220.026)
Removing,
installing
1 Remove door Model AR72.12-P-
liner from rear 220.026/028/063/065/070/075/128/165/170/173/175/178; 1010M
door 220.875/878 without electrically adjustable curtains, code
P082
Model 220.875/878 with electrically adjustable curtains, AR72.12-P-
code P082 1010MP
2 Unscrew
screws (1)
3 Disconnect
connector
4 Unclip left and
right rear door
keyless go
antenna
(A2/39, A2/41)
and remove
5 Install in the
reverse order
Removing and installing Keyless Go antenna - AR82.62-P-8000MC
MODEL 215, 220 with CODE (889) Keyless Go in bumper

Fig. 66: Identifying Keyless Go Antenna Remove/Install Components (Model 220)
1 Remove rear bumper Model 215 AR88.20-P-2200N
Model 220 AR88.20-P-2200M
connector (1) on Keyless
Go control module
(N69/5)
3 Unclip cover (2) on
bumper
4 Unclip bumper guard (3)
5 Press in pin (4a), remove
spreading clip (4) and
remove Keyless Go rear
bumper antenna (A2/31)
from bumper
Removing and installing Keyless Go antenna - AR82.62-P-8000MD
MODEL 215, 220 with CODE (889) Keyless Go in trunk
Left side
Fig. 67: Identifying Keyless Go Antenna Remove/Install Components - Model 220 (Left Side)
Right side
Fig. 68: Identifying Keyless Go Antenna Remove/Install Components - Model 220 (Right Side)
1 Remove paneling in trunk Right side, remove AR68.30-P-4600M
right side paneling only
2 Release and remove
electrical connector (1)
from Keyless Go control
module (N69/5)
3 Press locks on left and Observe wire routing
right antenna elements
(A2/35a1, A2/35a2) in
trunk in direction of
arrow and remove
left/right antenna
elements (A2/35a1,
A2/35a2)
REMOVE/INSTALL ANTENNA AMPLIFIER MODULE - AR82.62-P-8300I
MODEL 215, 220
Shows model 220
Fig. 69: Identifying Antenna Amplifier Module Remove/Install Components (Shows Model 220)
Remove/install
Information on preventing AH54.00-P-0001-01A
damage to electronic
components due to
electrostatic discharge
1 Disconnect battery ground AR54.10-P-0003I
cable
2 Remove headliner Model 215 AR68.30-P-4300N
Model 220.0/1 AR68.30-P-4300M
3 Detach couplings (1) on
antenna amplifier module
(A2/12)
4 Remove nuts/bolts (2)
5 Slightly lower antenna Installation: Ensure
amplifier module (A2/12) correct positioning of
and, together with the sliding contacts (3a) on
contact arms (3), slide contact arms (3).
towards the luggage
compartment and out of
the guides
REMOVE/INSTALL CD PLAYER WITH CHANGER - AR82.64-P-7507
Remove/install CD player with changer - AR82.64-P-7507I
MODELS 215.3, 220.0 /1 up to 31.8.02 with CODE (819) 6-disc CD changer
Shown on model 220 with sound system (code 810)
Fig. 70: Identifying CD Player With Changer Remove/Install Components (Shown On Model 220 With
Sound System (Code 810))
Remove/Install Do not buckle or

extend fiber optical
cable, routing radii
must be greater than 25
mm! Do not damage
standard wiring
harness (23).
1 Connect no load current *WH58.30-Z-1012-09A
retention unit
of battery
3 Remove coverings in Floor covering, rear AR68.30-P-4600M
trunk end center assembly
paneling and side
paneling on left-hand
side.
4 Unscrew bolts (1) and
nuts (2) and take out
implement carrier (3)
5 Unplug connectors Do not buckle or
extend fiber optical
cable, routing radii
must be greater than 25
mm!
If the CD player with
changer (in luggage
compartment) (A2/6) is
to remain removed over a
longer period of time,
install an adapter to close
the D2B ring.
6 Remove CD player with
changer (in luggage
compartment) (A2/6) from
implement carrier
8 Perform a function test

Number Designation
Remove/install CD player with changer - AR82.64-P-7507MN
MODELS 220.0 /1, 215.3 as of 1.9.02 with CODE (819) 6-disc CD changer
Common bracket for CD changer and navigation processor
Shown on model 220 as of model year 2004 (code 804) with MOST fiber optical cable and sound system
(code 810)
Fig. 71: Identifying CD Player With Changer Remove/Install Components (Shown On Model 220)
Only for COMAND APS (with navigation) code (527a)
Fig. 72: Identifying CD Player With Changer Remove/Install Components (COMAND APS (With
Navigation) Code (527a))
Fig. 73: Identifying Bracket, CD Player With Changer And Bolts
Remove/install
caused by
swallowing battery
injury caused by
burns to skin and
eyes from battery
acid or when
handling damaged
lead-acid batteries
1 Disconnect battery AR54.10-P-0003I
ground line
Notes on battery All models AH54.10-P-0001-
01A
Notes on AGM Model 215 as of 1.1.01. AH54.10-P-0002-
battery Model 220.028 with code (450) Taxi 01A
version.
Models 220.070/075/175/178/875/878
as of 1.1.01.
2 Remove coverings in Left side paneling. AR68.30-P-4600M
trunk
3 Unscrew screws (2).
4 Unscrew nut (3) and
bolt (4) from bracket
(1).
5 Remove CD player Do not kink or stretch fiber optic
with changer (in cables! Do not damage standard
luggage wiring harness (23).
compartment) (A2/6)
with bracket (1) from
the left wheelhouse
recess
6 Unlock fiber optical Do not buckle or extend fiber
cable coupling (11) optical cable, routing radii must be
at CD player with greater than 25 mm!
changer (in luggage If the CD player with changer (in
compartment) (A2/6) luggage compartment) (A2/6) is to
and detach remain removed over a longer period of
time, install an adapter to close the fiber
optical cable ring.
7 Detach black, 3-pin
coupling (24)
(voltage supply)
from CD player with
changer (in luggage
compartment) (A2/6)
8.1 Detach black, 8-pin Only for COMAND APS (with
coupling (33) navigation) code (527a)
(voltage supply of
navigation
processor), blue
coupling (34) (GPS
antenna line) and
fiber optical cable
coupling (31) from
navigation processor
(N41/1)
9 Unscrew the 4 bolt
M4x6 (21) to the
right and left at
bracket (1) and
remove CD player
with changer (in
luggage
compartment) (A2/6)
from bracket (1)
10 Install in the reverse Bracket (1) is locked in bracket (6)
order with the locking tabs (25).
Check
11 Perform function See owner's manual.
check
REMOVING AND INSTALLING VOICE CONTROL SYSTEM CONTROL MODULE - AR82.70-P-

0003
Removing and installing voice control system control module - AR82.70-P-0003I
MODEL 215, 220 up to 30.6.00 with CODE (813b) Voice control system (VCS) with CODE (316) MB
GSM cellular telephone (D2B) with CODE (317) GSM portable cellular telephone (D2B)
MODEL 215, 220 as of 1.7.00 with CODE (813b) Voice control system (VCS) with CODE (853) MB
standard cellular telephone with CODE (854) MB portable cellular telephone with CODE (855) TELE
AID
Shown on model 220

Fig. 74: Identifying Voice Control System Control Module Remove/Install Components (Shown On
Model 220)
retention unit
*WH58.30-Z-1012-09A
of battery
3.1 Remove rear seat cushion Model 215. AR91.12-P-1020N
Model 220. AR91.12-P-1020MA
3.2 Remove bucket seat Model 220 with code AR91.12-P-1020M
401, right side only.
4 Remove seat adjustment Model 220 with code AR91.12-P-1520M
device on rear seat 401, right side only.
nuts (2) and remove
assembly plate (3) from
vehicle floor
from voice control
(A35/11)
7 Disconnect D2B Do not bend D2B
connection (5) from voice wires.
control system control If the voice control
module (A35/11) system control module
(A35/11) should be
removed for a longer
period of time, install
adapter for closing the
D2B ring.
order

Number Designation
Removing and installing voice control system control module - AR82.70-P-0003M
MODEL 215, 220 as of 1.7.00 with CODE (813b) Voice control system (VCS) with CODE (853) MB
standard cellular telephone with CODE (855) TELE AID
Shown on model 220
Fig. 75: Identifying Voice Control System Control Module Remove/Install Components (Shown On
Model 220)

1 Connect quiescent current *WH58.30-Z-1012-09A
retention unit
Risk of explosion from No fire, sparks, naked AS54.10-Z-0001-01A
explosive gas. Risk of flames or smoking.
poisoning and caustic Wear acid-protective
burns from swallowing gloves, clothing and eye
battery electrolyte. Risk protection. Pour battery
of injury from caustic electrolyte only into
burns to eyes and skin suitable and appropriately
from battery electrolyte marked containers.
or from handling
damaged lead acid
batteries.
of battery
Notes on battery All models AH54.10-P-0001-01A
Model 220. AR91.12-P-1020MA
3.2 Remove bucket seats Model 220 with code AR91.12-P-1020M
401, right side only
device on rear seat 401, right side only
5 Fold back cover mats
from voice control
(A35/11)
7 Unscrew screws (4) from
assembly plate (3)
order

Number Designation
REMOVING AND INSTALLING FIBER OPTIC CABLE - AR82.70-P-0004
Removing and installing fiber optic cable - AR82.70-P-0004MA
MODEL 215, 220
Between COMAND or radio/left side of trunk
Removing fiber optic cable M1

Fig. 76: Fiber Optic Cable Diagram - Illustrated On Model 220
Notes on fiber optic AH82.70-P-0001-02A
cables
from battery
2.1 Remove radio Model 215 AR82.60-P-7502N
Model 220 AR82.60-P-7502I
2.2 Remove operating, Model 215 with code AR82.85-P-7472N
display and control 352a
module
Model 220 with code AR82.85-P-7472I
352a
3 Remove floor cover in Model 215 AR68.20-P-4800N
rear
Model 220 AR68.20-P-4800M
4 Open left wiring duct
5.1 Remove rear seat AR91.12-P-1620MA
backrest
5.2 Remove rear seat Model 220 AR91.12-P-1620M
backrest with bucket seats (code
401), left side only
6.1 Remove seat adjustment Model 220 AR91.10-P-1450M
device with bucket seats (code
401), left side only
7 Remove paneling in trunk Left paneling and on AR68.30-P-4600M
rear wall
8 Remove rear wall in
trunk
9 Cover fiber optic cable Do not kink or AR82.95-P-0005-01A
stretch fiber optic cable
D2B
Install caps on fiber
optic cable connector and
module connection
10 Leave fiber optic cable AR82.70-P-0004-01A
module disconnected
12 Start up and check for
proper function
Remove, install fiber optic cable module - AR82.70-P-0004-01A
1. Detach connection couplings at the corresponding control modules.

2. Unlock retainer clip (1) on the straight coupling (arrow).
3. Pull out fiber optical cable module.
Fig. 77: Unlocking Retainer Clip On Straight Coupling
4. Unclip coupling housing cover (arrows) and lift up cover (2)

5. Remove fiber optical cable module.
6. Cut off the defective fiber optical cable module at the ends
No longer required.
Fig. 78: Identifying Housing Cover & Couplings
7. Route new fiber optical module carefully in the vehicle.
When routing, the inserts must always have cover caps (3).
8. Insert the new fiber optical cable module into the corresponding coupling.
The connection pieces (inserts) are provided with coding lugs (arrow).
Fig. 79: Identifying Cover Caps & Coding Lugs
The information flows from white to red. The ray must always enter the white insert (ws) in the optical fiber
(coupling, chamber 1) and exit at the red insert (rt) (coupling, chamber 2).
The inserts cannot be separately changed! As soon as an insert is removed from a fiber optic module, the
module should be exchanged.
Fig. 80: Identifying White Insert And Red Insert Of Optical Fiber
Removing and installing fiber optic cable - AR82.70-P-0004MB
MODEL 215, 220
Between left side of trunk/right rear seat
cables
from battery
Model 220 AR82.60-P-7502I
module
Model 220 with with AR82.85-P-7472I
code 352a
rear
Model 220 AR68.20-P-4800M
4.1 Open right wiring duct
4.2 Open left wiring duct
401)
6 Remove installation plate
from floor
D2B
module connection
module disconnected
proper function
Removing and installing fiber optic cable - AR82.70-P-0004MC
MODEL 215, 220
Between COMAND or radio/right rear seat

cables
from battery
Model 220 AR82.60-P-7502I
module
Model 220 with code AR82.85-P-7472I
352a
rear
Model 220 AR68.20-P-4800M
4 Open right wiring duct
401)
from floor
D2B
module connection
module disconnected
proper function
Removing and installing fiber optic cable - AR82.70-P-0004MD
MODEL 215, 220
Between trunk control modules
cables
1 Remove paneling in trunk Left paneling AR68.30-P-4600M
2 Remove control module
(sound amplifier and CD
player) from floor and lift
out upward
D2B
module connection
module disconnected
proper function
Removing and installing fiber optic cable - AR82.70-P-0004ME
MODEL 215, 220
Between control modules right rear seat
cables
1.1 Remove rear seat cushion AR91.12-P-1620MA
1.2 Remove rear seat cushion Model 220 AR91.12-P-1620M
with bucket seats (code
401), right side only
401), right side only
from floor
D2B
module connection
module disconnected
proper function
REMOVING AND INSTALLING GSM 1800 MHZ NETWORK COMPENSATOR - AR82.70-P-0010
Removing and installing GSM 1800 MHz network compensator - AR82.70-P-0010AD
MODEL 215 as of 1.7.00 with CODE (854) MB cellular telephone
Fig. 85: Identifying GSM 1800 MHz Network Compensator Remove/Install Components - Model 215 As
Of 1.7.00 With Code (854)
retention unit
*WH58.30-Z-1012-09A
explosive gas. Risk of flames or smoking. Wear
poisoning and caustic acid-protective gloves,
burns from swallowing clothing and eye
or from handling
damaged lead acid
batteries.
of battery
Notes on battery All models. AH54.10-P-0001-01A
4 Release connector on E-
network compensator
(A28/3) and disconnect
5 Disconnect antenna
connections
6 Unscrew sheet metal
screws (2) and lift off
cradle (1) with E-network
compensator (A28/3)
7 Unscrew nut (3)
8 Remove E-network
compensator (A28/3)
order

Number Designation
Removing and installing GSM 1800 MHz network compensator - AR82.70-P-0010AE
MODEL 220 as of 1.7.00 with CODE (854) MB cellular telephone

Fig. 86: Identifying GSM 1800 MHz Network Compensator Remove/Install Components - Model 220 As
Of 1.7.00 With Code (854)
retention unit
*WH58.30-Z-1012-09A
or from handling
damaged lead acid
batteries.
of battery
4 Release connector on E-
network compensator
5 Disconnect antenna
connections
6 Unscrew nut (3)
7 Remove E-network
compensator (A28/3)
order

Number Designation
REMOVING AND INSTALLING CELLULAR TELEPHONE INTERFACE - AR82.70-P-7379I
MODEL 215, 220 up to 30.6.00 with CODE (316) MB GSM cellular telephone (D2B)
Shown on model 220
Fig. 87: Identifying Cellular Telephone Interface Remove/Install Components (Shown On Model 220)
retention unit
*WH58.30-Z-1012-09A
of battery
Model 220. AR91.12-P-1020MA
mechanism on rear seat 401, right side only.
6 Unscrew bolt (1) and nuts
(2)
7 Remove mounting plate
turn over
8 Release clips (4) and
remove D2B interface for
permanently installed
telephone (A59) from
mounting plate
9 Release connectors (5a,
5b) and disconnect
10 Release D2B connector Do not kink D2B
(5c) and disconnect connector.
If the D2B interface
for permanently installed
telephone (A59) remains
removed for a longer
period of time, it is
necessary to install an
adapter to close the DB2
ring.
order

Number Designation
REMOVING AND INSTALLING TRANSMITTER/RECEIVER UNIT - AR82.70-P-8911
Removing and installing transmitter/receiver unit - AR82.70-P-8911I
MODEL 215, 220 up to 30.6.00 with CODE (316) MB GSM cellular telephone (D2B)
Shown on model 220

Fig. 88: Identifying Transmitter/Receiver Unit Remove/Install Components (Shown On Model 220)
retention unit
*WH58.30-Z-1012-09A
of battery
Model 220. AR91.12-P-1020MA
remove cradle (2)
and antenna connection
(4) from telephone
transmitter/ receiver
(A35)
order

Number Designation
Removing and installing transmitter/receiver unit - AR82.70-P-8911M
MODEL 215, 220 as of 1.7.00 with CODE (853) MB standard cellular telephone
Shown on model 220
Fig. 89: Identifying Transmitter/Receiver Unit Remove/Install Components (Shown On Model 220)
1 Connect quiescent current *WH58.30-Z-1012-
retention unit 09A
explosive gas. Risk of flames or smoking.
poisoning and caustic burns Wear acid-protective
from swallowing battery gloves, clothing and eye
electrolyte. Risk of injury protection. Pour battery
from caustic burns to eyes and electrolyte only into
skin from battery electrolyte suitable and
or from handling damaged appropriately marked
lead acid batteries. containers.
2 Disconnect ground cable of AR54.10-P-0003I
battery
Model 220. AR91.12-P-1020MA
5 Unscrew screws (1) and nuts
(2) and remove mounting plate
6 Release connectors on D2B
telephone transmitter/receiver
7 Unscrew sheet metal screws
(4)

Number Designation
REMOVING AND INSTALLING HANDSET - AR82.70-P-8912M
MODEL 215, 220 up to 30.6.00 with CODE (316) MB GSM cellular telephone (D2B) in center arm rest
Shown on model 220
Fig. 90: Identifying Handset Remove/Install Components (Shown On Model 220)
1 Open stowage compartment
(1)
3 Remove adapter plate (3) from The adapter plate (3)
stowage compartment (1) is held by 4 screws (2)
together with telephone only.
handset (A34) until handset
transmitter/ receiver connector
(X39/5) is accessible
4 Disconnect handset
transmitter/receiver connector
(X39/5)
REMOVING AND INSTALLING HANDSET IN STOWAGE COMPARTMENT ARMREST OR

STOWAGE COMPARTMENT - AR82.70-P-8915M
MODEL 220 as of 1.7.00 with CODE (853) MB standard cellular telephone
Fig. 91: Identifying Handset In Stowage Compartment Armrest Or Stowage Compartment

Remove/Install Components
1 Open stowage shell and
unscrew screws (4)
2 Disconnect CTEL handset
connector (A34x1)
3 Remove CTEL handset (A34)
from handset receptacle (8)
4 Open flap (10) at rear of
center console and disconnect
handset transmitter/receiver
connector (X39/5)
5 Carefully pull plate (3) out of Carefully pull
stowage shell connection lead trough
passage in stowage
shell.
7 Remove adapter for handset
receptacle (9) and handset
receptacle (8)
REMOVE AND INSTALL BRACKET FOR PORTABLE CTEL - AR82.70-P-8918M
MODELS 220, 215 as of 1.7.00 with CODE (852) CTEL preinstallation assembly at dome with CODE
(854) MB portable CTEL
Shown on Model 220
Fig. 92: Identifying Bracket For Portable CTEL Remove/Install Components (Shown On Model 220)
1 Remove cellular telephone
from cradle (5)
2 Open stowage shell and
unscrew screws (4)
3 Open flap (10) at rear on
center console
4 Separate handset
transmitter/receiver connector
(X39/5) and antenna
connection (17)
5 Carefully pull plate (3) out of Carefully pull
stowage shell connection leads
through passage in
stowage compartment.
7 Disconnect and remove
adapter lead (12) and antenna
extension lead (14)
REMOVING AND INSTALLING VEHICLE INTERFACE (CELLULAR TELEPHONE) - AR82.70-P-

8920I
MODEL 215, 220 up to 30.6.00 with CODE (317) GSM cellular telephone (D2B)
MODEL 215, 220 as of 1.7.00 with CODE (854) MB cellular telephone
Shown on model 220
Fig. 93: Identifying Vehicle Interface (Cellular Telephone) Remove/Install Components - Shown On
Model 220
retention unit
*WH58.30-Z-1012-09A
of battery
Model 220. AR91.12-P-1020MA
nuts (2) and remove
mounting plate (3) from
vehicle floor
7 Release connectors (5) on Do not bend D2B
D2B interface for cellular wires.
telephone (A59/1) and
disconnect
If the D2B interface
for cellular telephone
(A59/1) remains removed
for a longer period of
time, it is necessary to
install an adapter to close
the DB2 ring.
order

Number Designation
REMOVE/INSTALL ANTENNA - AR82.70-P-8951
Remove/install antenna - AR82.70-P-8951I
MODEL 220
Telephone/GPS antenna on rear window

Fig. 94: Identifying Antenna Remove/Install Components (Model 220)
Remove/install
components due to
1 Detach roof antenna for Do not damage rear
telephone and GPS window.
(A2/49) from rear
window using preheated
spatula
2 Remove roof antenna and Installation: Remove
remove adhesive pad on adhesive residues on
bottom side of antenna antenna and glue a new
adhesive pad onto bottom
side of antenna. When
gluing on the antenna,
make sure that after
removing the protective
foil on the adhesive pad,
it is stuck to the rear
window immediately.
Once positioned, apply
approx. 20 kg pressure to
the antenna for approx. 5
seconds
3 Remove adhesive residues *BR00.45-Z-1025-04A
on rear window using
window cleaning agent
Installation: Apply *BR00.45-Z-1023-02A
glass primer to bonding
surface on rear window
4 Remove coverings in Model 220.0/1 AR68.30-P-4600M
trunk
Model 220.8 AR68.30-P-4600MP
Right side trim panel
6 Remove lines (2) with Note installation of
rubber grommet (3) to lines in luggage
cable duct (4) compartment
Installation: Coat
rubber grommet with
soapy water
7 Remove ornamental Ornamental frame at AR67.20-P-2200M
frame (5a, 5b) on rear right and below
wall window
8 Remove lines from Installation: Use
ornamental frame suitable tool to insert
lines into the trim strip
rubber section

A220 817 00 21 Spare adhesive pad 1
REPAIR MATERIALS
BR00.45-Z-1023-02A Glass primer A 006 989 39 71
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Remove/install antenna - AR82.70-P-8951N
TELE AID backup antenna in bumper
Shows model 215

Fig. 95: Identifying Antenna Remove/Install Components (Shows Model 215)
Remove/install
components due to
1 Remove rear bumper (1) Model 215 with CODE AR88.20-P-2200N
(550) Trailer hitch
Model 215 without AR88.20-P-2200NA
CODE (550) Trailer hitch
Model 220 AR88.20-P-2200M
3 Slide TELE AID backup
antenna (A2/50) out of
guides on bumper
Remove/install antenna - AR82.70-P-8951NA
MODEL 215
Telephone or GPS antenna in trunk lid

Fig. 96: Identifying Antenna Remove/Install Components (Telephone Or GPS Antenna In Trunk Lid)
Remove/install
components due to
1 Open trunk lid
2 Release bracket (1) and
remove hazard warning
triangle (2) from bracket
3 Slide bracket (1) to the
left and remove
4 Unclip cover (3)
5 Remove trunk lid inner
panel (4)
6 Unplug connector (5)
7.1 Remove bolt (6) and
remove telephone antenna
(A2/22) in direction of
arrow
7.2 Remove bolt (6) and
remove GPS antenna
(A2/23) in direction of
arrow
REMOVING AND INSTALLING HANDS-FREE SYSTEM MICROPHONE - AR82.70-P-8969I

MODEL 215, 220
Fig. 97: Identifying Cover And Hands-Free System Microphone
2 Unclip cover (1)
4 Unclip hands-free system
microphone (B25)
REMOVE AND INSTALL COMAND OPERATING, DISPLAY AND CONTROL MODULE - AR82.85-
P-1000M

Fig. 98: Identifying Cover And COMAND Operating, Display And Control Unit
Fig. 99: Identifying Bolts And COMAND Operating, Display And Control Unit
Remove/install
caused by
swallowing battery
injury caused by
burns to skin and
eyes from battery
acid or when
handling damaged
lead-acid batteries
cable of battery
01A
Models 220.070/075/175/178/875/878
as of 1.1.01.
2 Remove control and AR83.40-P-
operating unit 6350MA
3 Unclip cover (2) Cover (2) above COMAND
from mounts on right operating, display and control module
and left with (40/3)
assembly wedge
Installation wedge Fig. 16
5 Pull COMAND Until electrical connectors and fiber
operating, display optic cable are accessible.
and control module
(40/3) out of center
console
6 Disconnect fiber Do not kink or stretch fiber optic
optic cable and cable.
electrical connectors
and remove
COMAND
operating, display
and control module
(40/3)
7.1 Cover fiber optic Only vehicles up to 31.8.03 with AR82.95-P-0005-
cable D2B. 01A
order
9 Read diagnostic
trouble code memory
and erase
Connect STAR AD00.00-P-2000-
DIAGNOSIS, 04A
interrogate fault
memory
STAR DIAGNOSIS system. *WH58.30-Z-1048-
13A
10 Perform function
check
Fig. 100: Identifying Mounting Wedge(110 589 03 59 00)

Number Designation
REMOVING AND INSTALLING COMAND OPERATING, DISPLAY AND CONTROL MODULE -

AR82.85-P-7472
Remove/install operating / display unit with control unit - AR82.85-P-7472I
MODEL 220 up to 31.8.02 with CODE (352a) COMAND operating and display system
Fig. 101: Identifying Bolts And COMAND Operating, Display And Control Unit
Remove/install
1 Connect no load AR54.10-P-1030-
CMP 12.2 quiescent current retention *WH58.30-Z-1012-
unit 09A
caused by
swallowing battery
injury caused by
burns to skin and
eyes from battery
acid or when
handling damaged
lead-acid batteries
cable of battery
01A
Models 220.070/075/175/178/875/878
as of 1.1.01.
3 Remove cover on AR68.20-P-2350M
center console
4 Unscrew bolts (1) Use screwdriver with magnetic tip on
and pull out bolts not easily accessible
COMAND
operating, display
and control module
(40/3)
connectors
order

Number Designation
Removing and installing COMAND operating, display and control module - AR82.85-P-7472N
MODEL 215 with CODE (352a) COMAND operating and display system
Fig. 102: Identifying COMAND Operating, Display And Control Module Remove/Install Components
retention unit
from battery
3 Remove cover on center AR68.20-P-2350N
console (1)
connectors
pull out COMAND
operating, display and
control module (A40/3)
REMOVING AND INSTALLING TELE AID EMERGENCY CALL SYSTEM PUSHBUTTON

SWITCH - AR82.95-P-0002I

Fig. 103: Identifying Cover And TELE AID Pushbutton Switch
2 Unclip cover (1)
3 Unclip TELE AID
pushbutton switch
(S93/3)
REMOVING AND INSTALLING TELE AID EMERGENCY CALL SYSTEM CONTROL MODULE -
AR82.95-P-0005
Removing and installing TELE AID emergency call system control module - AR82.95-P-0005M
MODEL 215, 220 with CODE (347) TELE AID emergency call system (D2B)

Fig. 104: Identifying Tele AID Emergency Call System Control Module Remove/Install Components
(Model 220)
Notes on TELE AID AH82.95-P-0001-01A
1 Disconnect ground lead The roll-over sensor in AR54.10-P-0003I
from battery the TELE AID control
module (A35/8)
recognizes an accident
and triggers an
emergency alarm. For
this reason it is absolutely
necessary to disconnect
the ground lead when the
assembly plate (1) is
removed
2.1 Remove rear seat cushion Model 215 AR91.12-P-1020N
Model 220 AR91.12-P-1020MA
2.2 Remove rear seat cushion Model 220 AR91.12-P-1020M
with bucket seats (code
401)
401)
4 Remove assembly plate
turn
remove bracket (3)
6 Lift TELE AID control Do not damage wiring
module (A35/8) from harness
assembly plate (1)
7 Disconnect all antenna Installation: Observe
leads (4, 7) from TELE color coding when
AID control module connecting
(A35/8)
from TELE AID control
module (A35/8) and pull
off
9 Disconnect fiber optic Do not kink or stretch
cable connector (6) and fiber optic cable D2B.
pull off fiber optic cable Install caps on fiber optic
cable connector and
module connection
Cover fiber optic cable - AR82.95-P-0005-01A
Do not remove protective covers too early from the fiber optic cable coupling (3) or the device connection
(4) because contaminated or scratched surfaces may absorb the light. Fiber optic cables must not be kinked,
routed over sharp edges or bent in radii of less than 25 mm, otherwise the fiber optic cable core will be
yellowed and broken. Yellowed or broken fiber optic cables weaken the light.
The work procedure is shown on components of the digital data bus (D2B).
1. Carefully detach the fiber optic cable coupling (3) from the device connection (4) and cover it with a
protective cap (1), stop plug (2) or a clean rag.
The protective cap (1) and stop plug (2) for the digital data bus (D2B) components are not separately
available. The protective caps (1) and plugs (2) of installed replacement parts must be used. The components of
the Media Oriented System Transport (MOST) must be covered up with clean rags, as generally they are not
fitted with protective caps (1) and plugs (2).
Fig. 105: Covering Fiber Optic Cable Coupling And Device Connection With Protective Cap
Removing and installing TELE AID emergency call system control module - AR82.95-P-0005MA
MODEL 215, 220 as of 1.7.00 with CODE (855) TELE AID
Shown on model 220
Fig. 106: Identifying TELE AID Emergency Call System Control Module Remove/Install Components
or from handling
damaged lead acid
batteries.
1 Disconnect ground cable Perform all work with AR54.10-P-0003I
of battery vehicle disconnected
from electrical power to
avoid erroneous actuation
of TELE AID system.
Model 220 AR91.12-P-1020MA
nuts (2) and remove
vehicle floor
5 Remove connectors on
TELE AID control
module (A35/8)
6 Unscrew sheet metal
screws (4)
order
Activate/deactivate service mode in TELE AID emergency call system - AR82.95-P-0005-03AM
Activate service mode in emergency call system (PIN of TELE AID SIM card is known).
1.1 Switch on ignition. Switch on telephone Enter *#4610# on telephone handset. Confirm message "No
telematics service" with "OK." Switch off ignition and remove ignition key. Switch off telephone
Activate service mode in emergency call system (PIN of TELE AID SIM card not known)
1.2 Switch on ignition. Switch on telephone Hold C-button pressed for 5 seconds. Enter *#4610# on
telephone handset. Confirm message "No telematics service" with "OK." Switch off ignition and remove
ignition key. Switch off telephone
Activate service mode in emergency call system (with STAR DIAGNOSIS).
1.3 via STAR DIAGNOSIS in TELE AID control module under

--> Menu for control module adaptations
--> Read control module coding and if necessary change
--> Additional battery
--> Service mode
Deactivate service mode in emergency call system.
2.1 Switch on ignition.
Confirm handset message "exit service mode" by confirming with "OK."
Confirm message "No telematics service" with "OK." Switch off ignition
Deactivate service mode in emergency call system (with STAR DIAGNOSIS).
2.2 via STAR DIAGNOSIS in TELE AID control module under
--> Menu for control module adaptations
--> Read control module coding and if necessary change
--> Additional battery
--> Service mode
REMOVING AND INSTALLING SERVICE AND BREAKDOWN ASSISTANCE, EMERGENCY

CALL PUSH-BUTTON GROUP - AR82.95-P-0006A
MODEL 202, 210, 220 with CODE (316) MB GSM cellular telephone (D2B) with CODE (348a)
Emergency call system with CODE (494a) US version
Fig. 107: Identifying Service And Breakdown Assistance, Emergency Call Push-button Group - Model
202
1 Fold up stowage
compartment
2 Remove base plate (g)
3 Disconnect service and
breakdown assistance,
emergency call push-
button group (S93/6)
4 Unclip switch from base
plate (g)
AUTHORIZATION FOR TELE AID - AR82.95-P-0011
Authorization for TELE AID - AR82.95-P-0011A
MODEL 129, 140, 170, 202, 208, 210, 220 with SIM card from debitel for D1 GSM network
Notes on TELE AID Models 140, 210 AH82.95-P-0001-01A

1 Check and/or perform TELE AID control
version coding for TELE module must be coded.
AID control module
TELE AID emergency Models 129, 140, 202, AD82.95-P-2000-05A
call system control 208.3, 210
module version coding
2 Check whether SIM card A SIM card should
is inserted directly in the not be inserted. A SIM
card reader of the card in the telephone card
telephone reader would lock the
authorization of the
vehicle.
3 Insert SIM card for The fully operational
emergency call SIM card for emergency
call should be inserted in
the CTEL transmitter and
receiver (A35) The
vehicle should be parked
outside (GPS
availability).
The CTEL transmitter
and receiver (A35) is
located in the trunk.
Observe location of
components in the
following document.
Refer to: ?
TELE AID, location of Model 140 except GF82.95-P-0001-01A
components 140.063/07
Model 140.063/07 GF82.95-P-0001-01C
Model 202 GF82.95-P-0001-01F
Model 210.2 GF82.95-P-0001-01D
4 HHT diagnosis module The vehicle should
not be in the diagnosis
mode.
5 Switch telephone off at Telephone display
the handset disappeared.
6 Withdraw ignition key LED "SOS" of the
emergency push-button
should be "off".
7 Send fax application filled The fax application
out to Tegaron should include all
specifications of the
vehicle and authorized
dealer required for
performing the function
check.
Use the following
document listed as form
for the fax. Refer to: ?
Authorization and Print out form and fill OF82.95-P-3000-01A
function check for taxi out, if not filled out
emergency call form previously.
8 Contact Tegaron service For this purpose a
by telephone telephone independent of
the vehicle is required.
For the duration of the
authorization the
telephone contact to
Tegaron is maintained.
9 Switch ignition on Depending on the
telephone manufacturer
the steps can vary.
Observe instructions of
Tegaron service.
10 Switch on telephone on The LED "SOS" in
handset the TELE AID
emergency call push-
button switch (S93/3)
should come on the
overhead control panel.
11 Enter PIN number
12 Press "MENU" button
three times
13 Confirm with "Okay".
14 when checking PIN, press
"#" button three times
16 Changing "PIN number",
press "#" button twice
18 Enter old "PIN number"
19 Enter new "PIN number"
21 Enter new "PIN number"
again
23 Store "Export PIN"
25 Press "C" button three The network provider
times "D1Telekom" appears on
the display.
26 Allow telephone to be The data exchange
switched on, wait 3 between the TELE AID
minutes control module (vehicle)
and service provider
Tegaron is accomplished
now.
27 Wait for call/instructions When the
of the Tegaron service authorization is
provider performed successfully
the LED "SOS" in the
TELE AID emergency
call push-button switch
(S93/3) should be go out.
Contact person from
Tegaron gives
instructions for function
test.
28 Trigger manual The manual
emergency call pressing emergency call over the
"SOS" TELE AID "SOS" TELE AID push-
emergency call pushbutton switch (S93/3) in
button switch (S93/3) the overhead control
panel runs to the vehicle
over a bi-directional
voice connection. The
test can therefore be
communicated by
making contact with the
service provider
(Tegaron).
29 Perform additional On vehicles equipped
function checks for taxi with taxi emergency call
emergency call additional function tests
must be performed before
authorization is
completed. On vehicles
only equipped with
TELE AID emergency
call step "29" is
eliminated; complete
authorization with step
"30".
Perform authorization for MODEL 129, 140, 170, AR82.95-P-0012A
taxi emergency call 202, 208, 210, 220
equipped with taxi
emergency call
30 Wait for fax answer from Without fax answer
Tegaron the vehicle cannot be
delivered to the customer
with authorization. If
confirmation is not
received, contact
Tegaron.
Carry out authorization for TELE AID - AR82.95-P-0011B
MODELS 129, 140, 170, 202, 208, 210, 220 with SIM card for the D2 GSM network
Notes regarding the Tele-Aid Models 140, 210 AH82.95-P-0001-01A

Authorize TELE AID with SIM card for
emergency call system ? the D2 GSM network
Precondition check list:
 Emergency call
controller programmed
(Note VIN No.,
equipment, vehicle
parameters, high and
low case orthography)
 TELE AID service
applied for
 SIM card for
emergency call in the
card internal reader and
functional
 No further SIM card in
the front card reader
 Vehicle is in the open
air (GPS availability)
LED of the emergency call
button must be off (ignition
key removed, head unit off,
telephone display
extinguished)
1 Switch telephone on at the
handset
2 Wait 15 seconds
3 Switch telephone off at the
handset
4 Wait 15 seconds
5 Switch telephone on at the
handset
6 Wait 3 minutes
7 Open the telephone card letter
and input the PIN number
8 Press menu 3 x Telephone settings
9 Confirm with OK
10 Press menu 3 x PIN code necessary
11 Confirm with OK
12 Change PIN code
13 Confirm with OK
14 Input old PIN
15 Confirm with OK
16 Input new PIN
17 Confirm with OK
18 Repeat new PIN No.
19 Confirm with OK
20 Store export PIN
21 Confirm with OK
22 Press menu 3 x D2 Private
23 End Terminate connection
REMOVING AND INSTALLING TILTING CONE SENSOR - AR82.95-P-0013A
MODEL 215, 220 as of 1.7.00 with CODE (855) TELE AID
Shown on model 220

Fig. 108: Identifying Tilting Cone Sensor Remove/Install Components (Shown On Model 220)
explosive gas. flames or smoking. Wear
Risk of poisoning and acid-protective gloves,
caustic burns from clothing and eye
swallowing battery protection. Pour battery
electrolyte. Risk of electrolyte only into
injury from caustic burns suitable and appropriately
to eyes and skin from marked containers.
battery electrolyte or
from handling damaged
lead acid batteries.
1 Disconnect ground cable Perform all work with AR54.10-P-0003I
of battery vehicle disconnected
from electrical power to
avoid erroneous actuation
of TELE AID system.
Model 220 AR91.12-P-1020MA
4 Unscrew screws (1) and Do not kink or stretch
nuts (2) and remove D2B fiber optic cable
vehicle floor
5 Remove connectors from
tilting cone sensor (B66)
6 Unscrew nut (4)
7 Remove tilting cone
sensor (B66)
order
Electrical System - Basic Knowledge - Body - 215 & 220 Chassis
BASIC KNOWLEDGE
DIGITAL DATA BUS (D2B), FUNCTION - GF82.00-P-0001A
MODEL 129 as of 1.6.98, 163, 168 as of 1.9.98, 170, 202 as of 1.6.98, 203, 208, 210 as of 1.6.98, 215, 220
Component sequence, exemplified on model 220 with code (819) 6-disc CD changer, with code (810)
sound system, with code (813) voice control system (VCS) and with code (855) TELE AID
Fig. 1: Identifying Digital Data Bus (D2B), Function
Digital Data Bus (D2B)
The Digital Data Bus (D2B) is a data transmission system for the communication and information components,
which utilizes the optical data transfer options. Data transfer is conducted by means of optical pulses, which are
transferred over fiber optical cables to the connected communication and information components. Audio and
command signals are converted in the source components into optical pulses and transmitted via fiber optical
cables. The optical signal is converted back to an electronic signal in the target component. Because of the high
transfer rate, the Digital Data Bus (D2B) can transfer audio and command signals simultaneously. Simultaneous
transfer of source data and command data over the Digital Data Bus (D2B) significantly reduces the amount of
cabling. The connected components require 2 lines for the voltage supply (electrical) and 2 lines (input/output)
for the fiber optical cable of the Digital Data Bus (D2B) and one line for the wake-up signal (electrical).
In addition to this the fiber optical cable can transfer several pieces of source data simultaneously (e.g. music
and voice from 2 components), without compromising the data content.
Functional sequence on example of "Play CD" on model 220
Pressing "Play" on the radio (A2) sends a command signal over the Digital Data Bus (D2B) to the CD player
with changer (in trunk) (A2/6), for vehicles with code (819) 6-disc CD changer. The audio signals from the CD
player with changer (in the trunk) (A2/6), for vehicles with code (819) 6-disc CD changer, are then sent over the
Digital Data Bus(D2B) as source data to the Sound amplifier (A2/13), or for vehicles with code (810) to the
sound system. The target components, the Sound amplifier (A2/13), or for vehicles with code (810) the sound
system, the source data are then converted back to electrical signals and reproduced as sound.
Data transfer using fiber optic cables has the following advantages:
 Extremely high data transmission rate

 Prevents tapping and cross talk
 Insensitive to electromagnetic radiation
 Short-circuit resistance
 Zero potential connection of components
 No oxidation
 Low weight of fiber optical cable
 Minimum diameter of wiring harness
The digital data bus (D2B) has a closed ring structure. The communication and data components are arranged
here in a distributor line (in-series circuit). This arrangement is type specific and is illustrated by way of an
example on model 220 as follows:
 Radio (A2)
 CD player with changer (in trunk) (A2/6), with code (819) 6-disc CD changer
 Sound amplifier (A2/13), with code (810) Sound System
 Voice control system control unit (A35/11), with code (813) voice control system (VCS)
 Telephone and TELE AID transmitter/receiver, D2B (A35/17), with code (855) TELE AID
Data transfer is conducted here in one direction only, i.e. the optical pulses for the voice control system control
unit (A35/11), for vehicles with code (813) voice control system (VCS), on model 220 pass through all
components connected to the ring, before arriving at the target components.
When the system is first put into operation, a system test is performed. In doing so the individual components
and their sequence in the ring structure of the Digital Data Bus (D2B) are registered by the component with the
master function.
A type-specific sequence is stored ex-factory. In turn, the storing of a sequence ex-factory means: if the radio
(A2) is taken from one model series and installed into another one, then during a system test the different
sequence of the components and an error message are filed in the diagnostic trouble code memory.
An error message is also filed if the radio (A2) is exchanged within a model series with different equipment
components. The system goes to the operational state regardless of the error message. STAR DIAGNOSIS
enables the sequence of the components to be subsequently altered in the Digital Data Bus (D2B).
The Digital Data Bus (D2B) is diagnosis capable via the data link connector (X11/4), except for models 129
and 202.
The operating principle of the Digital Data Bus (D2B) is the same for all model series; all that changes is the
sequence of components depending on the national version and equipment specification.
Data transfer, function GF82.00-P-2000A
MOST RING, FUNCTION - GF82.00-P-0004AB
MODELS 215, 220 as of 1.9.03
MOST ring components, shown for USA version
Fig. 2: MOST Ring Function Chart
Digital MOST bus (Media Oriented System Transport)
The digital MOST bus is a data transfer system that utilizes the possibilities of optical information transfer.
With this system, the data are transferred by light pulses. These are transmitted over a fiber optical cable to the
components connected to the bus system (e.g. COMAND operating, display and control unit (A40/3), sound
amplifier (A2/13)).
Commands for the components, e.g. pressing "Play" button on COMAND operating, display and control unit
(A40/3) for the CD player with changer (in trunk) (A2/6) have to be converted to light pulses (optical data)
before being forwarded via the MOST.
Light pulses are then converted back to electronic signals in the receiver components so that they can execute
the commands. Because of its extremely high transfer rate the MOST ring source data and control data can be
transmitted simultaneously. This reduces the quantity of wiring considerably. For this reason the connected
components only require 2 lines for voltage supply, 2 lines (input/output) for the fiber optical cable of the
digital MOST bus and one line for the wake-up signal.
Additionally, several audio frequency (AF) signals can be sent via the fiber optical cable, without
compromising data content.
Data transfer using a fiber optical cable has many advantages:
 Extremely high data transmission rate

 Prevents tapping and crosstalk
 Data transmission is not sensitive to electromagnetic radiation
 Short-circuit resistance
 Potential-free connection of bus components
 No oxidation
 Low weight of fiber optical cable
 Minimum diameter of wiring harness
The MOST has an enclosed ring structure. The components are arranged in a ring line (series circuit). This
arrangement is adapted according to the series.
Data transfer ensues in one direction only, i.e. light pulses for the E-call control unit (A35/8) pass through all
the components before it in the ring.
Within the ring structure of the digital MOST bus the COMAND operating, display and control unit (A40/3)
contains a primary function. This enables all other ring subscribers to be served.
When the system is first put into operation, a system test is performed. In doing so the individual components
and their sequence in the ring structure of the digital MOST bus are recorded by the audio gateway control unit
(N93/1) and compared against the source and control data of the equipment-specific sequence of the data stored
at the plant.
With the assistance of STAR DIAGNOSIS the components in the audio gateway control unit (N93/1) can be re-
coded (e.g. variant coding).
The digital MOST Bus is rendered diagnosis capable via the audio gateway control unit (N93/1).
Data transfer, function GF82.00-P-2000AB
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR MOST RING - GF82.00-P-0996AB
MODELS 215, 220 as of 1.9.03
MOST ring, function GF82.00-P-0004AB

Data transfer, function GF82.00-P-2000AB
Wake-up, function GF82.00-P-2001AB
Overview of MOST ring system GF82.00-P-9995AB
components,
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF DIGITAL DATA BUS (D2B) - GF82.00-P-

0999ZZ
Digital data bus (D2B), function GF82.00-P-0001A

Data transfer, function GF82.00-P-2000A
Wake-up, function GF82.00-P-2001A
Survey of system components, digital GF82.00-P-9999A
data bus (D2B),
DATA TRANSFER, FUNCTION - GF82.00-P-2000
Data transfer, function - GF82.00-P-2000A
The Digital Data Bus (D2B) contains the master unit, e.g. the radio (A2) except for model 129, and model 202,
which triggers all the components in the Digital Data Bus system (D2B). The master unit also serves as an
interface (Gateway) to the CAN interior (CAN-B). For this purpose, signals arriving at the master unit are
converted so that they can be transmitted from the Digital Data Bus (D2B) to the CAN interior (CAN B) and
vice versa. Moreover, the master unit serves as a timing circuit which provides the clock pulse with which the
information frames are transferred on the Digital Data Bus (D2B). A frame consists of 2 subframes. A series of
many data frames contains the complete information for proper operation of the components located at the
Digital Data Bus (D2B). The conversion of optical pulses into electrical signals and vice versa is done by
transmitter and receiver diodes, that are integrated into each component. Each of the components receives or
transmits the electrical signals from the chip of the Digital Data Bus system (D2B) as a "D2B log". Source data
and control data are transmitted.
The source data are transferred synchronously, for example as present on a music CD, as 32 bit blocks into the
subframes. By contrast, control data are transferred asynchronously. They are divided up (2 bits per subframe)
and distributed over several subframes. The control data are provided with an address, which indicates for
which components the data are intended in the Digital Data Bus (D2B). The individual data packages are joined
together again in the components and they can then be processed. A data frame can therefore contain highly
differing types of information (source and control data from all components mounted in the digital data bus
(D2B)). The transmission and reception diodes as well as the digital data bus (D2B) chip are switched off when
not required in order to reduce the quiescent current (sleep mode). Switch-off is accomplished immediately
when the master unit or circuit 15 is switched off. After restart, the digital data bus system (D2B) can be
activated either by the components or by the master unit by means of an electrical signal in the wake-up line for
optical data transmission.
Regardless whether the information is intended for a component, it feeds an edited light signal back into the
digital data bus (D2B) at full intensity (repeater function).
Wake-up, function GF82.00-P-2001A

Data transfer, function - GF82.00-P-2000AB
MODELS 215, 220 as of 1.9.03
Data transfer in the MOST bus
The audio gateway control unit (N93/1) makes it possible to provide all the data on the CAN interior
compartment to each respective component. It acts as an interface (gateway). To this end signals arriving at the
audio gateway control unit (N93/1) are converted such that they can be sent by the MOST to the CAN interior
compartment and vice versa. It acts as the clock generator, with which data sections (data frames) are sent to the
bus system. A data frame here consists of 2 subframes.
The sequence of several data frames then contains the entire data required for operation of the components in
the MOST ring.
Light pulses are converted into electrical signals and back again by means of the optical transmitter and receiver
diodes, which are integrated into every MOST component.
The components can then receive or transmit the electrical signals. Source data (music and language) and
control data (CD selection and muting during incoming telephone calls) are transmitted. The source data are
sent synchronously, such as, for example on a music CD, as blocks in subframes. By contrast, the control data
are transferred asynchronously. They are split up, distributed using several subframes and transmitted.
The control data are provided with an address (Code), which indicates for which components the information is
intended in the MOST ring.
Data arriving at the components are combined to form individual data packages and can then be edited. A data
frame can thus contain the most varied of information (source and control data of all the components in the
MOST ring).
The transmitting and receiving units are switched off when they are not required, in order to lower the quiescent
current (sleep mode). They are switched off immediately after the operating unit is turned off or after the
transmitter key is removed (A8/1).
With a new optical information transmission start, the bus system can be activated with the help of the "ON"
switch (ON/OFF) of the operating module or by turning the transmitter key (A8/1) to "terminal 15R ON",
provided that the system was not shut off before the transmitter key (A8/1) was removed. This activation occurs
by means of an electrical signal in the wake-up line, triggered by the audio gateway control unit (N93/1).
If a telephone is integrated and the transmitter key inserted, a wake-up can also be triggered in the event of
an incoming call.
Irrespective of whether information is intended for a component at the start, the processed light pulse reenters
the bus at full intensity.
Wake-up, function GF82.00-P-2001AB

WAKE-UP, FUNCTION - GF82.00-P-2001
Wake-up, function - GF82.00-P-2001A
Normal wake-up
Since the transmitting and receiving diodes along with the digital data bus system's (D2B) chip are
automatically shut off if they are not needed (sleep mode), a wake-up pulse, which activates the system, is
required to start a new data transfer. This is accomplished via the separate wake-up line. For this purpose, the
master unit actuates the wake-up signal (electrical signal), which allows the voltage in the wake-up line to
decrease to a defined value. The chip of the digital data bus system (D2B) in the components recognizes on
account of the duration of the signal that this is a wake-up signal, and the digital data bus (D2B) is then
activated. Therefore the digital data bus (D2B) is then in an activated state. A "wake-up" can take place in a
quiescent system (sleep mode) even without the wake-up pulse of the master unit by activation of a component
located at the digital data bus (D2B).
Wake-up diagnosis
For diagnosis of the wake-up circuit in the components, the master unit can trigger a wake-up diagnosis signal
using STAR DIAGNOSIS and the data link connector (X11/4). This signal differs from the wake-up signal by
the fact that it has a significantly longer duration. The components react to this long wake-up pulse with a signal
on the wake-up line (message to master unit). This allows the master unit to recognize which components have
received the long wake-up pulse. The wake-up diagnosis signal can only be actuated when the digital data bus
(D2B) cannot be activated due to an error. If all components reply to the master unit, then their voltage supply is
correct.
Fiber optical cable, Except model 208.4 GF82.00-P-4000A

Wake-up, function - GF82.00-P-2001AB
MODELS 215, 220 as of 1.9.03
Normal wake-up (all)
As the transmission and receiver diodes are automatically switched off when not required (sleep mode) at the
start of new data transfer a command is required by the COMAND operating, display and control unit (A40/3)
and/or a wake-up pulse which activates the system. This happens over a separate wake-up line.
For this purpose the audio gateway control unit (N93/1) triggers a wake-up signal (electrical signal), which
lowers the voltage in the wake-up line to a defined value. A chip in the components recognizes on account of
the signal's duration that the signal in question is a wake-up signal, and the MOST ring is then activated. A
wake-up can also be triggered by an incoming telephone call through the corresponding component during the
run-out phase.
Diagnosis wake-up
For diagnosis of the wake-up circuit in the components, the audio gateway control unit (N93/1) can be
instructed by STAR DIAGNOSIS to trigger a wake-up diagnosis signal.
This signal differentiates itself from the wake-up signal through its distinctly longer duration. The components
for their part react with a signal to the wake-up line (message to the audio gateway control unit (N93/1)).
With this the audio gateway control unit (N93/1) can then detect, which components have received the long
wake-up pulse. The diagnosis wake-up signal can only be triggered if the optical ring cannot be activated due to
a fault. If all components answer the audio gateway control unit (N93/1), the voltage supply is correct.
Fiber optical cable, GF82.00-P-4000AB

FIBER OPTIC CABLE, LOCATION/TASK/FUNCTION - GF82.00-P-4000
Fiber optic cable, location/task/function - GF82.00-P-4000A
MODEL 129 as of 1.6.98, 163, 168 as of 1.9.98, 170, 202 as of 1.6.98, 203, 208.3, 210 as of 1.6.98, 215, 220
Exemplified on model 215 with code (819) 6-disc CD changer, with code (810) Sound System and with
code (382) MB phone "CTEL" in console on right side of dome
Fig. 3: Identifying Fiber Optic Cable, Location/Task/Function
Fiber optic cable, location Model 129 GF82.00-P-4000-01D

Model 163 as of 01.09.01 GF82.00-P-4000-01GH
Model 168 GF82.00-P-4000-01E
Model 170 GF82.00-P-4000-01C
Model 202, 208 GF82.00-P-4000-01B
Model 203 GF82.00-P-4000-01G
Model 210 GF82.00-P-4000-01A
Models 215, 220 GF82.00-P-4000-01F
Fiber optic cable, purpose The fiber optical cable is
responsible for the optical
data transfer of the
components located at the
digital data bus (D2B).
Fiber optic cable, GF82.00-P-4000-04A
function
Fiber optic cable, location - GF82.00-P-4000-01F
Fiber optic cable, function - GF82.00-P-4000-04A
The fiber optical cable consists of plastic with a fiber diameter of 1 mm. Each fiber optical cable is protected
against mechanical damage and against admission of outside light with the help of an orange-colored insulation.
The light for the data transfer in the digital data bus (D2B) has a wavelength of 650 nm; by comparison, visible
light lies in the range of blue with 400 nm to red with 800 nm. Optical attenuation of the light signal can occur
in the fiber optic cable. Attenuation of the optical signal in the fiber optical cable is dependent on:
 the length of the line between the individual components

 the bending radii when routing the fiber optical cable, which must have min. bending radius = 25 mm
 the condition of the insulation of the fiber optical cable
 A passive connector; this is used when a component is removed from the digital data bus (D2B) due to a
fault.
To ensure the functional availability of the remaining components, the digital data bus (D2B) is closed again
using a passive connector. The fiber optical cable has two different connection ends:
 The fiber optical cable input, which is the output to each control unit. This is marked in "white".
 The fiber optical cable output, which is the input to each control unit. This is marked in "red".
Fiber optical cable, location/task/function - GF82.00-P-4000AB
MODELS 215, 220 as of 1.9.03
Location, shown on model 220 USA version
Fig. 5: Fiber Optical Cable Function Chart - Shown On Model 220 USA Version
Fiber optical cable, The location depends on

location the vehicle's respective
equipment level.
Fiber optical cable, task Optical data transfer
between the ring
subscribers (for example
the CD player with CD
changer (in the trunk)
(A2/6) and the audio
gateway control unit
(N93/1).
Fiber optic cable, GF82.00-P-4000-04AB
function
Fiber optic cable, function - GF82.00-P-4000-04AB
The fiber optical cable is a transfer medium in which the signal is transmitted by means of modulated light. The
basis material used for the fiber optical cable is plastic with a fiber diameter of approx. 1 mm. A reflection layer
in the core enables light signals to be transmitted between several control units. Each integrated control unit can
transmit and receive signals and data. Located at the input and output of the fiber optical cable is an
optoelectronic converter. The source device converts electrical signals into light signals and sends them via the
fiber optical cable to the target device. Once at the target device they are converted back to electrical signals
again.
The light for the data transfer in the MOST has a wavelength of 650 nm (unit: nanometer). By way of
comparison: visible light lies in a range of blue with 400 nm to red with 800 nm.
Optical attenuation of the light signal may occur in the fiber optical cable. The attenuation is dependent on:
 the length of the line between the components

 bending radius when routing (minimum bending radius 25 mm).
 the condition of the insulation of the fiber optical cable (mechanical damage, pinching).
 Passive connectors:
These are used when a component is removed from the MOST because it has failed.
In order to assure the functional availability of the remaining components, the ring can be closed again with the
passive connector.
OVERVIEW OF MOST RING SYSTEM COMPONENTS, LOCATION/TASK/DESIGN/FUNCTION -

GF82.00-P-9995AB
MODELS 215, 220 as of 1.9.03
Fiber optical cable, GF82.00-P-4000AB

location/task/Function
Table of contents, function GF82.00-P-0996AB
description for MOST ring
SURVEY OF SYSTEM COMPONENTS, DIGITAL DATA BUS (D2B), LOCATION/

TASK/DESIGN/FUNCTION - GF82.00-P-9999A
Fiber optic cable, Except model 208.4 GF82.00-P-4000A

Table of contents, function GF82.00-P-0999ZZ
description of digital data bus
(D2B)
HEADLAMP RANGE CONTROL (HRC), FUNCTION - GF82.10-P-0001S

MODEL 220 with CODE (612b) Xenon headlamp unit
Electric headlamp range adjustment is required by law for vehicles with xenon headlamps to prevent dazzling
oncoming traffic. The headlamp range adjustment automatically keeps the inclination angle of the low beams
within the legally defined limit regardless of how the vehicle is loaded.
The headlamp range adjustment control module utilizes the signals from the level sensors on the front and rear
axles for control and adjustment of the low beams. The pneumatic suspension control module processes the
signals from the level sensors and transfers these to the headlamp range adjustment control module via the data
bus (CAN).
The headlamp range adjustment control module compares the signals with the headlamp adjustment and, if
necessary actuates the headlamp range adjustment motors in the headlamps to correct the angle of inclination.
In addition to the signals from the level sensors the headlamp range adjustment control module also processes a
wheel speed signal proportional to the vehicle speed transferred on the data bus from the ASR/ESP control
module.
Evaluation of this wheel speed signal indicates to the headlamp range adjustment control module whether the
vehicle is driving at constant speed, accelerating or decelerating.
At constant vehicle speed the headlamp range adjustment operates in the "static mode" with minimum headlamp
motor adjustment speed.
During acceleration or deceleration the "dynamic mode" with high adjustment speed is actuated.
Headlamp range GF82.10-P-2101A

adjustment motors,
location/purpose
Headlamp range GF82.10-P-2102S
adjustment control module,
location/purpose
Headlamp range adjustment (HRA), location of components - GF82.10-P-0001-01F
Model 220 with code (612b) Xenon headlamp unit

Fig. 6: Identifying Headlamp Range Adjustment Location Of Components
ELECTRICAL SYSTEM, LOCATION OF XENON HEADLAMP COMPONENTS - GF82.10-P-0002
Electrical system, location of xenon headlamp components - GF82.10-P-0002-01C
MODEL 220 up to 31.8.02 with CODE (612b) Xenon headlamp lamp unit
Fig. 7: Identifying Electrical System Location Of Xenon Headlamp Components
Electrical system, location of xenon headlamp components - GF82.10-P-0002-01CA
MODEL 220 as of 1.9.02 with CODE (614) bi-xenon headlamp unit

Electrical system, location of xenon headlamp components - GF82.10-P-0002-01D
MODEL 215 with CODE (614) Bi-xenon headlamp units
EXTERIOR LIGHTING, FUNCTION - GF82.10-P-0003
Exterior lighting, function - GF82.10-P-0003A
MODELS 129, 140, 202, 208, 210 with CODE (612b) xenon headlamp unit
Headlamp range adjustment MODEL 208 with code GF82.10-P-0001-01A
(HRA), location of 612b xenon headlamp
components unit
MODEL 210 with code GF82.10-P-0001-01B
612b xenon headlamp
unit
MODEL 129 with code GF82.10-P-0001-01C
612b xenon headlamp
unit
MODEL 140 with code GF82.10-P-0001-01D
612b xenon headlamp
unit
Model 202 with code GF82.10-P-0001-01E
612b xenon headlamp
unit
Xenon headlamp MODELS 129, 140, 208, GF82.10-P-0002-01A
(XENON), location of 210 with code 612b
components xenon headlamp unit
Model 202 with code GF82.10-P-0002-01B
612b xenon headlamp
unit
Headlamp range adjustment MODELS 129, 140, 202, GF82.10-P-0001A
(HRA), function 208, 210 with code 612b
xenon headlamp unit
Xenon headlamp, MODELS 129, 140, 202, GF82.10-P-2001A
position/function 208, 210, 220 with code
612b xenon headlamp
unit
Exterior lights, function - GF82.10-P-0003B
MODEL 215.###, 220.02# /06# /07# /12# /16# /17# 1#
The exterior lighting equipment
 front lamp units,

 tail lights,
 the license plate lamps,
 center high-mounted stop lamp,
 the turn signal lamps,
are no longer actuated with voltage direct from their controls.
The switch positions of the controls are first read by the assigned control modules and transmitted as signals to
the data bus.
Assignment of controls and control modules:
 Exterior lamp switch S1 a N10/6left front SAM control module

 Combination switch (S4) a steering column module (N80)
 Hazard warning system switch (N72/1s5) a Upper control panel control module (N72/1)
 Stop lamp switch (S9/1) a Traction systems control module (N47).
The backup lamp signal is transmitted from the electronic selector lever module control module (N15/5)
directly on the data bus.
The data bus signals for the exterior lights are received by
 the left front SAM control module (N10/6),

 the right front SAM control module (N10/7),
 rear SAM control module (N10/8),
 the left front door control module (N69/1),
 the right front door control module (N69/2)
where they are evaluated and converted into appropriate voltage signals for the lights.
An exception to this is the actuation of the stop lamps, as these are actuated via the data bus and additionally via
a direct line. The direct line is intended to prevent any time delay in switching on the stop lamps.
On vehicles with trailer hitch, the trailer recognition control module (N28/1) uses the data bus signals of the
vehicle exterior lights to actuate the trailer illumination.
Exterior lighting, Up to 31.8.02 with trailer GF82.10-P-0003-01A

interlinkage of hitch code 299.
components
Standing light actuation, GF82.10-P-3000A
function
Position lamp control, GF82.10-P-3001A
function
headlamp actuation, GF82.10-P-2009A
function
Fog lamp actuation, GF82.10-P-3006A
function
Rear fog lamp actuation, GF82.10-P-3007A
function
Turn signal lamp GF82.10-P-3008A
actuation, function
Hazard warning flasher GF82.10-P-3009A
actuation function
Stop lamp actuation, GF82.10-P-3010A
function
Backup lamp actuation, GF82.10-P-3011A
function
Substitute lamp actuation, GF82.10-P-3012A
function
Emergency lamp GF82.10-P-3013A
actuation, function
Exterior lighting, trailer, with trailer hitch code GF82.10-P-2010A
function 550.
Headlamp range Model 220 with code GF82.10-P-0001S
adjustment (HRA), 612b Xenon headlamp
function lamp unit.
Exterior lighting, networking of the components - GF82.10-P-0003-01A
Exterior lighting without trailer coupling

Fig. 10: Exterior Lighting Networking Components Diagram - Without Trailer Coupling
Extension of exterior lights with trailer hitch

Fig. 11: Exterior Lighting Networking Components Diagram - With Trailer Hitch
Exterior lighting, networking of the components - GF82.10-P-0003-01AA
Exterior lighting without trailer coupling

Fig. 12: Exterior Lighting Networking Components Diagram - Without Trailer Coupling
Extension of exterior lights with trailer hitch

Fig. 13: Exterior Lighting Networking Components Diagram - With Trailer Hitch
CONTENTS, FUNCTION DESCRIPTION OF EXTERIOR LIGHTING - GF82.10-P-0999B
MODEL 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Exterior lighting function GF82.10-P-0003B

Exterior lighting, networking of the up to 31.8.02 with GF82.10-P-0003-
components trailer hitch (code 01A
299).
as of 1.9.02 with GF82.10-P-0003-
trailer hitch (code 01AA
299).
Standing lamp actuation, function GF82.10-P-3000A
Position lamp control, function GF82.10-P-3001A
Headlamp control, function GF82.10-P-2009A
Low-beams actuation, function GF82.10-P-3002A
Automatic headlamp actuation, up to 31.5.00. GF82.10-P-3003A
function
as of 1.6.00. GF82.10-P-3003AA
High beam control, function GF82.10-P-3004A
Daytime running light control, function GF82.10-P-3005A
Headlamp switch-off delay function up to 31.5.00. GF80.20-P-2003S
as of 1.6.00. GF80.20-P-2003SA
Fog lamp control, function GF82.10-P-3006A
Rear fog lamp actuation, function GF82.10-P-3007A
Turn signal indicator actuation, GF82.10-P-3008A
function
Hazard warning lamp control, function GF82.10-P-3009A
Stop lamp actuation, function GF82.10-P-3010A
Reversing lamp control, function GF82.10-P-3011A
Substitute light actuation, function GF82.10-P-3012A
Emergency lamp control, function GF82.10-P-3013A
Trailer exterior lighting actuation, with trailer hitch GF82.10-P-2010A
function (code 550), for
retrofitted trailer
hitch in line with
current production
configuration.
Trailer sensing, function with trailer hitch GF82.10-P-3014A
(code 550).
Trailer lighting control, function with trailer hitch GF82.10-P-3015A
(code 550).
Trailer antitheft alarm, function with anti-theft alarm GF82.10-P-3016A
system (ATA) (code
551a), with trailer
hitch (code 550).
Headlamp range adjustment, function Model 220 for xenon GF82.10-P-0001S
headlamp lamp unit
(code 612b).
Overview of exterior lighting system GF82.10-P-9999A
components,,
XENON HEADLAMP, LOCATION/FUNCTION - GF82.10-P-2001
Xenon headlamp, location/function - GF82.10-P-2001A
MODELS 129, 140, 202, 208, 210, 220 up to 31.08.01 with CODE (612b) xenon headlamp unit
When the low beam lamps are switched on the xenon headlamp control module (E1n1, E2n1) activates the
xenon headlamp control module and ignition module (E1n2, E2n2) via the control voltage within a few
milliseconds.
A high-voltage surge from the ignition device ignites the xenon lamps, and in doing so an electric arc is formed
between the electrodes. When an arc of sufficient stability is detected, the control electronics of the xenon lamp
control module (E1n1, E2n1) switches over to power-limiting mode.
A voltage transformer generates the voltage required for reliable xenon lamp operation.
For technical reasons the xenon lamp has a timed startup characteristic. After switch on, 50 % of the luminosity
is reached within 1 to 2 seconds and full luminosity is achieved after another approx. 30 seconds.
Xenon headlamp control MODEL 220 up to GF82.10-P-2104A

module, location/task 31.8.02 with Xenon
headlamp lamp unit
(Code 612b),
with bi-xenon headlamp
unit (Code 614).
Xenon headlamp ignition MODEL 220 up to GF82.10-P-2105A
module, location/task 31.8.02 with Xenon
headlamp lamp unit
(Code 612b),
unit (Code 614).
Xenon headlamp, location/function - GF82.10-P-2001AA
MODEL 220 as of 1.9.02 with CODE (614) Bi-xenon headlamp unit
Fig. 14: Identifying Xenon Headlamp Location
The headlamps in model 215 differ from the previous xenon headlamps on account of their entirely new
lighting technology development, which the xenon light uses for low and high beam lights.
The new lighting technology, known as Bi-Xenon , is located in the outer headlamps.
milliseconds.
between the electrodes. If an electric arc of sufficient stability is detected the control circuit switches the control
modules (E1n1, E2n1) over to power-limiting mode.
With the bi-xenon headlamps, the light generated in the previous manner in a gas discharge lamp (D2S lamp)
travels directly through the optical system without being reflected.
A voltage converter generates the required voltage for the reliable function of the xenon headlamp.
The entire luminous flux is made available for the high-beam lights. When switching over to low-beam
operation a screen is moved into position between the gas-discharge lamp and the lens, which covers up the
luminous flux directed into the distance and thus helps to prevent oncoming traffic from being dazzled.
The shield (B) is controlled electro-mechanically by the solenoids in the right and left high beams (E1l1, E2l1).
Xenon headlamp control GF82.10-P-2104A

module, location/task
Xenon headlamp ignition GF82.10-P-2105A
unit, location/task
Xenon headlamps position/function - GF82.10-P-2001B
MODEL 215
Fig. 15: Identifying Xenon Headlamps Components - Model 215
The headlamps in model 215 differ from the previous xenon headlamps on account of their entirely new
lighting technology development, which the xenon light uses for low and high beam lights.
The new lighting technology known as Bi-Xenon 70 , is located in the outer headlamps.
milliseconds.
between the electrodes. If an electric arc of sufficient stability is detected the control circuit switches the control
modules (E1n1, E2n1) over to power-limiting mode.
The light that was generated up until now in a gas-discharge lamp (D2S lamp) is not reflected in a bi-xenon 70-
headlamp, but sent directly through a lens with a diameter of 70 mm.
A voltage transformer generates the voltage required for reliable xenon lamp operation.
The entire luminous flux is made available for the high-beam lights. When switching over to low-beam
operation a screen is moved into position between the gas-discharge lamp and the lens, which covers up the
luminous flux directed into the distance and thus helps to prevent oncoming traffic from being dazzled.
The screen (B) is controlled electro-mechanically by means of a magnetizing coil (M).
In order to make the extremely bright light more acceptable to other road users, the lens aperture area with its
dotted characteristic is optically enlarged.
This is possible on account of the specially formed areas which surround the lens. Additionally, the light can
trickle through several chrome-plated strips at the rear. A portion of the diffused light is intercepted by the
lower section of the surface area and reflected to the upper section of the chrome-plated longitudinal strips.
Xenon headlamp control GF82.10-P-2104A

module, position/task
Xenon headlamp ignition GF82.10-P-2105A
device, position/task
DAYTIME RUNNING LAMPS, FUNCTION - GF82.10-P-2002S
MODEL 220.### 1#
Fig. 16: Daytime Running Lamps Function Diagram
Function sequence
 Engine started
 Light switch in position "0"
1. Circuit 61 connected through to right front SAM control module (N10/7) (generator running).
2. The right front SAM control module (N10/7) transfers a signal (4) to the left front SAM control module
(N10/6) via the data bus (CAN).
3. The instrument cluster (A1) sends a signal (1) to the left front SAM control module (N10/6) via the data
bus indicating that the daytime running light feature is activated.
4. The electronic ignition/starter switch control module (N73) sends a signal (2) to the left front SAM
control module and right front SAM control module indicating the specific national coding.
5. The left front SAM control module (N10/6) sends a signal (3) to the right front SAM control module
(N10/7) and rear SAM control module (N10/8) via the data bus.
6. The left front SAM control module (N10/6), right front SAM control module (N10/7) and rear SAM
control module (N10/8) switch on the following lights:
 Left low beam (E1e2)
 Right low beam (E2e2)
 Left standing and parking lamp (E1e3)

 Right standing and parking lamp (E2e3)
 Left tail and parking lamp (E3e2)
 Right tail and parking lamp (E4e2)
 Left license plate lamp (E19/1)
 Right license plate lamp (E19/2)
When the daytime running lamp feature is switched on, the high beams cannot be switched on (the high beam
flasher function is still available.)
The daytime running lamp feature can be activated and deactivated by the user on the instrument cluster.
On national versions , , , , , the daytime running lamp feature is set so that it

cannot be deselected due to legal regulations.
The daytime running lamp is deactivated beginning with the parking lamp position on the light switch.
On national version vehicles the daytime running lamp feature is deactivated beginning with the low
beam position. The daytime running lamps are switched off after three minutes when the engine is running and
the gear selector lever is not moved to a drive position.
Left signal acquisition and GF54.21-P-4101S

actuation module (SAM),
location/purpose/design/ function
Right signal acquisition and GF54.21-P-4102S
Rear signal acquisition and GF54.21-P-4103S
Electronic ignition/starter switch GF80.57-P-4102S
control module (EIS),
AUTOMATIC LOW BEAM SWITCH-ON, FUNCTION - GF82.10-P-2003S
MODEL 220.### 1#
Fig. 17: Automatic Low Beam Switch-On Function Diagram
Function sequence
 Ignition: ON
 Light switch in position "0"
 "Automatic low beam switch-on" activated
1. The overhead control panel control module (N70) evaluates the following input variables:
 signal from automatic light switch daylight sensor (B32/1)
 rain sensor signal (B38) or position of wiper switch
 vehicle speed signal
2. The overhead control panel control module (N70) transfers a corresponding signal (2) to the left front
SAM control module (N10/6) via the data bus.
The headlamps are switched on upon recognition of:
 Darkness/dusk
 Driving through a tunnel
 Rain or snow (not fog)
 Failure of a sensor
3. The instrument cluster (A1) transfers a signal (1) into the left front SAM control module (N10/6) via the
data bus indicating that the "automatic headlamp/tunnel circuit feature" is activated.
4. The left front SAM control module (N10/6) transfers signals (3, 4) to the right front SAM control module
(N10/7), rear SAM control module (N10/8) and trailer recognition control module (N28/1) via the data
bus.
control module (N10/8) switch on the following lights:
 Left low beam (E1e2)
 Right low beam (E2e2)
 Left standing and parking lamp (E1e3)
 Left tail and parking lamp (E3e2)
 Right tail and parking lamp (E4e2)
 Left license plate lamp (E19/1)
 Right license plate lamp (E19/2)
6. The trailer recognition control module (N28/1) actuates the trailer hitch socket (13-pin, X58).
Extraneous light, e.g. from other traffic, street lights, light reflections and advertising do not cause the
headlamps to switch off.
The automatic headlamp/tunnel switch-on feature is a pure convenience feature and does not relieve the driver
of the responsibility of observing the traffic laws. The rotary light switch always has the highest priority for
switching on the headlamps. The high beams can be switched on when the automatic headlamp/tunnel switch-
on feature is active.
The following lamps are switched on automatically in the event of simple malfunctions in the electronic
circuitry regardless of the adjustable "automatic low beam switch-on feature":
 In the event of a failure of the data bus (CAN) or the left front SAM control module (N10/6):
 Left low beam headlamp (E1e2)
 Left and right tail and parking lamps (E3e2, E4e2)
 Left and right license plate lamps (E19/1, E19/2)
 In the event of a failure in the rear SAM control module (N10/8):
Prerequisite: Ignition: ON
 Left and right tail and parking lamps (E3e2, E4e2)

 Left and right license plate lamps (E19/1, E19/2)
 In the event of a failure in the trailer recognition control module (N28/1):
Prerequisite: Ignition: ON
 Trailer tail lamps

Overhead control panel control GF82.20-P-4101S
module, location/purpose/design/
function
Trailer recognition control module, GF82.10-P-2106S
location/ purpose
FOG LAMPS, FUNCTION - GF82.10-P-2005S
MODEL 220.### 1#
Fig. 18: Fog Lamps Function Diagram
Fog lamp switch-on sequence
 Rotary light switch (S1) in parking light or low beam position

 Rotary light switch pulled out to first catch position
1. The position of the rotary light switch (S1) is read in by the left front SAM control module (N10/6) (1).
2. The left SAM control module (N10/6) sends a signal (2) to the instrument cluster (A1) and the right front
SAM control module (N10/7) via the data bus (CAN).
3. The left front SAM control module (N10/6) switches on the left fog lamp (E1e4).
4. The right front SAM control module (N10/7) switches on the right fog lamp (E2e4).
Function sequence for switching on rear fog lamp
 Rotary light switch (S1) in parking light or low beam position

 Fog lamps switched on
 Rotary light switch pulled out to second catch position
1. The position of the rotary light switch (S1) is read in by the left front SAM control module (N10/6) (1).
2. The left front SAM control module (N10/6) sends a signal (3) to the instrument cluster (A1), the rear
SAM control module (N10/8) and the trailer recognition control module (N28/1) via the data bus (CAN).
3. The rear SAM control module switches on the left rear fog lamp (E2e5), except
On national version vehicles the right rear fog lamp (E4e5) is switched on.
4. The trailer recognition control module (N28/1) actuates the trailer hitch socket (13-pin, X58).

location/ purpose
TRAILER RECOGNITION, FUNCTION - GF82.10-P-2006S
MODEL 220 with CODE (299) Trailer hitch
Fig. 19: Trailer Recognition Function Diagram
The trailer recognition fulfills the following functions:
 Actuation of the trailer lighting

 Monitoring of the trailer
 Monitoring of the pivoting trailer hitch
Control of trailer lighting
The trailer recognition control module (N28/1) receives the following signals from the data bus (CAN):
 From electronic ignition/starter switch control module (N73)

 Stop lamp on/off
 Reverse lamp on
 Rear SAM control module (N10/8)

 Tail/parking lamp on
 Rear fog lamp on
 Turn signal lamp on
 Anti-theft alarm on
The trailer recognition control module switches on the following lamps on the trailer via the 13-pin trailer hitch
socket (X58) depending on the requirements:
 Tail lamps/parking lamps

 Stop lamp
 Reverse lamp
 Rear fog lamp
 Turn signal lamps
 License plate lamps
In the event of a defect in the trailer recognition control module or the data bus the tail lamps are switched on.
Monitoring of pivoting trailer hitch
The trailer recognition control module monitors the towing hitch release switch (S62/24).
If the control module recognizes that the trailer hitch is not properly arrested, it sends a corresponding signal to
the instrument cluster (A1) via the data bus and switches on the LED display on the towing hitch release (A63)
for max. 30 sec.
Trailer recognition
When a trailer is connected to the trailer hitch socket the trailer recognition microswitch (X58s1) is connected
to ground. The trailer recognition control module sends the signal "trailer recognized" via the data bus when the
trailer recognition microswitch is connected to ground or a stop lamp is recognized.
Monitoring the trailer
The trailer recognition control module checks all lamps on the trailer and sends a signal to the instrument cluster
via the data bus if any of the lamps are defective.
When the anti-theft-alarm is activated a small current flows through the trailer stop lamps at regular intervals.
The trailer recognition control module recognizes an increase in the voltage when the circuit is interrupted, i.e.
connector disconnected or wire cut, and sends a signal to trigger the alarm via the data bus.

location/purpose
Jacket tube module, GF54.21-P-4104S
Rear signal acquisition and actuation GF54.21-P-4103S
module (SAM), location/purpose/design/
function
module (EIS),
LIGHT REMINDER FUNCTION - GF82.10-P-2008M
MODELS 215.###, 220.### 1#
Light reminder function for manually actuated standing or driving light
Fig. 20: Light Reminder Function Diagram - Manually Actuated Standing Or Driving Light
Light reminder function for automatically sensor controlled driving light

Fig. 21: Light Reminder Function Diagram - Automatically Sensor Controlled Driving Light
Light reminder functional sequence for manually actuated standing or driving lights
1. Basic requirement:
 The electronic key is located in the EIS control module's (N73) starter switch.
 The exterior lamp switch module (S1) is set to the "Standing lamp ON" or "Driving
light ON" position.
 At instrument cluster (A1) the signals
 "Key in starter switch",
 "Standing lamp ON"
and
 "Left front door locked"
are applied by way of the databus (1).
2. The electronic key is removed from the starter switch.

3. The left front door is opened:
 The rear SAM control module with fuse and relay module (N10/8) recognizes that the door is
unlocked by means of the left front door contact switch (S17/3) signal and transmits a "Door
open" signal to the instrument cluster.
4. The instrument cluster registers the change in the signal situation and trips the acoustic light warning
signal with buzzer (A1h1), because the "Parking lamp ON" signal from the front SAM control module
with fuse and relay module (N10/1) is still present.
Light reminder functional sequence for automatically sensor controlled driving light
 The engine has stopped, terminal 61 is switched off.
 The electronic key in the EIS control module's (N73) starter switch is in position "0" (terminal
15C).
 The automatic driving light switch is activated in the instrument cluster (up to 31.5.00)
 Exterior lamp switch (S1) is set to the "Auto" position (as of 01.06.00).
 At instrument cluster (A1) the signals
 "Terminal 15C ON",
 "Standing lamp ON"
and
 "Left front door locked"
are applied by way of the databus (1).
2. The left front door is opened:

 The rear SAM control module with fuse and relay module (N10/8) recognizes that the door is
unlocked by means of the left front door contact switch (S17/3) signal and transmits a "Door
open" signal to the instrument cluster.
3. The instrument cluster registers the change in the signal situation because of
 the "Standing lamp ON" signal from the front SAM control module with fuse and relay module
(N10/1)
and
 the "Terminal 15C ON" signal from the EIS control module (N73)
still being present, and therefore it triggers the light warning with buzzer (A1h1).
Signal flow at left control module GF54.21-P-4101S

Signal flow at right control module GF54.21-P-4102S
Signal flow at control module/rear GF54.21-P-4103S
position/ task/task/design
Exterior lamp switch module, GF82.10-P-4104M
position/task/ design
Trailer recognition control module, Model 215 GF82.10-P-2106M
position/task
Model 220 GF82.10-P-2106S
Door light switch, GF82.20-P-4102S
position/task/task/design
HEADLAMP ACTUATION, FUNCTION - GF82.10-P-2009A
MODEL 203, 215, 220.02 /06 /07 /12 /16 /17
The headlamp actuation encompasses the low and high beams lights.
The headlamps can be actuated:
 Manually with exterior lamp switch (S1s1) (model 203) and exterior lamp switch (S1) (models 215, 220)
 Automatically (sensor-controlled) or in dependency on "circuit 61 ON" (daytime running lamps)
Automatic headlamp actuation
The automatic driving light actuation is activated:
 By pre-selection on the instrument cluster (A1) (models 215, 220 up to 31.5.00)

 "Auto" position of exterior lamp switch (S1) (models 215, 220 as from 1.6.00) and exterior lamp switch
(S1s1) (model 203)
The basic conditions for automatic driving light actuation are:
 Slackening daylight intensity as occurs during dusk,

 Darkness
 Rain or snowfall (automatic light switch daylight sensor (B32/1))
 Failure of automatic light switch daylight sensor (B32/1)
Fog and secondary light influences, e.g. through oncoming traffic, road lighting or through light reflections, do
not lead to automatic driving light actuation.
Automatic driving light actuation when starting a journey and during it
 Automatic driving lamp actuation takes place as from "Circuit 61 ON"

 When the engine is switched off and the circuit status is "circuit 15R ON" or "circuit 15 ON" only the
standing lamp is actuated.
 Driving light actuation is disabled as soon as one of the basic prerequisites changes, e.g. when changing
from darkness to daylight after driving through a tunnel.
Automatic headlamp actuation at the end of a journey or in darkness
 After switching off the engine (e.g. "circuit 15 ON", "circuit 15R ON" or "circuit 15C ON") the standing
lamp remains on.
 The standing lamp is not switched off until the transmitter key (A8/1) (circuit 15C OFF) is removed.
Daytime running lamps
The daytime running lamps, forced switch on every time the engine is started (Circuit 61 on), are for statutory
reasons in vehicles of the following country versions preset in the instrument cluster
(A1) and cannot be deactivated. For all other national versions the daytime running lamps can be activated and
deactivated using the left multifunction steering wheel (S110) and right multifunction steering wheel (S111) key
groups in the instrument cluster (A1).
Switching off daylight running lights
The daytime running lamps function is canceled by:
 Engine switched off

 Manual switch-on of the driving lamps with the exterior lamp switch (S1s1) (model 203) and exterior
lamp switch (S1) (models 215, 220 as from 1.6.00)
High beam actuation
The high beam can be switched on as a steady light only when low beam is "ON" by pushing the combination
switch (S4) away. The high beam is actuated when the combination switch (S4) is already set to the "high beam
ON" position:
 During the journey immediately by switching on the driving lamps

 When the engine is switched off and the "low beam ON" position of the exterior lamp switch (S1s1)
(model 203) and of the exterior lamp switch (S1) (models 215, 220 as from 1.6.00) as from position
"circuit 15R ON"
Actuation of the headlamp flasher function is dependent on the low beam.
Low-beams actuation, Models 215, GF82.10-P-3002A

function 220.02/06/07/12/16/17 for left-
hand drive vehicles
Model 203 except (code 612b) for GF82.10-P-3002B
xenon headlamp lamp unit
Model 203 with code (612b) GF82.10-P-3002C
Xenon headlamp unit
Model 203 as from 1.7.02 except GF82.10-P-3002PM
code (614) bixenon headlamp unit
Automatic headlamp Models 215, GF82.10-P-3003A
actuation, function 220.02/06/07/12/16/17 up to
31.5.00 for left-hand drive
vehicles
Models 215, GF82.10-P-3003AA
220.02/06/07/12/16/17 as from
1.6.00 for left-hand drive vehicles
Model 203 GF82.10-P-3003B
High-beams actuation, Models 215, GF82.10-P-3004A
function 220.02/06/07/12/16/17 for left-
hand drive vehicles
Model 203 up to 30.6.02 GF82.10-P-3004B
Model 203 as of 1.7.02 with code GF82.10-P-3004BA
(614) bi-xenon headlamp unit
Light warning, Model 203 GF82.10-P-2008C
function
Models 215, 220 for left-hand GF82.10-P-2008M
drive vehicles
Daytime running light Models 215, GF82.10-P-3005A
control, function 220.02/06/07/12/16/17 for left-
hand drive vehicles
Model 203 GF82.10-P-3005B
EXTERIOR LIGHTING, TRAILER, FUNCTION - GF82.10-P-2010A
MODELS 203, 215, 220.02 /06 /07 /12 /16 /17 with CODE (550) Trailer hitch for retrofitted trailer hitch
as for current production configuration
The trailer recognition control module (N28/1) sets up the interface between the trailer's lighting system and the
vehicle's exterior lighting.
The task of the trailer recognition control module (N28/1) is:
 to detect and monitor a connected trailer, and in combination with the vehicle's exterior lights to actuate
the trailer's lamps.
 monitoring of the connected trailer in combination with the anti-theft alarm system (ATA) when the
vehicle is parked.
Trailer sensing, function GF82.10-P-3014A

Trailer lighting control, GF82.10-P-3015A
function
Trailer anti-theft device, With code 550 trailer GF82.10-P-3016A
function hitch
With code 551a anti-theft
alarm system (ATA).
HEADLAMP RANGE ADJUSTMENT MOTORS, LOCATION/PURPOSE - GF82.10-P-2101A
MODEL 129, 140, 202, 208, 210, 220 with CODE (612b) Xenon headlamp unit
Electric headlamp range Model 129 GF82.10-P-0001-01C

adjustment (HRA),
Model 140 GF82.10-P-0001-01D
Model 202 GF82.10-P-0001-01E
Model 208 GF82.10-P-0001-01A
Model 210 GF82.10-P-0001-01B
Model 220 GF82.10-P-0001-01F
Headlamp range The headlamp range
adjustment motors, adjustment motors in the
purpose left and right headlamps
adjust the inclination
angle of the reflectors
depending on the
actuation by the control
module.
The position of the
reflectors is indicated to
the control module by
potentiometers in the
motors.
HEADLAMP RANGE ADJUSTMENT CONTROL MODULE, LOCATION/PURPOSE - GF82.10-P-

2102S
MODEL 220 with CODE (612b) Xenon headlamp unit
Electric headlamp range GF82.10-P-0001-01F

adjustment (HRA),
Headlamp range The control module
adjustment control evaluates the signals from
module, purpose the pneumatic suspension
control modules and
ABS/ASP control
modules as well as the
headlamp range
adjustment motors. It
actuates the headlamp
range adjustment motors
depending on the vehicle
load, vehicle status and
position of the
headlamps.
XENON HEADLAMP CONTROL MODULE, LOCATION/TASK - GF82.10-P-2104A
MODELS 129, 140, 202, 208, 210, 215, 220 up to 31.8.02 with CODE (612b) Xenon headlamp unit

(XENON), location of 210
components
Model 202 GF82.10-P-0002-01B
Model 215 GF82.10-P-0002-01D
MODEL 220 up to GF82.10-P-0002-01C
31.8.02 with Xenon
headlamp lamp unit (code
612b).
MODEL 220 as of 1.9.02 GF82.10-P-0002-01CA
unit (code 614).
Xenon headlamp control The xenon headlamp
module, task control module (E1n1,
E2n1) activates the xenon
headlamp control module
and ignition module
(E1n2, E2n2) via the
control voltage and
regulates the voltage
supply to the xenon
headlamps.
XENON HEADLAMP IGNITION UNIT, LOCATION/TASK - GF82.10-P-2105A
MODELS 129, 140, 202, 208, 210, 215, 220 up to 31.8.02 with CODE (612b) Xenon headlamp unit

(XENON), location of 210
components
Model 202 GF82.10-P-0002-01B
Model 215 GF82.10-P-0002-01D
MODEL 220 up to GF82.10-P-0002-01C
31.8.02 with Xenon
headlamp lamp unit (code
612b).
MODEL 220 as of 1.9.02 GF82.10-P-0002-01CA
unit (code 614).
Xenon headlamp ignition The xenon headlamp
unit, purpose ignition device, (E1n2,
E2n2) ignites the xenon
lamps by means of a
high-voltage surge.
TRAILER RECOGNITION CONTROL MODULE, LOCATION/TASK - GF82.10-P-2106
Trailer recognition control module, location/task - GF82.10-P-2106M
MODEL 215 except CODE (550) Trailer hitch
Fig. 22: Identifying Trailer Recognition Control Module Location
Trailer recognition GF82.10-P-2106-01S

control module, position
Trailer recognition  Evaluation of signals
control module (N28/1), from CAN interior
task
 Detects when a
trailer has been
coupled
 Actuation of the
trailer lights
 Monitors the trailer
and the trailer
coupling
Trailer recognition control module, position - GF82.10-P-2106-01S
Models 215, 220 with CODE (299) trailer coupling
Shown on model 220
Fig. 23: Identifying Trailer Recognition Control Module - Shown On Model 220
Trailer recognition control module, location/task - GF82.10-P-2106S
MODELS 203, 220 except CODE (550) Trailer hitch
Shown on model 203
Fig. 24: Identifying Trailer Recognition Control Module - Shown On Model 203
Trailer recognition The trailer recognition
control module, position control module (N28/1) is
located at the rear on the left
side.
Model 220 GF82.10-P-2106-01S
Trailer recognition  Evaluation of the
control module (N28/1), signals of the CAN
task interior and the
microswitch for trailer
recognition (model 220
to 4.99)
 Detects when a trailer
has been coupled
 Actuation of the trailer
lights
 Monitors the trailer
and the trailer coupling
SIDE LIGHT ACTUATION FUNCTION - GF82.10-P-3000A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Fig. 25: Side Light Actuation Function Diagram
Operating procedure
1. Exterior lamp switch (S1) is set to parking lights position and notifies the left front SAM control
module (N10/6) of "Parking lights ON" .
2. The left front SAM control module actuates the standing and parking lamp (E1e3) in the left-hand lamp
unit and simultaneously sends the "Parking lights ON" signal over the databus (1) the
 instrument cluster (A1),
 right front SAM control module (N10/7) and the
 rear SAM control module (N10/8).
3. The right front SAM control module (N10/7) actuates the standing and parking lamp (E2e3) in the right-
hand lamp unit.
4. The rear SAM control module (N10/8) actuates the
 outer tail and parking lamp in the left and right-hand tail and parking lamps (E3e2 and E4e2),
 inner tail lamp in the left and right-hand auxiliary tail lamps (E3e8 and E4e8),
and the
 left and right license plate light (E19/1 and E19/2).

5. For trailer couplings the "Parking light ON" signal is sent over the databus (1) to the trailer recognition
control module (N28/1) and current for the trailer's tail lamps and license plate lamps switched to the
trailer hitch socket, 13-pin (X58).
Actuating the instrument cluster (A1) with the "Parking lights ON" signal triggers an acoustic warning
signal if the electronic key has been removed and the driver's door is open.
Left signal acquisition and actuation GF54.21-P-4101S

module, position/task/design/function
Right signal acquisition and actuation GF54.21-P-4102S
position/ task
Lights-on buzzer, function GF82.10-P-2008M
PARKING LIGHT ACTUATION FUNCTION - GF82.10-P-3001A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 26: Parking Light Actuation Function Diagram
Operating procedure
1 The exterior lamp switch (S1) is set to left parking light or right parking light and notifies the
left front SAM control module (N10/6) of "Left parking light ON" or "Right parking light ON" .
2.1 Left parking light ON:
The left front SAM control module actuates the standing and parking lamp (E1e3) in the left-hand lamp
unit and sends simultaneously the "Left parking light ON" signal over the databus (1)
2.2 Right parking light ON:

 The left front SAM control module sends the signal over the databus (1) for "Right parking light
ON"
 the right front SAM control module (N10/7)
and
 the rear SAM control module (N10/8).

 The right front SAM control module (N10/7) actuates the standing and parking lamp (E2e3) in the
right-hand lamp unit.
3 Depending on the parking light position the rear SAM control module (N10/8) actuates the outer tail
and parking lamp in the left or right-hand tail and parking lamp (E3e2 or E4e2) an.
4 For trailer couplings the "Left parking light ON" or "Right parking light ON" signal is sent over the
databus (1) to the trailer recognition control module (N28/1) and the current for the trailer's left or right-
hand tail and parking lamp is switched to the trailer hitch socket, 13-pin (X58).
If one of the outer tail and parking lamps in the left or right-hand tail and parking lamps (E3e2 or
E4e2) is faulty the inner auxiliary tail lamp (E3e8 or E4e8) is switched on as a replacement for the
parking light.

position/task
Model 220 GF82.10-P-2106S
LOW-BEAM ACTUATION, FUNCTION - GF82.10-P-3002A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Fig. 27: Low-Beam Actuation Function Diagram
Functional sequence
 Steering column switch (S4) in "low beam" position
 The exterior lamp switch (S1) is set to parking lamp :

 the standing and parking lamps (E1e3 and E2e3) in the right-hand lamp assemblies,
 "terminal 15R ON",
 the standing and parking lamps (E3e2, E3e8, E4e2 and E4e8) in the rear lighting system and
the license plate lamps (E19/1 and E19/2) are driven.
 Where a trailer coupling is present the trailer recognition control module (N28/1) switches
additional power to the trailer's tail lamps and license plate lamp to the AHV, 13-pin trailer hitch
socket (X58).
2. The exterior lamp switch (S1) is set to low-beam position and sends a "Driving light ON" signal to
the left front SAM control module (N10/6).
3. The left front SAM control module registers the new switching situation, actuates the low beam lamp
(E2e2) in the right-hand lamp assembly and at the same time it sends "Driving light ON" to the right
front SAM control module (N10/7) signals over the databus (1).
4. The right front SAM control module (N10/7) actuates the low-beam (E1e2) in the left-hand lamp
assembly.
The standing and parking lamps in the left and right-hand lamp assemblies remain active when the
driving light is switched on. Actuating the instrument cluster (A1) with the "Driving light ON" signal
triggers an acoustic warning signal if the electronic key has been removed and the driver's door is open.

Signal acquisition and actuation GF54.21-P-4103S
module, rear
position/ task
Light reminder, function GF82.10-P-2008M
AUTOMATIC DRIVING LIGHT ACTUATION, FUNCTION - GF82.10-P-3003
Automatic driving light actuation, function - GF82.10-P-3003A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1# up to 31.5.00

Fig. 28: Automatic Driving Light Actuation Function Diagram
Function sequence driving through a tunnel
1. Basic prerequisite:
 Vehicle speed signal applied to instrument cluster.
 The daylight provides sufficient visibility.
 It is not raining nor snowing, the windshield wiper is switched off.
 The exterior lamp switch is set to position "0"
 The automatic driving light function is switched on and the instrument cluster (A1) notifies this to
the left front SAM control module (N10/6) over the databus (1).
2. The overhead control panel control module (N70) along with the rain sensor and the position of the
windshield wiper monitors the automatic light switch daylight sensor (B32/1).
Monitoring of the rain sensor and the position of the windshield wiper switch allows the overhead
control panel control module to automatically actuate the headlamps in the event of rain or snow.
3. The automatic light switch daylight sensor (B32/1) together with the sunlight sensor monitors the
intensity of the daylight and in conjunction with the forward-looking light sensor it also measures the
light conditions in the direction of travel.
4. The vehicle approaches a tunnel:
 The forward-looking light sensor of the automatic light switch daylight sensor (B32/1) detects a
darkened tunnel entrance.
The light switch sensor unit actuates the overhead control panel control module (N70) using a
"Darkness, lights ON" signal.
5. The upper control panel control module evaluates the signal and sends the signal over the databus (1) for
"Driving lights ON" to the left front SAM control module (N10/6).
6. The left front SAM control module (N10/6), which is actuated over the databus by the instrument cluster
with the "Automatic driving light switch activated" signal, forwards the "Driving light ON" signal
over the databus to the right front SAM control module (N10/7) and rear SAM control module (N10/8)
and then simultaneously activates
 the standing and parking lamp (E1e3) in the right-hand lamp assembly
and
driving light (E2e2) in the right-hand lamp unit.

7. The right front (N10/7) and rear (N10/8) SAM control modules receive the "Driving light ON" signal.
8. The right front SAM control module (N10/7) actuates the
 the standing and parking lamp (E2e3) in the right-hand lamp unit,
and
driving light (E1e2) in the left-hand lamp assembly.

9. The rear SAM control module (N10/8) actuates
 the standing and parking lamp (E3e2, E3e8, E4e2 and E4e8) in the left and right-hand tail lamps
and
 the left and right-hand license-plate lamps (E19/1 and E19/2)

10. For trailer couplings the "Driving light ON" signal is also sent to the trailer recognition control module
(N28/1) and current for the trailer's tail lamps and license plate lamps switched to the trailer hitch socket,
13-pin (X58).
11. The driving lights are switched on automatically, the vehicle then enters the tunnel with its lights on.
12. The automatic light switch daylight sensor (B32/1) remains active when in a tunnel and automatically
switches off the driving lights when it detects light at the end of the tunnel.

location/purpose
Model 220 GF82.10-P-2106S
Automatic driving light actuation, function - GF82.10-P-3003AA
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1# as of 1.6.00
Fig. 29: Automatic Driving Light Actuation Function Diagram
 Vehicle speed signal applied to instrument cluster.
 The daylight provides sufficient visibility.
 It is not raining nor snowing, the windshield wiper is switched off.
 The exterior lamp switch is set to position "Auto"
 The automatic driving-light is thus switched on.
2. The overhead control panel control module (N70) along with the rain sensor and the position of the
windshield wiper monitors the automatic light switch daylight sensor (B32/1).
Monitoring of the rain sensor and the position of the windshield wiper switch allows the overhead
control panel control module to automatically actuate the headlamps in the event of rain or snow.
3. The automatic light switch daylight sensor (B32/1) together with the sunlight sensor monitors the
intensity of the daylight and in conjunction with the forward-looking light sensor it also measures the
light conditions in the direction of travel.
4. The vehicle approaches a tunnel:
 The forward-looking light sensor of the automatic light switch daylight sensor (B32/1) detects a
darkened tunnel entrance.
 The light switch sensor unit actuates the overhead control panel control module (N70) using a
"Darkness, lights ON" signal.
5. The upper control panel control module evaluates the signal and sends the signal over the databus (1) for
"Driving lights ON" to the left front SAM control module (N10/6).
6. The left front SAM control module (N10/6), which is actuated by the exterior lamp switch's (S1) "Auto"
function, forwards the "Driving light ON" signal over the databus to the right front SAM control module
(N10/7) and rear SAM control module (N10/8) and then simultaneously activates
and
driving light (E2e2) in the right-hand lamp unit.

7. The right front (N10/7) and rear (N10/8) SAM control modules receive the "Driving light ON" signal.
8. The right front SAM control module (N10/7) actuates
and
driving light (E1e2) in the left-hand lamp assembly.

and

10. For trailer couplings the "Driving light ON" signal is also sent to the trailer recognition control module
(N28/1) and current for the trailer's tail lamps and license plate lamps switched to the trailer hitch socket,
13-pin (X58).
11. The driving lights are switched on automatically, the vehicle then enters the tunnel with its lights on.
12. The automatic light switch daylight sensor (B32/1) remains active when in a tunnel and automatically
switches off the driving lights when it detects light at the end of the tunnel.

location/purpose
Model 220 GF82.10-P-2106S
Exterior lamp switch, GF82.10-P-4104M
MAIN BEAM ACTUATION FUNCTION - GF82.10-P-3004A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Fig. 30: Main Beam Actuation Function Diagram
Operating procedure
1. Basic requirements:
 The electronic key in the starter switch of the EIS control module (N73) is set at least to position
"2" (terminal 15R).
 The exterior lamp switch (S1) is set to the driving lights or as of 06.00 the "AUTO" position
 the standing and parking lamp and the driving light in the lamp units,
 the standing and parking lamp in the lamp units
and
 the license plate lamps are actuated.

 For trailer couplings the trailer recognition control module switches additional voltage for the
trailer's tail lamps and license plate lamps to the trailer hitch's socket, 13-pin.
 The daytime running light function enables the headlamp flasher only.
2. The combination switch lever (S4) is moved to the high beam position.
3. The steering column module (N80) records the combination switch's position and sends the "Driving
lights ON" signal over the databus (1).
 left front SAM control module (N10/6),
 right front SAM control module (N10/7) and the
 instrument cluster (A1).
4. The left and right SAM control modules actuate the driving light (E1e1 and E2e1) in addition to the low
beam lights in the left and right-hand lamp units.
5. The instrument cluster actuates the blue high beam indicator lamp (A1e3) and thus notifies optically that
the high beam lights are switched on.
The instrument cluster (A1) triggers an acoustic warning signal, as for the low beam lights, when the
high beam is switched on, the electronic key has been removed and the driver's door is open.
Operational sequence for actuating headlamp flasher
 The operational sequence when activating the headlamp flasher is equivalent, in relation to the signal
flow, to that of the driving light. The only difference lies in the activation of the switching operation. To
operate the headlamp flasher the combination switch lever (S4) must be pulled into the switching position
opposite the driving light one (LH) and held in this position.
 The headlamp flasher a and therefore the driving light a remains active for as long as the lever is held in
the headlamp flasher position.

Steering column module, GF54.21-P-4104S
Light warning, function GF82.10-P-2008M
DAYTIME RUNNING LIGHT ACTUATION, FUNCTION - GF82.10-P-3005A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 31: Daytime Running Light Actuation Function Diagram
Operational sequence
 The exterior lamp switch (S1) is set to "0 or driving light" , as of 06.00 also to "AUTO".
 The "daytime driving light" function can be activated by the instrument cluster, or is
preprogrammed ex-factory for certain country versions and cannot be altered.
2. The engine is started and the EIS control module (N73) sends the (1) country-specific code via the data
bus to the left front SAM control module (N10/6), right front SAM control module (N10/7) and rear SAM
control module (N10/8).
3. The instrument cluster (A1) recognizes via terminal 61 that the engine has started and sends the
"Daytime running light ON" signal via the data bus (1) to the left front SAM control module (N10/6).
4. The left front SAM control module (N10/6), forwards the "Daytime running light ON" signal via the
data bus to the right front SAM control module (N10/7) and rear SAM control module (N10/8) and then
simultaneously activates
and
 the low beam (E2e2) in the right-hand lamp assembly.

5. The right front (N10/7) and rear (N10/8) SAM control modules receive the "Daytime running light
ON" signal.
6. The right front SAM control module (N10/7) actuates
and
the low beam (E1e2) in the left-hand lamp assembly.

and
For trailer couplings the "Daytime running light ON" signal is registered via the data bus (1) by the trailer
recognition control module (N28/1) and power for the trailer's tail and license plate lamps is switched to the
trailer hitch socket, 13-pin (X58).
As of model year 2002 only the low beams are switched on the USA and Canada version. Parking
lamps, taillamps and license plates lamps are no longer activated.

Electronic ignition switch control module, GF80.57-P-4102S
location/purpose
Model 220 GF82.10-P-2106S
Exterior lamp switch, GF82.10-P-4104M
FOG LAMP ACTUATION FUNCTION - GF82.10-P-3006A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 32: Fog Lamp Actuation Function Diagram
Functional sequence
 The exterior lamp switch (S1) is set to the "Driving light ON" or "Standing lamp ON"
position:
 the low beam (E1e2 and E2e2) or the standing and parking lamps (E1e3 and E2e3) in the
lamp assemblies
and
 the standing and parking lamps (E3e2 and E4e2) in the tail lamps are switched on
2. The exterior lamp switch (S1) is also pulled out to the 1st notch stage "Fog lamps ON".
3. Alongside the exterior lamp switch's standing lamp or low beam positions the left front SAM control
module (N10/6) also records the "Fog lamp ON" signal.
4. The left front SAM control module actuates the fog lamp (E1e4) in the left-hand lamp assembly and also
sends a "Fog lamp ON" signal over the databus (1) to the right front SAM control module (N10/7).
5. The right front SAM control module (N10/7) actuates the fog lamp (E2e4) in the right-hand lamp
assembly.

module, rear
Exterior lamp switch module, position/ GF82.10-P-4104M
function/design
REAR FOG LAMP ACTUATION FUNCTION - GF82.10-P-3007A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Fig. 33: Rear Fog Lamp Actuation Function Diagram
Functional sequence
 The exterior lamp switch module (S1) is set to the "Driving light ON" or "Standing light ON"
position:
 the low beam (E1e2 and E2e2) or the standing and parking lamp (E1e3 and E2e3) in the
lamp assemblies
and
 the standing and parking lamps (E3e2 and E4e2) in the tail lamps are switched on
 The exterior lamp switch (S1) is pulled out to the 1st notched position Fog lamp ON":
 the fog lamps (E1e4 and E2e4) in the left and right-hand lamp units are switched on.
2. The exterior lamp switch (S1) is pulled out to the 2nd notched position "Fog lamps ON" .
3. Alongside the exterior lamp switch's standing lamp or low beam lights and fog lamp positions the left
front SAM control module (N10/6) also records the "Fog lamp ON" signal.
4. The left front SAM control module sends the "Fog lamp ON" signal over the databus (1) to the rear SAM
5. The rear SAM control module (N10/8) actuates the "fog lamp" in the left-hand tail lamp.
6. If a trailer coupling is present the "Fog lamp ON" signal is also sent over the databus (1) to the trailer
recognition control module (N28/1).
7. The trailer recognition control module (N28/1) verifies whether a trailer is coupled, if this is so it sends a
signal over the databus authorizing the rear SAM control module (N10/8) to switch off the fog tail lamp,
while simultaneously supplying power to the AHV, 13-pin (X58) trailer hitch socket's fog lamp.

module, rear
position/ task
Exterior lamp switch module, position/ GF82.10-P-4104M
function/design
TURN SIGNAL LAMP ACTUATION FUNCTION - GF82.10-P-3008A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 34: Turn Signal Lamp Actuation Function Diagram
Operational sequence turn indicators
 Ignition on (terminal 15)
2. The combination switch lever (S4) is set to "Left turn" or "Right turn" position.
3. The steering column module (N80) registers the combination switch's turn signal position and sends the
"Left turn" or "Right turn" signals over the databus (1) to the corresponding control module for
actuation of the turn signal lamps.
4.1 Left turn:

 The left front SAM control module (N10/6) actuates the left turn signal lamp (E1e2) in the left-
hand lamp unit.
 The left front door control module (N69/1) actuates the left exterior mirror turn signal (E6/5).
 The rear SAM control module (N10/8) actuates the turn signal lamp (E3e1) in the left-hand tail
lamp.
4.2 Right turn:
 The right front SAM control module (N10/7) actuates the turn signal lamp (E2e5) in the right-hand
lamp unit.
 The right front door control module (N69/2) actuates the right exterior mirror turn signal (E6/6).
 The rear SAM control module (N10/8) actuates the turn signal lamp (E4e1) in the right-hand tail
lamp.
5 The instrument cluster (A1) registers the turn signal procedure by optical and acoustical means, by
actuating the indicator lamps, left turn or right turn (A1e1 or A1e2) and the audible turn signal indicator
(A1h2).
6 The upper control panel control module (N72/1) with the hazard warning indicator switch blocks the
hazard warning indicator function, because the "Left turn" or "Right turn" databus signal recognizes
that turn indicator lamps have priority over hazard warning indicators.
7 For trailer couplings the "Left turn" or "Right turn" signal is sent over the databus (1) to the trailer
recognition control module (N28/1) and the flasher frequency current for the trailer's left or right-hand
turn signal lamp is switched to the trailer hitch socket, 13-pin (X58).
 The turn signal lamp's flashing procedure is ended self-acting by countersteering or manually by
returning the combination switch lever to its original position.
 If a turn signal lamp malfunctions the flashing frequency is doubled for the indicator lamp turn left
or turn right in the instrument cluster. The frequency of the turn signal lamps remains unchanged.
Operational sequence turn signal lamp touch control
 The operational sequence for the turn signal lamp touch control is the same, in relation to the signal flow,
as that for the turn signal indicator. The difference lies in the actuation and ending of the turn signal
procedure only.
 For the touch control function, the combination switch lever need only be moved briefly (less than 500
ms) into the desired turn signal lamp position. Without the lever engaging into place this procedure will
activate 3 turn signal cycles.
 Touch control is interrupted by activating the hazard warning light function, or by pushing the
combination switch in the opposite direction.

position/task/design/ function
position/ task/design/function
position/task
Model 220 GF82.10-P-2106S
HAZARD WARNING LIGHT ACTUATION FUNCTION - GF82.10-P-3009A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
Fig. 35: Hazard Warning Light Actuation Function Diagram
Operational sequence hazard warning lights
1. The hazard warning system switch (N72/1s5) is actuated and displays this by flashing on and off.
2. The upper control panel control module (N72/1) has registered the hazard warning system switch's
applied position and sends the "Hazard warning lights ON" signal over the databus (1) to the steering
column module (N80).
3. The steering column module (N80) implements the hazard warning system signal and sends a "Turn left
and right" signal over the databus (1) to the corresponding control module and the instrument cluster.
4. The hazard warning system is active:
 The left front SAM control module (N10/6) actuates the left turn signal (E1e5) and the right front
SAM control module (N10/7) activates the right turn signal (E2e5) in the lamp unit.
 The left front door control module (N69/1) and right front (N69/2) actuate the left exterior mirror
turn signal lamp (E6/5) and right exterior mirror (E6/6).
 The rear SAM control module (N10/8) actuates the turn signal lamps (E3e1 and E4e1) in the left
and right-hand tail lamps.
 The instrument cluster (A1) registers the turn signal procedure by optical and acoustical means, by
actuating the turn signal lamps, left turn or right turn (A1e1 or A1e2) and the audible turn signal
indicator (A1h2).
5. For trailer couplings the "Left turn" or "Right turn" signal is sent over the databus (1) to the trailer
recognition control module (N28/1) and the flasher frequency current for the trailer's left and right-hand
turn signal lamp is switched to the trailer hitch socket, 13-pin (X58).
If the steering column module (N80) malfunctions the "left turn and right turn" signals are sent directly
over the databus from the upper control panel control module (N72/1) to the corresponding control
modules.

position/ task/design/function
position/task
Model 220 GF82.10-P-2106S
STOP LIGHT ACTUATION FUNCTION - GF82.10-P-3010A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 36: Stop Light Actuation Function Diagram
Operating procedure
 The electronic key in the ignition and starter switch is set to position "2" (terminal 15) and the
service brake is actuated.
2. The stop lamp switch's (S9/1) switching contact feeds voltage to the traction systems control module
(N47) and the EIS control module (N73).
3. The EIS control module (N73) transforms the voltage signal and sends a "Stop lamp ON" signal over
the databus (1) to the rear SAM control module (N10/8). Simultaneously, the traction systems control
module (N47) feeds the stop lamp switch's voltage signal direct to the rear SAM control module.
The direct actuation of the rear SAM control module by the traction systems control module is
intended to prevent any time delay in forwarding the stop lamp signal from the EIS control module over
the databus.
4. The rear SAM control module actuates the stop lamp in the left and right-hand tail lamps (E3e4 and
E4e4) and the center high mounted stop lamp (E21).
5. For trailer couplings the "Stop lamp ON" signal from the rear SAM control module is also sent to the
trailer recognition control module (N28/1) and current for the trailer's stop lamps switched to the trailer
hitch socket, 13-pin (X58).
The "Stop lamp ON" message to the trailer recognition control module ensues over the databus (1) and
simultaneously also by way of a direct voltage signal.
Next to its actual specified task, the actuation of the stop lamps, the stop lamp signal is also of
significance for other functional areas in the vehicle. Thus the stop lamp signal from the EIS control
module and the traction systems control module is sent over the databus (1 and 2)
 from the (ME-SFI) control module (N3/10),

 from the electronic selector lever control module (N15/5),
 from the DTR control module (N63/1),
 from the Keyless Go control module (N69/5),
 from the headlamp range adjustment control module (N71),
 from brake Assist (BAS)
and
 from the electronic transmission control (ETC)
where it is received, analyzed and used for the actuation of system-specific functions.

module position/task/design/function
position/task
Model 220 GF82.10-P-2106S
REVERSING LAMP ACTUATION FUNCTION - GF82.10-P-3011A
MODEL 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Fig. 37: Reversing Lamp Actuation Function Diagram
Operating procedure
 The electronic key in the ignition and starter switch is in position "2".
 The selector lever of the electronic selector lever control module (N15/5) is in position "R".
2. The electronic selector lever control module notifies the EIS control module (N73) over the databus (2) of
"Reverse gear ON" .
3. The EIS control module (N73) transforms the signal and sends a "Reversing lamp ON" signal over the
databus (1) to the rear SAM control module.
4. The rear SAM control module) actuates the reversing lamps in the left and right-hand tail lamps (E3e1
and E4e1).
5. For trailer couplings the "Reversing lamp ON" signal is also sent over the database (1) to the trailer
recognition control module (N28/1) and current for the trailer's reversing lamps is switched to the trailer
hitch socket, 13-pin (X58).
Actuation of the reversing lamps is interrupted when another stage is selected on the electronic
selector lever control module (N15/5).

module position/task/design/function
position/task
Model 220 GF82.10-P-2106S
SUBSTITUTE LIGHT ACTUATION FUNCTION - GF82.10-P-3012A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
When the exterior lights are switched on the bulbs are monitored by the control module circuits:
 left front SAM (N10/6)

 right front SAM (N10/7)
and
 rear SAM (N10/8)
constantly for short and or open circuits.
If safety-relevant bulbs fail, substitute lights are operated.
The scope of the substitute light operation is dependent on the country-specific version. Flashing lamp functions
have a higher priority than steady light ones.
Substitute light for European Union vehicle versions
Faulty bulbs Substitute lights Remarks

Left inside tail lamp (E3e8) Rear fog lamp (E3e5)
Right inside tail lamp (E4e8) Rear fog lamp (E4e5)
Left outside tail and parking lamp Left inside tail lamp (E3e8) for parking lights only
(E3e2)
Right outside tail and parking
lamp (E3e2)
Right inside tail lamp (E4e8) for parking lights only
Substitute lights for non European Union vehicle versions
Faulty bulbs Substitute lights Remarks

Left stop lamp (E3e4) Left reversing lamp (E3e3)
Right stop lamp (E4e4) Right reversing lamp (E4e3)
Left front turn signal lamp (E1e5) Left fog lamp (E1e4)
Left rear turn signal lamp (E3e1) Left reversing lamp (E3e3)
Right front turn signal lamp Right fog lamp (E2e4)
(E2e5)
Right rear turn signal lamp (E4e1) Right reversing lamp (E4e3)
Tail lamp (E3e8), left inside Rear fog lamp (E3e5)
Left standing and parking lamp Left fog lamp (E1e4)
(E1e3)
Right standing and parking lamp Right fog lamp (E2e4) for parking lights only
(E2e3)
Left outside tail and parking lamp Left inside tail lamp (E3e8) for parking lights only
(E3e2)
Right outside tail and parking Right inside tail lamp (E4e8) for parking lights only
lamp (E4e2)
for parking lights only

EMERGENCY LIGHT ACTUATION FUNCTION - GF82.10-P-3013A
MODELS 215.###, 220.02# /06# /07# /12# /16# /17# 1#
The emergency light actuation function is intended to prevent the complete breakdown of the exterior light
system occurring through a single error, e.g. through a faulty processor.
Emergency light actuation in event of databus or left front SAM control module (N10/6) malfunction
When the ignition is switched on (terminal 15) the right front SAM control module (N10/7) actuates the
 standing and parking lamp (E2e3) in the right-hand lamp unit,
and
 and low beam lamp (E1e2) in the left-hand lamp unit.
The rear SAM control module (N10/8) actuates
 the outer tail and parking lamps (E3e2 and E4e2) in the left and right-hand tail lamps,
and
 the left and right-hand license plate lamps (E19/1 and E19/2).
Emergency light actuation in event of databus or right front SAM control module (N10/7) malfunction
When the ignition is switched on (terminal 15) the left front SAM control module (N10/6) actuates the
 standing and parking lamp (E1e3) in the left-hand lamp unit,

and
 and low beam (E2e2) in the right-hand lamp unit.
The rear SAM control module (N10/8) actuates
 the outer tail and parking lamps (E3e2 and E4e2) in the left and right-hand tail lamps,
and
 the left and right-hand license plate lamps (E19/1 and E19/2).
Emergency light actuation in event of processor malfunction in rear SAM control module (N10/8)
When the ignition is switched on (terminal 15) an emergency function in the rear SAM control module switches
on the
 outer tail and parking lamps (E3e2 and E4e2) in the left and right-hand tail lamps,
and
 and left and right-hand license plate lamps (E19/1 and E19/2).
Emergency light actuation in event of processor malfunction in trailer recognition control module
(N28/1)
When the ignition is switched on (terminal 15) an emergency function in the trailer recognition control module
switches the supply for the trailer's tail lamps to the trailer hitch socket, 13-pin (X58).

position/task
Model 220 GF82.10-P-2106S
TRAILER SENSING, FUNCTION - GF82.10-P-3014A
MODELS 203, 215, 220.02 /06 /07 /12 /16 /17 with CODE (550) Trailer hitch
Shown on Model 220

Fig. 38: Trailer Sensing Function Diagram - Shown On Model 220
Operating procedure
Basic conditions:
 Circuit 15 ON
 The trailer is mechanically coupled.
1. The trailer's connecting line is plugged in to the trailer hitch socket, 13-pin (X58):
 Model 220 up to 4.99
The switching contact of the trailer recognition microswitch in the trailer hitch socket closes and switches
ground to the trailer recognition control module (N28/1).
 Model 220 as of 5.99, model 203 and model 215
The circuits of the left trailer turn signal lamp and trailer stop lamps are energized briefly by the trailer
recognition control module (N28/1).
2. The trailer recognition control module (N28/1) detects at the ground signal of the microswitch (model
220 up to 4.99) the trailer connected electrically to the closed circuit of the turn signal lamp and/or of the
stop lamps.
3. The trailer recognition control module (N28/1) reports "Trailer connected" to the control module with
rear fuse and relay module Fond (N10/2) or the rear SAM control module (N10/8) (models 215, 220) via
the interior CAN".
4. The rear SAM control module with fuse and relay module (N10/1) or rear SAM control module (N10/8)
(models 215, 220) activates the actuation and monitoring of the trailer lighting system.
Vehicles with code 220a PARKTRONIC The signal "trailer connected" transmitted by the interior CAN
causes the Parktronic control module (N62) to switch off the Parktronic sensors in the rear bumper.
Trailer recognition GF82.10-P-2106S

control module,
location/task
Model 215 GF82.10-P-2106M
TRAILER LIGHTING CONTROL, FUNCTION - GF82.10-P-3015A
MODELS 203, 215, 220.02 /06 /07 /12 /16 /17 with CODE (550) Trailer hitch
Shown on Model 220
Fig. 39: Trailer Lighting Control Function Diagram - Shown On Model 220
Operating procedure
Basic conditions:
 The trailer recognition control module (N28/1) has detected the coupled trailer.
 Circuit 15R ON
(models 215, 220) receives via the interior CAN the signals for actuating the rear lighting devices.
(models 215, 220) actuates the lighting devices of the vehicle and simultaneously passes on the signals
for actuating the trailer lighting via the interior CAN to the trailer recognition control module (N28/1).
3. The trailer recognition control module (N28/1) actuates the corresponding lighting devices of the trailer
via the 13-pin trailer hitch socket (X58).
Rear fog lamp
The rear SAM control module with fuse and relay module (N10/2) or rear SAM control module (N10/8)
(models 215, 220) interrupts the actuation of the vehicle's own rear fog lamp when the trailer is detected (E3e5
and E4e5). Then, only the trailer's rear fog lamp is actuated.
Lamp failure indicator
A lamp failure on the vehicle or trailer is displayed in the instrument cluster (A1).

control module,
location/task
Model 215 GF82.10-P-2106M
TRAILER ANTI-THEFT DEVICE, FUNCTION - GF82.10-P-3016A
MODELS 203, 215, 220.02 /06 /07 /12 /16 /17 with CODE (551a) Anti-theft alarm system (ATA) with
CODE (550) Trailer hitch
Trailer anti-theft device, function
Fig. 40: Trailer Anti-Theft Device Function Diagram
Operating procedure
Basic conditions:
 The trailer recognition control module (N28/1) has detected the coupled trailer.
 The vehicle is locked and the anti-theft alarm system (ATA) primed.
 The trailer recognition control module has detected the activated ATA.
1. The trailer recognition control module monitors the trailer's stop lamps (2 and 3) by applying current to
them cyclically.
2. The electronics of the trailer recognition control module (N28/1) detects a discontinuity in the stop lamp
circuit and immediately sends via the interior CAN the "Alarm" signal to the rear SAM control module
with fuse and relay module (N10/2) or to the rear SAM control module (N10/8).
evaluates the signal and triggers the acoustic and optical alarm:
The rear SAM control module with fuse and relay module (N10/2) or rear SAM control module (N10/8)
actuates the alarm signal horn with additional battery (H3/1) and rear lighting devices directly for an acoustic
and optical alarm display.
Model 203
Actuated by the interior CAN, the front SAM control module with fuse and relay module (N10/1) triggers the
optical alarm display of the front lighting devices.
Models 215/220
Actuated via the interior CAN, the left front SAM control module and right front SAM control module (N10/6
and N10/7) trigger the optical alarm display of the front lighting devices.

control module,
location/task
Model 215 GF82.10-P-2106M
EXTERIOR LAMP SWITCH MODULE, LOCATION/PURPOSE/DESIGN - GF82.10-P-4104M
MODELS 215, 220
Shown on model 215 as of 1.6.00

Fig. 41: Identifying Exterior Lamp Switch Module Location - Shown On Model 215 As Of 1.6.00
Exterior lamp switch, The exterior lamp switch

purpose (S1) is used as a control
element
 the exterior lighting
and
 The headlamp
cleaning system
Exterior lamp switch, GF82.10-P-4104-02M
design
Exterior lamp switch, design - GF82.10-P-4104-02M
Shown on model 215 as of 1.6.00
Fig. 42: Identifying Exterior Lamp Switch - Shown On Model 215 As Of 1.6.00
OVERVIEW OF EXTERIOR LIGHTING SYSTEM COMPONENTS,
LOCATION/TASK/DESIGN/FUNCTION - GF82.10-P-9999A
MODEL 215.###, 220.02# /06# /07# /12# /16# /17# 1#

Signal acquisition and actuation module, GF54.21-P-4103S
rear, location/task/design/function
Steering column module, location/function/ GF54.21-P-4104S
design/function
location/ task/design/function
Electronic ignition switch control module GF80.57-P-4102S
location/function/design/function
Trailer recognition control module, MODEL 220 with GF82.10-P-2106S
location/task/design trailer hitch (code
299).
MODEL 215 with GF82.10-P-2106M
trailer hitch (code
299).
location/ task/design/function
Headlamp leveling system motor, Model 220 for GF82.10-P-2101A
location/task/design/function xenon headlamp
lamp unit (code
612b)
Headlamp leveling system control module, Model 220 for GF82.10-P-2102S
location/task/design/function xenon headlamp
lamp unit (code
612b)
Xenon headlamp control module, MODEL 220 up to GF82.10-P-2104A
location/task 31.8.02 with Xenon
headlamp lamp unit
(code 612b),
MODEL 220 as of
1.9.02 with bi-
xenon headlamp
unit (code 614).
Xenon headlamp ignition unit, MODEL 220 up to GF82.10-P-2105A
location/task 31.8.02 with Xenon
headlamp lamp unit
(code 612b),
MODEL 220 as of
1.9.02 with bi-
xenon headlamp
unit (code 614).
Xenon headlamp, location/function MODEL 220 up to GF82.10-P-2001A
31.8.02 with Xenon
headlamp lamp unit
(code 612b).
MODEL 220 as of GF82.10-P-
1.9.02 with bi- 2001AA
xenon headlamp
unit (code 614).
MODEL 215 GF82.10-P-2001B
Contents, function description of exterior GF82.10-P-0999B
lighting
HEADLAMP CLEANING SYSTEM (HCS), FUNCTION - GF82.15-P-0002S
MODEL 215, 220 with CODE (600a) Headlamp cleaning system
Function precondition:
 Circuit 15 ON
Manual operation
 The headlamp cleaning system (HCS) is switched on by pressing the HCS switch (S1s1).
 This connects the corresponding input of the left front SAM control unit (N10/6), which reads in the
signal of the HCS switch (S1s1), to ground.
 The left front SAM control unit (N10/6) places the switch-on pulse onto the class B Controller Area
Network bus (interior) (CAN-B) as a message.
 The right front SAM control unit (N10/7) reads in this message and connects circuit 15 to the HCS pump
(M5/2) for a switch-on time of approx. 1 s via an electronic switch (transistor).
 The HCS pump (M5/2) builds up water pressure in the line.
 The water pressure acts against the return springs in the telescopic nozzle.
 Before the telescopic nozzles extend, spraying water on the headlamp lenses.
 After expiration of the switch-on time, the pressure in the water line decreases and the telescopic nozzles
are retracted to their initial position by the spring force.
Pressing the HCS switch (S1s1) again when a headlamp cleaning cycle is being performed has no effect.
Another headlamp cleaning cycle cannot be activated until the preceding one has completed.
Automatic operation (in vehicles as of 1.6.04)

After the windshield washer system has been operated 15 times the HCS pump (M5/2) is actuated
automatically. This automatic control is performed by the right front SAM control unit (N10/7).
Function
For each actuation of the windshield washer fluid pump (M5/1) the internal counter in the right front SAM
control unit (N10/7) is incremented by 1 until it reaches the value "15", then the HCS pump (M5/2) is actuated
and the counter is reset to "0".
The internal counter is always reset to "0" with circuit 15 off.
Headlamp cleaning system (HCS), GF82.15-P-0002-

Headlight cleaning system (HCS) GF82.15-P-0002-
component network 04S
Telescopic nozzle for headlamp GF82.15-P-2100S
cleaning system,
Headlamp cleaning system (HCS), location of components - GF82.15-P-0002-03S
Location of components Illustrated on model 220
Fig. 43: Identifying Headlamp Cleaning System Components Location - Illustrated On Model 220
Headlamp cleaning system (HCS), interlinkage of components - GF82.15-P-0002-04S
Interlinkagae of components
Fig. 44: Headlamp Cleaning System Components Interlinkage Chart
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF HEADLAMP CLEANING SYSTEM (HCS)

- GF82.15-P-0998SZ
Headlamp cleaning system (HCS), GF82.15-P-0002S

function
interlinkage of components 04S
Telescoping nozzle headlamp cleaning GF82.15-P-2100S
system (HCS),
Left signal-acquisition and actuation GF54.21-P-4101S
module (SAM),
Right signal-acquisition and actuation GF54.21-P-4102S
module (SAM),
TELESCOPING NOZZLE HEADLAMP CLEANING SYSTEM (HCS),

MODEL 215, 220 with CODE (600a) Headlamp cleaning system
Telescoping nozzle GF82.15-P-2100-01S

headlamp cleaning
system (HCS), location
Telescoping nozzle The telescoping nozzles
headlamp cleaning are hydraulically
system (HCS), purpose extending telescopic
tubes with integrated
return spring. They are
not connected
electrically.
Telescoping nozzle Cleaning headlamp
headlamp cleaning lenses.
system (HCS), design
Telescoping nozzle GF82.15-P-2100-04B
headlamp cleaning
system (HCS), function
Telescoping nozzle headlamp cleaning system, location - GF82.15-P-2100-01S
Fig. 45: Identifying Telescoping Nozzle Headlamp Cleaning System Location
Telescoping nozzle headlamp cleaning system, function - GF82.15-P-2100-04B
When it starts running the washing water pump builds up pressure in the washing water line. The nozzles
extend in a telescopic manner at a pressure of 1-1.6 bar. When a pressure of 3 bar is exceeded a valve opens on
each telescoping nozzle and a precise quantity of washing water is sprayed onto the headlamp lenses.
Eddy chambers are attached to the tips of the telescopic nozzles which control the spray from the water jets
even at high vehicle speeds. Following the cleaning process the telescopes are retracted to the initial position by
return springs.
INTERIOR LIGHTING (IL), FUNCTION - GF82.20-P-0002S
MODEL 220
A summary of the primary interior lights is listed here:
 Front dome lamp (N70e1)

 Left rear dome lamp (E15/10) with:
 Reading lamps (E15/10e1) and
 Interior and vanity mirror lamps (E15/10e2)
 Right rear dome lamp (E15/11) with:

 Reading lamps (E15/11e1)
 Interior and vanity mirror lamps (E15/11e2)
 Interior rearview mirror unit (A67) with:

 Left reading lamp (A67e1)
 Right reading lamp (A67e2)
 Ambient lamp (A67e3)
 Left front door entrance/exit lamp (E17/3)

 Right front door entrance/exit lamp (E17/4)
 Left rear door entrance/exit lamp (E17/5)
 Right rear door entrance/exit lamp (E17/6)
 Left front inside door illumination (E17/11)
 Right front inside door illumination (E17/12)
 Left rear door inside handle illumination (E17/13)
 Right rear door inside handle illumination (E17/14)
 Trunk lamp (E18/1)
 Glove compartment illumination with switch (E13/2)
Some of the interior illumination lamps can be consolidated in the subcategory "Search illumination".
The search illumination is dependent of the state of circuit 58.
In addition to the switch lights the following lights are included in the search illumination:
 Right front footwell lamp (E17/15)

 Left front footwell lamp (E17/16)
 Right rear footwell lamp (E17/17)
 Left rear footwell lamp (E17/18)
 Front ashtray illumination (E9/7)
 Left rear ashtray illumination (E9/8)
 Right rear ashtray illumination (E9/9)
 Rear air outlet illumination (E10/5)
 Glove compartment lock illumination (E13/7)
 Stowage compartment illumination (E13/3)
 Eyeglasses compartment illumination (E13/4)
 Illumination for front cigar lighter (R3e1)
Actuation of the lights is accomplished via various control modules. The overhead control panel control
module (N70) takes over the master function .
The instrument cluster (A1) is also significant for the search illumination due to their dependence on circuit
58d.
A more precise description for the individual lights is given in the documents listed below.
Interior lighting (IL), GF82.20-P-0002-01S

Switching on/off front GF82.20-P-2019S
dome lamp, function
Switching on/off rear GF82.20-P-2020S
dome lamp, function
Search illumination, GF82.20-P-0003S
function
Switching on/off GF82.20-P-2022S
entrance/exit lamps,
function
Switching on/off ambient GF82.20-P-2021S
lamp, function
Switching on/off door GF82.20-P-2013S
interior lighting, function
vanity mirror lamps,
function
vanity mirror lamps,
function
reading lamps, function
reading lamps, function
Switching on/off glove GF82.20-P-2014S
compartment lighting,
function
Interior lighting (IL), location of components - GF82.20-P-0002-01S
Fig. 46: Identifying Interior Lighting Components Location - Front
Location of components (front)

Fig. 47: Identifying Interior Lighting Components Location - Rear
Location of components (rear)
SEARCH ILLUMINATION, FUNCTION - GF82.20-P-0003S
MODEL 220
Fig. 48: Search Illumination Function Diagram
Interlinkage of components
The following lights are switched on and off under the same conditions:
 Front ashtray illumination (E9/7)

 Illumination for front cigar lighter (R3e1)
 Left rear ashtray illumination (E9/8)
 Right rear ashtray illumination (E9/9)
 Stowage compartment illumination (E13/3)
 Eyeglasses compartment illumination (E13/4)
 Right front footwell lamp (E17/15)
 Left front footwell lamp (E17/16)
 Right rear footwell lamp (E17/17)
 Left rear footwell lamp (E17/18)
Switching on lights
 By manually switching on the parking and driving lights with the exterior lamp switch (S1) or
 Automatically when the automatic driving light delayed switch-off feature is activated and night is
recognized.
Switching off lights
 Switch-off is accomplished immediately when the above requirements are no longer fulfilled or when the
voltage is too low or too high.
Actuation of rear ashtray illumination
Actuation of the left rear ashtray illumination (E9/8) and right rear ashtray illumination (E9/9) is accomplished
with pulse width modulation via the corresponding door control modules (N69/3, N69/4). The door control
modules actuate the lights with the on/off ratio predefined by the instrument cluster (A1).
Required data:
 Status c. 58d on instrument cluster (A1)
Actuation of remaining lights
Actuation of the lights is accomplished via the right front SAM control module (N10/7) except for the rear
ashtray illumination (E9/8, E9/9).
The control module actuates the lights as soon as it receives the CAN message on/off ratio c. 58d > 5 % from
the instrument cluster (A1). The lights cannot be dimmed.
Required data:
 Status c. 58d on instrument cluster (A1)
 With the exception of the illumination for front cigar lighter (R3e1) and the rear ashtray illumination
(E9/8, E9/9) illumination is accomplished via diodes.
 Only the left rear ashtray illumination (E9/8) and right rear ashtray illumination (E9/9) are dimmable in
addition to the switch illumination. The setting is accomplished via the brightness control for the
instrument and search illumination rheostat (A1r1).
Interior lighting (IL), location of GF82.20-P-0002-

components 01S
Exterior-light-dependent control of interior GF82.20-P-3003S
lighting, function
Adjusting search illumination, function GF54.30-P-2010S
module (SAM),
module (SAM),
Rear door control module, GF72.29-P-4102S
Exterior lighting, function GF82.10-P-0003A
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF INTERIOR LIGHTING (IL) - GF82.20-P-

0998SZ
MODEL 220
Interior lighting (IL), function GF82.20-P-0002S

components 01S
Search illumination, function GF82.20-P-0003S
Switching on/off door interior lighting, GF82.20-P-2013S
function
Switching on/off glove compartment light, GF82.20-P-2014S
function
Switching on/off rear vanity mirror lamps, GF82.20-P-2015S
function
Switching on/off front vanity mirror GF82.20-P-2016S
lamps, function
Switching on/off front reading lamps, GF82.20-P-2017S
function
Switching on/off rear reading lamps, GF82.20-P-2018S
function
Switching on/off front dome lamp, GF82.20-P-2019S
function
Switching on/off rear dome lamp, function GF82.20-P-2020S
Switching on/off entrance/exit lamps, GF82.20-P-2022S
function
Switching on/off ambient lamp, function GF82.20-P-2021S
lighting, function
Dimming interior lighting, function GF82.20-P-3002S
Switching on interior lighting with anti- GF82.20-P-2007S
theft alarm (ATA), function
Interior rearview mirror unit, GF68.49-P-2100S
Rear dome lamp, GF82.20-P-4109S
module (EIS),
module (SAM),
module (SAM),
Rear signal-acquisition and actuation GF54.21-P-4103S
module (SAM),
Left front door control module, GF72.29-P-4105S
Right front door control module, GF72.29-P-4106S
Door contacts, GF82.20-P-4102S
SWITCHING ON INTERIOR LIGHTING WITH ANTI-THEFT ALARM, FUNCTION - GF82.20-P-

2007S
MODEL 220
When the anti-theft alarm (ATA) or a taxi emergency alarm is triggered the front and rear dome lamps are
switched on without dimming.
If the alarm is canceled, the lights are switched off again.
Actuation
 In the event of an ATA alarm the left front SAM control module (N10/6) transmits the message "Switch
on interior light, ATA" and in the event of a taxi emergency alarm the special vehicle multifunction
control module (SVMCM, N26/9) send the message "Switch on interior light, SVMCM" to the CAN bus
(passenger compartment).
 The overhead control panel control module (N70) reads this message and actuates the following lights:
 Interior and vanity mirror lamps (E15/10e2) in left rear dome lamp
 Interior and vanity mirror lamps (E15/11e2) in right rear dome lamp
 Front dome lamp (N70e1)
Behavior when voltage is too low or too high
The ATA alarm and taxi emergency alarm function are available even when the voltage is slightly low.
function
Anti-theft alarm (ATA), function GF80.50-P-0001S
module (SAM),
TRUNK LAMPS, FUNCTION - GF82.20-P-2008S
MODEL 220
Interlinkage
Fig. 49: Trunk Lamps Function Diagram
Two trunk lamps (E18/1) are installed below the trunk lid.
Switching on trunk lamps:
When the trunk lid is opened the trunk lamps (E18/1) are switched on automatically.
Switching off trunk lamps:
When the trunk lid is closed the trunk lamps (E18/1) are switched off automatically.
If the trunk lid remains open for longer than 30 minutes, the trunk lamps (E18/1) are switched off
automatically to avoid discharging the battery.
To switch on again the trunk lid must be closed momentarily or the striker actuated directly.
Actuation:
The trunk lamps (E18/1) are actuated by the rear SAM control module (N10/8) .
The trunk lid closing assist locking eye microswitch (S88/3) (in trunk lid lock) provides the necessary switch-on
signal. This switch is read in directly by the rear SAM control module (N10/8).

components 01S
module (SAM),
SWITCHING ON/OFF DOOR INTERIOR LIGHTING, FUNCTION - GF82.20-P-2013S
MODEL 220
Fig. 50: Switching On/Off Door Interior Lighting Function Diagram
The inside door illumination (E17/11-E17/14) allows vehicle passengers to find the interior door handle more
easily.
The door interior lighting can be switched on:

 by manually switching on the parking and driving lights with the exterior lamp switch (S1)
 by switching on c. 15 r
Switching off door interior lighting:
 Switch-off is accomplished automatically 5 minutes following the last request.
Actuation
The door interior lighting is actuated by the output of the corresponding door control module (N69/1 - N69/4).
For this purpose the door control modules read the following CAN messages (passenger compartment):
 circuit 15r ON/OFF from electronic ignition/starter switch control module (N73)
 ON/OFF ratio from circuit 58d on instrument cluster (A1); Circuit 58d is active (ON/OFF ratio > 12 %)
as soon as the instrument cluster (A1) receives the message "Parking lamp ON" from the left front SAM
The door interior illumination (LED's) cannot be dimmed.

components 01S
module (SAM),
lighting, function
SWITCHING ON/OFF GLOVE COMPARTMENT LIGHT, FUNCTION - GF82.20-P-2014S
MODEL 220
Switching on the glove compartment light
The glove compartment illumination with switch (E13/2) switches on when the glove compartment is opened.
The glove compartment light is switched off
 when the glove compartment is closed or

 automatically to protect the vehicle battery when there is no activity on the bus for 15 minutes.
Switching back on after automatic switch-off
If the light has switched off after no activity is present on the bus for 15 minutes, it is switched back on only
after the bus has been activated by opening a door, etc.
In this case it cannot be switched back on by closing the glove compartment and opening it again.
Power supply/control
The glove compartment illumination with switch (E13/2) is supplied with + 12 V by a separate output on the
right front SAM control module (N10/7). Power is present at this output up to 15 minutes following the last
activity on the CAN bus. A switch is integrated into the light, which switches the light on and off when the
glove compartment is opened and closed.

module (SAM),
SWITCHING ON/OFF REAR VANITY MIRROR LAMPS, FUNCTION - GF82.20-P-2015S
MODEL 220
The left and right rear interior and vanity mirror lamps (E15/10e2, E15/11e2) are located in the rear dome lamps
(E15/19, E15/11). The lights have two functions :
 Illumination of the rear vanity mirrors

 Illumination of the rear passenger compartment (rear dome lamp )
They are actuated and switched on and off differently depending on the function.
Switching on vanity mirror lights
 When the vanity mirror is pivoted down the associated light is switched on
Switching off vanity mirror lights
 The light is switched off as soon as the mirror is pivoted back up or
 automatically when no activity has been present on the bus for 30 minutes
However the lights also act as dome lights , whereby this function is switched on and off as described
elsewhere.
However the following always applies: If the vanity mirror is pivoted down, the associated light always burns
until it is switched off when no activity has been present on the bus for 30 minutes.
Power supply and control of vanity mirror lights
The vanity mirror lights are supplied with + 12 Volts by the output on the overhead control panel control
module (N70). The overhead control panel control module switches this power off when no activity has been
present on the bus for 30 minutes. A change-over switch integrated into the rear dome lamps (E15/10, E15/11)
switches on/off the lights when the vanity mirror is put down or up. When the mirror is up the dome light
function can be actuated, when it is down, the 12 Volt output on the overhead control panel control module
mentioned above is connected to the light.

SWITCHING ON/OFF FRONT VANITY MIRROR LAMPS, FUNCTION - GF82.20-P-2016S
MODEL 220
The sun visors contain vanity mirrors, which are illuminated by the left front vanity mirror lamp (E14/6) and
right front vanity mirror lamp (E14/7) .
The lamps are located in the headliner above the sun visors.
Switching on the left or right front vanity mirror lamps (E14/6) (E14/7):
 The lamps are switched on when the associated mirror cover is opened, when the sun visor is caught in
the mount
Switching off the left or right front vanity mirror lamps (E14/6) (E14/7) :
 By closing associated vanity mirror cover or

 automatically when no signals have been present on the bus for 30 minutes for protection of the battery.
Actuation:
The left front vanity mirror lamp (E14/6) and right front vanity mirror lamp (E14/7) are supplied with power by
the overhead control panel control module (N70) via outputs c. 31 and +12 V.
Voltage of +12 V is present at the output:
 when c. is 15 ON
 when c. is 15 OFF up to 30 minutes after the last signal is detected on the bus.
The left front vanity mirror illumination switch (S101) and right front vanity mirror illumination switch
(S102) are installed in the sun visors for switching the illumination on and off. These switches are connected in
series with the lamps.

SWITCHING ON/OFF FRONT READING LAMPS, FUNCTION - GF82.20-P-2017S
MODEL 220
The left and right front reading lamps (A67e1, A67e2) are located in the interior rearview mirror unit (A67) for
dazzle-free use.
Switching on the reading lamps:
When the left front reading lamp switch (N70s6) or the right front reading lamp switch (N70s7) on the overhead
control panel control module (N70) is actuated the corresponding reading lamp is switched on.
Switching off:
The front reading lamps can be switched off as follows:
 by actuating the switch again or

 automatically after 30 minutes when no signals are received on the bus to protect the battery.
Actuation
The two front reading lamps are actuated directly by the overhead control panel control module (N70).

SWITCHING ON/OFF REAR READING LAMPS, FUNCTION - GF82.20-P-2018S
MODEL 220
The reading lamps (E15/10e1, E15/11e1) are located in the rear dome lamps (E15/10, E15/11).
Switching on the reading lamps
The reading lamps (E15/10e1, E15/11e1) can be switched on by actuating the switch in the middle of the
associated dome lamp.
Switching off the reading lamps

 by actuating the switch or
 automatically after 30 minutes when no signals are received on the bus
Power supply to reading lamps in rear
The reading lamps are supplied with power via a +12 volt output of the overhead control panel control module
(N70). The overhead control panel switches off this voltage after 30 minutes when no signals are received.

SWITCHING ON/OFF FRONT DOME LAMP, FUNCTION - GF82.20-P-2019S
MODEL 220
Fig. 51: Switching On/Off Front Dome Lamp Function Diagram
Manually switching on and off front dome lamp:
The front dome lamp (N17e1) is faded on when the interior lamp ON and OFF switch (N70s4) in the overhead
control panel control module (N70) is actuated.
The front dome lamp is faded off by turning the switch to the original position or automatically after 30 minutes
when no signals are presents on the bus to protect the battery.
If the lamp is switched on manually , none of the automatic features described below are performed.
Prerequisites for automatic features
 automatic driving light circuit switched on instrument cluster (A1) and

 door contact ON and OFF switch (N70s3) switched on (switch in center position) and
 light sensor has recognized night
or :
 automatic driving light circuit switched off on instrument cluster (A1) and
 door contact ON and OFF switch (N70s3) switched on (switch in center position)
Automatic features for front dome lamp
 When one of the front doors is opened the front door lamp (N17e1) is faded on.
Switch-off is accomplished:
 with c.15 ON: lamp is faded off immediately after the last front door is closed or automatically 30
minutes after the last front door is opened.
 with c.15 OFF: front dome lamp is faded off 8 s after the last front door is closed or automatically 5
minutes after the last front door is opened.
 The front door lamp is faded on when the vehicle is unlocked. Switch-off is accomplished:
 Fade off 30 s after unlocking
 The front dome lamp (N17e1) is faded on when the ignition key is removed .
Switch-off is accomplished automatically according to the interior light shut-off delay time set on the
instrument cluster (A1) (possible settings are 0 s, 5 s, 10 s, 15 s, and 20 s.)
 If c.15 is switched on while the automatic light feature is active; the dome lamp is faded off
immediately.
 If the prerequisites (door contact ON/OFF switch position or light sensor information) change during
performance of an automatic feature, the change is read in.
Example:
If the dome lamp is switched on because one of the front doors is open and the light sensor information
changes from "night" to "day", the dome lamp is faded off immediately. (Prerequisites: automatic driving
light circuit switched on!)
ATA and taxi emergency alarm
The lamp is switched on immediately without the fade on function in the event of an ATA or taxi-emergency
alarm.
Actuation
The actuation of the lamp is accomplished internally in the overhead control panel control module (N70) in
which the lamp and rocker switch is integrated.
For this purpose the overhead control panel control module receives the following information:
 Brightness; for this purpose the automatic light switch daylight sensor (B32/1) is read in directly by the
overhead control panel control module (N70),
 the status of the front door contact switch (S17/3 and S17/4); are read in by the rear SAM control module
(N10/8) and relayed on via the CAN bus (passenger compartment)
 the set interior light shut-off delay; this is relayed to the overhead control panel control module by the
instrument cluster (A1) via the CAN bus (passenger compartment).
Voltage too high/too low
If the voltage is too low the lamp is switched off immediately without fade-out . When the correct voltage
returns the lamp is switched back on without fade-on .
In the event of an ATA or taxi emergency alarm the light is not switched off when the voltage is too high/too
low.

components 01S
lighting, function
Anti-theft alarm (ATA), function GF80.50-P-0001S
module (SAM),
SWITCHING ON/OFF REAR DOME LAMP, FUNCTION - GF82.20-P-2020S
MODEL 220
Fig. 52: Switching On/Off Rear Dome Lamp Function Diagram
The lights have two functions:
 Illumination of the rear passenger compartment (rear dome lamp )

 Illumination of the rear vanity mirror (see vanity mirror)
They are actuated and switched on/off differently depending on the function.
The following always applies :
If the vanity mirror is folded down, the corresponding light always burns until it is switched off automatically
30 minutes after the last signal on the bus.
The switch-on/switch-off possibilities described here then have no effect.
Manually switching on/off the rear dome lamps:

When the rear dome lamp switch (N70s2) in the overhead control panel control module is actuated the interior
and vanity mirror lamps (E15/10e2, E15/11e2) are faded on.
Fade-off is accomplished when the switch is actuated again or automatically to protect the battery 30 minutes
after the last bus signal.
If the lamps are switched on manually none of the automatic features described below are possible.
Prerequisites for automatic features
 automatic driving light circuit switched on on instrument cluster (A1) and

 door contact ON and OFF switch (N70s3) switched on (switch in the center position)
 light sensor has recognized night
or :
 automatic driving light circuit switched off on instrument cluster (A1) and
 Door contact ON and OFF switch (N70s3) switched on (switch in the center position)
Automatic features for rear dome lamps (interior and vanity mirror lamps (E15/10e2, E15/11e2))
 The lamps are faded on when one of the rear doors is open . Switch-off is accomplished:
 With c.15 on: lamps are faded off immediately after closing the last front door or automatically 30
minutes after the last rear door was opened,
 with c.15 off: lamps are faded off 8 s after closing the last rear door.
 The rear dome lamps are faded on when the vehicle is unlocked .
 Fade-off 30 s after unlocking

 The lamps are faded on when the ignition key is removed .
Switch-off is accomplished automatically according to the interior light shut-off delay time set in the instrument
cluster (A1). (Possible settings are 0s, 5s, 10s, 15s and 20s.)
 If c.15 is switched on during an automatic active light function, the dome lamps are faded off
immediately.
 If the prerequisites (door contact on/off switch position or light sensor information) change while an
automatic feature is being performed, the change is taken into consideration immediately.
Example:
If the dome lamps are switched on because one of the rear doors is open and the light sensor information
changes from "night" to "day", the dome lamps are faded off immediately. (Prerequisites: automatic driving
light circuit switched on!)
ATA and taxi emergency alarm
In the event of an ATA or taxi emergency alarm the lamps are switched on immediately without fade-on .
Actuation
The lamps are actuated by the overhead control panel control module (N70). For this purpose the overhead
control panel control module receives the following information:
 Brightness; for this purpose the automatic light switch daylight sensor (B32/1) is read in directly by the
overhead control panel control module (N70),
 the status of the rear door contact switches (S17/5 and S17/6) is read in by the rear SAM control module
(N10/8) and relayed on via the CAN bus (passenger compartment),
 the set interior light shut-off delay time is relayed to the overhead control panel control module by the
instrument cluster (A1) via the CAN bus (passenger compartment).
Voltage too high/too low
If the voltage is too low the lamps are switched off immediately without fade-out. When the correct voltage
returns the lamps are switched back on without fade-on .
In the event of an ATA or taxi emergency alarm the lamps are not switched off when the voltage is too
high/too low.

function
components 01S
lighting, function
Switching on/off rear vanity mirror lamps, GF82.20-P-2015S
function
Anti-theft alarm (EDW), function GF80.50-P-0001S
module (SAM),
SWITCHING ON/OFF AMBIENT LAMP, FUNCTION - GF82.20-P-2021S
MODEL 220
The ambient lamp (A67e3) is a bright LED located in the interior rear view mirror (A67). It serves for
illumination of the center console.
Switching ambient lamp on/off
The ambient lamp is switched on automatically when c.15r switched on and switched off automatically when
c.15r is switched off .
Control
The ambient lamp (A67e3) is controlled directly by the overhead control panel control module (N70). The
overhead control panel control module (N70) receives the information "Status c.15r" for this purpose via the
CAN bus from the electronic ignition/starter switch control module (N73).
The ambient lamp is independent of the automatic light switch daylight sensor (B32/1) and the position of
the door contact ON and OFF switch (N70s3).

module (EIS),
SWITCHING ON/OFF ENTRANCE/EXIT LAMPS, FUNCTION - GF82.20-P-2022S
MODEL 220
Fig. 53: Switching On/Off Entrance/Exit Lamps Function Diagram
Interlinkage
An entry/exit lamp is located at the bottom edge of each of the doors.
 Overhead control panel control module (N70) has recognized "night" via the automatic light switch
daylight sensor (B32/1).
 Door contact ON and OFF switch (N70s3) in position ON
 Voltage not too low/too high
Only the entry/exit lamps in the open doors are actuated!
Switch-on of entry/exit lamps:
 An entry/exit lamp is switched on as soon as a corresponding door is opened.
Switch-off of entry/exit lamps:
 The entry/exit lamp is switched off when the corresponding door is closed.
If the door remains open for longer than 15 minutes the lamp is switched off automatically.
Switching back on following automatic switch-off
The switch-on time is increased or started again when:
 A change in status occurs at any of the door contacts (S17/3, S17/4, S17/5 or S17/6)
 Circuit 15 is switched on
 The vehicle is locked or unlocked.
Actuation
The entry/exit lamps are actuated by the associated door control module (N69/1, N69/2, N69/3 or N69/4).
The door control modules require the following CAN-messages for this purpose:
 Ambient brightness (night/day) , this message is generated using the data from the automatic light switch
daylight sensor (B32/1) in the overhead control panel control module (N70).
 The status of the door contact switches (S17/3, S17/4, S17/5 or S17/6). All door contact switches are
read in by the rear SAM control module (N10/8).
 The locking and unlocking signal and the circuit 15 status are relayed on the CAN bus by the electronic
ignition/ starter switch control module (N73).
 If the automatic light switch daylight sensor (B32/1) is defective the lamps are actuated as if
night were recognized .
 The entry/exit lamps are independent of the setting on the automatic driving light circuit in the
instrument cluster (A1)!

lighting, function
module (SAM),
DIMMING INTERIOR LIGHTING, FUNCTION - GF82.20-P-3002S
MODEL 220
The front dome lamp (N70e1) and interior and vanity mirror lamps (E15/10e2, E15/11e2) in the rear dome
lamps are faded on. The overhead control panel control module (N70) regulates the power to the lamps during
switch-on/switch-off for this purpose.
 During switch-on the power to the lamps is increased to full power in 1 second.
 During switch-off the power to the lamp is decreased over a period of 3 seconds.
Exceptions
In the event of an ATA or taxi emergency alarm the lamps are switched on immediately without the fade-on
feature.
If the voltage is too high/low the lamps are switched off immediately without the fade-off feature. When the
correct voltage returns the lamps are switched on without fade-on feature.
The fade-on/off feature described here refers only to the switch-on and switch-off characteristic. It should
not be mixed up with the dimming feature for the switch and search illumination via c.58d.

dome lamp, function
dome lamp, function
EXTERIOR LIGHT-DEPENDENT CONTROL OF INTERIOR LIGHTING, FUNCTION - GF82.20-P-

3003S
MODEL 220
All CAN signals refer to the passenger compartment CAN bus. The CAN arrows serve only for illustration
of the data flow. In each case they refer to the same CAN bus!
Data flow chart

Fig. 54: Exterior Light-Dependent Control Of Interior Lighting Function Diagram
Some of the internal and external lighting features can be controlled depending on the brightness of the outdoor
light. For this purpose the "driving light circuit" must be switched to automatic on the instrument cluster (A1).
Three functions can be differentiated for the interior lighting:
 Brightness depending light function for dome lamps

 Brightness depending light function for search illumination (c.58d)
 Light function for entry/exit lamps (always brightness dependent)
Prerequisites:
 Door contact ON and OFF switch (N70s3) in ON position

 (For search illumination and dome lamps only)
"Driving light circuit" set to automatic on instrument cluster (A1). The instrument cluster (A1) then
generates the CAN signal "automatic driving light function on " (1).
Brightness dependent light function for dome lamps
 The overhead control panel control module receives the CAN signal "automatic driving light function on
" (1) and
 the brightness signal (2) from the automatic light switch daylight sensor (B32/1).
 if the overhead control panel control module interprets the brightness signal (3) as "night" , the dome
lamps are switched on request, e.g. when a door is opened, by the overhead control panel control module.
Brightness dependent light function for search illumination
 The overhead control panel control module receives the CAN signal "automatic driving light function on
" (1) and
 brightness signal (2) from the automatic light switch daylight sensor (B32/1).
 If the overhead control panel control module interprets the brightness signal (3) as "night" , it switches
the CAN signal "automatic driving light switch-on/switch-off" (3) to ON.
 The left front SAM control module (N10/6) receives the signal and generates the CAN signal "switch on
parking lights" (4) .
 The instrument cluster (A1) receives the signal and activates the CAN signal c.58d.
 The control modules to which the lights for search illumination are connected, receives the CAN signal
c.58d and switches on the lights.
C.58d is a pulse width-modulated signal, whose on/off ratio can be set between 12 % and 100 % by means of
the instrument and search illumination rheostat (A1r1) as soon as the CAN signal "switch on parking lights" (4)
is active. If the automatic light switch daylight sensor (B32/1) is defective the search illumination acts as if
"night" were recognized.
Light function for entry/exit lamps
 The overhead control panel control module interprets the brightness signal (3) as "night" , then it
switches on the CAN signal " switch-on/off exit lamps".
 The door control modules (N69/1, N69/2, N69/3, N69/4) receive the signal and actuate the entry/exit
lamps accordingly when a door is opened.
If a malfunction is present, the entry/exit lamps act as if night were recognized and switch on the CAN
signal " switch on/off exit lamps". If the voltage is too high/too low, the CAN signal "switch on/off exit lamps"
is never switched on.
Change in brightness or door contact ON and OFF switch (N70s3) during brightness dependent light
function
If the brightness information for the position of the door contact ON and OFF switch (N70s3) changes, this
change is taken into consideration.
Search illumination, function GF82.20-P-0003S

Adjusting search illumination, function GF54.30-P-2010S
function
Switching on/off entry/exit lamps, function GF82.20-P-2022S
OVERHEAD CONTROL PANEL CONTROL UNIT, LOCATION/TASK/DESIGN/FUNCTION -
GF82.20-P-4101S
MODELS 215.3, 220.0 /1
Overhead control Model 220.0/1 GF82.20-P-4101-01I

panel control unit,
location
Overhead control GF82.20-P-4101-02S
panel control unit,
purpose
Model 215.3 in conjunction with GF82.20-P-4101-
automatic air conditioning. 02N
Models 220.0/1 in conjunction with GF82.20-P-4101-02I
automatic air conditioning.
Design of overhead GF82.20-P-4101-03S
control panel control
unit
Function
Interior lights (IBL), Model 220 GF82.20-P-0002S
function
Exterior lighting Models 215, GF82.10-P-0003B
function 220.02 /06 /07 /12 /16 /17 left-hand
drive vehicles.
Heated rear window, GF67.29-P-0003S
function
Central locking (CL GF80.20-P-0005S
[ZV]) function
Power sliding / tilting Model 215.3 GF77.20-P-0001S
roof (SR), function Models 220.0 /1 with electric
tilting/sliding roof in glass code 414a
Models 220.0 /1 with USA version
code 491
Models 220.075 /175 with Japan
version code 498
Automatic dimming GF68.49-P-0003S
inside rearview
mirror, function
Automatically dim Models 220.063 /065 with automatic GF88.79-P-2003S
driver-side outside dimming inside rearview mirror and
mirror, function outside mirror (driver) code 249b.
Models 215, 220 / (except
220.063 /065)
Overhead control panel control unit, location - GF82.20-P-4101-01I

The overhead control panel control unit (N70) is located in the roof area of the inside rearview mirror.
Fig. 55: Identifying Overhead Control Panel Control Unit Location
Overhead control panel control unit, purpose - GF82.20-P-4101-02I
Measuring in-car temperature, purpose
The inside sensor blower in the overhead control panel control unit (N70) is actuated upon request of the
automatic air conditioning control and operating unit via the CAN interior. First perform diagnosis on sensor
blower.
The overhead control panel control unit (N70) then returns the status and the measured interior temperature to
the automatic air conditioning control and operating unit via the CAN interior.
The automatic air conditioning control and operating unit also requests that the blower be turned on upon
certain operating conditions even if the ignition is switched off (e.g., residual engine heat utilization).
Comfort closing, purpose
If comfort closing is activated by pressing the air recirculation button ( ) or the activated charcoal filter
button ( ) > or = 1.5 s, a signal is sent to the overhead control panel control unit (N70) via the CAN
interior, whereupon the position of the tilting/sliding roof (SR) (M12) is stored and, if the tilting/sliding roof is
open (SHD) (M12), it is closed automatically.
If the button is pressed again for > or = 1.5 seconds, the tilting/sliding roof (SR) (M12) returns to the previously
saved position.
Overhead control panel control unit, purpose - GF82.20-P-4101-02N
Measuring in-car temperature, purpose

The inside sensor blower in the overhead control panel control unit (N70) is actuated upon request of the
automatic air conditioning control and operating unit via the CAN interior. First perform diagnosis on sensor
blower.
Next, the overhead control panel control unit (N70) returns the status and the measured interior temperature to
the automatic air conditioning control and operating unit via the CAN interior.
The automatic air conditioning control and operating unit also requests that the blower be turned on upon
certain operating conditions even if the ignition is switched off (e.g., residual engine heat utilization).
Overhead control panel control unit, purpose - GF82.20-P-4101-02S
Models 215.3, 220.0/1
The overhead control panel control unit (N70) has the following purpose:
 Control of dimming functions of the inside rearview mirror (A67) and the outside rearview mirror
 Control of light functions of the interior lights
 Reading of integral switches and sensors:
 Sliding/tilting roof switch (N70s1)
 Rear dome lamp switch (N70s2)
 Dome lamp switch (N70s3)
 Left front reading lamp switch (N70s6)
 Right front reading lamp switch (N70s7)
 In-car temperature sensor (N70b1)
 Reading of sensors (on the windshield):

 Rain sensor (B38)
 Automatic light switch daylight sensor (B32/1)
 Rain/light sensor (B38/2), as of 9/1/02
 Sliding roof actuation

 Reading data of the rear window antenna amplifier module (A2/12) and transmitting data on CAN
interior
 Actuation of the integral front dome lamp (N70e1)
 Reading and actuating of components of the inside rearview mirror unit (A67):
 Left reading lamp (A67e1)
 Right reading lamp (A67e2)
 Ambient lamp (A67e3)
 Sensor for automatic dimming mirror, forward(A67h1)
 Sensor for automatic dimming mirror, backward (A67h2)
 Motor vertical adjustment (A67m1)
 Motor horizontal adjustment (A67m2)

 Potentiometer vertical position (A67r1)
 Potentiometer horizontal position (A67r2)
Design of overhead control panel control unit - GF82.20-P-4101-03S
Models 215.3, 220.0/1
Shown on Model 220
Fig. 56: Overhead Control Panel Control Unit Design - Shown On Model 220
DOOR CONTACT SWITCH, LOCATION/TASK/DESIGN/FUNCTION - GF82.20-P-4102S
Models 215, 220
Fig. 57: Identifying Door Contact Switch Location

Door contact switches, Model 220 GF82.20-P-4102-01S
position
Door contact switch, The door contact
purpose switches transmit an
electrical signal
indicating the status of
the vehicle doors (open,
closed).
Door contact switch, The door contacts are
design designed as normally
closed contacts
(switching contacts are
open when doors are
closed).
Door contact switch, When a door is opened
function the associated door
contact switch connects
ground to the
corresponding input of
the rear SAM control
module (N10/8).
The rear SAM control
module (N10/8) sends the
message about the status
of the doors to the
interior CAN.
Door contact switch position - GF82.20-P-4102-01S
Model 220
Model 220
Fig. 58: Identifying Door Contact Switch Position
REAR DOME LAMPS, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.20-P-4109S
MODEL 220
Rear dome lamps, GF82.20-P-4109-01S

location
Rear dome lamps,  Illumination of rear
purpose passenger compartment
 Illumination of vanity
mirror (rear)
 Provide reading light
Rear dome lamps, GF82.20-P-4109-03S
design
Rear dome lamps, The light is switched over to
function another input by the
changeover switch depending
on the mirror position.
Rear dome lamps, location - GF82.20-P-4109-01S

Fig. 59: Identifying Rear Dome Lamps Location
Rear dome lamps, design - GF82.20-P-4109-03S
Fig. 60: Identifying Rear Dome Lamps Design
Since the same lamps (E15/10e2, E15/11e2) are used for the passenger compartment lighting as well as for the
vanity mirror illumination, the switch, which is actuated when the vanity mirror is put down, is designed as a
changeover switch.
SPECIAL SIGNAL SYSTEM OFFICIAL AND EMERGENCY SERVICE VEHICLES, FUNCTION -

GF82.25-P-0001S
MODEL 220
Official and emergency service vehicles

The special signal system on official and emergency service vehicles serves for controlling the light signals for
emergency operations with beacon.
All functions are actuated by the special vehicle multifunction control module (SVMCM) (N26/9) in
combination with the control module (PAS) and special signal system (N26/12) .
The status of the switch in the special signal system pushbutton control module (A48/1) is read in by the
control module (HAS) and the special signal system (N26/12) and is indicated to the SVMCM over a discrete
line. In the event of an emergency operation with beacon the SVMCM actuates the following lamps according
to the control module coding:
 Blue light (E22/5)

 Front strobe light (SA)
 Front left and right high beams (E1e1, E2e1) or
 Front left and right fog lamps(E1e4, E2e4)
In addition the fanfares (H2) are actuated corresponding to the switch position of special signal system
pushbutton control module (A48/1) and the fanfare horn pushbuttons (S110s5, S110s5):
Switch position A48/1 Optical signal Acoustic signal

Position A ON OFF
Position B ON when the fanfare switch is
actuated a tone sequence is played
Position B, switch pulled out ON Tone sequence is played
permanently
Special signal system without control module (PAS) and special signal system (N26/12)
If the control module (PAS) and special signal system (N26/12) is not present the special signal system
pushbutton control module (A48/1) is replace by a beacon switch which is read in by the SVMCM. This
switch is equipped with an LED which indicates the status of the blue light (switched on/not switched on). The
LED is also actuated by the SVMCM.
Ambient-light-dependent optical signals for emergency operations with beacon
To prevent dazzling other traffic participants during emergency operations with beacon the front strobe lights
flash alternately with the fog lamps, not with the high beams in the dark. For this purpose the SVMCM
evaluates the status of the automatic light switch daylight sensor unit (B32/1) (CAN message from overhead
control panel). This is done in consideration of the additional options, daytime running lamps and automatic
headlamp switch-on, because unit switch-over from the high beams to fog lamps is accomplished only when it
is actually dark.
Combination possibilities for optical signals (emergency operations with beacon)
In the following table all possible combinations are listed which are supported by the special vehicle
multifunction control module (SVMCM) (N26/9) . They can be programmed with the STAR DIAGNOSIS
tool.
Separate switch for control, read in by SVMCM; only present when control module (PAS) and special signal
system (N26/12) is not installed.
Combination Blue light Switch Light Fog lamp High Strobe Beacon
possibilities recognition position status beam light, front
(over N26/12)
1 - ON - - - Flashing 1 -
Hz
OFF - - - -
2 - ON - Flashing 1 - Flashing 1 -
Hz Hz
- OFF - - - - -
3 - ON Low - Flashing 1 Flashing 1 -
beam off Hz Hz
- ON Low Flashing 1 - Flashing 1 -
beam on Hz Hz
- OFF - - - - -
4 ON - Low - Flashing 1 - -
beam on Hz
- Low Flashing 1 - - -
beam off Hz
OFF - - - - - -
5 - ON Low - Flashing 1 Flashing 1 ON
beam off Hz Hz
- ON Low Flashing 1 - Flashing 1 ON
beam on Hz Hz
- OFF - - - - OFF
Special vehicle multifunction control GF82.25-P-4102S

module (SVMCM),
Special signal system pushbutton control GF82.25-P-2101S
module, location/purpose
Special signal system official and emergency service vehicles, location of components - GF82.25-P-0001-01S
Fig. 61: Identifying Special Signal System Official And Emergency Service Vehicles Components
Location
PANIC ALARM SYSTEM (PAS) FUNCTION - GF82.25-P-0005MB
MODEL 220.175 with CODE (979) Special protected version with panic alarm system (PAS)
Fig. 62: Panic Alarm System Function Diagram
The following functions are made possible by the panic alarm system (PAS) :
 Audible alarm signals (through exterior speaker)

 Visual alarm signals (flashing of headlights or foglights and turn signal lights)
 Automatic locking of central locking system
 Transmitting emergency call (option)
 Electronic voice link interior/exterior (irrespective of activation of alarm)
The link to the standard vehicle electrical system and the actuation of the system components is implemented by
the special vehicle multifunction control module (SVMCM) through the interior bus (CAN B).
As a result of the modular design, the panic alarm system (PAS) can be expanded to include the functions of
the special signal system.
Activating function GF82.25-P-2005MB

Deactivating function GF82.25-P-2006MB
Intercom function GF82.25-P-2007FB
PANIC ALARM FOR PRIVATE VEHICLES, FUNCTION - GF82.25-P-0007S
MODEL 220 only with panic alarm
The panic alarm for private vehicles (SA) is a protective device for the driver and other passengers. It can only
be triggered in one stage via the emergency alarm activation switch (S62/6) (installation location according to
customer request).
All functions of the private vehicle panic alarm are monitored and controlled by the special vehicle
multifunction control module (SVMCM) (N26/9) .
The following functions are supported:
 the fanfare horns (H2) sound intermittently

 high beams (E1e1, E2e1) flash
 roof symbol (if present) flashes
 all turn signals flash
 front dome lamp (N70e1) and left and right rear dome lamps (E15/10, E15/11) are switched on
 on vehicles with TELE AID emergency alarm system (D2B) (code 347) a radio emergency call is
triggered
 the central locking system locks
National versions are available for ECE and Switzerland.
Additional options on vehicles equipped with panic alarm:
 Control module outlet for two-way radio

 Control module outlet for taximeter
 Control module outlet for socket
Interior lighting (IL), function GF82.20-P-0002S

Turn signals/hazard warning flashers, GF82.25-P-0002A
function
TELE AID, function with CODE (347) GF82.95-P-0001A
TELE AID
emergency call
system (D2B)
module (SVMCM),
Transmitter for remote actuation of GF82.25-P-4105S
emergency alarm, purpose
WINDSHIELD DEFROSTER, FUNCTION - GF82.25-P-0008S
MODEL 220
 Engine running (speed > 500 rpm)
If applicable it is necessary to activate this function (SA) of the special vehicle multifunction control module
(SVMCM) (N26/9) with the STAR diagnosis tool.
This releases the following inputs/outputs on the control module:
 Windshield defroster switch (S14/1) with integrated LED

 Windshield defroster relay module (K13/2) with connected load, windshield defroster (R22/2)
The windshield defroster can be switched on by pressing the button once and switched off by pressing the
button again. The heating mode is time-controlled.
Display of function status on LED
The LED integrated into the switch is directly actuated by the special vehicle multifunction control module
(SVMCM) (N26/9).
The following functions are possible:
Heater LED
ON comes on
ON + power too low flashes (1.5 Hz)
OFF does not come on
Time-controlled heating mode
The heat duration depends on the vehicle speed.
Speed (km/h) Time (min)

0 6
60 7
80 9
100 11

module (SVMCM),
INTERCOM, FUNCTION - GF82.25-P-0011MB
MODEL 220.175 /178 with CODE (979) Special protection version with intercom
Fig. 63: Intercom Function Diagram
General
The intercom can be operated at any time regardless of the position of the drive switch.
The interior microphone (B25/3) is located in the glove compartment.

The acoustic signals from outside of the vehicle are picked up by the two microphones in the right and left
outside rearview mirrors (B25/4, B25/5) and can be heard on the interior loudspeaker (H10/1). Transmission is
accomplished by the exterior loudspeaker (H10).
Voice connection from outside to inside
By actuating the microphone switch (1) the exterior microphones (B25/4, B25/5) are activated. The radio
switched on is simultaneously set to "mute".
In this operating position the external noises are audible, it is therefore possible to talk to the vehicle passengers.
The interior loudspeaker (H10/1) located in the right A-pillar paneling makes the sound audible in the passenger
compartment.
An additional loudspeaker is integrated in the interior microphone (B25/3) so that it is possible to hold the
interior microphone directly against your ear similar to a telephone when it is difficult to understand.
The communication distance to the vehicle is between 3 and 5 m depending on the ambient noise.
Voice communications from inside to outside
Voice connection from inside to outside is always possible when the speaking key (1) is actuated regardless of
the microphone switch (2).When the speaking key (1) is actuated the exterior microphones (B25/4, B25/5) are
deactivated.
The acoustic signals are always preamplified in the interior microphone (B25/3).
The voice reproduction is accomplished via an external loudspeaker (H10) located in the left front area below
the bumper.
The volume can be set with the control key (3).
Fig. 64: Identifying Interior Microphone (B25/3) Components
Intercom control module, GF82.25-P-3101MB

location/purpose
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR INTERCOM - GF82.25-P-0991MB
Intercom, function GF82.25-P-

0011MB
Survey of system components for GF82.25-P-
intercom, location/purpose/design/function 9991MB
PANIC ALARM SYSTEM (PAS) FUNCTION DESCRIPTION CONTENTS - GF82.25-P-0995MB
Panic alarm system (PAS) function GF82.25-P-0005MB

Intercom function GF82.25-P-2007FB
Activating function GF82.25-P-2005MB
Deactivating function GF82.25-P-2006MB
Alarm status function GF82.25-P-3000MB
Panic alarm system (PAS) survey of GF82.25-P-9995MB
system components
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF TURN SIGNALS/HAZARD WARNING

FLASHERS - GF82.25-P-0998ZZ
MODEL 170, 202 as of 1.6.97, 208, 210.081 /281, 210 as of 1.3.97, 215
Turn signals/hazard warning GF82.25-P-0002A

flashers, function
Turn signals, function Model 202, 208, 210 GF82.25-P-2003A
Hazard warning flashers, function Model 202, 208, 210 GF82.25-P-2004A
Turn signals/hazard warning Model 202, 208, 210 GF82.25-P-0002-01A
flashers, location of components
Turn signals/hazard warning Model 202, 208, 210 GF82.25-P-0002-02A
flashers, interlinkage of
components
Outside rearview mirror turn Model 170 as of GF82.25-P-4010A
signals, location/purpose/design 01.02.00
Model 208.3/4 as of
01.08.99
Model 210 as of
01.07.99
Model 215
TURN SIGNAL LAMPS, FUNCTION - GF82.25-P-2003B
MODEL 220
Fig. 65: Turn Signal Lamps Function Diagram
Function sequence
 Ignition: ON
 Combination switch (S4) switched to left or right turn signal position.
1. The position (1) of the combination switch is read in by the jacket tube module (N80).
2. The jacket tube module generates the turn signal message and transfers it via a signal (2, 2a,3) on the
CAN bus to the
 instrument cluster (A1),
 left front SAM control module (N10/6),
 right front SAM control module (N10/7),
 rear SAM control module (N10/8),
 trailer recognition control module (N28/1),

 left front door control module (N69/1),
 right front door control module (N69/2) and
 upper control panel control module (N72/1).
3. The instrument cluster (A1) actuates the audible turn signal indicator(A1h2) as well as the left or right
turn signal indicator lamps (A1e1, A1e2).
control module (N10/8) actuate the following lights depending on the requirements:
 left front turn signal lamp (E1e5) and
 left rear turn signal lamp (E3e1),
or
right front turn signal lamp (E2e5) and

 right rear turn signal lamp (E4e1).
5. The left front door control module (N69/1) and right front door control module (N69/2) actuate the
following lamps depending on the requirements:
 left exterior mirror turn signal lamp (E6/5) or
 right exterior mirror turn signal lamp (E6/6).
6. The trailer recognition control module (N28/1) actuates the trailer turn signal lamps via the trailer hitch
socket (13-pin, X58).
If one of the bulbs in the actuated turn signal lamps is burned out, the flashing frequency of the left or right turn
signal indicator lamp in the instrument cluster doubles. The flashing frequency of the turn signal lamps itself
remains unchanged.
If the hazard warning flashers are switched on at the same time as the turn signals, the turn signals have priority.

function
function
function
location/purpose
HAZARD WARNING LAMPS, FUNCTION - GF82.25-P-2004B
MODEL 220
Fig. 66: Hazard Warning Lamps Function Diagram
Function sequence
 Hazard warning flasher switch actuated.
1. The position of the hazard warning flasher switch is read in by the upper control panel control module
(N72/1).
2. The upper control panel control module sends a signal (1) to the jacket tube module (N80) via the CAN
bus.
3. The jacket tube module generates the flasher message and sends a signal (2) via the CAN bus to the
 instrument cluster (A1),
 left front SAM control module (N10/6),
 right front SAM control module (N10/7),

 rear SAM control module (N10/8),
 trailer recognition control module (N28/1),
 left front door control module (N69/1 and
 right front door control module (N69/2).
4. The instrument cluster (A1) actuates the audible turn signal indicator (A1h2), the left or right turn signal
indicator lamp (A1e1, A1e2).
control module (N10/8) actuate the following lamps:
 left front turn signal lamp (E1e5),
 right front turn signal lamp (E2e5),
 left rear turn signal lamp (E3e1)
 right rear turn signal lamp (E4e1).
6. The left front door control module (N69/1) and right front door control module (N69/2) actuate the
following lamps:
 left exterior mirror turn signal lamp (E6/5) and
 right exterior mirror turn signal lamp (E6/6).
7. The trailer recognition control module (N28/1) actuates the trailer hitch socket (13-pin, X58), if
necessary.
If the jacket tube module fails, the flashing signal for the hazard warning flashers is generated by the upper
control panel control module.

function
function
function
location/purpose
ACTIVATING FUNCTION - GF82.25-P-2005MB

The alarm is activated by the activate buttons:
 Emergency alarm system activate button, left knee bolster (S62/16),

 Emergency alarm system activate button, right knee bolster (S62/17),
 Emergency alarm system activate button, rear fresh air vent (S62/18)
irrespective of the state of the ignition and in any vehicle operating state.
If anyone of the activate buttons is operated, a ground signal is passed to the appropriate input of the PAS
control module (N26/8). The PAS control module activates the alarm outputs.
Fig. 67: Identifying Alarm Activate Buttons
Alarm status function GF82.25-P-3000MB
DEACTIVATE THE FUNCTION - GF82.25-P-2006MB
MODEL 220.175 /176 /178 with CODE (Z04) Light armoring with panic alarm system (PAS [GAS])
MODEL 220.175 /176 /178 with CODE (Z07) Top protection with panic alarm system (PAS [GAS])
Shown on model 220 up to model refinement 2002

Fig. 68: Identifying Emergency Alarm System Cancel Button - Shown On Model 220 Up To Model
Refinement 2002
Shown on model 220 as of model refinement 2002
Fig. 69: Identifying Interior Microphone Components - Shown On Model 220 As Of Model Refinement
2002
When the emergency alarm system cancel button (S62/5) is operated, a ground signal is forwarded to the
corresponding input of the PAS (GAS) control unit (N26/8). The alarm functions are deactivated.
The operating conditions of the previously switched-on standard components, such as the exterior lights, are
active again and can be operated as usual. The central locking system can be opened again via the inner lock.
With model 220 as of model refinement 2002, the emergency alarm system cancel button (S62/5) was
integrated into the microphone talk button (1). When an alarm is triggered, it is deleted again by pressing the
microphone talk button (1) one time. Once the alarm has been deleted, the talk button is available again
automatically.
PAS (GAS) control unit, GF82.25-P-3101MB

location/task
INTERCOM FUNCTION - GF82.25-P-2007FB

MODEL 210 with CODE (979) Special protection version Panic alarm system (PAS [GAS])
MODEL 220.175 /176 /178 with CODE (Z04) Light armoring Panic alarm system (PAS [GAS])
MODEL 220.175 /176 /178 with CODE (Z07) Top protection Panic alarm system (PAS [GAS])
Fig. 70: Identifying Intercom Components
The intercom system can be started up at any time and independently from a triggered alarm. The inside
microphone (B25/3) is installed in the glove box.
The volume can be regulated with the volume control (3). The acoustic signals from outside of the vehicle are
recorded by 2 microphones, the left outside mirror microphone (B25/4) and the right outside mirror microphone
(B25/5), and output via the inside speaker (H10/1).
The transmission takes place through the outside speaker (H10) in the front section of the vehicle.
The microphone switch (2) always has to be switched off after it has been used, otherwise the acoustic
"Help" signal is not triggered in the event of an alarm.
Voice connection from outside toward inside
The voice connection possibility from outside toward inside is initiated by operating the microphone switch (2).
If the "Help" signal had been triggered beforehand, then this is interrupted in the process.
Voice connection from inside toward outside
When the microphone talk button (1) is operated, the outside microphones are switched off and the voice
connection possibility from inside toward outside is activated.
When the microphone talk button (1) is pressed, it is possible to talk from the inside toward the outside
regardless from the switch position of the microphone switch (2).
PAS (GAS) control unit, Model 210 GF82.25-P-3100FB

location/function
PAS (GAS) control unit, Model 220 GF82.25-P-3101MB
location/task
SPECIAL SIGNAL SYSTEM PUSHBUTTON CONTROL MODULE, LOCATION/PURPOSE -
GF82.25-P-2101S
MODEL 220 Official and emergency service vehicles
Fig. 71: Identifying Special Signal System Pushbutton Control Module Location
Special signal system GF82.25-P-2101-02S

pushbutton control
module, purpose
Special signal system pushbutton control module, purpose - GF82.25-P-2101-02S
Fig. 72: Identifying Special Signal System Pushbutton Control Module
Signal switch (1) in position A
The blue light is actuated. The operating state of the left and right blue lights is indicated by the indicator lamps
(2).
Signal switch (1) in position B
The blue light is actuated. The function of the left and right blue lights is indicated by the indicator lamps (2). If
one of the fanfare horn (S110s5, S111s5) buttons is pressed momentarily a tone sequence cycle is transferred
to the fanfare horns (H2) . It is possible to repeat this function as often as possible.
Signal switch (1) in position B and pulled

The optical and acoustic signal is permanently actuated.
The function of the right and left blue lights is indicated by the indicator lamps (2).
The optical signal can be triggered independently of the ignition. The acoustic signal sounds only with c. 15
and left blue light switched on.
INTERCOM CONTROL MODULE, LOCATION/PURPOSE - GF82.25-P-2110MB
Fig. 73: Identifying Intercom Control Module Location
Intercom control module, The intercom control

location module (N26/13) is
located in the trunk on
the right side wall
Intercom control module, Control of individual
purpose functions of intercom
ALARM STATUS FUNCTION - GF82.25-P-3000MB
MODEL 220 with CODE (979) Special protected version with panic alarm system (PAS)
The following functions are activated as a result of the alarm status:
 Audible signal
Electronic "YELP" signal is activated. Function:
The frequency of the signal is generated by means of an audio generator in the PAS control module
(N26/8). The alarm signal is emitted by the exterior speaker (H10) fitted to the front area of the vehicle.
 All turn signal lights flash

When an alarm is triggered, all the turn signal lights are activated irrespective of the position of the turn
signal switch.
The flash frequency is approx. 2 Hz.
Function:
A request is transmitted by the SVMCM control module over the interior bus (CAN B). The steering
column module (N80) generates the message and transmits the signal to the SAM control modules
(N10/6, N10/7, N10/8) and to the door control modules (N69/1, N69/2). The control modules actuate the
individual turn signal lights.
 Flashing headlights
The headlights flash with a frequency of approx. 1 Hz irrespective of the function previously set (side
lights/main beam/low beam). The low beam is switched on in this case as the basic lighting. This function
cannot be influenced by the standard controls, such as light/main beam/low beam switch.
On models fitted with daytime running lamps, the standard function is likewise canceled in the event of
an alarm, and replaced by the alarm function. The same also applies to models fitted with a light sensor.
Function:
A request is transmitted by the special vehicle multifunction control module (SVMCM) over the interior
bus (CAN B). The SAM control modules (N10/6, N10/7) receive the message and actuate the main beam
headlights through the front fuse and relay module (K40/6, K40/7).
 Central locking closes
If a door is only in the initial detent, or open, the remaining doors are nevertheless locked. After this door
is closed, the door is also locked if the alarm has been activated.
It is not possible to open the CL by means of the central locking interior switch until after the alarm has
been canceled.
Function:
A request is transmitted by the SVMCM control module over the interior bus (CAN B). The PSE control
module (A37) receives this request and locks the doors pneumatically.
 Intercom system
The voice link from the exterior to the interior is established when the microphone switch is switched on.
The radio switches to "mute".
The "YELP" alarm signal is stopped.

Function:
The intercom system is controlled by the PAS control module (N26/8).
 Radio emergency call (option)
If desired, an emergency two-way radio system can be activated when the alarm is triggered. In this case,
the SVMCM control module generates the signal which is used for activating an emergency call.
Function in combination with special signal system:
If the panic alarm system is coupled with a special signal system, the panic alarm system always has function
priority.
All the alarm functions described above take priority until the PAS cancel button is pressed.
In other words, if the PAS and special signal system are switched on at the same time, the special signal siren
system and special signal exterior light control are suppressed and superimposed by the PAS functions.
The special signal system is not activated again until after the PAS cancel button is pressed.
PAS control module GF82.25-P-3101MB

position/task
Special vehicle GF82.25-P-4104MB
multifunction control
module (SVMCM)
position/task
PAS (GAS) CONTROL UNIT, LOCATION/TASK - GF82.25-P-3101MB
MODEL 220.175 /176 /178 with CODE (Z04) Light armoring with panic alarm system (PAS)
MODEL 220.175 /176 /178 with CODE (Z07) Top protection with panic alarm system (PAS)
Fig. 74: Identifying PAS (GAS) Control Unit Location
PAS (GAS) control The PAS (GAS) control unit

unit, location (N26/8) is located in the
luggage compartment on the
right sidewall.
PAS (GAS) control Control/actuation of:
unit, task
 Outside speaker
 Intercom system
 Blue light
 Transmission of requests
to the special vehicle
unit (SVMCU [MSS])
(N26/9)
EXTERIOR REARVIEW MIRROR TURN SIGNAL LAMP, LOCATION/PURPOSE/ DESIGN -

GF82.25-P-4010A
MODEL 170 as of 1.2.00, 208 as of 1.8.99, 210 as of 1.7.99, 215, 220
Exterior rearview mirror Models 215, 220 GF82.25-P-4010-01A

turn signal lamp, location
Models 208.3/4 as of GF82.25-P-4010-01B
01.08.99
Model 210 as of 01.07.99 GF82.25-P-4010-01C
Model 170 as of 01.02.00 GF82.25-P-4010-01D
Exterior rearview mirror The exterior rearview
turn signal lamp, purpose mirror turn signal lamps
(E6/5 and E6/6) replace
the side turn signal lamps
in the front fenders. The
location of the exterior
rearview mirror turn
signal lamps ensures that
the turn signals can be
recognized easily from
the front and side.
Exterior rearview mirror GF82.25-P-4010-02A
turn signal lamp, design
Exterior rearview mirror turn signal lamp, location - GF82.25-P-4010-01A
Models 215, 220

Fig. 75: Identifying Exterior Rearview Mirror Turn Signal Lamp Location - Illustrated On Model 220
Exterior rearview mirror turn signal lamp, design - GF82.25-P-4010-02A
The turn signal lamp consists of a white turn signal lens installed in the exterior rearview mirror housing behind
which rows of yellow LED's are located.
Failure of one LED is not recognized by the bulb check feature due to the low current consumption. Only
complete failure of all LED's is displayed.
SPECIAL PROTECTION MULTIFUNCTION CONTROL MODULE,

MODEL 220 with CODE (930) Taxi emergency call with CODE (934) Taxi emergency alarm unit
The special vehicle multifunction control module (SVMCM [MSS]) (N26/9) is located on the right side wall
in the trunk, under the paneling.
Fig. 76: Identifying Special Protection Multifunction Control Module Location
Special vehicle GF82.25-P-4102-02S

module (SVMCM
[MSS]), task
Special vehicle Integrated, CAN-capable
multifunction control control module with 33-
module (SVMCM pin plug.
[MSS]), design
Special vehicle Only one version of the
multifunction control control module is
module (SVMCM available. Adaptation to
[MSS]), function the special systems which
are installed is carried out
via the STAR diagnostic
tool. Depending on
programming, the control
module's inputs and
outputs are connected and
initialized in various
manners.
Special vehicle multifunction control module, purpose - GF82.25-P-4102-02MB
In combination with passenger alarm system (PAS):
The SVMCM multifunction control module transmits the requests of the PAS control module to the passenger
compartment CAN bus (CAN B) (interface to standard vehicle electrical system). For actuating:
 Main-beam headlamps
 Turn signal lamps
 Central locking
In combination with windshield defroster:
Control of all functions (switch-on time, switch-off) of windshield defroster.
Special vehicles multifunction control module task - GF82.25-P-4102-02S
The special vehicle multifunction control module (SVMCM [MSS]) (N26/9) is used to monitor and control
special functions for special vehicles.
The control module is able to differentiate between two basic statuses :
 Taxi
 Special-purpose vehicles:
 Official and special protection vehicles
 Police and emergency vehicles
 At the request of the customer, a panic alarm for private vehicles is available.
Depending on control module encoding and installation, the SVMCM assumes the following tasks:
 Taxi roof sign system control

 Taxi emergency alarm system control
 Partial special signal system function control
 Panic alarm function control (private vehicles)
 Control and regulation of the heated wind shield (special protection vehicles)
Control module encoding
Control module encoding is carried out with the Star diagnostic tool via the EIS control module (N73) .
Exception:
The heated windshield and police vehicle disguised as a taxi functions are encoded directly in the SVMCM.
SPECIAL VEHICLE MULTIFUNCTION CONTROL MODULE, LOCATION/PURPOSE - GF82.25-P-

4104MB
MODEL 220.175 /178 with CODE (979) Special protection version

Fig. 77: Identifying Special Vehicle Multifunction Control Module Location
Special vehicle The special vehicle

multifunction control multifunction control
module (SVMCM), module (SVMCM) is
location located in the trunk on
the right side wall.
Special vehicle GF82.25-P-4102-02MB
module (SVMCM),
purpose
TRANSMITTER FOR EMERGENCY ALARM RADIO REMOTE ACTIVATION POSITION/TASK -

GF82.25-P-4105S
MODEL 202, 203, 210, 220 with CODE (930) Taxi emergency call with CODE (934) Taxi emergency
alarm unit
Fig. 78: Identifying Transmitter For Emergency Alarm Radio Remote Activation Components
Radio-wave remote- GF82.25-P-4105-01S

control transmitter for
emergency SOS call
Transmitter for emergency alarm remote actuation task - GF82.25-P-4105-01S
A prespecified procedure exists for checking the functions of the taxi emergency call!
In combination with driving authorization and locking system components, radio remote actuation (FFA) via
the transmitters for emergency alarm remote actuation (A8/4) enables the actuation of an emergency
call/emergency alarm from the immediate vicinity of the vehicle.
In order to avoid unintentional actuation, the ALARM button on the transmitter for emergency alarm remote
actuation (A8/4) must be pressed twice within three seconds.
Depending on the variant code in the special vehicle multifunction control module (SVMCM [MSS])
(N26/9), no acoustic/visual feedback regarding the actuation of the emergency alarm system is provided. The
"taxi emergency call" proceeds unnoticed.
Assignment to the vehicle can be checked as follows without actuating the alarm:
As described under programming, a vehicle key is placed onto the transmitter for emergency alarm remote
actuation (A8/4) . After depressing the TEST button, the tone sequence 1 x long, 5 x short sounds if the battery
voltage is correct. Within the next second, the open or close button of the vehicle key must be pressed, as a
result of which the transmission of an IR protocol is actuated. After receiving the IR telegram, the transmitter
for emergency alarm remote actuation (A8/4) checks that the ID code corresponds. Only if the transmitter
for emergency alarm remote actuation (A8/4) and the key belong to the same vehicle does a short piezotone
sound.
Programming
The transmitter for emergency alarm remote actuation (A8/4) is programmed with the vehicle-specific ID
code via the IR signal of a key which belongs to the relevant vehicle. In order to achieve this, the end face
(direction of IR radiation) of the vehicle key is placed onto the corresponding mark on the IR-permeable base of
the transmitter for emergency alarm remote actuation's (A8/4) housing. After depressing the TEST button,
the tone sequence 1 x long, 5 x short sounds if the battery voltage is correct. Within the next 5 seconds, the open
or close button of the vehicle key must be pressed, as a result of which the transmission of an IR protocol is
actuated.
A continuous tone sounds for 2 s following successful programming.
After the IR signal from the vehicle key has been correctly received by the transmitter for emergency alarm
remote actuation (A8/4) this is programmed to the vehicle code, and is simultaneously protected against
further attempts at programming.
The programmed/unprogrammed status can be checked via the piezo sequence when the TEST button on the
transmitter for emergency alarm remote actuation (A8/4) is pressed. The piezo tone sequence of the
unprogrammed transmitter for emergency alarm remote actuation (A8/4) differs from the programmed one
in the following manner:
Programmed: 1 x long, 5 x short, brief pause (1 s)

Unprogrammed: 1 x long, 5 x short, 5 seconds pause
SURVEY OF SYSTEM COMPONENTS FOR INTERCOM,

LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.25-P-9991MB
Intercom control module, GF82.25-P-3101MB

location/purpose
Table of contents, function GF82.25-P-0991MB
description for intercom
PANIC ALARM SYSTEM (PAS) SURVEY OF SYSTEM COMPONENTS

POSITION/TASK/DESIGN/FUNCTION - GF82.25-P-9995MB
PAS control module GF82.25-P-3101MB

position/task
Special vehicle GF82.25-P-4104MB
module position/task
Panic alarm system GF82.25-P-0995MB
(PAS) function
description contents
WIPER SYSTEM (WS), FUNCTION - GF82.30-P-0003S
Models 215, 220

Fig. 79: Wiper System Function Diagram
Networking of components
Preconditions for function:
 Circuit 15R ON
The windshield wiper system is operated using the combination switch (S4).
The following functions are possible:
 Touch wiping : A single wipe is performed. (To do this, push the combination switch (S4) to the detent)
 Intermittent wiper valid up to 8/31/02 : with automatic intermittent wipe control via the rain sensor
(B38). To do this, turn the combination switch (S4) to position 1.
 Intermittent wiper valid as of 9/1/02 : with automatic intermittent wipe control via the rain/light sensor
(B38/2). To do this, turn the combination switch (S4) to position 1.
 Intermittent wiping with slow speed (stage 1, approx. 40 cycles/min.) To do this, turn the combination
switch (S4) to position 2.
 Wiping at high speed (stage 2, approx. 60 cycles/min). To do this, turn the combination switch (S4) to
position 3.
 Washing : The windshield is wiped with additional water. To do this, push the combination switch (S4)
beyond detent.
A data transfer between the left SAM control unit (N10/6) and the overhead control panel control unit (N70)
only takes place if the data has changed or one of the two control units has been initialized. Operation is
interrupted when "circuit 15R OFF".
Switch positions
At combination switch (S4) position: interval (rain sensor position) the wiper requests are sent by the rain
sensor (B38) or as of 9/1/02 by the rain/light sensor (B38/2) via the overhead control panel control unit (N70).
If another wiper position is selected using the combination switch (S4), the request is transmitted directly to the
wiper by the left SAM control module (N10/6).
The combination switch (S4) information and the requests from the overhead control panel control unit
(N70) are provided by the interior CAN.
A two-stage standard wiper control is used. It is actuated directly by the left SAM control unit (N10/6).
Wiper system (WS), up to 31.5.00 GF82.30-P-0003-01S

Wiper system (WS), as of 6/1/00 GF82.30-P-0003-01SN
Windshield wiper, GF82.30-P-3004S
function
Windshield intermittent GF82.30-P-3003S
wipe, function
Windshield washer, GF82.35-P-3002S
function
Washing nozzle and GF82.35-P-3003S
washing nozzle hose
heater, function
Heating wiper system, GF82.30-P-2003S
function
Wiper system (WS), location of components - GF82.30-P-0003-01S
Wiper system, location of components shown on Model 220

Fig. 80: Identifying Wiper System Components Location - Shown On Model 220
Wiper system (WS), location of components - GF82.30-P-0003-01SN
Fig. 81: Identifying Wiper System Components Location - Shown On Model 220
Wiper system, location of components shown on Model 220
CONTENTS, FUNCTION DESCRIPTION OF WIPER SYSTEM (WS) - GF82.30-P-0998S
Models 215, 220
Wiper system (WS), function GF82.30-P-0003S

Wiper system (WS), location of up to 31.5.00 GF82.30-P-0003-
components 01S
as of 6/1/00 GF82.30-P-0003-
01SN
Windshield wiper, function GF82.30-P-3004S
Windshield intermittent wipe, function GF82.30-P-3003S
Safety switch-off (WS), function as of 6/1/00 GF82.30-P-3005SN
Heating wiper system, function GF82.30-P-2003S
Wiper system automatic speed GF82.30-P-4006S
reduction, function
Slowing down wiper motor, function GF82.30-P-4007S
Anti-block device for wiper motor, GF82.30-P-4008S
function
Windshield washer, function GF82.35-P-3002S
Washing nozzle and washing nozzle GF82.35-P-3003S
hose heater, function
Coolant/washer fluid level voltage GF54.30-P-4001S
coding, function
Survey, system components, wiper GF82.30-P-9998SN
system (WS),
WIPER REST HEATER, FUNCTION - GF82.30-P-2003S
MODEL 215.### 1#, 220
Interlinkage of components Illustrated on model 220

Fig. 82: Wiper Rest Heater Function Diagram - Illustrated On Model 220
Prerequisites for operation of wiper rest heater:
 Engine: ON
Function
At outdoor temperatures below 5 °C the windshield is heated directly in the area where the wiper blades rest by
the wiper rest heater (R2/10).
If the outdoor temperature increases to above 7°C the wiper rest heater is switched off.
Actuation of wiper rest heater (R2/10)
When switch-on conditions are fulfilled the left front SAM control module (N10/6) actuates the wiper rest
heater relay (K40/6kA) on the left front fuse and relay module (K40/6). The wiper rest heater relay (K40/6kA)
then switches on circuit 30 to the wiper rest heater (R2/10).
Required data:
 Outdoor temperature:
The outdoor temperature sensor (B14) is read in directly by the left front SAM control module (N10/6) to
check the outdoor temperature.
 Status of circuit 61 (generator):
The status of c.61 is read in by the right front SAM control module (N10/7) and relayed to the left front
SAM control module (N10/6) via the CAN bus (passenger compartment).
module (SAM),
Outdoor temperature sensor, GF83.57-P-2103S
COMBINATION SWITCH, LOCATION / TASK / DESIGN / FUNCTION - GF82.30-P-2100S
Models 215, 220
Location of the component shown on MODEL 220
Fig. 83: Identifying Combination Switch Location
Combination switch, The combination switch (S4)

location is fitted to the steering column
underneath the steering wheel.
It is attached directly onto the
steering column module
(N80) and it is contacted by
means of an integral
connector; in other words, no
wires are necessary.
Combination switch, Control of the following
purpose systems:
Turn signals, high and low
beam headlamps, headlamp
flasher, windshield wiper and
windshield washer.
Combination switch,  Left and right turn
design signal indicator
 Switching on headlamp
flasher and high beam
 Low beam switch
 Windshield washer
system switch
 Horn contact
 Wiper switch
(intermittent, slow/fast
Combination switch, GF82.30-P-2100-04S
function
Combination switch, function - GF82.30-P-2100-04S
The illustration shows the internal circuit of the combination switch (S4) .
The combination switch (S4) has various switch groups for the various function.
All switch positions are read in by the jacket tube module (N80) and their status is transferred as a message to
the CAN bus (passenger compartment).
In addition to the contacts the switches also contain resistors for voltage coding. This means that the connector
requires only 5 pins for all functions.
Fig. 84: Combination Switch Function Diagram
Left and right turn signal switch (S4s1):
The left and right turn signal switch (S4s1) has three positions:
 Turn signals off (a2 ),

 Left turn signals (a3 ),
 Right turn signals (a1 ).
Headlamp flasher switch (S4s2)
As long as the headlamp flasher switch (S4s2) is actuated the corresponding contact (S4s2) is closed.
Low beam switch (S4s3)
When the low beam switch (S4s3) is actuated the corresponding contact (S4s3) remains closed as long as the
switch is actuated.
Windshield washer system switch (S4s4):
The windshield washer switch (S4s4) has three positions:
 Non-actuated position (b1 ),

 One-touch wipe (b2 ),
 Wash (b3 )
Wipe switch (S4s5):
The wipe switch (S4s5) has four positions:
 Windshield wiper off (c1 ),

 Intermittent wiping (c2 ),
 Slow wiping (c3 ),
 Fast wiping (c4 ).
WINDSHIELD INTERMITTENT WIPING, FUNCTION - GF82.30-P-3003S
Models 215, 220
Operational sequence:
 The intermittent wiping function is switched on by turning the combination switch (S4) to position 1.
 The position of the combination switch (S4) is read in by the steering column module (N80) and sent to
the interior compartment CAN as a message
 The left front SAM control module (N10/6) receives this message and initiates one wipe cycle (if the
wiper was already moving, this wipe cycle is first brought to an end)
 After one wipe cycle, the wiper motor (M6/1) is stopped
 The intermittent pause is started.
 At the end of the pause, the next wipe cycle is executed.
Control of wiper motor

The left front SAM control module (N10/6) controls the wiper motor (M6/1) by means of the wiper stage 1 and
2 relay (K40/6kG) and wiper On and Off relay (K40/6kH) so that the wiper wipes at speed stage 1.
Interruption of intermittent pause
If another wiper function is requested during an intermittent pause, this function is executed without taking the
intermittent pause into consideration. After completion of this function, the intermittent pause is started again.
Control of the intermittent pause
The intermittent pause is dependent on the amount of moisture present on the windshield. The left front SAM
control module (N10/6) analyses for this purpose the data from the rain/light sensor (B38/2). The exchange of
data between the left front SAM control module (N10/6) and the rain/light sensor (B38/2) takes place via the
interior compartment CAN and, because the rain/light sensor (B38/2) is not connected directly to the interior
compartment CAN, via the overhead control panel control module (N70) as an interface.
In the event of a failure of the rain/light sensor (B38/2) the intermittent time is set to approx. 5 s.
As of 1.6.00 there is a safety cutout when the front door is open.
System functions
 Circuit 15R ON
Windshield wipers
Switch position I = intermittent = pause duration dependent on quantity of moisture; can be regulated upward to
continuous wiping stage 2.
Switch position II = stage 1 = continuous wiping 40 cycles/min
Switch position III = stage 2 = continuous wiping 60 cycles/min
A two-stage standard wiper control is used. This is actuated directly from the left SAM control module (N10/6).
Data are only transferred between the left SAM control module (N10/6) and the overhead control panel
control module (N70) when there is a change to the data, or when one of the two control modules is initialized.
The functions are interrupted with "Circuit 15R OFF".
Intermittent wipe (valid as of 1.9.02)
Continuous wiper control by the rain/light sensor (B38/2)
The top priority for switching on the wiper is always assigned to the combination switch (S4). Information such
as the vehicle speed, the position of the wiper switch, the ambient light conditions as well as the outside
temperature are received by the overhead control panel control module (N70) and processed in the algorithm
implemented. The wiper system is actuated via the interior compartment CAN by means of the left SAM
The wiper is controlled depending on the particular quantity and frequency of moisture by:
 Individual wipe cycles

 Continuous wipe
 Continuous wiping with the selection of the required wiper speed
The intermittent time is determined by the rain/light sensor (B38/2) (up to stage 2 continuous wiping). If
communication with the overhead control panel control module (N70) fails at switch position I the intermittent
wiping function is activated. If intermittent wiping is transmitted from position 0, the wipe cycle takes place
immediately. After interrupting intermittent wiping by a wiper function, the intermittent pause elapses.
Intermittent times (emergency mode) :
 1st intermittent time T/1 = 5 s ± 1 s

 2nd intermittent time T/2 = 1.5 s (T/1 with automatic speed reduction)
The rain/light sensor (B38/2) is activated by switching on the intermittent wiper setting and thus the CAN
message generated by the left SAM control module (N10/6) via the overhead control panel control module
(N70). The left SAM control module (N10/6) receives the request for intermittent wiping via the interior
compartment CAN.
Switch positions (valid as of 1.9.02)
With the combination switch (S4) position: intermittent (rain sensor position) the requests for the wiper take
place via the overhead control panel control module (N70) from the rain/light sensor (B38/2).
If using the combination switch (S4) another wiper setting is selected, the request comes directly from the left
SAM control module (N10/6) to the wiper.
The combination switch (S4) information as well as the requests from the overhead control panel control
module (N70) are supplied by means of the interior compartment CAN.
Safety switch-off (WS), as of 1.6.00 GF82.30-P-3005SN

function
WIPER, FUNCTION - GF82.30-P-3004S
Models 215, 220
Slow wiping (stage 1) function sequence:

 The slow windshield wiping function is switched on by turning the combination switch (S4) to position 2
 The left front SAM control module (N10/6) receives this message and controls the wiper On and Off
relay (K40/6kH)
 Circuit 15R is switched via the wiper stage 1 and 2 relay (K40/6kG) to "circuit 53" (slow wiping) by the
wiper motor (M6/1). (The wiper stage 1 and 2 relay (K40/6kG) is then not actuated.)
 The wiper motor operates at slow speed
Fast wiping (stage 2) function sequence:
 The fast windshield wiping function is switched on by turning the combination switch (S4) to position 3
 The left front SAM control module (N10/6) receives this message and actuates the wiper On and Off
relay (K40/6kH) and the wiper stage 1 and 2 relay (K40/6kG)
 Circuit 15R is switched via the wiper stage 1 and 2 relay (K40/6kG) to "circuit 53b" (fast wiping) by the
wiper motor (M6/1). (The wiper stage 1 and 2 relay (K40/6kG) is then actuated.)
 The wiper motor runs at high speed
Switching off wiping function:
 If the combination switch (S4) has been turned to position 0, the above-mentioned message is no longer
on the interior compartment CAN
 If the wiper motor now reaches the park position, the left front SAM control module (N10/6) ensures that
the wiper stops (EIf switch-off was accomplished from stage 2, the wiper motor is switched back to the
slow stage until it reaches the park position)
 The wiper motor stops in the park position
The wiper motor (M6/1) can be switched back to intermittent wiping by the automatic speed reduction.
As of 1.9.02 the functions anti-lock protection, lock detection, stopping and final wiping are monitored
independently by the reversing wiper system (UWA).
Windshield intermittent GF82.30-P-3003S

wiping, function
SAFETY SWITCH-OFF (WS), FUNCTION - GF82.30-P-3005SN
MODELS 215, 220 as of 1.6.00
Networking of safety cutout Intermittent wipe

Fig. 85: Safety Switch-Off Function Diagram
Safety cutout with the intermittent wiping function
The following safety precaution has been incorporated in order to minimize the risks of possible injuries:
 The intermittent wiping function (combination switch in position 1) is suppressed at a vehicle speed of
less than 5 km/h as soon as one of the front doors is opened.
 The function is possible again as soon as both front doors are closed
In order to permit the intermittent wiping function even in the event of a defective door contact switch (S17/3,
S17/4), the states of the door contact switches have no effect at speeds above 3 km/h.
A wipe cycle which has already commenced, is not interrupted. The wiper moves as far as the park position.
Networking
For the safety cutout, the signals of the front door contact switch are needed. These are read in by the rear SAM
control module (N10/8) and are sent via the interior compartment CAN to the left front SAM control module
(N10/1).
The vehicle speed signal comes from the instrument cluster (A1) via the interior compartment CAN to the left
front SAM control module (N10/1).
Fault analysis:
 Failure of the serial communication interface to the left SAM control module (N10/6) - wiper motor
In the event of a failure of the serial communication interface or a fault report from the wiper motors (e.g.: Hall
sensors defective), even when there is as yet no wiper request, an error message is sent from the left SAM
control module (N10/6) via the interior compartment CAN to the instrument cluster (A1).
The rain sensor and light information are sent from the overhead control panel control module (N70) only in the
event of changes.
Fault report of the wiper
If, due to the internal thermal protection, the wiper signals the overload bit, this is signaled by the left SAM
control module (N10/6) to the instrument cluster as a wiper fault.
Failure or lack of CAN communication to the overhead control panel
In the event of an incorrect message, the wiper request is rejected and only responded to again with the next
correct message. In the event of five incorrect messages, the intermittent wipe control takes place as under 1 (T
= 5 s +/- 1 s). If correct communication with the rain/light sensor (B38/2) can be established again, then the
system switches back to rain/light sensor mode.
No fault is displayed in the instrument cluster.
Wiper startup suppression
Suppression of the wiper function with the driver or passenger door open to prevent accidents.
The wiper function is suppressed when:
 Combination switch (S4) is in position 1 (intermittent stage)

 Driver or passenger door is open
 v < 5 km/h and
 Shift lever position is in P or N
If the driver or passenger door is open at v > 3 km/h, there is no wiper startup suppression.
Actuation of the wiper after a suppressed actuation takes place if:
 the wiper switch has been pressed

 an engaged drive position is detected, or a gear is engaged
 v > 3 km/h
Timeout of the wiper startup suppression

For door contacts (rear SAM): doors closed (default value) For combination switch (S4) request (electronic
ignition switch/steering column module): last valid value
For v-signal: v > 3km/h
The function can be coded out.
Anti-lock protection, lock detection, stopping, final wiping
The functions are carried out independently by the UWA (reversal wiper system).
Special case for wiper startup suppression
A wipe cycle that has already been initiated (with request via combination switch (S4) "position 1" or "final
wiping") is not interrupted by opening the driver or passenger doors. The wiper movement takes place until it
reaches the park position. Further wiper requests (with combination switch (S4) "position 1") are, however,
suppressed with the above-described criteria.
Wiper system automatic GF82.30-P-4006S

speed reduction, function
WIPER SYSTEM AUTOMATIC SPEED REDUCTION, FUNCTION - GF82.30-P-4006S
Models 215, 220
The automatic speed reduction has an effect on the functions (valid as of 1.9.02):
 Wiping in stage "1"

 Wiping in stage "2"
If the vehicle speed drops below 5 km/h, then the left front SAM control module (N10/6) switches the wiper
motor (M6/1) from these functions back to intermittent wiping. The intermittent pause is controlled in this case
by the rain/light sensor (B38/2).
Switching back to the selected wiper stage (valid until 31.8.02)
If with increasing vehicle speed the value of 8 km/h is exceeded, the left front SAM control module (N10/6)
switches the wiper motor (M6/1) automatically back again to the wiper stage ("1" or "2") set at the combination
switch (S4).
The speed reduction can be reset manually by pressing the combination switch (S4) again for each desired
function.
Switching back to the selected wiper stage (valid as of 1.9.02)
If a rain/light sensor (B38/2) is provided, the system always switches back to rain sensor mode. For this
purpose, the rain/light sensor (B38/2) must be activated and "circuit 15 ON". If the rain/light sensor (B38/2) is
present but defective, the standard way of switching back (switching back one stage) is carried out.
The vehicle speed signal required for the speed reduction is received at the left front SAM control module
(N10/6) via the interior compartment CAN from the instrument cluster (A1).
Instantaneous status: v-back-switching not in USA.
Anti-lock protection for GF82.30-P-4008S

wiper motor, function
SLOWING DOWN WIPER MOTOR, FUNCTION - GF82.30-P-4007S
Models 215, 220
Following the completion of a wiping operation, the wipers must come to a stop in the park position.
Stopping wiper motor
To stop the motor, the wiper On and Off relay (K40/6kH) is switched off by the left front SAM control module
(N10/6). Through the opening of this relay:
 The connection circuit 53 for the wiper motor (M6/1) is disconnected from the voltage supply circuit 15R
 The connection circuit 53 for the wiper motor (M6/1) is connected to ground via an electronic switch
(FET) of the SAM; this short-circuits the motor
 This short circuit decelerates the motor (eddy current dynamometer)
Prerequisites for stopping wiper motor
The stopping of the wiper motor (M6/1) is only initiated if:
 The wiper motor is switched off (combination switch (S4) in position 0) or

 Intermittent wiping is switched on (combination switch (S4) in position 1) and an intermittent pause has
just started
 The cam switch is closed, and thus the park position has been reached
In order to detect the park position, the wiper motor (M6/1) has a cam switch. When the motor runs through
the park position, the cam switch is actuated.
The signal from the cam switch is interrogated continuously by the left front SAM control module (N10/6).
Wiper motor, location / task / design / GF82.30-P-4104S

function
Rain/light sensor location/task/function as of 1.9.02 GF54.21-P-4123Q
Rain sensor, location/task/function up to 31.8.02 GF82.30-P-4103S
ANTI-LOCK PROTECTION FOR WIPER MOTOR, FUNCTION - GF82.30-P-4008S
Models 215, 220
Lock-up recognition
Lockup of the wiper motor (M6/1) is detected by the left front SAM control module (N10/6) by the lack of
signals from the cam switch.
Anti-lock protection for wiping in "stage 2" function
If this signal from the cam switch is missing for more than 4 s, then the left front SAM control module (N10/6)
switches the wiper motor (M6/1) to "stage 1".
If the signal is still missing for a further 8 s, then the left front SAM control module (N10/6) switches the wiper
motor (M6/1) off.
Anti-lock protection for the functions one-touch wiping, intermittent wiping, washing and wiping in
"stage 1"
With these functions the left front SAM control module (N10/6) switches the wiper motor (M6/1) off, if the
signals from the cam switch do not appear for more than 12 seconds.
In all cases, the anti-lock protection is canceled if: the corresponding function is requested again by pressing
the combination switch (S4) or "circuit 15R" is switched on again
If the wiper motor (M6/1) still locks after canceling the anti-lock protection, the wiper motor (M6/1) is switched
off again as described above.
Slowing down wiper GF82.30-P-4007S

motor, function
RAIN SENSOR, LOCATION/TASK/DESIGN/FUNCTION - GF82.30-P-4103S
MODELS 203.0 /2 /7 up to 31.5.03, 215, 220 up to 31.8.02 with CODE (345a) Rain sensor
Shown on MODEL 220

Fig. 86: Identifying Rain Sensor Location - Shown On Model 220
Rain sensor, location The rain sensor (B38) is

glued to the inside of the
windshield.
Rain sensor, purpose The rain sensor (B38)
measures the quantity of
moisture on the
windshield and controls
the intermittent time of
the wiper system.
Rain sensor, design The rain sensor (B38)
consists of an IR
transmitter unit and
receiver as well as an
electronic switch which
serves for evaluation and
as interface.
Function of rain sensor Type 203.0/2/7 GF82.30-P-4103-02PP
Model 215, 220 GF82.30-P-4103-02S
Function of rain sensor - GF82.30-P-4103-02S
Function principle
Infrared light is radiated from the infrared transmitter (2) through the lens (1) to the windshield (4). The
intensity of the light reflected at the windshield is measured by the IR receiver (3) which is located at the other
end of the lens.
 Windshield is dry (figure A)

If the windshield is dry in the vicinity of the rain sensor, almost all of the light is reflected: the IR receiver
(3) measures high light intensity.
 Windshield is wet (figure B)
If the windshield is wet in the area of the reflection surface a portion of the light escapes from the
windshield glass. This reduces the intensity of the reflected light, the IR receiver unit (3) measures a
lower light intensity.
The light intensity measured by the IR receiver (3) is a measure for the quantity of water on the windshield (4)
The smaller the measured intensity the larger the quantity of water on the windshield (4).
Fig. 87: Rain Sensor Function Diagram
Reading out rain sensor
The rain sensor is connected to the class B Controller Area Network bus (interior) (CAN-B) via the overhead
control panel control module as an interface. The front left SAM control unit transmits a request via CAN-B to
the rain sensor, which notifies the front left SAM control unit of the current quantity of water in response to
each request.
WIPER MOTOR, LOCATION / TASK / DESIGN / FUNCTION - GF82.30-P-4104S
Models 215, 220
Shown on Model 220

Fig. 88: Identifying Wiper Motor Location - Shown On Model 220
Wiper motor, location The wiper motor is

located in the water
trough underneath the
windshield.
Wiper motor, purpose Driving the windshield
wipers with two speed
stages.
Exact end position of the
wipers.
Wiper motor, design The drive for the
windshield wipers
consists of an electric
motor with three brushes,
gear and the cam switch
on the output shaft.
Wiper motor, function GF82.30-P-4104-01S
Wiper motor, function - GF82.30-P-4104-01S
Function
The wiper motor (M6/1) is a DC motor with three brushes. Depending on which pair of brushes is energized,
the wiper motor operates at different speeds.
Cam switch
The cam switch is closed when the wiper is in the park position. With each wiping cycle the cam switch opens
and closes when the non-actuated state is reached. This generates the signal c. 31b.
The circuit 31b signal is used to detect whether the wiper motor (M6/1)
 is operating correctly,
 locked up,
 or in the park position.
SURVEY, SYSTEM COMPONENTS, WIPER SYSTEM (WS),

LOCATION/TASK/DESIGN/FUNCTION - GF82.30-P-9998SN
Models 215, 220
Combination switch, GF82.30-P-2100S

Rain/light sensor location/task/function as of 1.9.02 GF54.21-P-4123Q
Rain sensor, up to 31.8.02 GF82.30-P-4103S
Wiper motor, GF82.30-P-4104S
Door contact switch, GF82.20-P-4102S
Outside temperature sensor, GF83.57-P-2103S
Washer pump, GF82.35-P-4101S
Contents, function description of wiper GF82.30-P-0998S
system (WS)
WINDSHIELD WASHER, LOCATION OF COMPONENTS - GF82.35-P-0001-01S
Shown on model 220

Fig. 89: Identifying Windshield Washer Components Location - Shown On Model 220
WINDSHIELD WASHER, FUNCTION - GF82.35-P-3002S
MODEL 215, 220
Windshield washer function
The windshield is wiped while water is sprayed .
Function sequence
 Press combination switch (S4) beyond catch point

 The signal from the combination switch (S4) is read in by the jacket tube module (N80) and the
corresponding message is transferred to the CAN bus (passenger compartment),
 The left front SAM control module (N10/6) and right front SAM control module (N10/7) receive this
message.
 The left front SAM control module (N10/6) starts the wiper motor (M6/1) , the right front SAM control
module (N10/7) actuates the windshield washer fluid pump (M5/1) :
 The windshield washer fluid pump (M5/1) runs as long as the combination switch (S4) is actuated.
 When the combination switch (S4) is released, the wiper motor (M6/1) continues to run to wipe off the
remaining water. The number of wiping cycles depends on the time the combination switch (S4) was
activated:
 If actuated less than 1 second the wiper wipes one more time,
 If actuated longer, 3 wiping cycles are completed.
 After completion of the wiping operation the wiper motor (M6/1) is decelerated .
The wiper motor (M6/1) runs in stage 1 for washing.

Wiping is accomplished at speed 2 only when the wipers were simultaneously set to speed 2.
Control of washer pump
The windshield washer fluid pump (M5/1) is actuated directly by the right front SAM control module (N10/7).
During the washing operation the windshield washer fluid pump (M5/1) is connected to ground by an
electronic switch (transistor) in the control module.
In the event of an overload the pump is switched off by the right front SAM control module (N10/7).
Wiping windshield, function GF82.30-P-3004S

Washer pump, GF82.35-P-4101S
Decelerating wiper motor, function GF82.30-P-4007S
Wiper motor, GF82.30-P-4104S
Combination switch, GF82.30-P-2100S
Left signal-acquisition and control module GF54.21-P-4101S
Right signal-acquisition and control GF54.21-P-4102S
module location/purpose/design/function
WINDSHIELD WASHER NOZZLE AND WINDSHIELD WASHER NOZZLE HOSE HEATER,

MODEL 215, 220
Washer nozzle and washer nozzle hose heater function
The heated windshield washer nozzle (R2/1) and washer nozzle hose heater (R2/11) are switched on
automatically when:
 C. 61 ON (engine: ON) and

 outdoor temperature less than 5°C
is recognized.
 C.61 OUT (engine: OFF) or

 outdoor temperature greater than 7°C
are recognized.
If the values (outdoor temperature, c.61) are not present or not logical the heater elements are not switched
on!
Control of heater elements
The heater elements for the heated windshield washer nozzle (R2/1) and washer nozzle hose heater (R2/11) are
connected in parallel. Control of the heated windshield washer nozzles (R2/1) and washer nozzle hose heater
(R2/11) is accomplished directly from the right front SAM control module (N10/7). For this purpose the SAM
completes circuit 30 to the heater elements.
Required data
 The ambient temperature is recorded by the ambient temperature display temperature sensor (B14). The
left front SAM control module (N10/6) reads in the sensor and sends the measured value as a message on
the CAN (interior).
 The status of c.61 (generator G2) is read in directly by the right front SAM control module (N10/7).
Left signal-acquisition and control module, GF54.21-P-4101S

Right signal-acquisition and control GF54.21-P-4102S
Windshield washer, location of GF82.35-P-0001-
components 01S
Outdoor temperature sensor, GF83.57-P-2103S
WASHER PUMP, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.35-P-4101S
MODEL 215, 220
Washer pump, location GF82.35-P-4101-02S

Washer pump, purpose Pumping windshield
washer fluid for washing
the windshield.
Washer pump, design The windshield washer
fluid pump (M5/1) is
driven by a DC motor
integrated into the pump
housing.
Washer pump, function GF82.35-P-4101-01S
Washer pump, function - GF82.35-P-4101-01S

For operation of the windshield washer the windshield washer fluid pump (M5/1) pumps the windshield
washer fluid from the windshield washer reservoir through the hoses and windshield washer nozzles to the
windshield.
For this purpose ground is connected to the motor for the windshield washer fluid pump (M5/1) by the right
front SAM control module (N10/7).
This actuation is accomplished directly by an electronic switch (transistor) in the control module and not by
a relay.
Washer pump position - GF82.35-P-4101-02S
Fig. 90: Identifying Washer Pump Position
RADIO MODE, FUNCTION - GF82.60-P-2001D
MODEL 215, 220 with CODE (352) COMAND operating and display system
Fig. 91: Block Diagram Of COMAND Radio System Up To 31.8.03 - Shown On Model 220
Block diagram of COMAND radio system up to 31.8.03, shown on model 220 with code (810) Sound
system and code (819) CD changer (6-disk)
Fig. 92: Block Diagram Of COMAND Radio System As Of 1.9.03, Shown On Model 215
Block diagram of COMAND radio system as of 1.9.03, shown on model 215 with code (810) Sound system
and code (819) CD changer (6-disk)
On vehicles as of 1.9.03, all audio signals of the audio components, voice signals as well as the signals of the
navigation processor (N41/1) are transmitted via the Media Oriented System Transport (MOST).
Controller Area Network bus class B (interior) (CAN-B) and the Media Oriented System Transport (MOST).
The audio signals are then sent to the audio gateway control unit (N93/1) and output via the vehicle speakers.
The radio menu is activated by pressing the "RADIO" button on the COMAND operating, display and control
unit (A40/3).
Radio system function
The antennae in the rear window receive FM, MW and LW high-frequency signals.
The music, voice or data signals are modulated upon these high frequency signals. The rear window antenna
amplifier module (A2/12) filters the radio frequency band frequencies from the received high-frequency signals
and amplifies these. The amplified signals are then transmitted to the radio receiver by the rear window antenna
amplifier module (A2/12) via a coaxial cable (FM, AM).
The radio receiver demodulates the high frequency signals, in other words it separates the useful information
(audible frequencies) from the carrier signal (inaudible).
The demodulated audio signals are amplified and then converted to sound signals by the vehicle speakers.
The COMAND operating, display and control unit (A40/3) also offers the option for requesting information on
the current weather conditions at any time. This information is transmitted via the weather channels.
FM antenna diversity, function
With the antenna diversity function a switchover which is dependent on reception is performed between the 4
FM antenna of the rear window. The function is automatic and is carried out by the rear window antenna
amplifier module (A2/12). The radio tuner of the COMAND operating, display and control unit (A40/3) merely
generates the "IF" signal which serves the rear window antenna amplifier module (A2/12) as a reference for
switching from one FM antenna to the other.
The COMAND operating, display and control unit (A40/3) offers the following options for station selection:
 Manual station search

 Automatic station search with scan function (the stations in the frequency range are each played for 8 s)
 station selection from the memory (10 stations per waveband)
 Station selection by frequency input using the number keypad
Satellite radio reception
Optionally a receiver for satellite radio can be installed. The reception of digital radio stations via satellite can
be requested with the SAT-button on the COMAND operating, display and control unit (A40/3). However, the
system has to be enabled by a service provider. Once the system has been enabled, up to 224 additional stations
can be received.
Volume/tone adjustments, function GF82.60-P-2003AB

Sound amplifier, With code (810) GF82.62-P-3100A
location/task/design/function Sound system up to
31.8.03
With code (810) GF82.62-P-3100AB
Sound system as of
1.9.03
Radio satellites, location/task as of 1.9.03 GF82.85-P-3113B
Radio satellite antenna, location/task as of 1.9.03 GF82.62-P-4109B
CD-PLAYER MODE, FUNCTION - GF82.60-P-2002AB
version
COMAND with CD changer block circuit diagram, Shown on model 220 with code (810) Sound system
up to 31.8.03
Fig. 93: COMAND With CD Changer Block Circuit Diagram - Shown On Model 220
The CD player with changer (in luggage compartment) (A2/6) is operated via the COMAND operating, display
and control unit (A40/3) and actuated via the Digital Data Bus (D2B). The audio signals of the CD changer are
likewise transmitted via the Digital Data Bus (D2B) and amplified via the COMAND operating, display and
control unit (A40/3). With code (810) Sound system, the signals are amplified by the sound amplifier (A2/13).
Acoustic emission is carried out via the vehicle's loudspeaker system.
Controller Area Network bus class B (interior) (CAN-B) and the Media Oriented System Transport (MOST).
The audio signals are then sent to the audio gateway control unit (N93/1) and output via the vehicle speakers.
Only 12 cm CDs may be used; do not use any 8 cm CD adapters.
The CD player with changer (in trunk) (A2/6) offers the following functions:
 SCAN functionn
The tracks of one CD or the 1st track of all CDs in the magazine are played for 8 seconds. After this has
been run through completely, the scan function is automatically terminated.
 Track selection
The tracks of a CD can be selected via a rocker or a numerical keypad.
 Random function
All the titles on a CD or the entire CD magazine are played in accordance with the random principle.
 Repeat function
Alternatively a title, a CD or the entire CD magazine is repeated.
 Fast forward or reverse (music search)
The music played is audible during fast forward or reverse. Certain parts of a title can therefore be
specifically played or skipped.
CD title allocation, function
Each CD contains a permanently stored table of contents, the so called Table of Contents (TOC) record.
The COMAND operating, display and control unit (A40/3) clearly recognizes the respective CD based on this
entry and is able to automatically name it after the one-time user allocation of the track (even if the CD is
subsequently inserted in another CD magazine). The TOC record additionally contains information regarding
the number of titles on a CD and the CD's total playing time. The COMAND operating, display and control unit
(A40/3) has an integrated CD disk drive which is used for loading the navigation data or for playing audio CDs
(no audio CDs can be played during navigation mode).
On vehicles as of 1.9.02, it is possible to listen to audio CDs during navigation mode. Only the navigation
CD has to be loaded previously.
CD player with changer, up to 31.8.03 GF82.64-P-3114B

location/task/design With code (819) CD
changer (6-disk)
CD player with changer, as of 1.9.03 GF82.64-P-3113BA
location/task/design/function With code (819) CD
changer (6-disk)
VOLUME/TONE ADJUSTMENTS, FUNCTION - GF82.60-P-2003AB
version
Volume setting
Changing the volume of an audio source has an identical effect on all other audio sources.
The volume is also jointly regulated within the service sources in the same manner.
Audio sources are
 Radio
 Cassette player
Service sources include:
 Telephone
 Voice output with navigation system
 Voice control system
The volume of voice output for navigation can be changed during voice output. In the process a difference
between the volume of the audio signal and voice output of at least 12.5 dB is maintained automatically. This
ensures that voice output remains easily audible.
Tone setting
The COMAND operating, display and control unit (A40/3) can be used for different tone settings (e.g., treble,
bass, balance, fader) for each audio source. The tone setting selected for the radio simultaneously applies to the
traffic information radio channel message.
Adjustments which have been selected for voice output during navigation also influence the voice control
system with code (813) Voice control system (VCS).
Depending on the equipment installed, different sound patterns for optimization of the audio sources can be
requested.
Sound adjustments without code (810) Sound system
Bass and treble adjustment or acoustic patterns:
 Pop
 Classical
 Language
Sound adjustments with code (810) Sound system
Bass and treble adjustment and sound optimization:
 Simulation of rooms (small, medium, large)

 Driver optimized
 Language
With a change in sound emphasis (balance, fader), the ratio of the volume between the individual speakers
changes. The signal processing required for the volume/sound settings is taken over either by the audio
component integrated in the COMAND operating, display and control unit (A40/3) or, with code (810) Sound
system, the sound amplifier (A2/13).

CD-player mode, function GF82.60-P-2002AB
Telephone mode, function GF82.85-P-2007C
Cassette mode, function up to 31.8.02 GF82.85-P-2010AB
Navigation mode, function GF82.85-P-2012A
Data transfer between COMAND and GF82.85-P-3008AB
instrument cluster function
as of 1.9.02 GF82.85-P-3114DA
CONTINUOUS POSITION FINDING, FUNCTION - GF82.61-P-2002CA
version
Fig. 94: Identifying Basic Position Finding (Compound Position Finding) Via Points Of Compass And
Mileage Covered
Basic position finding (compound position finding) via points of the compass and mileage covered
Fig. 95: Identifying Map-Based Position Finding
Map-based position finding
Fig. 96: Identifying GPS Satellite Position Finding
GPS satellite position finding
Continuous position finding involves calculating the current position of the vehicle. Continuous position finding
is active when the ignition is switched on, and it is carried out by the navigation processor. During the switch-
on phase (software is loaded), only basic position finding is available.
After switching the ignition off, all important positioning parameters are stored for the duration of the run-on
time (approx. 30 min).
Continuous position finding uses the following 3 methods which supplement each other and thereby ensure
extremely precise and reliable position finding:
 Basic position finding (compound position finding)

 Map-based position finding
 GPS position finding
Manual input of the vehicle's location
The location can be input manually at the operating and display unit. This can be useful in the following
situations:
 After the vehicle has been transported (e.g. by ferry or train)

 If no GPS reception is available at the start of the journey.
Basic position finding, GF82.61-P-3006CA

function
NAVIGATION, FUNCTION - GF82.61-P-2003M
Function
The navigation control menu is activated with the "navigation" command. Following this the VCS (voice
control system) is responsible for the navigation commands. One complete destination can be entered via voice
input. Depending on size, place names can be spoken directly, or spelled out at any given time. Street names,
centering points, intersections have to be spelled out. Once the destination has been entered, navigation can be
started. An ongoing navigation can be aborted via voice command. No destination can be entered while a
navigation process is running.
Spelling and matching
To be able to find the most likely match for the spelled words, the so-called matching is necessary.
Matching (comparison of letters and a list on the navigation CD) is described in the following. While the letters
are being entered, the navigation system prepares the matching process. The preparation mainly consists of
building the necessary matching list from the entries on the navigation CD. This build-up can occur directly
from the entries on the navigation CD. The VCS transmits the recognition results to the navigation system
(approx. 5 alternative sequences of letters, sorted by recognition probability). The recognition result is evaluated
or compared to the already created matching list by using the matching algorithm. The result is a list of the most
probable options.
The programs and data for matching and the structure of the matching list are provided by the navigation
manufacturer. The matching algorithm is a method that is used to filter the most likely meaning from an
existing list out of a sequence of letters that is incorrectly spelled. The results after matching are then shown in
the display.
The user can now select a city from this list by speaking the number of the desired location.
Entering an address
The COMAND operating, display and control unit (A40/3) has to be in navigation mode to be able to enter the
address. The address can be entered in several entry steps (entry of the location, entry of the street, intersection,
and house number). Next, navigation can be started.
There are 2 entry options; either a complete address can be entered via voice command, or one part is specified
via voice command and the rest in written form.
Entering a city
Following entry of an "Enter place" command in VCS, the vocabulary for entering place names as whole words
is activated. The size of the vocabulary, in other words the number of cities that can be entered using whole
words depends on the VCS destination hardware. These cities can be spoken "naturally" (e.g., Stuttgart,
Munich, Ulm).
The results of the voice recognition are numbered and, sorted by recognition probability, shown on the display.
The user can select the desired destination city by speaking the appropriate number. The user is presented with a
selection of available commands on the display after pressing the VCS switch (S93/2) when in initial user
mode. The first line shows the destination (city or street) that was last entered either in written form or via voice
command.
Only the names of larger cities can be spoken. Smaller villages and cities can only be entered by spelling
them out or in written form.
Spelling the city
With this function all city names can be entered in semi-spelling mode. For this purpose it is usually sufficient
to say the first 5 to 6 letters of the city name in order to clearly identify it. In doing so, the voice recognition
system is activated in order to spell. After entering the first letters, a comparison with the database of the
navigation system takes place. The results are shown in the display. If the desired city name appears in the
displayed lists, then the desired city can be accepted by using the "accept number X" command.
Entering the street
The street name is entered by using the spelling mode the same way the city name is entered. In doing so, the
entire number of possible streets that exist in the selected city are represented by the navigation system. If no
digitized streets are available, then this is notified to the user by the voice control system.
The system retrieves the current destination data from the navigation system and shows a window with the
possible commands. Usually it is sufficient to speak the first 5 to 6 letters of the street name, in order to clearly
designate it.
Entering a house number or starting navigation
The user can now either start the navigation or, if this is possible for the selected street, also enter a house
number. In larger cities the streets are digitized down to the appropriate house numbers. It is now possible to
select the desired house number via voice command.
Again, a window shows a list of possible commands. The user can now select the desired entry as usual.
Entering a complete address
After entering an initial command to enter a destination address, the user is guided by the voice control system
through the entire dialog. This command can be used to enter an entire destination without any break.
Starting navigation
If a valid destination was entered, then navigation can be started via voice dialog.
Save the navigation destination memory (entered destination)
If a destination was entered into the navigation system in written form or via a voice command, then the current
destination can be transferred into the address book by using the "save destination" command. If the spoken
sequence number already exists, then the destination is saved there, else a new entry is created in the address
book.
Changing the destination area
A DVD is available for navigation systems on which several countries are digitized. These countries can only
be addressed individually, in other words only the destinations of the country that is currently active on the
DVD are selected. In order to be able to select a different country on the DVD via voice command, the "change
destination area" voice command was introduced.

location/task
Electrical System, Equipment & Instructions - Testing & Repair - 215 & 220 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - AR54.00-Z-9215AA
MODEL 215
Disconnecting and connecting AR54.10-P-

MODEL 215, 220
ground cable at battery 0003I
AR54.10-P-
Removing and installing battery MODEL 215, 220
0005I
Treatment of battery if vehicle taken AR54.10-P-
MODEL 215, 220
out of service 0006I
Check quiescent current AR54.10-P-
MODEL 215, 220, 230
consumption 1030I
AR54.10-P-
Check condition of battery MODEL 215, 220, 230
1129I
AR54.10-P-
Charge battery MODEL 215, 220, 230
1130I
MODEL 163, 164, 168, 169, 170, 171, 203, 204,
Check battery condition before AR54.10-P-
208, 209, 211, 215, 216, 219, 220, 221, 230, 240,
vehicle delivery 1132A
245, 251, 414 ...
Removing and installing fuse and
AR54.15-P-
relay box in engine compartment, Models 215, 220
1257I
left front
AR54.15-P-
relay box in engine compartment at MODEL 215, 220
1258I
right front
AR54.18-P-
Install headliner wiring harness MODEL 215
0020N
AR54.18-P-
Install cable harness MODEL 215, 220 ...
0056M
AR54.18-P-
Repairing wiring harness MODEL 215, 220 ...
0100IA
AR54.18-P-
0100IB
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 ...
Removing and installing Distronic MODEL 215, 220 with CODE (219a) Distronic AR54.21-P-
control module (DTR) 0005I
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
Programming of control units 203, 204, 208, 209, 211, 215, 216, 219, 220, 221,
0014Y
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0014Z
230, 240, 245, 251, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
SCN coding of control units 203, 204, 208, 209, 211, 215, 216, 219, 220, 221,
0015X
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
Removing and installing traction AR54.21-P-
MODEL 215, 220
system control module 0816I
Removing and installing SAM
AR54.21-P-
control module with fuse and relay MODEL 215, 220
1259I
box in rear
AR54.21-P-
1260I
box, front left
AR54.21-P-
1261I
box, front right
Removing, installing control module AR54.21-P-
MODEL 215
of upper control panel 1262N
AR54.25-P-
Remove/install combination switch MODEL 215, 220, 230.4
2800I
Remove/install steering column AR54.25-P-
MODEL 215, 220, 230
module 2802I
AR54.25-P-
Remove/install cruise control switch MODEL 215, 220, 230.4
2803I
Removing and installing steering AR54.25-P-
MODEL 215, 220, 230.4
column adjustment switch 2804I
Removing and installing light AR54.25-P-
MODEL 215
module 3260N
Removing and installing instrument AR54.30-P-
MODEL 215, 220
cluster 6015I
Removing and installing bulbs of AR54.30-P-
MODEL 215, 220
instrument cluster 6049I
MODEL 215
temperature indicator sensor 6341N
AR54.35-P-
Removing and installing claxon MODEL 215
1555N
Remove/install Parktronic system MODELS 215, 220 with CODE (220a) Parktronic AR54.65-P-
(PTS) sensors in front bumper System (PTS) 0001I
(PTS) sensors in rear bumper System (PTS) 0002I
Removing and installing Parktronic
MODEL 208, 215, 220 with CODE (220a) AR54.65-P-
system (PTS) warning indicator on
Parktronic system (PTS) 0003B
instrument panel
system (PTS) warning indicator in
rear dome lamp
Removing and installing Parktronic MODEL 215 with CODE (220a) Parktronic System AR54.65-P-
System (PTS) switch (PTS) 0005N
Removing and installing Parktronic MODEL 215, 220 with CODE (220a) Parktronic AR54.65-P-
system (PTS) control module system (PTS) 0006I
MODEL 215, 220 with CODE (219a) Distronic AR54.70-P-
Remove/install sensor
(DTR) 0001I
MODEL 220

MODEL 215, 220
AR54.10-P-
0005I
MODEL 215, 220
MODEL 215, 220, 230
consumption 1030I
AR54.10-P-
1129I
AR54.10-P-
1130I
MODEL 163, 164, 168, 169, 170, 171, 203, 204,
208, 209, 211, 215, 216, 219, 220, 221, 230, 240,
245, 251, 414 ...
AR54.15-P-
1257I
left front
AR54.15-P-
1258I
right front
AR54.18-P-
Install headliner wiring harness MODEL 220.0 /1 except code (494a) USA version
0020M
Install headliner wiring harness MODEL 220.0 /1 with CODE (494a) USA version AR54.18-P-
0020MA
AR54.18-P-
0056M
AR54.18-P-
0100IA
AR54.18-P-
0100IB
MODEL 124, 126, 129, 140, 163, 164, 168, 169,
Repair supplemental restraint 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, AR54.18-P-
system (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,
AR54.21-P-
0014Y
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0014Z
230, 240, 245, 251, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0015X
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 215, 220
AR54.21-P-
1259I
box in rear
AR54.21-P-
1260I
box, front left
AR54.21-P-
1261I
box, front right
Removing and installing upper AR54.21-P-
MODEL 220
control panel control module 1262M
AR54.25-P-
2800I
MODEL 215, 220, 230
module 2802I
AR54.25-P-
2803I
MODEL 215, 220, 230.4
Remove/install light module MODEL 220 AR54.25-P-
3260I
MODEL 215, 220
cluster 6015I
MODEL 215, 220
Remove/install outside temperature AR54.30-P-
MODEL 220
indicator sensor 6341I
Removing and installing fanfare AR54.35-P-
MODEL 220
horns 1555I
instrument panel
rear dome lamp
Removing and installing Parktronic MODEL 220 with CODE (220a) Parktronic system AR54.65-P-
system (PTS) switch (PTS) 0005I
(DTR) 0001I
DISCONNECTING AND CONNECTING GROUND CABLE AT BATTERY - AR54.10-P-0003I
MODEL 215, 220
Shown on model 220

Fig. 1: Identifying Ground Cable - Shown On Model 220

1 Fold back trunk cover
Connect quiescent current AR54.10-P-
2
retention unit 1030-07I
Loosen nut (2) and disconnect
3
ground lead (1) from battery
Perform work described below only if
4 Connect ground lead quiescent current retention unit was not
connected
5 Code radio Owner's Manual
6 Set time on instrument cluster
AR46.10-P-
7 Activate steering angle sensor
0300-01I
8 Synchronize power windows Owner's Manual
9 Synchronize sliding/pop-up roof Owner's Manual
10 Synchronize jacket tube module
REMOVING AND INSTALLING BATTERY - AR54.10-P-0005I
MODEL 215, 220
Shown on model 220

Fig. 2: Identifying Battery Remove/Install Components - Shown On Model 220
Explosion hazard from explosive
gas. Danger of poisoning and
acid burns when battery acid is Flames, sparks, open light and smoking
swallowed. prohibited. Wear acid resistant gloves, clothing AS54.10-Z-
Danger of acid burns to skin and and goggles. Store battery acid only in suitable, 0001-01A
eyes from battery acid or when appropriately marked containers.
handling damaged lead-acid
batteries.
AH54.10-P-
Notes on batteries All models
0001-01A
1 Remove ignition key
2 Pivot trunk cover up
3
holder
4
Disconnect ground lead (3) from
5
battery
Remove gas vent line (5) from Installation: Ensure that gas vent line is
6
battery (G1) routed through the line passage to the outside
Remove positive pole cover (4)
7
upward
Disconnect positive lead (2) from
8
battery
9 Remove battery (G1)
Connect positive lead (2) first, then ground
lead (3)
TREATMENT OF BATTERY IF VEHICLE TAKEN OUT OF SERVICE - AR54.10-P-0006I
MODEL 215, 220
No fire, sparks, open flames or

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 eyes from battery acid or when
battery acid into suitable and
appropriately marked containers.
AR54.10-
1 Check battery, charge battery if necessary
P-1129I
When the vehicle is laid up
for more than 4 weeks. This AR54.10-
2.1 Disconnect battery ground cable prevents the battery being P-0003I
discharged by closed-circuit
accessories.
When battery is disconnected
every 6 months at the latest and AR54.10-
3 Charge battery
when the battery is connected P-1130I
every 6 weeks at the latest.
CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P-1030I
MODEL 215, 220, 230
Check
1 Open luggage compartment lid
Preparing test with quiescent AR54.10-P-1030-
2.1
Electrical connection set Fig. 6
*WH58.30-Z-
Multimeter 1001-09A
*WH58.30-Z-
Quiescent current retention unit CMP 12.2 1012-09A
Prepare test without quiescent AR54.10-P-1030-
2.2
*WH58.30-Z-
Multimeter 1001-09A
 Withdraw ignition key
 Switch off stationary heater
 Switch off car phone
 Switch off interior motion sensor
 Switch off make-up mirror
 Switch off reading light
 Turn exterior lamp switch to "0" position
 Close doors
3 Switch off all consumers
The interior lights must go out automatically

after a few seconds.
 Switch off radio

 With COMAND:
Remove CD-ROM from COMAND and

switch off COMAND.
4 Check quiescent current AR54.10-P-1030-03I
Multimeter *WH58.30-Z-
If specification for total quiescent current is not 1001-09A
achieved: ?
Determine circuit with excessive quiescent AR54.10-P-1030-
current consumption 04I
Quiescent current test adapter 1 Fig. 15
Specification not achieved: ? 1001-09A
Establish fused components with excessive AR54.10-P-1030-
quiescent current consumption 05I
Establishing unfused components with excessive AR54.10-P-1030-
*WH58.30-Z-
Multimeter 1001-09A
AR54.10-P-1030-
To check, re-test quiescent current 03I
*WH58.30-Z-
Multimeter 1001-09A
Fig. 3: Identifying Electrical Connection Set (201 589 00 99 00)
Fig. 4: Identifying Quiescent-Current Test Adapter 1 (140 589 12 21 00)
Fig. 5: Identifying Quiescent Current Test Adapter 2 (140 589 13 21 00)

Number Designation
WH58.30-Z-1001-09A Multimeter
Preparing test with quiescent current retention unit - AR54.10-P-1030-01I


Number Designation
Work procedures shown on model 220
1. Switch on quiescent current retention unit (7).

2. Connect quiescent current retention unit (7) as follows:
 Connect positive terminal (8) of quiescent current retention unit (7) to the positive lead of the
battery.
 Connect negative terminal (9) of the quiescent current retention unit (7) to ground (battery) (W10).
Fig. 7: Identifying Quiescent Current Retention Unit, Positive And Negative Terminal -
Shows On Model 220
3. Disconnect negative terminal (1) from battery.

4. Connect the multimeter as follows; use the "electrical connection kit" for this purpose:
 Connect positive test cable (+) to negative battery cable (1).
 Connect negative test cable (-) to negative battery terminal (3).

Fig. 8: Identifying Battery Cable And Terminals
5. Switch on multimeter (2) (do not select measuring range in amp(s) too small. When the central locking
system operates, a current of about 20 A flows).
6. Switch off and disconnect quiescent current retention unit.
7. Take multimeter (2) out of the luggage compartment.
The measurement cables (6) must not loosen in the process.
8. Close trunk lid.
Fig. 9: Identifying Multimeter And Measurement Cables
Prepare test without quiescent current retention unit - AR54.10-P-1030-02I

Number Designation
Do not disconnect the negative terminal clip!
1. Loosen the negative terminal clip (1) nut on the battery .

2. Prepare multimeter for the test; use "electrical connection set" for this purpose.
3. Connect measurement cable, positive (+) to ground (battery) (W10).
4. Switch on multimeter (do not select measuring range in amp(s) too small. When the central locking
5. After fastening the measurement cable, negative (-) to negative terminal, disconnect the negative terminal
clip (1).
Fig. 11: Identifying Negative Terminal Clip And Ground (Battery)
6. Carefully pull negative terminal clip (1) on the battery upwards and in the process simultaneously connect
the measurement cable, negative (-) to the negative terminal under the negative terminal clip (1).
Do not break the circuit when detaching the negative terminal clip otherwise any existing faults will be
erased. Remove the negative terminal clip completely only after the multimeter test cable is firmly
clipped to the negative terminal.
7. Take the multimeter (2) with measurement cable (6) out of the luggage compartment to the right.
8. Close trunk lid.
Check quiescent current - AR54.10-P-1030-03I


Number Designation
Observe the limits of the multimeter connected for current measurements. When the central locking system
operates, a current of about 20 A flows .
Do not activate any other electrical components during the test otherwise observe a renewed run-on time of
about 20 minutes.
1. Lock the vehicle and wait for approx. 20 minutes (run-on time for electronic components): ?
Display < or =0.050 A = specified value achieved: ?
Carry out procedure 2.
Carry out procedure.
Display >0.050 A : ? Note value displayed and determine circuit with increased quiescent current consumption.
Determine circuit with excessive quiescent current consumption - AR54.10-P-1030-04I


Number Designation
Fig. 17: Identifying Multimeter Components
1. Check trunk illumination, if necessary replace defective parts and close trunk lid.
2. Unclip trunk illumination, detach insulated cable lugs and measure power consumption with multimeter
(measuring range in amp (s)).
After testing observe renewed run-on time of approx. 20 minutes.
Total quiescent current q0.050A achieved, end of test.

Specified value Total specified current not achieved: ?
3. Open fuse box in engine compartment (driver/front passenger) and fuse panel in rear (panel in rear right
footwell illumination).
With measurements on the fuse box in the rear, observe that the door contact switch is operated (e.g.
with adhesive tape).
4. On vehicles with code (551a) anti-theft alarm system (ATA), operate engine hood contact (e.g. with
adhesive tape).
5. Open overvoltage protection cover.
6. Lock vehicle.
Observe Up-to-date Information (AI) bulletin! First of all, check circuits of the components which are
listed in the Information Update.
7. Connect measurement cable (6) and test adapter (13) to a second multimeter (12) (measuring range in
amp(s)).
Remove the fuse for the ELECTRONIC ALARM SYSTEM only on unlocked vehicles (alarm signal).
8. Remove the first fuse and connect the second multimeter and read the standby current after 5 seconds.
Standby current q0.020A (20 mA):
The fuse-protected circuit is in order.
9. Insert fuse again and wait for 5 seconds.

10. Check quiescent current consumption at all fuses.
After inserting the fuse or test adapter, the connected components can briefly exhibit an increased
quiescent current, the radio up to 0.240 A (240 mA). By switching the radio on and off the standby
current draw is raised.
On vehicles with navigation system after inserting the navigation computer fuse an increased quiescent
current of approx. 800 mA occurs for the duration of the computer run-up (approx. 20 minutes).
Standby current >0.020A (20 mA):
Wait for 20 minutes, then read off again.
The fused circuit is faulty: ?
Determine fuse-protected components with increased quiescent current consumption.

The specific value of the entire standby current is not achieved: ?
Determine non-fuse protected components with increased quiescent current consumption.
Establish fused components with excessive quiescent current consumption - AR54.10-P-1030-05I
Fuse assignment, as-built configuration 215/220 GF54.15-P-1256I

230.4 GF54.15-P-1256R
Relay assignment, production details 215/220 GF54.15-P-1257I
230.4 GF54.15-P-1257R

Number Designation
1. Determine possible standby current consumers on the problem fuses.
Refer to assignment and cable connections of fuse blocks, insertion sheet or "Wiring Diagrams Model
215/220/230".
Obtain the location of components from the "Wiring diagrams 215, 220, 230" or STAR diagnosis.
2. Unplug connector at the possible quiescent current consumer.

3. Read the standby current on the second multimeter.
If measurements are to be made at the radio fuse or if the radio coupling is disconnected, it must be
observed that the quiescent current consumption rises by approx. 0.240 A (240 mA) when the radio is
reconnected. By switching the radio on and off the standby current draw is raised.
current of approx. 800 mA occurs for the duration of the computer run-up (approx. 20 minutes). This also
applies when the coupling is separated from the computer and connected again.
Standby current >0,020 A (20 mA):
Quiescent current error remains after disconnecting the connector. Component is okay, fit connector in
again at the component tested.
4. Carry out checking as described with all components at the fuse about which there has been a complaint.
Standby current < or =0,020 A (20 mA):
Quiescent current error is rectified after disconnecting the connector of the relevant component.
Component is defective, replace: ?
5. To be sure check the total standby current again.
Establishing unfused components with excessive quiescent current consumption - AR54.10-P-1030-06I

Number Designation
1. Determine non-fuse protected components, they are for example:

 Consumers of the exhaust gas recirculation (EGR) assembly
 Consumers of the airbag assembly (AB)
 Consumers of the anti-knock control (AKC) assembly
 Consumers of the electronic ignition system assembly
 Devices for protecting against breaking and entering and theft, e.g. anti-theft alarm system (ATA).
 Consumers of the idle speed control (ISC) assembly and
 Alternator, starter, ignition switch.
See "Wiring diagrams, models 215, 220, 230" or STAR diagnosis. Observe run-on time for electronic
components: approx. 20 minutes.
2. Read and note the value of the total standby current on the multimeter that is connected to the battery.
3. Separate coupling or connection on potential closed-circuit accessories and tie back in a manner which
avoids contact if necessary.
The radio may cause quiescent-current consumption to increase by approx. 0.240 A (240 mA). By
switching the radio on and off the standby current draw is raised.
On vehicles with navigation system after the navigation computer is connected an increased quiescent
4. Read and note total standby current on the multimeter.
Is there a decrease in the standby current < or =0,020A ( 20 mA): Component is OK.
5. Connect coupling or connection to component again.

6. Repeat testing with all closed-circuit accessories as described.
If the drop in quiescent current >0.020A (20 mA):
7. Replace component. To check, re-test quiescent current.
Connecting and disconnecting quiescent current retention unit - AR54.10-P-1030-07I
Quiescent current retention unit, refer to GOTIS:

Connect positive terminal (8) of quiescent current retention unit to positive cable of battery.
 Connect negative terminal (9) of the quiescent current retention unit to battery ground (W10).
3. Disconnect negative terminal at battery and insulate negative terminal with insulation tape.
4. Disconnect positive terminal at battery (only if battery is removed).
Fig. 22: Identifying Quiescent Current Retention Unit, Positive And Negative Terminal Shows On
Model 220
CHECK CONDITION OF BATTERY - AR54.10-P-1129I
MODEL 215, 220, 230
MODIFICATION NOTES
25.4.07 Check fluid level with service fill level indicator added Step 5.2
Removing
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.
AH54.10-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
Unhook trunk retractable
1 Model 230 to test on-board electrical system battery.
partition
2 Remove spare tire cover For checking the on-board electrical system battery.
3 Open engine hood and move to Model 230 to test starter battery. AR88.40-
vertical position P-1000R
Check
Visually inspect battery for If leaks are found, replace battery, see: ?
4
external leaks Remove/install battery
AR54.10-
Model 215, 220
P-0005I
AR54.10-
Model 230 on-board electrical system battery
P-0005RA
AR54.10-
Model 230 starter battery
P-0005RB
OS54.10-
Dispose of battery P-0001-
01Z
Check fluid level in battery,
Without service fill level indicator, not on
5.1 replenish with distilled water if
absorbent glass mat battery.
necessary
With service fill level indicator, not on absorbent
glass mat battery.
Fluid check via service fill level indicator, acid
5.2 Check fluid level of battery
level is too low if colored white: Replace battery,
see: ?
Remove/install battery
AR54.10-
Model 215, 220
P-0005I
AR54.10-
P-0005RA
OS54.10-
01Z
AR54.10-
6 Check battery P-1129-
01A
Cold cranking amps as per EN *BE54.10-
Midtronics battery tester with test clamps P-1002-
http://gotis.aftersales.daimlerchrysler.com 01A
On a battery that is disconnected from the onboard
electrical system and with the message "Surface
voltage" in the display of the Midtronics battery
AR54.10-
Reduce increased voltage after tester.
7 P-1129-
charging process Midtronics battery tester Volt/amp tester
03A
After reducing increased voltage, test battery
again.
8 Charge battery With the test code "Charge and check" on the
Midtronics battery tester. AR54.10-
After charging, test battery again. P-1130I
Install
AR88.40-
9 Close engine hood Model 230 after test of starter battery.
P-1000R
After checking the on-board electrical system
10 Install spare tire cover
battery.
Install trunk retractable Model 230 after test of on-board electrical system
11
partition battery.
TEST AND ADJUSTMENT VALUES FOR BATTERY

Number Designation 12 Ah 30 Ah 35 Ah 46 Ah
BE54.10-P-1002-01A Cold test current as per EN A 170 540 520 420

Number Designation 60 Ah VRLA 60 Ah VRLA 62 Ah
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

Check battery; Risk of injury - AR54.10-P-1129-01A

by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses.
swallowing battery acid. Only pour battery acid
Risk of injury caused by into suitable and
burns to skin and eyes appropriately marked
from battery acid or when containers.
handling damaged lead-
acid batteries
Reduce increased voltage AR54.10-P-1129-03A
after charging process
MODIFICATION NOTES
24.2.06 Cold test current 12 Ah *BE54.10-P-1002-01A
BE54.10-P- Cold test as per EN A 170 540 520 420
1002-01A current

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. 23: 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. 24: Screen Display - In Vehicle And Not In Vehicle

 12 - 114 AH (battery capacity 12 -114 Ah)
 115 AH > (capacity of battery < or = 115 Ah)
Confirm selection with "Enter".
Fig. 25: Screen Display - 12 - 114 AH And 115 AH
4. Follow menu and select battery type:

 Normal
 VRLA
Fig. 26: 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. 27: 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. 28: 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. 29: Screen Display - Cars And Taxi

 > 0°C
 < 0°C

If this message appears, the battery condition cannot be evaluated.
Fig. 30: Screen Display - Above 0 Degrees C And Below 0 Degrees C

 Before charge
 After charge
Fig. 31: 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.
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 No fire, sparks, open AS54.10-Z-0001-01A

poisoning and caustic flames or smoking. Wear
burns Risk of injury 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. 32: Identifying Volt-Amp(S)-Tester, Operating Lever, Knob, Clamps And Terminal
CHARGE BATTERY - AR54.10-P-1130I
MODEL 215, 220, 230
Checking
Risk of explosion caused by oxyhydrogen
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves, AS54.10-
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-1129I
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.
3 Charge battery max.
10 A charging current for a 100 Ah
battery.
Rapid charging: charging current max.
50 % of battery capacity for 30 min:
e.g. max.
battery.
AF54.10-
Problems with charging battery Only with AGM battery. P-6005A
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-1129I
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 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
CHECK CHARGE STATE OF BATTERY - AR54.10-P-1136-01A
Test instructions for disconnected battery:
 Connect the digital multimeter to the battery and read off the voltage.
 Voltage: > or = 12.5 V Battery OK

 Voltage: < 12.5 V Charge battery
 After charging, remove the surface voltage of the battery. To do so, switch on the driving lights for
approx. 60 s.
In the case of batteries disconnected from the on-board electrical system, the procedure for removal of the
surface voltage is described in a separate document (pay attention to the literature).
Generally, the following guideline values (ambient temperature approx. 20 °C) apply in the case of open
circuit voltage measurement without current load (disconnected or removed battery):
Voltage Capacity
> or = 12.7 V 100%
12.5 to 12.6 V 80%
12.2 to 12.4 V 50%
12.0 to 12.1 V 30%
11.5 to 11.7 V 0%
< 10.5 V deep discharged
REMOVING AND INSTALLING FUSE AND RELAY BOX IN ENGINE COMPARTMENT, LEFT
FRONT - AR54.15-P-1257I
Models 215, 220
Shows model 220
Fig. 33: Identifying Fuse And Relay Box Remove/Install Components, Left Front - Shown On Model 220
Remove/Install
AR54.10-P-
1 Connect quiescent current retention unit
1030-07I
AR54.10-P-
0003I
AR88.40-P-
3 Open engine hood and position upright
1000M
Unlock and remove cover (1) of left fuse box
4
(F1)
Remove left SAM control unit (N10/6) with AR54.21-P-
5
left fuse and relay module (K40/6) 1260I
Remove AIRmatic with ADS control unit Model 220 except code (487a) AR32.22-P-
6.1
(N51) Active Body Control (ABC) 6000I
Active body control (ABC)N51/2, control Model 215, 220 with CODE (487a) AR32.50-P-
6.2
unit Active body control (ABC) 0023I
AR54.21-P-
7 Remove traction system control unit (N47)
0816I
AR68.10-P-
8 Remove cover below left of instrument panel Model 220 1500M
AR68.10-P-
Model 215 1500N
AR30.12-P-
9 Remove accelerator pedal
1321I
10 Remove floor lining on driver's side
Loosen line to accelerator pedal from vehicle
11
floor and pull back to left fuse box
AR82.30-P-
12 Remove wiper arms
6100M
AR83.25-P-
13 Remove water deflector above wiper system
1406M
Separate separable cable ducts inside the left
14
fuse box
Pull back the remaining wiring harnesses to
15
the left fuse box
Installation: Check gasket on cable
16 Unscrew bolts (2) and remove left fuse box
duct of fuse box/vehicle interior
REMOVING AND INSTALLING FUSE AND RELAY BOX IN ENGINE COMPARTMENT AT

RIGHT FRONT - AR54.15-P-1258I
MODEL 215, 220
Shown on model 220

Fig. 34: Identifying Fuse And Relay Box Remove/Install Components, Right Front - Shown On Model
220
AR54.10-P-
1030-07I
AR54.10-P-
2 Disconnect ground lead from battery
0003I
Open engine hood and move to upright AR88.40-P-
3
position 1000M
Release and remove cover (1) on left fuse
4
box (F1)
AR07.08-P-
5 Remove CFI control module (N3)
7008I
Remove right SAM control module (N10/7)
AR54.21-P-
6 with right front fuse and relay module
1261I
(K40/7)
AR27.19-P-
7 Remove ETC control module (N15/3)
1719I
8 Remove vent tube (3)
Pull wiring harnesses back to right fuse box
9
(F1/1)
Installation: Check seal on wire
10 Unscrew screws (2) and remove fuse box
passage from fuse box/vehicle interior
INSTALL HEADLINER WIRING HARNESS - AR54.18-P-0020

Install headliner wiring harness - AR54.18-P-0020MA
MODEL 220.0 /1 with CODE (494a) USA version
Shown on model 220.1 with code (414a) electric glass tilting/sliding roof and code (220a) Parktronic
system and code (882b) interior monitoring (only with anti-theft alarm system)
Fig. 35: Overview Of Headliner Wiring Harness - Shown On Model 220.1 With Code (414a, 220a And
882b)
Shown on model 220.1 with code (414a) Electric glass tilting/sliding roof
Fig. 36: Overview Of Headliner Wiring Harness - Shown On Model 220.1 With Code (414a) Electric
Glass Tilting/Sliding Roof
Install
A new main wiring harness (2) must only be
installed when replacing the headliner (1).
On vehicles with ribbon cable the relevant
normal main wiring harness (2) must be
used. The headliner model refinement was
only carried out from September 2002 to
January 2003.
Use the old headliner (1) as a guide for
routing the main wiring harness (2)
1 Place new headliner (1) on a clean surface
Do not use any hard or sharp-edged
Support the new headliner (1) with suitable objects, otherwise the covering of the
2 clean spacers, e.g. foamed material or new headliner (1) will be damaged.
styrofoam blocks. This prevents the new headliner (1)
from bending during the following steps.
Clip left front vanity mirror illumination
(E14/6) and right front vanity mirror
3
illumination (E14/7) into left and right
installation frame.
Connect wiring harness for vanity mirror

illumination (3) to left front vanity mirror
4 illumination (E14/6) and right front vanity
mirror illumination (E14/7)
Unclip covering from left and right sun visor
5
pivot bearing (4)
Install left and right sun visor pivot bearing
6
(4) in headliner (1) and clip in covering.
Route wiring harness for vanity mirror
illumination (3) and fasten to headliner (1)
7 using approx. 10 cm strips of adhesive tape
(Tesaband 4657) positioned approx. 10 cm
apart as illustrated.
*BR00.45-
Tesaband 4657
Z-1071-02A
Measure overhang of main wiring harness
(2) at C-pillar of old headliner (1) and ensure
8
new main wiring harness (2) hangs over the
same distance.
Route new main wiring harness (2) starting
at C-pillar on new headliner (1) and in Do not cross main wiring harness (2)
impact absorbers (11) and secure using and cable set attachments and press down
9
approx. 10 cm strips of adhesive tape strips of adhesive tape well otherwise
(Tesaband 4657) positioned approx. 10 cm short circuit can occur due to chafing.
*BR00.45-
Tesaband 4657
Z-1071-02A
Route cable set attachment for interior
motion sensor transmitter and receiver (10) Begin routing at wiring connector (9),
route excessive lengths in loops at main
10 and fasten to headliner (1) using approx. 10
cm strips of adhesive tape (Tesaband 4657) wiring harness (2) and secure using
positioned approx. 10 cm apart as illustrated. Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Fasten wiring connector (9) of cable set
On vehicles without code (882b) interior
attachment for interior motion sensor
11.1 monitoring (only with anti-theft alarm
transmitter and receiver (10) to headliner (1)
system)
using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Route cable set attachment for rear dome
lamp PTS warning indicator (7) and fasten to Begin routing at wiring connector (8),
12 headliner (1) using approx. 10 cm strips of route excessive lengths in loops at main
adhesive tape (Tesaband 4657) positioned wiring harness (2) and secure using
Tesaband 4657
approx. 10 cm apart as illustrated.
Tesaband 4657
*BR00.45-
Z-1071-02A
attachment for rear dome lamp PTS warning Vehicles without code (220a) Parktronic
13.1
indicator (7) to headliner (1) using Tesaband system (PTS)
4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Except model 220.0 with code (414a)
Route cable set attachment for dome lamp in Electric glass tilting/sliding roof
rear (5) on left and right and fasten to Begin routing at wiring connector (6),
14.1
headliner (1) using approx. 10 cm strips of route excessive lengths in loops at main
adhesive tape (Tesaband 4657) wiring harness (2) and secure using
Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Guide cable set attachment for dome lamp in
rear (5) on left and right underneath metal
frame for tilting/sliding roof (12) and secure On model 220.0 with code (414a) Electric
14.2
to headliner (1) with strips of adhesive tape glass tilting/sliding roof
(13) (Tesaband 4657) below metal frame for
tilting/sliding roof (12)
Press down strips of adhesive tape
well otherwise cable set attachment for
dome lamp in rear (5) on left and right
touches metal frame for tilting/sliding
roof (12) after dome lamps have been
installed and short circuit can occur due
to chafing.
Begin routing at wiring connector (6),
route excessive lengths in loops at main
wiring harness (2) and secure using
Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Connect up connector (14) of main wiring
Connector (14) and coupling (15) have
15 harness (2) and coupling (15) of vanity
distinct designs and are color coded.
mirror illumination wiring harness (3)
AR68.30-P-
16 Prepare headliner (1) for installation.
4305M
REPAIR MATERIALS
Install headliner wiring harness - AR54.18-P-0020N

MODEL 215
Fig. 37: Overview Of Headliner Wiring Harness - Model 215 (1 Of 2)
Install
installed when replacing the headliner (1). Use
the old headliner (1) as a guide for routing the
main wiring harness (2)
Do not use any hard or sharp-edged
objects, otherwise the covering of the
Support the new headliner (1) with suitable
new headliner (1) will be damaged.
2 clean spacers, e.g. foamed material or
styrofoam blocks. This prevents the new headliner (1)
from bending during the following
steps.
3
installation frame.
4
illumination (E14/6) and right front vanity
5
pivot bearing (7)
Install left and right sun visor pivot bearing (7)
6
in headliner (1) and clip in covering.
*BR00.45-
Tesaband 4657
Z-1071-02A
Measure overhang of main wiring harness (2)
at C-pillar of old headliner (1) and ensure new
8
main wiring harness (2) hangs over the same
distance.
Route new main wiring harness (2) starting at
C-pillar of new headliner (1) and fasten to Do not cross wiring harnesses and
press down strips of adhesive tape well
9 headliner (1) using approx. 10 cm strips of
adhesive tape (Tesaband 4657) positioned otherwise short circuit can occur due to
chafing.
Do not fasten cable set attachment
for rear dome lamp PTS warning
indicator with wiring connector (3)
from main wiring harness (2) to
headliner (1) with strips of adhesive
tape.
*BR00.45-
Tesaband 4657
Z-1071-02A
Route cable set attachment for interior motion

10
sensor transmitter and receiver (4) and fasten
to new headliner (1) using approx. 10 cm
strips of adhesive tape (Tesaband 4657)
positioned approx. 10 cm apart as illustrated.
*BR00.45-
Tesaband 4657
Z-1071-02A
On vehicles without code (882b)
11.1 interior monitoring (only with anti-
theft alarm system)
using Tesaband 4657
Connect up connector (9) of main wiring
Connector (9) and coupling (8) have
12 harness (2) and coupling (8) of vanity mirror
distinct designs and are color coded.
illumination wiring harness (6)
AR68.30-P-
4305N
REPAIR MATERIALS
INSTALL CABLE HARNESS - AR54.18-P-0056M
MODEL 215.373 /374 /376 /378, 220.073 /074 /173 /174 /176 /178 /878 with CODE (494) USA version
Fuel pump wiring harness conversion
Shown on model 220.0 with code 282 (Ski bag (through-loading feature))
Fig. 39: Identifying Cable Harness Install Components - Shown On Model 220.0 With Code 282 (Ski Bag
(Through-Loading Feature))
Fig. 40: Identifying Cable Harness Install Components - Illustrated On Model 220.0
Fig. 41: Identifying Fuel Pump Wiring Harness, Control Unit Bracket, Rear Sam Control Unit With
Connectors - Shown On Model 220.0
Fig. 42: Identifying Wiring Harness, Fuel Pump And Connector - Illustrated On Model 220.0
Removal
Model 220.0/1 without code (223) electrically
adjustable rear bench seat or without code (224) AR91.12-
1.1 Remove rear seat backrest
electrically adjustable individual rear seats, with seat P-1620MA
ventilation, seat heater and memory package
Model 220.878 with Vis-a-vis seats AR91.12-P-
Model 215.3 1620MP
Model 220.0/1 with code (223) Electrically adjustable
Remove seat adjustment rear bench seat or with code (224) Electrically
AR91.12-
2.1 mechanism of left and right adjustable individual rear seats, with seat ventilation,
P-1520M
rear seat cushion seat heater and memory package, or model 220.878
with Vis-a-vis seats
Remove armrest from rear- rear bench seat or with code (224) Electrically AR91.12-
3.1
seat backrest. adjustable individual rear seats, with seat ventilation, P-1745MB
seat heater and memory package
AR91.12-P-
Model 220.878 with Vis-a-vis seats
1745MP
Remove stowage box AR91.12-
4.1 individual rear seats, with seat ventilation, seat heater
between rear seats P-1760M
and memory package
AR91.12-
Model 215.3
P-1760N
With vehicles with code (282) ski bag (through-loading
Unscrew bolts (2) and pull
5.1 feature) or with code (308) cooling compartment in
housing (3) forwards.
center rear backrest
Loosen damping material
(4) from partition wall, fold
6
and place at top behind
head restraints in rear.
Remove expansion clips (5)
7 and take damping material
(6) out of vehicle.
Connect no load current AR54.10-
8
retention unit P-1030-07I
Disconnect battery ground AR54.10-
9
cable P-0003I
Remove right side cover in AR68.30-
10 Model 215.3, 220.0/1
the trunk P-4600M
AR68.30-P-
Model 220.8
4600MP
Install
Connect fuse holder (7) to
relay holder (8), position on
the partition wall (9) above
11 the tank filler pipe (14) and
mark the position of the
bore hole (arrow A) for the
relay holder (8)
Unscrew nut (10), remove
right (A2/35a2) antenna
12.1 On vehicles with code (889) Keyless go.
element and place to one
side.
Use 4mm dia. drill bit and afterwards remove drill
Drill hole (arrow A) for shavings.
13 Cordless drill/driver, wet/dry vacuum cleaner see
relay holder (8).
GOTIS
Secure relay holder (8) to
14 partition wall (9) using bolt
(11).
Fit new fuel pump relay in
The new fuel pump relay is included in the parts kit
15 socket base of relay holder
for the fuel pump wiring harness (1).
(8).
Unscrew nut (12) from
16 circuit 30Z terminal block
and fuse box (X4/22).
Fit connection eyelet at fuel
pump wiring harness (1) on
*BA54.10-
circuit 30Z terminal block
17 P-1016-
and fuse box (X4/22) and
01C
secure tightly using nut
(12).
Route ground connection of
fuel pump wiring harness Route ground connection of fuel pump wiring
(1) along existing wiring harness (1) free of tension and fix in place using cable
harness to ground (right ties.
18
taillamp in luggage
compartment) (W7/1).
ground (right taillamp in
19
luggage compartment)
(W7/1).
Fit ground connection of
fuel pump wiring harness
*BA54.10-
(1) on ground (right
20 P-1015-
taillamp in luggage
01C
compartment) (W7/1) and
secure using nut (13).
Route the wiring harness
for fuel pump (1) out of the
luggage compartment,
Route fuel pump wiring harness (1) free of tension
21 below the tank filler pipe
and fix in place using cable ties.
(14) along the existing
wiring harness into the
vehicle interior
In vehicle interior, remove
22 nut (16) and bolt (15) at
control unit holder (17).
Remove control unit holder
23 (17) and place in rear
footwell.
The rear SAM control unit (N10/8) is located below
24 from rear SAM control unit
the control unit holder (17).
(N10/8).
Unpin pin 13 (arrow B) and
Color of the line to the pin 13 (arrow B), red/blue.
25 pin 14 (arrow C) at
Color of the line to pin 14 (arrow C), green/black.
connector (18).
Fig. 43
Fig. 44
Unpin pin 11 at connector Model 215.374, 220.074/174
26.1
(18). Color of line to pin 11, blue/white.
Fig. 43
Fig. 44
The relevant position number can be seen on the
Plug pin 13 (arrow B) into
outside of the connector (19).
27 position 2 of connector
The plug (19) is included in the parts kit of the wiring
(19).
harness for the fuel pump (1).
28 Plug pin 14 (arrow C) into
position 1 of the connector The relevant position number can be seen on the
(19). outside of the connector (19).
In models 215.374, 220.074/174
Pin the pin 11 into the slot
29.1 The relevant position number can be seen on the
3 of plug (19)
Connect the connector (18)
30 to rear SAM control unit
(N10/8).
31 to fuel pump wiring
harness (1).
for the fuel pump (1)
unstressed, along the Route fuel pump wiring harness (1) in a straight line
32 existing wiring harness to near center tunnel and fix in place using suitable, self-
the left side of the vehicle adhesive felt strips.
and fix in position with
cable ties
platform and position the four support plates at the AS00.00-Z-
lifting platform support points specified by the vehicle 0010-01A
manufacturer.
Raise vehicle with lifting Only lift so far that the interior, right-hand side of
33
platform vehicle, is still accessible from outside.
Only loosen the cover (20)
of the fuel pump (M3) until
34 The cover (20) is fastened with three nuts.
the plug (21) on the fuel
pump (M3) is accessible
and pull wiring harness
35
(22) with grommet (23)
into vehicle interior.
Guide fuel pump wiring Moisten the grommet (23) on the wiring harness for
36 harness (1) outwards the fuel pump (1) with antifriction agent and position
through body floor. correctly.
*BR00.45-
Antifriction agent Z-1010-
06A
Connect the connector at
fuel pump wiring harness The cover (20) of the fuel pump (M3) is secured by
37
(1) to fuel pump (M3) and three nuts.
install cover (20).
Lower vehicle with lifting
38
platform
39 Strap down connector (21)

at wiring harness (22) using
suitable insulation tape.
Route fuel pump wiring
harness (1) in vehicle
Right side of vehicle
40 interior along existing
Route fuel pump wiring harness (1) free of tension.
wiring harness and fix in
place using cable ties.
Position right antenna
element (A2/35a2) and
41.1 On vehicles with code (889) Keyless go
secure in place using nut
(10).
Install right side paneling in AR68.30-
42 Model 215.3, 220.0/1
luggage compartment P-4600M
AR68.30-P-
Model 220.8
4600MP
Position damping material
43 (6) in vehicle and install Replace damaged expansion clips (5)
expansion clips (5).
Secure damping material
44
(4) to partition wall.
Connect ground cable to AR54.10-
45
battery P-0003I
Disconnect quiescent AR54.10-
46
current retention device P-1030-07I
Position the housing (3)
and tighten with bolts (2)
Install stowage box AR91.12-
and memory package
AR91.12-
Model 215.3
P-1760N
Install armrest at rear seat rear bench seat or with code (224) Electrically AR91.12-
49.1
backrest adjustable individual rear seats, with seat ventilation, P-1745MB
AR91.12-P-
With model 220.878 with Vis-a-vis seats
1745MP
Install seat adjustment rear bench seat or with code (224) Electrically
AR91.12-
P-1520M
rear seat cushion seat heater and memory package or model 220.878 with
Vis-a-vis seats
Model 220.0/1 without code (223) Electrically AR91.12-
51.1 Install rear seat backrest adjustable rear bench seat or without code (224) P-1620MA
Electrically adjustable individual rear seats, with seat
Model 215.3 1620MP
Remove fuse 52 originally
installed for fuel pump
52
relay from previous
installation location
Fuse assignment of rear
fuse and relay box
GF54.15-
Vehicles with production
P-1256-
date up to 31.8.02
01IH
Vehicles with production GF54.15-
date as of 1.9.02 up to P-1256-
31.8.03 01JH
31.5.04 01KH
GF54.15-
P-1256-
date as of 1.6.04
01LH
Remove originally installed
53 fuel pump relay from
previous installation
GF54.15-
Relay assignment of rear
P-1257-
fuse and relay box
01IH
Document new installation
location of relay holder (8) Cut out the view in the document and enclose the
54 for fuel pump relay and folding sheet of the fuse and relay assignment of the
fuse holder (7) in vehicle fuse and relay box in the rear.
documentation.
Fuse and relay assignment GF54.15-
of fuse and relay holder in P-1257-
luggage compartment 10M
BATTERY
BA54.10-P-1015-01C Nut to ground (taillamp in luggage compartment) M6 Nm 7 7
BA54.10-P-1016-01C Nut to circuit 30Z terminal block and fuse box M10 Nm 14 14
Fig. 43: Identifying Blade Holder With Clamping Pliers (220 589 01 99 50)
Fig. 44: Identifying SLK 2.8 - 97 Blade (220 589 01 99 63)
REPAIR MATERIALS
REPAIRING WIRING HARNESS - AR54.18-P-0100
Repairing wiring harness - AR54.18-P-0100IA
MODEL 215 with ENGINE 113 EC fan wiring harness as of code 802
MODEL 215 with ENGINE 137 EC fan wiring harness
MODEL 220 with ENGINE 112, 113 EC fan wiring harness as of code 802
MODEL 220 with ENGINE 137, 613, 628 EC fan wiring harness
Fig. 45: Identifying Terminal Point With Cutting Area
Removing
AR54.10-P-
0003I
AR82.10-P-
2 Remove left headlamp unit Model 215
4730N
AR82.10-P-
Model 220 except code (612b) Xenon headlamp unit
4730M
AR82.10-P-
4730MA
Unplug electrical connector from
3
suction fan
Expose fan wiring harness branch-
4
off line
Cut open insulation (fabric tape)
5
for a length of approx. 450mm
2
6 Cut wire (red, 12 mm ) in area Use cable shears to cut the wires.
(A)
Cut wire (black/violet, 0.5mm2 )
Always cut the individual wires at the parting
7 and wire (yellow/blue, 0.5mm2 )
point to different lengths.
in area (A)
2
8 Cut ground lead (brown, 12mm )
in area (A) and insulate
Installing
9 Attach cable lug to wire (red, 12
mm2 ) with shrink sleeve
Connect wire (black/violet,
0.5mm2 ) and wire (yellow/blue, AR00.19-P-
10 Use green cable connectors.
0.5mm2 ) with repair wiring 0100-09A
harness
Fasten terminal point (1) to A/C
11
pipe with two cable straps
Screw wire (red, 12 mm2 ) and
wire from repair wiring harness
12
(red, 12 mm2 ) onto terminal point
(1)
Screw ground lead (brown, 12
2
13 mm ) from repair wiring harness
to ground point (W3/7, bottom left
in wheelhousing)
Insulate all newly installed wires
14 and cable connectors with fabric
tape
Route fan repair wiring harness
15
and connect to fan
AR82.10-P-
16 Install left headlamp unit Model 215
4730N
AR82.10-P-
4730M
AR82.10-P-
4730MA
AR54.10-P-
0003I
Stored faults which can result from cables being
disconnected or from simulation during removal and
installation or test work, have to be processed and
18 Read and erase fault memory
erased in the fault memories after completing the
work. Refer to: ?
STAR DIAGNOSIS
19 Check function of fan
Repairing wiring harness using soldered terminal sleeve - AR54.18-P-0100-02A

Number Designation
1. Expose damaged cable or connector/socket at an easily accessible point and cut off.
Separate conductors in wiring harness offset by approx. 45 mm.
Fig. 46: Identifying Exposed Damaged Cable Or Connector/Socket At An Easily Accessible Point
2. Cut new cable to size matching the old part.
When cutting to size, allow an additional length of 50 mm for creating loops (cable grip).
3. Remove insulation at ends of cable over 15 mm.

4. Select soldered terminal sleeve according to the table below.
Fig. 47: Identifying Cutting Dimension Of Cable Ends
5. Insert cables into matching soldered terminal sleeve (Z), matching the total cross-section of the cable.
6. Turn soldered terminal sleeve (7) fully onto the cables.
Fig. 48: Turning Soldered Terminal Sleeve Onto Cables
7. Heat soldered terminal sleeve with a hot air gun (approx. 400 °C).
Begin at the tapered side until the soldered ring detaches and the sheathing has moved cleanly around
the cable.
Fig. 49: Heating Soldered Terminal Sleeve Using Hot Air Gun
8. Inspect solder point.
It must no longer be possible to see the soldered ring (1) on the soldered connector sleeve (Z). The
sheathing (2) must be resting cleanly against the cables.
Fig. 50: Identifying Solder Point - Correct/Incorrect
9. Position soldered connector sleeves at cable and wrap fabric tape around repaired area.
Soldered connector sleeves must not be positioned directly one above the other.
Fig. 51: Identifying Soldered Connector
Repairing wiring harness - AR54.18-P-0100IB
MODEL 215 with ENGINE 113 DC fan wiring harness up to code 801
MODEL 220 with ENGINE 112, 113 DC fan wiring harness up to code 801
Removing
AR54.10-P-
0003I
AR82.10-P-
2 Remove right headlamp unit Model 215
4730N
AR82.10-P-
4730M
AR82.10-P-
4730MA
3
suction fan
Remove lower engine AR61.20-P-
4 Right front.
compartment lining 1105M
Remove suction fan control
5 Replace suction fan control module (N65/2).
module (N65/2)
Expose fan wiring harness branch-
6
off line
Cut fan wiring harness branch-off
7 line in area of headlamp and Use cable shears to cut the wires.
insulate
Unpin wire (black, 10mm 2 ) from
8 right front fuse and relay module White 10-pin plug, pin 2.
(K40/7)
2
9 Cut wire (black, 10mm ) at
branch-off line and insulate
Installing
Pin wire (black, 10mm2 ) from
10 repair wiring harness in right front White 10-pin plug, pin 2.
fuse and relay module (K40/7)
Attach wire (black, 10mm2 ) from
11 repair wiring harness to engine Do not open the existing wiring harness.
wiring harness with cable straps
0.5mm2 ) and wire (yellow/blue, AR00.19-P-
12 Use green cable connectors.
0.5mm2 ) with repair wiring 0100-09A
harness
Screw ground lead (brown,
2
13 10mm ) from repair wiring
harness to ground point (W3/6,
bottom right in wheelhousing)
tape
Install suction fan control module
15
(N65/2)
16
and connect
AR82.10-P-
17 Install right headlamp unit Model 215
4730N
AR82.10-P-
4730M
AR82.10-P-
4730MA
AR54.10-P-
0003I
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. Refer to: ?
STAR DIAGNOSIS
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. 52: 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.
caused by up; do not expose to temperatures greater than 01B
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. 54
New passenger vehicle wiring harness repair Fig. 53
kit
Wire stripper Fig. 56
Reflector Fig. 55
Adapter Fig. 57
Welding bead catcher Fig. 60
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. 62
5 Install in the
reverse order
Fig. 53: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 54: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 55: Identifying Reflector (220 589 01 99 41)

Fig. 56: Identifying Wire Stripper (220 589 01 99 40)
Fig. 58: Identifying Electrical Connection Kit (220 589 00 99 00)
Fig. 59: Identifying 126-Pin Socket Box (129 589 00 21 00)

Fig. 60: Identifying Welding Bead Catcher (129 589 01 98 00)
Checking wiring harness - AR54.18-P-0600-01A
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.
REMOVING AND INSTALLING DISTRONIC CONTROL MODULE - AR54.21-P-0005I

MODEL 215, 220 with CODE (219a) Distronic (DTR)
Shown on model 220
Fig. 63: Identifying Distronic Control Module Remove/Install Components - Shown On Model 220
AR54.10-P-
1 Connect quiescent current retention unit Models 215, 220
1030-07I
AR54.10-P-
2 Disconnect ground cable of battery Models 215, 220
0003I
Fold back floor covering in passenger's footwell
3
and remove polystyrene panel
Detach mounting plate (1) in passenger's footwell Hold top of mounting plate
4
and fold out into footwell and fold into footwell.
5 Remove connectors (2a) and connection (2b)
Unscrew bolts (3) and remove DTR control
6
module (N63/1) from mounting plate
8 Perform basic setting with STAR Diagnosis
FLASHING CONTROL UNIT - AR54.21-P-0012-06A
Offline flashing with SD flash release CD

Number Designation
It must be ensured that the DAS-CD/DVD and SDflash Release CD are compatible.
Sequence of flashing when communication has taken place between Diagnosis Assistance System (DAS)
and control unit
1. Select vehicle.
2. Select control unit.
Select main menu, systems and control unit to be flashed.
3. Select the menu item "program control units" in the control unit menu.
4. Select control unit menu item "SD flash release CD".
5. Insert SD flash release CD in the disk drive and wait until the disk drive has started up.
Due to possible disk drive errors possible detection faults of the SDflash Release-CD can occur
(observe error message).
Repeat process if required (button F7).
After the disk drive starts up the SDflash Release-CD is checked for new software for the control unit.
Observe corresponding message in DAS.
6. With new software press the button F2 and flash (program) the control unit.
Sequence of flashing when communication (communication error) has not taken place between the DAS
and control unit
Support:
In the event of questions and problems please contact the STAR DIAGNOSIS Call Center.
1. If possible eliminate the cause of the error message using the test steps in the "error messages" menu.
If the cause of the error cannot be determined, please inform the STAR DIAGNOSIS CALL Center hotline.
Replace the control unit following discussion with the hotline.
2.1 Determine part number of control unit and replace control unit.
Only if necessary.
3.1 Select menu item "special functions" in the main menu, select "repair functions", carry out "replace
control unit".
Only if necessary.
SCN CODING - AR54.21-P-0013
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.
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
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.
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
20. Use "F5" to open the request form of SCN repair CD.
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".
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.
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.
"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.
"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.
35. Confirm note concerning successful SCN generation and coding string formation.
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
39.
1. Enter SCN coding data (SCN, coding string and check digit 2). Continue with "F3".
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.
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.
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014
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
Program control unit - AR54.21-P-0014-01Y
Offline programming with SDflash Release-CD.
1. Select vehicle.
Selection of main menu, systems and select the control unit to be programmed.
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.
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
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

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.
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
REMOVING AND INSTALLING TRACTION SYSTEM CONTROL MODULE - AR54.21-P-0816I
MODEL 215, 220
Shown on model 220
Fig. 64: Identifying Traction System Control Module Remove/Install Components - Shown On Model 220
AR54.10-P-
1030-07I
AR54.10-P-
0003I
AR88.40-P-
3 Open engine hood and move to upright position
1000M
4 Release and remove cover on left fuse box (F1)
Pull slide locks (1a) on both connectors (1) on traction The slide locks are
5 system control module (N47) out to stop in direction of located below the wire
arrow and remove connectors entries
Disconnect data bus connector (2) from traction system
6
control module
Remove traction systems control module (N47) from left
7
fuse box (F1) upwards out of the guides
REMOVING AND INSTALLING SAM CONTROL MODULE WITH FUSE AND RELAY BOX IN
REAR - AR54.21-P-1259I
MODEL 215, 220
Fig. 65: Identifying SAM Control Module Remove/Install Components (Rear) - Shown On Model 220
Shown on model 220
Connect quiescent current retention AR54.10-
1
unit P-1030-07I
Disconnect ground lead from AR54.10-
2
battery P-0003I
AR91.12-
3.1 Remove rear seat cushion Model 215
P-1020N
AR91.12-
Model 220
P-1020MA
AR91.12-
3.2 Remove bucket seats Model 220 with code 401, right-hand side only
P-1020M
Remove seat adjustment device on AR91.12-
4.1 Model 220 with code 401, right-hand side only
rear seat P-1520M
Unscrew screws (2) and nuts (1),
5 remove mounting plate (3) from
vehicle floor and pivot toward rear
Pivot arresting lever (5) for power
6
supply (c. 30) up and pull out wire
Unscrew nuts (4) and remove
control module unit (rear fuse and
7 relay module (K40/5) and SAM
control module in rear (N10/8))
from floor
Disconnect connectors from control
module unit (rear fuse and relay
8
module (K40/4) and SAM control
module in rear (N10/8))
GF54.15-
Fuse assignments, standard
P-1256I
GF54.15-
Relay assignments, standard
P-1257I
After pressing the retaining lugs (arrow) in
the direction of the arrow the fuse carriers can
be removed upward.
Unclip fuse carrier (6) from fuse The number of fuse carriers from the fuse
9
and relay module in rear and relay module in the rear can vary
depending on the equipment and vehicle. If
SAM control module in rear or fuse and relay
module in rear are defective: ?
Disconnect SAM control module from fuse and AR54.21-
relay module P-1259-01I
Separating SAM control module from fuse and relay box - AR54.21-P-1259-01I
Shown on rear SAM control module
1. Pry out SAM control module (N10/6, N10/7, N10/8) at the multiple plug of the fuse and relay module
(K40/5, K40/6, K40/7).
To do this drive a suitable screwdriver into the recesses (A, B) and turn screwdriver through 90°.
Observe data plate (2) on the SAM control module
2. Pull down the SAM control module until the control module can be removed from the guides (C, D).
Fig. 66: Identifying SAM Control Module, Data Plate And Guides - Shown On Rear SAM Control
Module
REMOVING AND INSTALLING SAM CONTROL MODULE WITH FUSE AND RELAY BOX,
FRONT LEFT/RIGHT - AR54.21-P-1260
Removing and installing SAM control module with fuse and relay box, front left - AR54.21-P-1260I
MODEL 215, 220

Fig. 67: Identifying SAM Control Module Remove/Install Components (Front Left) - Shown On Model
220
Shown on model 220
Connect quiescent current retention AR54.10-P-
1
unit 1030-07I
AR54.10-P-
0003I
3
Release and remove cover on left fuse
4
box (F1)
Fold up clamping lever (1) and
5
remove supply cable (terminal 30)
GF54.15-P-
Fuse assignment, build condition
1256I
GF54.15-P-
Relay assignment, build condition
1257I
Once the retaining lugs (arrow) have been
Unclip fuse carrier (2) on control pressed in the direction of the arrow, the fuse
module unit (driver-side SAM control carriers can be taken out from the top.
6
module (N10/6) with left front fuse The components fitted to the left front
and relay module (K40/6)). fuse and relay module may vary depending
on the equipment.
Remove the remaining couplings on
7
the left front fuse and relay module
Only pull out until the couplings (3) on
Pull out control module unit from control module unit (left front fuse and relay
8
above module (K40/6) and driver-side SAM
control module (N10/6)) are accessible
If driver-side SAM control module or left
9 Unlock and remove couplings (3)
front fuse and relay module are defective: ?
Disconnect SAM control module from fuse AR54.21-P-
and relay module 1259-01I
Removing and installing SAM control module with fuse and relay box, front right - AR54.21-P-1261I
MODEL 215, 220
Fig. 68: Identifying Sam Control Module Remove/Install Components (Front Right) - Shown On Model
220
Shown on model 220
AR54.10-P-
1 Connect quiescent retention device
1030-07I
AR54.10-P-
0003I
Open engine hood and position AR88.40-P-
3
upright 1000M
Unlock and remove cover on right
4
fuse box (F1.1)
Fold up clamping lever (1) of supply
5
(terminal 30) and remove cable
GF54.15-P-
1256I
GF54.15-P-
1257I
module unit (passenger-side SAM carrier can be taken out from the top.
6
control module (N10/7) with right The components fitted to the right front
front fuse and relay module (K40/7)). fuse and relay module may vary depending
on the equipment.
7
the front right fuse and relay module
Only pull out until the couplings (3) on
Pull out control module unit from control module unit (right front fuse and
8
above relay module (K40/7) and passenger-side
SAM control module (N10/6)) are accessible
If passenger-side SAM control module or
9 Unlock and remove couplings (3) right front fuse and relay module are
defective: ?
REMOVING, INSTALLING CONTROL MODULE OF UPPER CONTROL PANEL - AR54.21-P-1262
Removing and installing upper control panel control module - AR54.21-P-1262M
MODEL 220
Fig. 69: Identifying Upper Control Panel Control Module, Molding Strip And Screws
1 Molding strip Remove AR68.10-P-1180M
2 Screws Unscrew
N72/1 Upper control panel control module
Removing, installing control module of upper control panel - AR54.21-P-1262N
MODEL 215
Fig. 70: Identifying Upper Control Panel Control Module, Electric Connection, Cover And Screws
Illustration, item etc. Notes on the work

1 Center console cover remove AR68.20-P-2350N
2 Screws unscrew
3 Electrical connector pull off
REMOVE/INSTALL COMBINATION SWITCH - AR54.25-P-2800I
MODEL 215, 220, 230.4
Shown on model 220 with code (494) USA version

Fig. 71: Identifying Combination Switch Remove/Install Components - Shown On Model 220 With Code
(494) USA Version
MODIFICATION NOTES
21.11.05 Disconnect ground line replaced by switch off ignition Step 2.2
Remove/install
Connect no load current AR54.10-P-
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
Disconnect battery ground AR54.10-P-
2.1 on model 215, 220
cable 0003I
in case of model 230
On vehicles with code (889) Keyless Go, press the
Switch off the ignition and
Keyless Go start/stop button repeatedly until the ignition is
2.2 remove the transmitter key
switched off. Remove the Keyless Go transmitter card or
from the EIS control unit
transmitter key from the vehicle and store beyond the
reach of the transmitter (min. 2 m).
Remove jacket tube switch
3 See:?
module (1)
AR54.25-P-
Remove/install steering column module
2802I

Number Designation
REMOVE/INSTALL STEERING COLUMN MODULE - AR54.25-P-2802I
MODEL 215, 220, 230
Fig. 72: Identifying Steering Column Switch Module, Fanfare Horns And Airbag Clock Spring Contact
Shown on steering column switch module without voice control system
Fig. 73: Identifying Steering Column Switch Module - Shown On Steering Column Switch Module
Without Voice Control System
Remove/install
Remove fanfare horns and airbag clock Model 215, 220 without code (472) Electronic AR46.10-
1.1
spring contact (A45) Stability Program (ESP) P-0200I
Model 230
AR46.10-
1.2 Remove steering angle sensor Model 215, 220 with code (472) Electronic
P-0300I
Stability Program (ESP)
Loosen internal Torx bolt (arrow) and
Internal Torx bolt (arrow) is secured to
2 remove steering column switch module
prevent it falling out.
(1)
On model 215 with code (813) voice control
system the voice control system switch and the
Remove cover (2) and remove cruise TPM switch (S40) form a common module and
3 control switch (S40) upwards out of cannot be removed individually.
steering column switch module (1) Installation: Ensure that the studs (3) are
seated cleanly in the holes, by paying attention
to the guides on the cruise control switch (S40).
Remove switch group for steering Installation: Ensure that the studs (3) are
column adjustment and easy entry/exit seated cleanly in the holes, by paying attention
4
(S59/1) upwards out of steering column to the guides on the switch group for steering
switch module (1) column adjustment and easy entry/exit (S59/1).
5 combination switch (S4) upwards out
of steering column switch module (1)
Remove steering column module (N80)
6 upwards out of steering column switch
module (1)
REMOVE/INSTALL CRUISE CONTROL SWITCH - AR54.25-P-2803I
MODEL 215, 220, 230.4

Fig. 74: Identifying Cruise Control Switch Remove/Install Components - Shown On Model 220 With
Code (494) USA Version
MODIFICATION NOTES
Remove/install
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
2.1 on model 215, 220
cable 0003I
Switch off the ignition and
Keyless Go start/stop button repeatedly until the ignition is
2.2 remove the transmitter key
from the EIS control unit
On model 215 with code (813) voice control system the
voice control system switch and the TPM switch (S40)
3 form a common module and cannot be removed
module (1)
individually.
Refer to: ?
AR54.25-P-
2802I
Number Designation
REMOVING AND INSTALLING STEERING COLUMN ADJUSTMENT SWITCH - AR54.25-P-2804I
MODEL 215, 220, 230.4
Fig. 75: Identifying Steering Column Adjustment Switch Remove/Install Components - Shown On Model
220 With Code (494) USA Version
MODIFICATION NOTES
Remove/install
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
2.1 on model 215, 220
cable 0003I
Switch off the ignition and in case of model 230

2.2 remove the transmitter key On vehicles with code (889) Keyless Go, press the
from the EIS control unit Keyless Go start/stop button repeatedly until the ignition is
3 See:?
module (1)
AR54.25-P-
2802I

Number Designation
REMOVE/INSTALL LIGHT MODULE - AR54.25-P-3260
Remove/install light module - AR54.25-P-3260I
MODEL 220
Fig. 76: Identifying Light Module Remove/Install Components - Model 220
Remove, Install
1
retention device 1030-01I
Disconnect ground cable of AR54.10-P-
2
battery 0003I
Pull out release lever for parking
3
brake
4 Unscrew bolts (1)
Remove cover (2) with light Pull parking brake release lever until cover folds
5 module (N7-1) from instrument out of instrument panel in direction of arrow.
panel Observe clips (3).
Release connector (4) and
6
disconnect
Unhook control cable (5) from
7
release lever on parking brake.
Removing and installing light module - AR54.25-P-3260N
MODEL 215
AR54.10-P-
1030-07I
AR54.10-P-
0003I
Turn exterior lamp switch onto low beam and pull 1 detent
3
towards the driver (fog lamp switched on)
Push extractor hook (01) in area of low beam symbol (A) and side
4 light symbol (B) between rotary light switch (1) and light module Do not Fig. 78
cover (2) damage light
module
5 Turn extractor hook through 90° and pull out light module cover
7 Press clips (4) and remove light module (N7-1)
8 Unlock coupling (5) and pull off
Fig. 78: Identifying Extractor Hock (140 589 02 33 00)
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000
Perform adjustments to the control system - AR54.30-P-1000-02OPM
Check engine oil level.
The vehicle must be horizontal for at least 5 minutes with the engine switched off at operating temperature.
Otherwise measurement errors can occur.
Shown on model 220

Fig. 79: Identifying Multifunction Display And Buttons - Shown On Model 220
2. Press the system selection button (S110s3) repeatedly until the kilometer reading is displayed in the
3. Press the scroll back and forward button (S110s1) repeatedly until "CORRECT MEASUREMENT
ONLY WHEN VEHICLE IS STATIONARY AND ON THE LEVEL" appears in the multifunction
display (A1p13).
After approx. 3 seconds "ENGINE OIL MEASUREMENT RUNNING" is displayed.
4. Refill the engine with the engine oil quantity shown in the multifunction display (A1p13) and check the
engine oil quantity again.
Perform adjustments to the control system - AR54.30-P-1000-02RAM
Activate tire pressure monitor.
Before activating tire pressure monitoring system: correct tire pressure of all wheels.
3. Press the scroll forward/back button (S110s1) repeatedly until (A1p13) the tire pressure display or the
message "TIRE PRESSURE MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW
MINUTES, REACTIVATE WITH R-BUTTON" is shown in the multifunction display.
Fig. 80: Identifying Pressure Display And System Selection Button
4. Press reset button.

5. Inquiry "ACT. Confirm MONITOR TIRE PRESSURE?" in the multifunction display (A1p13) by
pressing the button + and -, setting specific functions and volume control (S111s1)
The message "TIRE PRESSURE MONITOR ACTIVATED" appears in the multifunction display
(A1p13).
6. Drive the vehicle for several minutes.
Until the individual tire pressure values are detected, the (A1p13) the message "TIRE PRESSURE
MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW MINUTES, REACTIVATE WITH
R-BUTTON" is shown in the multifunction display.
REMOVING AND INSTALLING INSTRUMENT CLUSTER - AR54.30-P-6015I
MODEL 215, 220

Fig. 81: Identifying Instrument Cluster Remove/Install Components - Shown On Model 220
Shown on model 220
1
Disconnect ground lead from AR54.10-P-
2
battery 0003I
Move steering wheel toward
3
driver and toward vehicle floor
4 Pull out instrument cluster (A1) To do this, push in slide (1)
Installation:
Press back retaining springs (arrow) on instrument
cluster (A1) removed and pull out slide (1)
Release lock on connector (2) and
5
remove connector

000 833 03 61 Slide 2
REMOVING AND INSTALLING BULBS OF INSTRUMENT CLUSTER - AR54.30-P-6049I

MODEL 215, 220
Fig. 82: Identifying Instrument Cluster And Indicator Lamps
1 Connect quiescent current retention unit AR54.10-P-1030-07I
2 Disconnect ground lead from battery AR54.10-P-0003I
3 Remove instrument cluster AR54.30-P-6015I
4 Remove bulbs Installation: ? AR54.30-P-6049-01Z
Install bulbs AR54.30-P-6049-02Z
Fig. 83: Identifying Installation Sleeve (129 589 01 09 00)
Removing bulbs - AR54.30-P-6049-01Z

Fig. 84: Identifying Pin Socket (129 589 00 09 00)
Fig. 85: Identifying Pin Socket (129 589 0109 00)
Turn bulbs to the left and remove using special tool
Fig. 86: Identifying Left Turn Bulb Position
Installing bulbs - AR54.30-P-6049-02Z

Insert bulbs and turn to the right using special tool.
Fig. 89: Identifying Right Turn Bulb Position
REMOVE/INSTALL OUTSIDE TEMPERATURE INDICATOR SENSOR - AR54.30-P-6341
Remove/install outside temperature indicator sensor - AR54.30-P-6341I
MODEL 220
Fig. 90: Identifying Ambient Temperature Display Temperature Sensor
Remove/install
left front AR61.20-P-

section 1105M
2 Unclip outside temperature indicator temperature sensor (B14)
Disconnect electrical connector for outside temperature indicator
3
temperature sensor
Removing and installing outside temperature indicator sensor - AR54.30-P-6341N
MODEL 215
Fig. 91: Identifying Electrical Connection And Ambient Temperature Display Temperature Sensor
Left front AR61.20-P-

1 Remove engine compartment lining
section 1105M
2 Unclip ambient temperature display temperature sensor (B14)
Unclip and pull off electrical connection of ambient temperature
3
display temperature sensor (1).
REMOVING AND INSTALLING FANFARE HORNS/CLAXON - AR54.35-P-1555
Removing and installing fanfare horns - AR54.35-P-1555I
MODEL 220
Fig. 92: Identifying Fanfare Horns

Engine compartment lining remove AR61.20-P-1105M
H2 Fanfare horns
Removing and installing claxon - AR54.35-P-1555N
MODEL 215
Fig. 93: Identifying Fanfare

H2 Fanfare horns
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN FRONT BUMPER - AR54.65-P-

0001I
MODELS 215, 220 with CODE (220a) Parktronic System (PTS)
Fig. 94: Identifying Front Bumper Parktronic System (PTS) Sensor Remove/Install Components - Shows
Model 220
Shows model 220
Remove/install
Using a suitable tool (e.g. plastic wedge) pry out of

1 Unclip bumper element (2) on bumper
bumper and remove in the direction of the arrow.
Disconnect coupling (3) from
2 Lift up lock tab (3a) slightly using a suitable tool.
Parktronic sensor (1)
Unclip bracket of Parktronic sensor (4) When removing the bracket together with the Parktronic
3
from bumper element sensor, this can fall out of the bracket.
4 Pull sensor out of the bracket Installation: Check sealing ring (5).
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN REAR BUMPER - AR54.65-P-

0002I

Fig. 95: Identifying Rear Bumper Parktronic System (PTS) Sensor Remove/Install Components - Shows
Model 220
Shows model 220
Remove/install
Use plastic wedge to pry out of bumper and remove in

1 Unclip bumper element (2) on bumper
direction of arrow
Unclip bracket of Parktronic sensor (4) When removing the bracket together with the
3
from bumper element Parktronic sensor, this can fall out of the bracket.
4 Pull Parktronic sensor out of the bracket Installation: Check sealing ring (5).
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) WARNING INDICATOR ON

INSTRUMENT PANEL - AR54.65-P-0003B
MODEL 208, 215, 220 with CODE (220a) Parktronic system (PTS)
Fig. 96: Identifying Parktronic System Warning Indicator On Instrument Panel Remove/Install
Components
Components
Figure item, etc. Work instructions

1 Electrical connections disconnect
A44/1 PTS warning indicator pull out upward
(on left of instrument
panel)
(on center of instrument
panel)
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) WARNING INDICATOR IN REAR

DOME LAMP - AR54.65-P-0004B
Fig. 98: Identifying Parktronic System Warning Indicator Remove/Install Components
1 Pull rear dome lamp Pull left side out of
(E15/3) together with headliner first (arrow)
PTS warning indicator
(A44/3) out of headliner
from dome lamp and PTS
warning indicator
3 Unclip cover (1) at rear
dome lamp
4 Unclip PTS warning
indicator from dome
lamp
5 Reinstall in opposite
order
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) SWITCH - AR54.65-P-0005
Removing and installing Parktronic system (PTS) switch - AR54.65-P-0005I
MODEL 220 with CODE (220a) Parktronic system (PTS)

Fig. 99: Identifying Parktronic System (PTS) Switch Remove/Install Components
AR68.10-P-
1 Remove molding strip (1)
1180M
AR54.21-P-
2 Remove upper control panel control module
1262M
Remove switch group with Parktronic system switch (S95) in direction of
3
arrow
4 Disconnect electrical connector (2)
Removing and installing Parktronic System (PTS) switch - AR54.65-P-0005N
MODEL 215 with CODE (220a) Parktronic System (PTS)

Fig. 100: Identifying Electrical Connection And PTS On/Off Switch
1 Remove center console cover AR68.20-P-2350N
2 Remove upper control panel control module AR54.21-P-1262N
3 Remove switch group with PTS on/off switch (S95)
4 Disconnect electrical connection (1)
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) CONTROL MODULE - AR54.65-P-

0006I
MODEL 215, 220 with CODE (220a) Parktronic system (PTS)
Shown on model 220

Fig. 101: Identifying Parktronic System (PTS) Control Module Remove/Install Components - Shown On
Model 220
AR54.10-P-
1030-07I
AR54.10-P-
0003I
AR91.12-P-
1020N
AR91.12-P-
Model 220
1020MA
Model 220
AR91.12-P-
3.2 Remove independent seats with code 401,
1020M
right-hand side
Model 220
AR91.12-P-
4.1 Remove rear seat adjustment mechanism with code 401,
1520M
right-hand side
Unscrew screws (1) and nuts (2) and remove mounting plate (3)
5
from vehicle floor
Release connectors (4) on Parktronic system control module
6
(N62) and disconnect
Push Parktronic system control module out of guide rails
7
(direction of arrow) and remove from mounting plate
REMOVE/INSTALL SENSOR - AR54.70-P-0001I

Shown on Model 220
Fig. 102: Identifying Sensor Remove/Install Components - Shown On Model 220
Fig. item, etc. Work instructions

Engine hood Open AR88.40-P-1000M
1 Bolts unscrew
2 Clutch detach
B29 DTR radar sensor
Check, correct Distronic (DTR) sensor adjustment AR30.30-P-1000R
Electrical System, Equipment & Instructions - Testing & Repair - 215 & 220 Chassis
TESTING & REPAIR

MODEL 215

MODEL 215, 220
AR54.10-P-
0005I
MODEL 215, 220
MODEL 215, 220, 230
consumption 1030I
AR54.10-P-
1129I
AR54.10-P-
1130I
MODEL 163, 164, 168, 169, 170, 171, 203, 204,
208, 209, 211, 215, 216, 219, 220, 221, 230, 240,
245, 251, 414 ...
AR54.15-P-
1257I
left front
AR54.15-P-
1258I
right front
AR54.18-P-
Install headliner wiring harness MODEL 215
0020N
AR54.18-P-
0056M
AR54.18-P-
0100IA
AR54.18-P-
0100IB
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,
AR54.21-P-
0014Y
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0014Z
230, 240, 245, 251, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0015X
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 215, 220
AR54.21-P-
1259I
box in rear
AR54.21-P-
1260I
box, front left
AR54.21-P-
1261I
box, front right
Removing, installing control module AR54.21-P-
MODEL 215
of upper control panel 1262N
AR54.25-P-
2800I
MODEL 215, 220, 230
module 2802I
AR54.25-P-
2803I
MODEL 215, 220, 230.4
Removing and installing light AR54.25-P-
MODEL 215
module 3260N
MODEL 215, 220
cluster 6015I
MODEL 215, 220
MODEL 215
temperature indicator sensor 6341N
AR54.35-P-
Removing and installing claxon MODEL 215
1555N
instrument panel
rear dome lamp
Removing and installing Parktronic MODEL 215 with CODE (220a) Parktronic System AR54.65-P-
System (PTS) switch (PTS) 0005N
(DTR) 0001I
MODEL 220

MODEL 215, 220
AR54.10-P-
0005I
MODEL 215, 220
MODEL 215, 220, 230
consumption 1030I
AR54.10-P-
1129I
AR54.10-P-
1130I
MODEL 163, 164, 168, 169, 170, 171, 203, 204,
208, 209, 211, 215, 216, 219, 220, 221, 230, 240,
245, 251, 414 ...
AR54.15-P-
1257I
left front
AR54.15-P-
1258I
right front
AR54.18-P-
Install headliner wiring harness MODEL 220.0 /1 except code (494a) USA version
0020M
Install headliner wiring harness MODEL 220.0 /1 with CODE (494a) USA version AR54.18-P-
0020MA
AR54.18-P-
0056M
AR54.18-P-
0100IA
AR54.18-P-
0100IB
MODEL 124, 126, 129, 140, 163, 164, 168, 169,
Repair supplemental restraint 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, AR54.18-P-
system (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,
AR54.21-P-
0014Y
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0014Z
230, 240, 245, 251, 461, 463 ...
MODEL 129, 163, 164, 168, 169, 170, 171, 199,
AR54.21-P-
0015X
230, 240, 245, 251, 450, 451, 452, 454, 461, 463 ...
MODEL 215, 220
AR54.21-P-
1259I
box in rear
AR54.21-P-
1260I
box, front left
AR54.21-P-
1261I
box, front right
Removing and installing upper AR54.21-P-
MODEL 220
control panel control module 1262M
AR54.25-P-
2800I
MODEL 215, 220, 230
module 2802I
AR54.25-P-
2803I
MODEL 215, 220, 230.4
Remove/install light module MODEL 220 AR54.25-P-
3260I
MODEL 215, 220
cluster 6015I
MODEL 215, 220
Remove/install outside temperature AR54.30-P-
MODEL 220
indicator sensor 6341I
Removing and installing fanfare AR54.35-P-
MODEL 220
horns 1555I
instrument panel
rear dome lamp
Removing and installing Parktronic MODEL 220 with CODE (220a) Parktronic system AR54.65-P-
system (PTS) switch (PTS) 0005I
(DTR) 0001I
DISCONNECTING AND CONNECTING GROUND CABLE AT BATTERY - AR54.10-P-0003I
MODEL 215, 220
Shown on model 220

Fig. 1: Identifying Ground Cable - Shown On Model 220

1 Fold back trunk cover
2
Loosen nut (2) and disconnect
3
ground lead (1) from battery
Perform work described below only if
4 Connect ground lead quiescent current retention unit was not
connected
5 Code radio Owner's Manual
6 Set time on instrument cluster
AR46.10-P-
7 Activate steering angle sensor
0300-01I
8 Synchronize power windows Owner's Manual
9 Synchronize sliding/pop-up roof Owner's Manual
10 Synchronize jacket tube module
REMOVING AND INSTALLING BATTERY - AR54.10-P-0005I
MODEL 215, 220
Shown on model 220

Fig. 2: Identifying Battery Remove/Install Components - Shown On Model 220
Explosion hazard from
explosive gas. Danger of
poisoning and acid burns when Flames, sparks, open light and smoking
battery acid is swallowed. prohibited. Wear acid resistant gloves, clothing AS54.10-Z-
Danger of acid burns to skin and goggles. Store battery acid only in suitable, 0001-01A
and eyes from battery acid or appropriately marked containers.
when handling damaged lead-
acid batteries.
AH54.10-P-
Notes on batteries All models
0001-01A
1 Remove ignition key
2 Pivot trunk cover up
3
holder
4
Disconnect ground lead (3) from
5
battery
Remove gas vent line (5) from Installation: Ensure that gas vent line is
6
battery (G1) routed through the line passage to the outside
Remove positive pole cover (4)
7
upward
Disconnect positive lead (2) from
8
battery
9 Remove battery (G1)
10 Install in opposite order Connect positive lead (2) first, then ground
lead (3)
TREATMENT OF BATTERY IF VEHICLE TAKEN OUT OF SERVICE - AR54.10-P-0006I
MODEL 215, 220

Risk of explosion caused by oxyhydrogen gas. Risk
smoking.
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 eyes from battery acid or when
AR54.10-
1 Check battery, charge battery if necessary
P-1129I
When the vehicle is laid up for
more than 4 weeks. This prevents AR54.10-
2.1 Disconnect battery ground cable
the battery being discharged by P-0003I
closed-circuit accessories.
When battery is disconnected
every 6 months at the latest and AR54.10-
3 Charge battery
when the battery is connected P-1130I
every 6 weeks at the latest.
CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P-1030I
MODEL 215, 220, 230
Check
1 Open luggage compartment lid
Preparing test with quiescent AR54.10-P-1030-
2.1
*WH58.30-Z-
Multimeter 1001-09A
*WH58.30-Z-
Quiescent current retention unit CMP 12.2 1012-09A
Prepare test without quiescent AR54.10-P-1030-
2.2
*WH58.30-Z-
Multimeter 1001-09A
 Withdraw ignition key
 Switch off stationary heater
 Switch off car phone
 Switch off interior motion sensor
 Switch off make-up mirror
 Switch off reading light
 Turn exterior lamp switch to "0" position
 Close doors
3 Switch off all consumers
The interior lights must go out automatically

after a few seconds.
 Switch off radio

 With COMAND:
Remove CD-ROM from COMAND and

switch off COMAND.
4 Check quiescent current AR54.10-P-1030-03I
If specification for total quiescent current is not 1001-09A
achieved: ?
Determine circuit with excessive quiescent AR54.10-P-1030-
current consumption 04I
Establish fused components with excessive AR54.10-P-1030-
Establishing unfused components with excessive AR54.10-P-1030-
*WH58.30-Z-
Multimeter 1001-09A
AR54.10-P-1030-
To check, re-test quiescent current 03I
*WH58.30-Z-
Multimeter 1001-09A

Number Designation
Preparing test with quiescent current retention unit - AR54.10-P-1030-01I


Number Designation
Work procedures shown on model 220

 Connect positive terminal (8) of quiescent current retention unit (7) to the positive lead of the
battery.
 Connect negative terminal (9) of the quiescent current retention unit (7) to ground (battery) (W10).
Fig. 7: Identifying Quiescent Current Retention Unit, Positive And Negative Terminal -
Shows On Model 220
3. Disconnect negative terminal (1) from battery.

4. Connect the multimeter as follows; use the "electrical connection kit" for this purpose:
 Connect positive test cable (+) to negative battery cable (1).
 Connect negative test cable (-) to negative battery terminal (3).

Fig. 8: Identifying Battery Cable And Terminals
5. Switch on multimeter (2) (do not select measuring range in amp(s) too small. When the central locking
6. Switch off and disconnect quiescent current retention unit.
7. Take multimeter (2) out of the luggage compartment.
8. Close trunk lid.
Prepare test without quiescent current retention unit - AR54.10-P-1030-02I

Number Designation
Do not disconnect the negative terminal clip!
1. Loosen the negative terminal clip (1) nut on the battery .

2. Prepare multimeter for the test; use "electrical connection set" for this purpose.
3. Connect measurement cable, positive (+) to ground (battery) (W10).
4. Switch on multimeter (do not select measuring range in amp(s) too small. When the central locking
5. After fastening the measurement cable, negative (-) to negative terminal, disconnect the negative terminal
clip (1).
Fig. 11: Identifying Negative Terminal Clip And Ground (Battery)
6. Carefully pull negative terminal clip (1) on the battery upwards and in the process simultaneously connect
the measurement cable, negative (-) to the negative terminal under the negative terminal clip (1).
Do not break the circuit when detaching the negative terminal clip otherwise any existing faults will be
erased. Remove the negative terminal clip completely only after the multimeter test cable is firmly
clipped to the negative terminal.
7. Take the multimeter (2) with measurement cable (6) out of the luggage compartment to the right.
8. Close trunk lid.
Check quiescent current - AR54.10-P-1030-03I


Number Designation
Observe the limits of the multimeter connected for current measurements. When the central locking system
operates, a current of about 20 A flows .
Do not activate any other electrical components during the test otherwise observe a renewed run-on time of
about 20 minutes.
Carry out procedure 2.
Carry out procedure.
Display >0.050 A : ? Note value displayed and determine circuit with increased quiescent current consumption.
Determine circuit with excessive quiescent current consumption - AR54.10-P-1030-04I


Number Designation
Fig. 17: Identifying Multimeter Components
1. Check trunk illumination, if necessary replace defective parts and close trunk lid.
2. Unclip trunk illumination, detach insulated cable lugs and measure power consumption with multimeter
(measuring range in amp (s)).
After testing observe renewed run-on time of approx. 20 minutes.
Total quiescent current q0.050A achieved, end of test.

Specified value Total specified current not achieved: ?
3. Open fuse box in engine compartment (driver/front passenger) and fuse panel in rear (panel in rear right
footwell illumination).
With measurements on the fuse box in the rear, observe that the door contact switch is operated (e.g.
with adhesive tape).
4. On vehicles with code (551a) anti-theft alarm system (ATA), operate engine hood contact (e.g. with
adhesive tape).
5. Open overvoltage protection cover.
6. Lock vehicle.
Observe Up-to-date Information (AI) bulletin! First of all, check circuits of the components which are
listed in the Information Update.
7. Connect measurement cable (6) and test adapter (13) to a second multimeter (12) (measuring range in
amp(s)).
Remove the fuse for the ELECTRONIC ALARM SYSTEM only on unlocked vehicles (alarm signal).
8. Remove the first fuse and connect the second multimeter and read the standby current after 5 seconds.
Standby current q0.020A (20 mA):
The fuse-protected circuit is in order.
9. Insert fuse again and wait for 5 seconds.

10. Check quiescent current consumption at all fuses.
After inserting the fuse or test adapter, the connected components can briefly exhibit an increased
quiescent current, the radio up to 0.240 A (240 mA). By switching the radio on and off the standby
current draw is raised.
Standby current >0.020A (20 mA):
Wait for 20 minutes, then read off again.
The fused circuit is faulty: ?
Determine fuse-protected components with increased quiescent current consumption.

The specific value of the entire standby current is not achieved: ?
Determine non-fuse protected components with increased quiescent current consumption.
Establish fused components with excessive quiescent current consumption - AR54.10-P-1030-05I
Fuse assignment, as-built configuration 215/220 GF54.15-P-1256I

230.4 GF54.15-P-1256R
Relay assignment, production details 215/220 GF54.15-P-1257I
230.4 GF54.15-P-1257R

Number Designation
1. Determine possible standby current consumers on the problem fuses.
Refer to assignment and cable connections of fuse blocks, insertion sheet or "Wiring Diagrams Model
215/220/230".
Obtain the location of components from the "Wiring diagrams 215, 220, 230" or STAR diagnosis.
2. Unplug connector at the possible quiescent current consumer.

3. Read the standby current on the second multimeter.
If measurements are to be made at the radio fuse or if the radio coupling is disconnected, it must be
observed that the quiescent current consumption rises by approx. 0.240 A (240 mA) when the radio is
reconnected. By switching the radio on and off the standby current draw is raised.
current of approx. 800 mA occurs for the duration of the computer run-up (approx. 20 minutes). This also
applies when the coupling is separated from the computer and connected again.
Standby current >0,020 A (20 mA):
Quiescent current error remains after disconnecting the connector. Component is okay, fit connector in
again at the component tested.
4. Carry out checking as described with all components at the fuse about which there has been a complaint.
Standby current < or =0,020 A (20 mA):
Quiescent current error is rectified after disconnecting the connector of the relevant component.
Component is defective, replace: ?
5. To be sure check the total standby current again.
Establishing unfused components with excessive quiescent current consumption - AR54.10-P-1030-06I

Number Designation
1. Determine non-fuse protected components, they are for example:

 Consumers of the exhaust gas recirculation (EGR) assembly
 Consumers of the airbag assembly (AB)
 Consumers of the anti-knock control (AKC) assembly
 Consumers of the electronic ignition system assembly
 Devices for protecting against breaking and entering and theft, e.g. anti-theft alarm system (ATA).
 Consumers of the idle speed control (ISC) assembly and
 Alternator, starter, ignition switch.
See "Wiring diagrams, models 215, 220, 230" or STAR diagnosis. Observe run-on time for electronic
components: approx. 20 minutes.
2. Read and note the value of the total standby current on the multimeter that is connected to the battery.
3. Separate coupling or connection on potential closed-circuit accessories and tie back in a manner which
avoids contact if necessary.
The radio may cause quiescent-current consumption to increase by approx. 0.240 A (240 mA). By
switching the radio on and off the standby current draw is raised.
On vehicles with navigation system after the navigation computer is connected an increased quiescent
4. Read and note total standby current on the multimeter.
Is there a decrease in the standby current < or =0,020A ( 20 mA): Component is OK.
5. Connect coupling or connection to component again.

6. Repeat testing with all closed-circuit accessories as described.
If the drop in quiescent current >0.020A (20 mA):
7. Replace component. To check, re-test quiescent current.
Connecting and disconnecting quiescent current retention unit - AR54.10-P-1030-07I
Quiescent current retention unit, refer to GOTIS:

Connect positive terminal (8) of quiescent current retention unit to positive cable of battery.
 Connect negative terminal (9) of the quiescent current retention unit to battery ground (W10).
3. Disconnect negative terminal at battery and insulate negative terminal with insulation tape.
4. Disconnect positive terminal at battery (only if battery is removed).
Fig. 22: Identifying Quiescent Current Retention Unit, Positive And Negative Terminal Shows On
Model 220
CHECK CONDITION OF BATTERY - AR54.10-P-1129I
MODEL 215, 220, 230
MODIFICATION NOTES
25.4.07 Check fluid level with service fill level indicator added Step 5.2
Removing
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.
AH54.10-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
Unhook trunk retractable Model 230 to test on-board electrical system
1
partition battery.
2 Remove spare tire cover For checking the on-board electrical system battery.
3 Open engine hood and move to Model 230 to test starter battery. AR88.40-
vertical position P-1000R
Check
Visually inspect battery for If leaks are found, replace battery, see: ?
4
external leaks Remove/install battery
AR54.10-
Model 215, 220
P-0005I
AR54.10-
P-0005RA
AR54.10-
Model 230 starter battery
P-0005RB
OS54.10-
01Z
Check fluid level in battery,
Without service fill level indicator, not on
5.1 replenish with distilled water if
absorbent glass mat battery.
necessary
With service fill level indicator, not on absorbent
glass mat battery.
Fluid check via service fill level indicator, acid
5.2 Check fluid level of battery
level is too low if colored white: Replace battery,
see: ?
Remove/install battery
AR54.10-
Model 215, 220
P-0005I
AR54.10-
P-0005RA
OS54.10-
01Z
AR54.10-
6 Check battery P-1129-
01A
Cold cranking amps as per EN *BE54.10-
Midtronics battery tester with test clamps P-1002-
http://gotis.aftersales.daimlerchrysler.com 01A
On a battery that is disconnected from the onboard
electrical system and with the message "Surface
voltage" in the display of the Midtronics battery
AR54.10-
Reduce increased voltage after tester.
7 P-1129-
charging process Midtronics battery tester Volt/amp tester
03A
After reducing increased voltage, test battery
again.
8 Charge battery With the test code "Charge and check" on the
Midtronics battery tester. AR54.10-
After charging, test battery again. P-1130I
Install
AR88.40-
9 Close engine hood Model 230 after test of starter battery.
P-1000R
After checking the on-board electrical system
10 Install spare tire cover
battery.
Install trunk retractable Model 230 after test of on-board electrical system
11
partition battery.



Number Designation 70 Ah VRLA 74 Ah 80 Ah VRLA 84 Ah

Check battery; Risk of injury - AR54.10-P-1129-01A

by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses.
swallowing battery acid. Only pour battery acid
Risk of injury caused by into suitable and
burns to skin and eyes appropriately marked
from battery acid or when containers.
handling damaged lead-
acid batteries
Reduce increased voltage AR54.10-P-1129-03A
after charging process
MODIFICATION NOTES
24.2.06 Cold test current 12 Ah *BE54.10-P-1002-01A
1002-01A current

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. 23: Identifying Clip Tester

 In vehicle (battery connected to on-board electrical system)
 Not in vehicle (battery disconnected from on-board electrical system) Confirm selection with
"Enter".
Fig. 24: Screen Display - In Vehicle And Not In Vehicle

 12 - 114 AH (battery capacity 12 -114 Ah)
 115 AH > (capacity of battery < or = 115 Ah)
Fig. 25: Screen Display - 12 - 114 AH And 115 AH
4. Follow menu and select battery type:

 Normal
 VRLA
Fig. 26: 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. 27: 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. 28: 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.

 Cars
 Taxi
Fig. 29: Screen Display - Cars And Taxi

 > 0°C
 < 0°C

If this message appears, the battery condition cannot be evaluated.
Fig. 30: Screen Display - Above 0 Degrees C And Below 0 Degrees C

 Before charge
 After charge
Fig. 31: 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.
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 No fire, sparks, open AS54.10-Z-0001-01A

poisoning and caustic flames or smoking. Wear
burns Risk of injury 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. 32: Identifying Volt-Amp(S)-Tester, Operating Lever, Knob, Clamps And Terminal
CHARGE BATTERY - AR54.10-P-1130I
MODEL 215, 220, 230
Checking
smoking. Wear acid-resistant gloves, AS54.10-
caused by swallowing battery acid. Risk of
clothing and safety glasses. Only pour Z-0001-
injury caused by burns to skin and eyes
battery acid into suitable and 01A
from battery acid or when handling damaged
lead-acid batteries
AR54.10-
1 Check condition of battery
P-1129I
Charging
Do not reverse polarity. Risk
of short circuit! Ensure that the vent
hose and battery stop plugs are
2 Connect charger to battery
installed in the correct position,
otherwise escaping battery acid will
damage the vehicle.
Normal charging: charging current
max. 10 % of battery capacity : e.g.
3 Charge battery max.
battery.
Rapid charging: charging current max.
50 % of battery capacity for 30 min:
e.g. max.
battery.
AF54.10-
Problems with charging battery Only with AGM battery. P-6005A
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-1129I
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 Model 203 up to 31.5.02 01A
a 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.
2.2 Check battery Model 164, 169, 171, 211.2, 211.6, 219, AR54.10-P-1129-
voltage by means of 240, 245, 251 02A
the instrument cluster
(IC)
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
CHECK CHARGE STATE OF BATTERY - AR54.10-P-1136-01A
Test instructions for disconnected battery:
 Connect the digital multimeter to the battery and read off the voltage.
 Voltage: > or = 12.5 V Battery OK

 Voltage: < 12.5 V Charge battery
 After charging, remove the surface voltage of the battery. To do so, switch on the driving lights for
approx. 60 s.
In the case of batteries disconnected from the on-board electrical system, the procedure for removal of the
surface voltage is described in a separate document (pay attention to the literature).
Generally, the following guideline values (ambient temperature approx. 20 °C) apply in the case of open
circuit voltage measurement without current load (disconnected or removed battery):
Voltage Capacity
> or = 12.7 V 100%
12.5 to 12.6 V 80%
12.2 to 12.4 V 50%
12.0 to 12.1 V 30%
11.5 to 11.7 V 0%
< 10.5 V deep discharged
REMOVING AND INSTALLING FUSE AND RELAY BOX IN ENGINE COMPARTMENT, LEFT
FRONT - AR54.15-P-1257I
Models 215, 220
Shows model 220
Fig. 33: Identifying Fuse And Relay Box Remove/Install Components, Left Front - Shown On Model 220
Remove/Install
AR54.10-P-
1030-07I
AR54.10-P-
0003I
AR88.40-P-
3 Open engine hood and position upright
1000M
Unlock and remove cover (1) of left fuse
4
box (F1)
Remove left SAM control unit (N10/6) AR54.21-P-
5
with left fuse and relay module (K40/6) 1260I
Remove AIRmatic with ADS control unit Model 220 except code (487a) AR32.22-P-
6.1
(N51) Active Body Control (ABC) 6000I
Active body control (ABC)N51/2, control Model 215, 220 with CODE AR32.50-P-
6.2
unit (487a) Active body control (ABC) 0023I
Remove traction system control unit AR54.21-P-
7
(N47) 0816I
Remove cover below left of instrument AR68.10-P-
8 Model 220
panel 1500M
AR68.10-P-
Model 215 1500N
AR30.12-P-
9 Remove accelerator pedal
1321I
10 Remove floor lining on driver's side
Loosen line to accelerator pedal from
11
vehicle floor and pull back to left fuse box
AR82.30-P-
12 Remove wiper arms
6100M
Remove water deflector above wiper AR83.25-P-
13
system 1406M
Separate separable cable ducts inside the
14
left fuse box
Pull back the remaining wiring harnesses
15
to the left fuse box
Installation: Check gasket on
Unscrew bolts (2) and remove left fuse
16 cable duct of fuse box/vehicle
box
interior
REMOVING AND INSTALLING FUSE AND RELAY BOX IN ENGINE COMPARTMENT AT

RIGHT FRONT - AR54.15-P-1258I
MODEL 215, 220
Shown on model 220

Fig. 34: Identifying Fuse And Relay Box Remove/Install Components, Right Front - Shown On Model
220
AR54.10-P-
1030-07I
AR54.10-P-
0003I
Open engine hood and move to upright AR88.40-P-
3
position 1000M
Release and remove cover (1) on left fuse
4
box (F1)
AR07.08-P-
5 Remove CFI control module (N3)
7008I
Remove right SAM control module
AR54.21-P-
6 (N10/7) with right front fuse and relay
1261I
module (K40/7)
AR27.19-P-
7 Remove ETC control module (N15/3)
1719I
8 Remove vent tube (3)
Pull wiring harnesses back to right fuse
9
box (F1/1)
Installation: Check seal on wire
10 Unscrew screws (2) and remove fuse box passage from fuse box/vehicle
interior
INSTALL HEADLINER WIRING HARNESS - AR54.18-P-0020
Install headliner wiring harness - AR54.18-P-0020MA
MODEL 220.0 /1 with CODE (494a) USA version
Shown on model 220.1 with code (414a) electric glass tilting/sliding roof and code (220a) Parktronic
system and code (882b) interior monitoring (only with anti-theft alarm system)
Fig. 35: Overview Of Headliner Wiring Harness - Shown On Model 220.1 With Code (414a, 220a And
882b)
Shown on model 220.1 with code (414a) Electric glass tilting/sliding roof
Fig. 36: Overview Of Headliner Wiring Harness - Shown On Model 220.1 With Code (414a) Electric
Glass Tilting/Sliding Roof
Install
A new main wiring harness (2) must only
be installed when replacing the headliner
(1). On vehicles with ribbon cable the
relevant normal main wiring harness (2)
must be used. The headliner model
refinement was only carried out from
September 2002 to January 2003.
Do not use any hard or sharp-
edged objects, otherwise the covering of
Support the new headliner (1) with
the new headliner (1) will be damaged.
2 suitable clean spacers, e.g. foamed
material or styrofoam blocks. This prevents the new headliner (1)
from bending during the following
steps.
3
installation frame.
4
Unclip covering from left and right sun
5
visor pivot bearing (4)
Install left and right sun visor pivot
6 bearing (4) in headliner (1) and clip in
covering.
7 using approx. 10 cm strips of adhesive
tape (Tesaband 4657) positioned approx.
10 cm apart as illustrated.
*BR00.45-
Tesaband 4657
Z-1071-02A
(2) at C-pillar of old headliner (1) and
8
ensure new main wiring harness (2) hangs
over the same distance.
Route new main wiring harness (2)
Do not cross main wiring
starting at C-pillar on new headliner (1)
harness (2) and cable set attachments
and in impact absorbers (11) and secure
9 and press down strips of adhesive tape
using approx. 10 cm strips of adhesive
well otherwise short circuit can occur
tape (Tesaband 4657) positioned approx.
due to chafing.
10 cm apart as illustrated.
*BR00.45-
Tesaband 4657
Z-1071-02A
motion sensor transmitter and receiver Begin routing at wiring connector
(10) and fasten to headliner (1) using (9), route excessive lengths in loops at
10
approx. 10 cm strips of adhesive tape main wiring harness (2) and secure
(Tesaband 4657) positioned approx. 10 cm using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
11.1 interior monitoring (only with anti-theft
transmitter and receiver (10) to headliner
alarm system)
(1) using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Route cable set attachment for rear dome
12 lamp PTS warning indicator (7) and fasten Begin routing at wiring connector
to headliner (1) using approx. 10 cm strips (8), route excessive lengths in loops at
of adhesive tape (Tesaband 4657) main wiring harness (2) and secure
positioned approx. 10 cm apart as using Tesaband 4657
illustrated.
*BR00.45-
Tesaband 4657
Z-1071-02A
attachment for rear dome lamp PTS Vehicles without code (220a) Parktronic
13.1
warning indicator (7) to headliner (1) system (PTS)
using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Except model 220.0 with code (414a)
Route cable set attachment for dome lamp Electric glass tilting/sliding roof
in rear (5) on left and right and fasten to Begin routing at wiring connector
14.1
headliner (1) using approx. 10 cm strips of (6), route excessive lengths in loops at
adhesive tape (Tesaband 4657) main wiring harness (2) and secure
using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Guide cable set attachment for dome lamp
in rear (5) on left and right underneath
metal frame for tilting/sliding roof (12) On model 220.0 with code (414a)
14.2
and secure to headliner (1) with strips of Electric glass tilting/sliding roof
adhesive tape (13) (Tesaband 4657) below
metal frame for tilting/sliding roof (12)
Press down strips of adhesive
tape well otherwise cable set attachment
for dome lamp in rear (5) on left and
right touches metal frame for
tilting/sliding roof (12) after dome
lamps have been installed and short
circuit can occur due to chafing.
Begin routing at wiring connector
(6), route excessive lengths in loops at
main wiring harness (2) and secure
using Tesaband 4657
*BR00.45-
Tesaband 4657
Z-1071-02A
Connect up connector (14) of main wiring Connector (14) and coupling (15)
15 harness (2) and coupling (15) of vanity have distinct designs and are color
mirror illumination wiring harness (3) coded.
AR68.30-P-
4305M
REPAIR MATERIALS
Install headliner wiring harness - AR54.18-P-0020N
MODEL 215
Install
installed when replacing the headliner (1).
Do not use any hard or
sharp-edged objects, otherwise the
Support the new headliner (1) with suitable covering of the new headliner (1) will
2 clean spacers, e.g. foamed material or be damaged.
styrofoam blocks. This prevents the new headliner
(1) from bending during the
following steps.
3
installation frame.
4
5
pivot bearing (7)
Install left and right sun visor pivot bearing
6
(7) in headliner (1) and clip in covering.
*BR00.45-
Tesaband 4657
Z-1071-02A
(2) at C-pillar of old headliner (1) and
8
ensure new main wiring harness (2) hangs
over the same distance.
Route new main wiring harness (2) starting
Do not cross wiring
at C-pillar of new headliner (1) and fasten to
9 harnesses and press down strips of
headliner (1) using approx. 10 cm strips of
adhesive tape well otherwise short
adhesive tape (Tesaband 4657) positioned
circuit can occur due to chafing.
Do not fasten cable set attachment

for rear dome lamp PTS warning
indicator with wiring connector (3)
from main wiring harness (2) to
headliner (1) with strips of adhesive
tape.
*BR00.45-
Tesaband 4657
Z-1071-02A
motion sensor transmitter and receiver (4)
and fasten to new headliner (1) using
10
approx. 10 cm strips of adhesive tape
*BR00.45-
Tesaband 4657
Z-1071-02A
11.1 interior monitoring (only with anti-
theft alarm system)
using Tesaband 4657
Connect up connector (9) of main wiring Connector (9) and coupling (8)
12 harness (2) and coupling (8) of vanity mirror have distinct designs and are color
illumination wiring harness (6) coded.
AR68.30-P-
4305N
REPAIR MATERIALS
INSTALL CABLE HARNESS - AR54.18-P-0056M
MODEL 215.373 /374 /376 /378, 220.073 /074 /173 /174 /176 /178 /878 with CODE (494) USA version
Fuel pump wiring harness conversion
Shown on model 220.0 with code 282 (Ski bag (through-loading feature))
Fig. 39: Identifying Cable Harness Install Components - Shown On Model 220.0 With Code 282 (Ski Bag
(Through-Loading Feature))
Fig. 40: Identifying Cable Harness Install Components - Illustrated On Model 220.0
Fig. 41: Identifying Fuel Pump Wiring Harness, Control Unit Bracket, Rear Sam Control Unit With
Connectors - Shown On Model 220.0
Fig. 42: Identifying Wiring Harness, Fuel Pump And Connector - Illustrated On Model 220.0
Removal
Model 220.0/1 without code (223) electrically
1.1 Remove rear seat backrest
electrically adjustable individual rear seats, with seat P-1620MA
Model 215.3 1620MP
Remove seat adjustment rear bench seat or with code (224) Electrically
mechanism of left and right adjustable individual rear seats, with seat ventilation,
AR91.12-
2.1 rear seat cushion seat heater and memory package, or model 220.878
P-1520M
with Vis-a-vis seats
Remove armrest from rear- rear bench seat or with code (224) Electrically AR91.12-
3.1
seat backrest. adjustable individual rear seats, with seat ventilation, P-1745MB
AR91.12-P-
Model 220.878 with Vis-a-vis seats
1745MP
Remove stowage box AR91.12-
and memory package
AR91.12-
Model 215.3
P-1760N
Unscrew bolts (2) and pull
housing (3) forwards.
Loosen damping material
(4) from partition wall, fold
6
and place at top behind
head restraints in rear.
Remove expansion clips
7 (5) and take damping
material (6) out of vehicle.
Connect no load current AR54.10-
8
retention unit P-1030-07I
Disconnect battery ground AR54.10-
9
cable P-0003I
Remove right side cover in AR68.30-
10 Model 215.3, 220.0/1
the trunk P-4600M
AR68.30-P-
Model 220.8
4600MP
Install
Connect fuse holder (7) to
relay holder (8), position
on the partition wall (9)
11 above the tank filler pipe
(14) and mark the position
of the bore hole (arrow A)
for the relay holder (8)
Unscrew nut (10), remove
right (A2/35a2) antenna
12.1 On vehicles with code (889) Keyless go.
element and place to one
side.
Use 4mm dia. drill bit and afterwards remove drill
shavings.
Drill hole (arrow A) for Cordless drill/driver, wet/dry vacuum cleaner see
13
relay holder (8). GOTIS
Secure relay holder (8) to
14 partition wall (9) using bolt
(11).
Fit new fuel pump relay in
The new fuel pump relay is included in the parts kit
15 socket base of relay holder
for the fuel pump wiring harness (1).
(8).
16 circuit 30Z terminal block
and fuse box (X4/22).
Fit connection eyelet at
*BA54.10-
(1) on circuit 30Z terminal
17 P-1016-
block and fuse box (X4/22)
01C
and secure tightly using nut
(12).
Route ground connection
of fuel pump wiring
Route ground connection of fuel pump wiring
harness (1) along existing
18 harness (1) free of tension and fix in place using cable
wiring harness to ground
ties.
(right taillamp in luggage
compartment) (W7/1).
ground (right taillamp in
19
luggage compartment)
(W7/1).
Fit ground connection of
*BA54.10-
(1) on ground (right
20 P-1015-
taillamp in luggage
01C
compartment) (W7/1) and
secure using nut (13).
for fuel pump (1) out of the
luggage compartment,
Route fuel pump wiring harness (1) free of tension
21 below the tank filler pipe
and fix in place using cable ties.
(14) along the existing
wiring harness into the
vehicle interior
In vehicle interior, remove
22 nut (16) and bolt (15) at
control unit holder (17).
Remove control unit holder
(17) and place in rear
23
footwell.
The rear SAM control unit (N10/8) is located below
24 from rear SAM control unit
the control unit holder (17).
(N10/8).
Unpin pin 13 (arrow B) and
Color of the line to the pin 13 (arrow B), red/blue.
25 pin 14 (arrow C) at
Color of the line to pin 14 (arrow C), green/black.
connector (18).
Fig. 43
Fig. 44
Unpin pin 11 at connector Model 215.374, 220.074/174
26.1
(18). Color of line to pin 11, blue/white.
Fig. 43
Fig. 44
Plug pin 13 (arrow B) into
27 position 2 of connector
The plug (19) is included in the parts kit of the wiring
(19).
harness for the fuel pump (1).
Plug pin 14 (arrow C) into
28 position 1 of the connector
(19).
In models 215.374, 220.074/174
Pin the pin 11 into the slot
29.1 The relevant position number can be seen on the
3 of plug (19)
30 to rear SAM control unit
(N10/8).
31 to fuel pump wiring
harness (1).
for the fuel pump (1)
unstressed, along the Route fuel pump wiring harness (1) in a straight line
32 existing wiring harness to near center tunnel and fix in place using suitable, self-
the left side of the vehicle adhesive felt strips.
and fix in position with
cable ties
platform and position the four support plates at the AS00.00-Z-
lifting platform support points specified by the vehicle 0010-01A
manufacturer.
Raise vehicle with lifting Only lift so far that the interior, right-hand side of
33
platform vehicle, is still accessible from outside.
Only loosen the cover (20)

of the fuel pump (M3) until
34 the plug (21) on the fuel The cover (20) is fastened with three nuts.
pump (M3) is accessible
and pull wiring harness
35
(22) with grommet (23)
into vehicle interior.
Guide fuel pump wiring Moisten the grommet (23) on the wiring harness for
36 harness (1) outwards the fuel pump (1) with antifriction agent and position
through body floor. correctly.
*BR00.45-
Antifriction agent Z-1010-
06A
Connect the connector at
fuel pump wiring harness The cover (20) of the fuel pump (M3) is secured by
37
(1) to fuel pump (M3) and three nuts.
install cover (20).
Lower vehicle with lifting
38
platform
Strap down connector (21)
at wiring harness (22)
39
using suitable insulation
tape.
Route fuel pump wiring
harness (1) in vehicle
Right side of vehicle
40 interior along existing
wiring harness and fix in Route fuel pump wiring harness (1) free of tension.
place using cable ties.
Position right antenna
element (A2/35a2) and
41.1 On vehicles with code (889) Keyless go
secure in place using nut
(10).
Install right side paneling AR68.30-
42 Model 215.3, 220.0/1
in luggage compartment P-4600M
AR68.30-P-
Model 220.8
4600MP
Position damping material
43 (6) in vehicle and install Replace damaged expansion clips (5)
expansion clips (5).
Secure damping material
44
(4) to partition wall.
Connect ground cable to AR54.10-
45
battery P-0003I
Disconnect quiescent AR54.10-
46
current retention device P-1030-07I
Position the housing (3)
and tighten with bolts (2)
Install stowage box AR91.12-
and memory package
AR91.12-
Model 215.3
P-1760N
Install armrest at rear seat rear bench seat or with code (224) Electrically AR91.12-
49.1
backrest adjustable individual rear seats, with seat ventilation, P-1745MB
AR91.12-P-
With model 220.878 with Vis-a-vis seats
1745MP
Install seat adjustment rear bench seat or with code (224) Electrically
AR91.12-
P-1520M
rear seat cushion seat heater and memory package or model 220.878 with
Vis-a-vis seats
Model 220.0/1 without code (223) Electrically
51.1 Install rear seat backrest
Electrically adjustable individual rear seats, with seat P-1620MA
Model 215.3 1620MP
Remove fuse 52 originally
installed for fuel pump
52
relay from previous
installation location
Fuse assignment of rear
fuse and relay box
GF54.15-
P-1256-
date up to 31.8.02
01IH
31.8.03 01JH
31.5.04 01KH
GF54.15-
P-1256-
date as of 1.6.04
01LH
Remove originally installed
53 fuel pump relay from
previous installation
GF54.15-
Relay assignment of rear
P-1257-
fuse and relay box
01IH
Document new installation
location of relay holder (8) Cut out the view in the document and enclose the
54 for fuel pump relay and folding sheet of the fuse and relay assignment of the
fuse holder (7) in vehicle fuse and relay box in the rear.
documentation.
Fuse and relay assignment GF54.15-
of fuse and relay holder in P-1257-
luggage compartment 10M
BATTERY
BA54.10-P-1015-01C Nut to ground (taillamp in luggage compartment) M6 Nm 7 7
BA54.10-P-1016-01C Nut to circuit 30Z terminal block and fuse box M10 Nm 14 14
Fig. 43: Identifying Blade Holder With Clamping Pliers (220 589 01 99 50)
Fig. 44: Identifying SLK 2.8 - 97 Blade (220 589 01 99 63)
REPAIR MATERIALS
REPAIRING WIRING HARNESS - AR54.18-P-0100
Repairing wiring harness - AR54.18-P-0100IA
MODEL 215 with ENGINE 113 EC fan wiring harness as of code 802
MODEL 215 with ENGINE 137 EC fan wiring harness
MODEL 220 with ENGINE 112, 113 EC fan wiring harness as of code 802
MODEL 220 with ENGINE 137, 613, 628 EC fan wiring harness
Fig. 45: Identifying Terminal Point With Cutting Area
Removing
1
battery P-0003I
AR82.10-
2 Remove left headlamp unit Model 215
P-4730N
Model 220 except code (612b) Xenon headlamp AR82.10-
unit P-4730M
Model 220 with code (612b) Xenon headlamp AR82.10-
unit P-4730MA
3
suction fan
Expose fan wiring harness
4
branch-off line
Cut open insulation (fabric tape)
5
for a length of approx. 450mm
6 Cut wire (red, 12 mm2 ) in area Use cable shears to cut the wires.
(A)
7 Cut wire (black/violet, 0.5mm2 ) Always cut the individual wires at the parting
2
and wire (yellow/blue, 0.5mm ) point to different lengths.
in area (A)
Cut ground lead (brown,
8
12mm2 ) in area (A) and insulate
Installing
Attach cable lug to wire (red, 12
9
mm2 ) with shrink sleeve
AR00.19-
0.5mm2 ) and wire (yellow/blue,
10 Use green cable connectors. P-0100-
0.5mm2 ) with repair wiring 09A
harness
Fasten terminal point (1) to A/C
11
pipe with two cable straps
Screw wire (red, 12 mm2 ) and
wire from repair wiring harness
12
(red, 12 mm2 ) onto terminal
point (1)
Screw ground lead (brown, 12
13 mm2 ) from repair wiring
bottom left in wheelhousing)
tape
15
and connect to fan
AR82.10-
16 Install left headlamp unit Model 215
P-4730N
unit P-4730M
unit P-4730MA
AR54.10-
P-0003I
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. Refer to: ?
STAR DIAGNOSIS
Repairing wiring harness using soldered terminal sleeve - AR54.18-P-0100-02A

Number Designation
1. Expose damaged cable or connector/socket at an easily accessible point and cut off.
Separate conductors in wiring harness offset by approx. 45 mm.
Fig. 46: Identifying Exposed Damaged Cable Or Connector/Socket At An Easily Accessible Point
2. Cut new cable to size matching the old part.
When cutting to size, allow an additional length of 50 mm for creating loops (cable grip).
3. Remove insulation at ends of cable over 15 mm.

4. Select soldered terminal sleeve according to the table below.
Fig. 47: Identifying Cutting Dimension Of Cable Ends
5. Insert cables into matching soldered terminal sleeve (Z), matching the total cross-section of the cable.
6. Turn soldered terminal sleeve (7) fully onto the cables.
Fig. 48: Turning Soldered Terminal Sleeve Onto Cables
7. Heat soldered terminal sleeve with a hot air gun (approx. 400 °C).
Begin at the tapered side until the soldered ring detaches and the sheathing has moved cleanly
around the cable.
Fig. 49: Heating Soldered Terminal Sleeve Using Hot Air Gun
8. Inspect solder point.
It must no longer be possible to see the soldered ring (1) on the soldered connector sleeve (Z).
The sheathing (2) must be resting cleanly against the cables.
Fig. 50: Identifying Solder Point - Correct/Incorrect

9. Position soldered connector sleeves at cable and wrap fabric tape around repaired area.
Soldered connector sleeves must not be positioned directly one above the other.
Fig. 51: Identifying Soldered Connector
Repairing wiring harness - AR54.18-P-0100IB
MODEL 215 with ENGINE 113 DC fan wiring harness up to code 801
MODEL 220 with ENGINE 112, 113 DC fan wiring harness up to code 801
Removing
1
battery P-0003I
AR82.10-
2 Remove right headlamp unit Model 215
P-4730N
unit P-4730M
unit P-4730MA
3
suction fan
4 Right front.
compartment lining P-1105M
Remove suction fan control
5 Replace suction fan control module (N65/2).
module (N65/2)
Expose fan wiring harness
6
branch-off line
Cut fan wiring harness branch-
7 off line in area of headlamp and Use cable shears to cut the wires.
insulate
Unpin wire (black, 10mm 2 )
8 from right front fuse and relay White 10-pin plug, pin 2.
module (K40/7)
9 Cut wire (black, 10mm2 ) at
branch-off line and insulate
Installing
Pin wire (black, 10mm2 ) from
10 repair wiring harness in right White 10-pin plug, pin 2.
front fuse and relay module
(K40/7)
Attach wire (black, 10mm2 )
11 from repair wiring harness to Do not open the existing wiring harness.
engine wiring harness with cable
straps
AR00.19-
0.5mm2 ) and wire (yellow/blue,
12 Use green cable connectors. P-0100-
0.5mm2 ) with repair wiring 09A
harness
Screw ground lead (brown,
13 10mm2 ) from repair wiring
bottom right in wheelhousing)
tape
Install suction fan control
15
module (N65/2)
16
and connect
AR82.10-
17 Install right headlamp unit Model 215
P-4730N
unit P-4730M
unit P-4730MA
AR54.10-
P-0003I
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. Refer to: ?
STAR DIAGNOSIS
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. 52: Identifying Supplemental Restraint System (SRS) Squib Wiring Harness Components
Remove/install
caused by up; do not expose to temperatures greater than 01A
or repair work on disconnect the power supply.
airbag or
emergency
tensioning
retractor units.
caused by up; do not expose to temperatures greater than 01B
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. 54
New passenger vehicle wiring harness repair Fig. 53
kit
Wire stripper Fig. 56
Reflector Fig. 55
Adapter Fig. 57
Welding bead catcher Fig. 60
Heat gun, see GOTIS
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. 62
5 Install in the
reverse order
Fig. 53: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 54: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 55: Identifying Reflector (220 589 01 99 41)
Fig. 56: Identifying Wire Stripper (220 589 01 99 40)

Fig. 60: Identifying Welding Bead Catcher (129 589 01 98 00)
Checking wiring harness - AR54.18-P-0600-01A
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.
REMOVING AND INSTALLING DISTRONIC CONTROL MODULE - AR54.21-P-0005I
Shown on model 220
Fig. 63: Identifying Distronic Control Module Remove/Install Components - Shown On Model 220
AR54.10-P-
1 Connect quiescent current retention unit Models 215, 220
1030-07I
AR54.10-P-
2 Disconnect ground cable of battery Models 215, 220
0003I
Fold back floor covering in passenger's
3
footwell and remove polystyrene panel
Detach mounting plate (1) in passenger's Hold top of mounting plate
4
footwell and fold out into footwell and fold into footwell.
5 Remove connectors (2a) and connection (2b)
Unscrew bolts (3) and remove DTR control
6 module (N63/1) from mounting plate
8 Perform basic setting with STAR Diagnosis
FLASHING CONTROL UNIT - AR54.21-P-0012-06A
Offline flashing with SD flash release CD

Number Designation
It must be ensured that the DAS-CD/DVD and SDflash Release CD are compatible.
Sequence of flashing when communication has taken place between Diagnosis Assistance System (DAS)
and control unit
1. Select vehicle.
Select main menu, systems and control unit to be flashed.
4. Select control unit menu item "SD flash release CD".
5. Insert SD flash release CD in the disk drive and wait until the disk drive has started up.
Due to possible disk drive errors possible detection faults of the SDflash Release-CD can occur
(observe error message).
Repeat process if required (button F7).
After the disk drive starts up the SDflash Release-CD is checked for new software for the control unit.
Observe corresponding message in DAS.
6. With new software press the button F2 and flash (program) the control unit.
Sequence of flashing when communication (communication error) has not taken place between the DAS
and control unit
Support:
In the event of questions and problems please contact the STAR DIAGNOSIS Call Center.
1. If possible eliminate the cause of the error message using the test steps in the "error messages" menu.
If the cause of the error cannot be determined, please inform the STAR DIAGNOSIS CALL Center hotline.
Replace the control unit following discussion with the hotline.
2.1 Determine part number of control unit and replace control unit.
Only if necessary.
3.1 Select menu item "special functions" in the main menu, select "repair functions", carry out "replace
control unit".
Only if necessary.
SCN CODING - AR54.21-P-0013
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
2. Select the menu item "SCN coding" in the further program run.
Continue with "F3".
3. Select menu item "Online (networked STAR DIAGNOSIS device)".
Continue 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".
"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.
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".
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.
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.
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.
"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".
The starts the interrogation of SCN coding data in the central system.
12. Confirm message about successful SCN generation and coding string formation.
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.
20. Print out the order log with "F11" and enclose the repair order.
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.
SCN coding of the control unit is thus successfully concluded.
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

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
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.
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:
9. Use "F4" to open the "Software Calibration Number" inquiry form.
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.
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
20. Use "F5" to open the request form of SCN repair CD.
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.
25. Insert the SCN Repair-CD in the CD-drive of STAR DIAGNOSIS. Continue with "F3".
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.
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.
"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.
 "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.
35. Confirm note concerning successful SCN generation and coding string formation.
37. Insert CD blank in the CD hot space and burn the data on the CD.
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
39.
1. Enter SCN coding data (SCN, coding string and check digit 2). Continue with "F3".
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.
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.
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014
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
Program control unit - AR54.21-P-0014-01Y
Offline programming with SDflash Release-CD.
1. Select vehicle.
Selection of main menu, systems and select the control unit to be programmed.
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.
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
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

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.
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
REMOVING AND INSTALLING TRACTION SYSTEM CONTROL MODULE - AR54.21-P-0816I
MODEL 215, 220
Shown on model 220

Fig. 64: Identifying Traction System Control Module Remove/Install Components - Shown On Model 220
AR54.10-P-
1030-07I
AR54.10-P-
0003I
AR88.40-P-
3 Open engine hood and move to upright position
1000M
4 Release and remove cover on left fuse box (F1)
Pull slide locks (1a) on both connectors (1) on traction The slide locks are
5 system control module (N47) out to stop in direction of located below the wire
arrow and remove connectors entries
Disconnect data bus connector (2) from traction system
6
control module
Remove traction systems control module (N47) from left
7
fuse box (F1) upwards out of the guides
REMOVING AND INSTALLING SAM CONTROL MODULE WITH FUSE AND RELAY BOX IN
REAR - AR54.21-P-1259I
MODEL 215, 220

Fig. 65: Identifying SAM Control Module Remove/Install Components (Rear) - Shown On Model 220
Shown on model 220
Connect quiescent current retention AR54.10-
1
unit P-1030-07I
Disconnect ground lead from AR54.10-
2
battery P-0003I
AR91.12-
P-1020N
AR91.12-
Model 220
P-1020MA
AR91.12-
3.2 Remove bucket seats Model 220 with code 401, right-hand side only
P-1020M
Remove seat adjustment device on AR91.12-
4.1 Model 220 with code 401, right-hand side only
rear seat P-1520M
Unscrew screws (2) and nuts (1),
5 remove mounting plate (3) from
vehicle floor and pivot toward rear
Pivot arresting lever (5) for power
6
supply (c. 30) up and pull out wire
Unscrew nuts (4) and remove
7 control module unit (rear fuse and
relay module (K40/5) and SAM
control module in rear (N10/8))
from floor
Disconnect connectors from control
module unit (rear fuse and relay
8
module (K40/4) and SAM control
module in rear (N10/8))
GF54.15-
Fuse assignments, standard
P-1256I
GF54.15-
Relay assignments, standard
P-1257I
After pressing the retaining lugs (arrow) in
the direction of the arrow the fuse carriers can
be removed upward.
Unclip fuse carrier (6) from fuse The number of fuse carriers from the fuse
9
and relay module in rear and relay module in the rear can vary
depending on the equipment and vehicle. If
SAM control module in rear or fuse and relay
module in rear are defective: ?
Disconnect SAM control module from fuse AR54.21-
and relay module P-1259-01I
Separating SAM control module from fuse and relay box - AR54.21-P-1259-01I
Shown on rear SAM control module
1. Pry out SAM control module (N10/6, N10/7, N10/8) at the multiple plug of the fuse and relay module
(K40/5, K40/6, K40/7).
To do this drive a suitable screwdriver into the recesses (A, B) and turn screwdriver through 90°.
Observe data plate (2) on the SAM control module
2. Pull down the SAM control module until the control module can be removed from the guides (C, D).
Fig. 66: Identifying SAM Control Module, Data Plate And Guides - Shown On Rear SAM Control
Module
REMOVING AND INSTALLING SAM CONTROL MODULE WITH FUSE AND RELAY BOX,
FRONT LEFT/RIGHT - AR54.21-P-1260
Removing and installing SAM control module with fuse and relay box, front left - AR54.21-P-1260I
MODEL 215, 220

Fig. 67: Identifying SAM Control Module Remove/Install Components (Front Left) - Shown On Model
220
Shown on model 220
Connect quiescent current retention AR54.10-P-
1
unit 1030-07I
AR54.10-P-
0003I
3
Release and remove cover on left
4
fuse box (F1)
Fold up clamping lever (1) and
5
remove supply cable (terminal 30)
GF54.15-P-
1256I
GF54.15-P-
1257I
module unit (driver-side SAM carriers can be taken out from the top.
6
control module (N10/6) with left The components fitted to the left front
front fuse and relay module (K40/6)). fuse and relay module may vary depending
on the equipment.
7
the left front fuse and relay module
Only pull out until the couplings (3)
Pull out control module unit from on control module unit (left front fuse and
8
above relay module (K40/6) and driver-side SAM
control module (N10/6)) are accessible
If driver-side SAM control module or left
9 Unlock and remove couplings (3)
front fuse and relay module are defective: ?
Removing and installing SAM control module with fuse and relay box, front right - AR54.21-P-1261I
MODEL 215, 220

Fig. 68: Identifying Sam Control Module Remove/Install Components (Front Right) - Shown On Model
220
Shown on model 220
AR54.10-P-
1 Connect quiescent retention device
1030-07I
AR54.10-P-
0003I
Open engine hood and position AR88.40-P-
3
upright 1000M
Unlock and remove cover on right
4
fuse box (F1.1)
Fold up clamping lever (1) of supply
5
(terminal 30) and remove cable
GF54.15-P-
1256I
GF54.15-P-
1257I
Unclip fuse carrier (4) on control Once the retaining lugs (arrow) have been
module unit (passenger-side SAM pressed in the direction of the arrow, the fuse
6 carrier can be taken out from the top.
control module (N10/7) with right
front fuse and relay module (K40/7)). The components fitted to the right front
fuse and relay module may vary depending
on the equipment.
7
the front right fuse and relay module
Only pull out until the couplings (3)
Pull out control module unit from on control module unit (right front fuse and
8
above relay module (K40/7) and passenger-side
SAM control module (N10/6)) are accessible
If passenger-side SAM control module or
9 Unlock and remove couplings (3) right front fuse and relay module are
defective: ?
REMOVING, INSTALLING CONTROL MODULE OF UPPER CONTROL PANEL - AR54.21-P-1262
Removing and installing upper control panel control module - AR54.21-P-1262M
MODEL 220
Fig. 69: Identifying Upper Control Panel Control Module, Molding Strip And Screws

1 Molding strip Remove AR68.10-P-1180M
2 Screws Unscrew
Removing, installing control module of upper control panel - AR54.21-P-1262N
MODEL 215
Fig. 70: Identifying Upper Control Panel Control Module, Electric Connection, Cover And Screws

1 Center console cover remove AR68.20-P-2350N
2 Screws unscrew
3 Electrical connector pull off
REMOVE/INSTALL COMBINATION SWITCH - AR54.25-P-2800I
MODEL 215, 220, 230.4

Fig. 71: Identifying Combination Switch Remove/Install Components - Shown On Model 220 With Code
(494) USA Version
MODIFICATION NOTES
Remove/install
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
Disconnect battery AR54.10-P-
2.1 on model 215, 220
ground cable 0003I
Switch off the ignition
Keyless Go start/stop button repeatedly until the
and remove the
2.2 ignition is switched off. Remove the Keyless Go
transmitter card or transmitter key from the vehicle
EIS control unit
and store beyond the reach of the transmitter (min. 2
m).
Remove jacket tube
3 See:?
switch module (1)
AR54.25-P-
2802I

Number Designation
REMOVE/INSTALL STEERING COLUMN MODULE - AR54.25-P-2802I
MODEL 215, 220, 230
Fig. 72: Identifying Steering Column Switch Module, Fanfare Horns And Airbag Clock Spring Contact
Shown on steering column switch module without voice control system
Fig. 73: Identifying Steering Column Switch Module - Shown On Steering Column Switch Module
Without Voice Control System
Remove/install
Remove fanfare horns and airbag Model 215, 220 without code (472) AR46.10-
1.1
clock spring contact (A45) Electronic Stability Program (ESP) P-0200I
Model 230
AR46.10-
1.2 Remove steering angle sensor Model 215, 220 with code (472) Electronic
P-0300I
Stability Program (ESP)
Loosen internal Torx bolt (arrow) and
Internal Torx bolt (arrow) is secured to
2 remove steering column switch
prevent it falling out.
module (1)
On model 215 with code (813) voice
control system the voice control system
switch and the TPM switch (S40) form a
Remove cover (2) and remove cruise common module and cannot be removed
3 control switch (S40) upwards out of individually.
steering column switch module (1) Installation: Ensure that the studs (3) are
seated cleanly in the holes, by paying
attention to the guides on the cruise control
switch (S40).
Remove switch group for steering Installation: Ensure that the studs (3) are
seated cleanly in the holes, by paying
column adjustment and easy
4 attention to the guides on the switch group
entry/exit (S59/1) upwards out of
for steering column adjustment and easy
steering column switch module (1)
entry/exit (S59/1).
5 combination switch (S4) upwards out
of steering column switch module (1)
Remove steering column module
6 (N80) upwards out of steering
column switch module (1)
REMOVE/INSTALL CRUISE CONTROL SWITCH - AR54.25-P-2803I
MODEL 215, 220, 230.4

Fig. 74: Identifying Cruise Control Switch Remove/Install Components - Shown On Model 220 With
Code (494) USA Version
MODIFICATION NOTES
Remove/install
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
2.1 on model 215, 220
ground cable 0003I
and remove the
2.2 ignition is switched off. Remove the Keyless Go
transmitter card or transmitter key from the vehicle
EIS control unit
m).
On model 215 with code (813) voice control system
the voice control system switch and the TPM switch
Remove jacket tube
3 (S40) form a common module and cannot be removed
switch module (1)
individually.
Refer to: ?
AR54.25-P-
2802I

Number Designation
REMOVING AND INSTALLING STEERING COLUMN ADJUSTMENT SWITCH - AR54.25-P-2804I
MODEL 215, 220, 230.4
Fig. 75: Identifying Steering Column Adjustment Switch Remove/Install Components - Shown On Model
220 With Code (494) USA Version
MODIFICATION NOTES
Remove/install
1.1 on model 215, 220
*WH58.30-
Z-1012-09A
2.1 on model 215, 220
ground cable 0003I
ignition is switched off. Remove the Keyless Go
and remove the
2.2 transmitter card or transmitter key from the vehicle
EIS control unit
m).
Remove jacket tube
3 See:?
switch module (1)
AR54.25-P-
2802I

Number Designation
REMOVE/INSTALL LIGHT MODULE - AR54.25-P-3260
Remove/install light module - AR54.25-P-3260I
MODEL 220
Remove, Install
1
retention device 1030-01I
Disconnect ground cable of AR54.10-P-
2 battery 0003I
Pull out release lever for
3
parking brake
4 Unscrew bolts (1)
Remove cover (2) with light Pull parking brake release lever until cover
5 module (N7-1) from folds out of instrument panel in direction of
instrument panel arrow. Observe clips (3).
Release connector (4) and
6
disconnect
Unhook control cable (5) from
7
release lever on parking brake.
Removing and installing light module - AR54.25-P-3260N
MODEL 215
AR54.10-P-
1030-07I
AR54.10-P-
0003I
3
Turn exterior lamp switch onto low beam and pull 1 detent
towards the driver (fog lamp switched on)
Push extractor hook (01) in area of low beam symbol (A) Do not
4 and side light symbol (B) between rotary light switch (1) damage light Fig. 78
and light module cover (2) module
Turn extractor hook through 90° and pull out light module
5
cover
7 Press clips (4) and remove light module (N7-1)
8 Unlock coupling (5) and pull off
Fig. 78: Identifying Extractor Hock (140 589 02 33 00)
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000
Perform adjustments to the control system - AR54.30-P-1000-02OPM
Check engine oil level.
The vehicle must be horizontal for at least 5 minutes with the engine switched off at operating
temperature. Otherwise measurement errors can occur.
Shown on model 220

Fig. 79: Identifying Multifunction Display And Buttons - Shown On Model 220
3. Press the scroll back and forward button (S110s1) repeatedly until "CORRECT MEASUREMENT
ONLY WHEN VEHICLE IS STATIONARY AND ON THE LEVEL" appears in the multifunction
display (A1p13).
After approx. 3 seconds "ENGINE OIL MEASUREMENT RUNNING" is displayed.
4. Refill the engine with the engine oil quantity shown in the multifunction display (A1p13) and check the
engine oil quantity again.
Perform adjustments to the control system - AR54.30-P-1000-02RAM
Activate tire pressure monitor.
Before activating tire pressure monitoring system: correct tire pressure of all wheels.
3. Press the scroll forward/back button (S110s1) repeatedly until (A1p13) the tire pressure display or the
message "TIRE PRESSURE MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW
MINUTES, REACTIVATE WITH R-BUTTON" is shown in the multifunction display.
Fig. 80: Identifying Pressure Display And System Selection Button
4. Press reset button.

5. Inquiry "ACT. Confirm MONITOR TIRE PRESSURE?" in the multifunction display (A1p13) by
pressing the button + and -, setting specific functions and volume control (S111s1)
The message "TIRE PRESSURE MONITOR ACTIVATED" appears in the multifunction display
(A1p13).
6. Drive the vehicle for several minutes.
Until the individual tire pressure values are detected, the (A1p13) the message "TIRE PRESSURE
MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW MINUTES, REACTIVATE WITH
R-BUTTON" is shown in the multifunction display.
REMOVING AND INSTALLING INSTRUMENT CLUSTER - AR54.30-P-6015I
MODEL 215, 220

Fig. 81: Identifying Instrument Cluster Remove/Install Components - Shown On Model 220
Shown on model 220
1
Disconnect ground lead from AR54.10-P-
2
battery 0003I
Move steering wheel toward
3
driver and toward vehicle floor
4 Pull out instrument cluster (A1) To do this, push in slide (1)
Installation:
Press back retaining springs (arrow) on
instrument cluster (A1) removed and pull out
slide (1)
Release lock on connector (2)
5
and remove connector

000 833 03 61 Slide 2
REMOVING AND INSTALLING BULBS OF INSTRUMENT CLUSTER - AR54.30-P-6049I

MODEL 215, 220
Fig. 82: Identifying Instrument Cluster And Indicator Lamps
1 Connect quiescent current retention unit AR54.10-P-1030-07I
2 Disconnect ground lead from battery AR54.10-P-0003I
3 Remove instrument cluster AR54.30-P-6015I
4 Remove bulbs Installation: ? AR54.30-P-6049-01Z
Install bulbs AR54.30-P-6049-02Z
Fig. 83: Identifying Installation Sleeve (129 589 01 09 00)
Removing bulbs - AR54.30-P-6049-01Z

Fig. 85: Identifying Pin Socket (129 589 0109 00)
Turn bulbs to the left and remove using special tool
Fig. 86: Identifying Left Turn Bulb Position
Installing bulbs - AR54.30-P-6049-02Z

Insert bulbs and turn to the right using special tool.
Fig. 89: Identifying Right Turn Bulb Position
REMOVE/INSTALL OUTSIDE TEMPERATURE INDICATOR SENSOR - AR54.30-P-6341
Remove/install outside temperature indicator sensor - AR54.30-P-6341I
MODEL 220
Fig. 90: Identifying Ambient Temperature Display Temperature Sensor
Remove/install
left front AR61.20-P-

section 1105M
Unclip outside temperature indicator temperature sensor
2
(B14)
Disconnect electrical connector for outside temperature
3
indicator temperature sensor
Removing and installing outside temperature indicator sensor - AR54.30-P-6341N
MODEL 215
Fig. 91: Identifying Electrical Connection And Ambient Temperature Display Temperature Sensor
Left front AR61.20-P-

1 Remove engine compartment lining
section 1105M
2 Unclip ambient temperature display temperature sensor (B14)
Unclip and pull off electrical connection of ambient
3
temperature display temperature sensor (1).
REMOVING AND INSTALLING FANFARE HORNS/CLAXON - AR54.35-P-1555
Removing and installing fanfare horns - AR54.35-P-1555I

MODEL 220
Fig. 92: Identifying Fanfare Horns

H2 Fanfare horns
Removing and installing claxon - AR54.35-P-1555N
MODEL 215
Fig. 93: Identifying Fanfare

H2 Fanfare horns
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN FRONT BUMPER - AR54.65-P-

0001I
Fig. 94: Identifying Front Bumper Parktronic System (PTS) Sensor Remove/Install Components - Shows
Model 220
Shows model 220
Remove/install
Unclip bumper element (2) on Using a suitable tool (e.g. plastic wedge) pry out of
1
bumper bumper and remove in the direction of the arrow.
Unclip bracket of Parktronic sensor When removing the bracket together with the
3
(4) from bumper element Parktronic sensor, this can fall out of the bracket.
4 Pull sensor out of the bracket Installation: Check sealing ring (5).
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) SENSORS IN REAR BUMPER - AR54.65-P-

0002I

Fig. 95: Identifying Rear Bumper Parktronic System (PTS) Sensor Remove/Install Components - Shows
Model 220
Shows model 220
Remove/install
Unclip bumper element (2) on Use plastic wedge to pry out of bumper and remove
1
bumper in direction of arrow
Unclip bracket of Parktronic sensor When removing the bracket together with the
3
(4) from bumper element Parktronic sensor, this can fall out of the bracket.
Pull Parktronic sensor out of the
4 Installation: Check sealing ring (5).
bracket
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) WARNING INDICATOR ON

INSTRUMENT PANEL - AR54.65-P-0003B
Components
Components
Figure item, etc. Work instructions

1 Electrical connections disconnect
(on left of instrument
panel)
(on center of instrument
panel)
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) WARNING INDICATOR IN REAR

DOME LAMP - AR54.65-P-0004B
Fig. 98: Identifying Parktronic System Warning Indicator Remove/Install Components
1 Pull rear dome lamp Pull left side out of
(E15/3) together with headliner first (arrow)
PTS warning indicator
(A44/3) out of headliner
from dome lamp and PTS
warning indicator
3 Unclip cover (1) at rear
dome lamp
4 Unclip PTS warning
indicator from dome
lamp
5 Reinstall in opposite
order
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) SWITCH - AR54.65-P-0005
Removing and installing Parktronic system (PTS) switch - AR54.65-P-0005I
MODEL 220 with CODE (220a) Parktronic system (PTS)

Fig. 99: Identifying Parktronic System (PTS) Switch Remove/Install Components
AR68.10-P-
1 Remove molding strip (1)
1180M
AR54.21-P-
2 Remove upper control panel control module
1262M
Remove switch group with Parktronic system switch (S95) in direction of
3
arrow
4 Disconnect electrical connector (2)
Removing and installing Parktronic System (PTS) switch - AR54.65-P-0005N
MODEL 215 with CODE (220a) Parktronic System (PTS)

Fig. 100: Identifying Electrical Connection And PTS On/Off Switch
1 Remove center console cover AR68.20-P-2350N
2 Remove upper control panel control module AR54.21-P-1262N
3 Remove switch group with PTS on/off switch (S95)
4 Disconnect electrical connection (1)
REMOVING AND INSTALLING PARKTRONIC SYSTEM (PTS) CONTROL MODULE - AR54.65-P-

0006I
MODEL 215, 220 with CODE (220a) Parktronic system (PTS)
Shown on model 220

Fig. 101: Identifying Parktronic System (PTS) Control Module Remove/Install Components - Shown On
Model 220
AR54.10-P-
1030-07I
AR54.10-P-
0003I
AR91.12-P-
1020N
AR91.12-P-
Model 220
1020MA
Model 220
AR91.12-P-
3.2 Remove independent seats with code 401,
1020M
right-hand side
Model 220
AR91.12-P-
4.1 Remove rear seat adjustment mechanism with code 401,
1520M
right-hand side
Unscrew screws (1) and nuts (2) and remove mounting plate
5
Release connectors (4) on Parktronic system control module
6
(N62) and disconnect
Push Parktronic system control module out of guide rails
7
(direction of arrow) and remove from mounting plate
REMOVE/INSTALL SENSOR - AR54.70-P-0001I

Shown on Model 220
Fig. 102: Identifying Sensor Remove/Install Components - Shown On Model 220
Fig. item, etc. Work instructions

Engine hood Open AR88.40-P-1000M
1 Bolts unscrew
2 Clutch detach
B29 DTR radar sensor
Check, correct Distronic (DTR) sensor adjustment AR30.30-P-1000R
Electrical System, Equipment & Instructions - Basic Knowledge - 215 & 220 Chassis
BASIC KNOWLEDGE
DATA BUS SYSTEM FUNCTION - GF54.00-P-0004A
MODELS 124, 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463
Fig. 1: Data Bus System Function Block Diagram
A data bus connects the individual control units and enables them to exchange data.
The signal from a sensor is passed on to the nearest control unit, processed by it and placed on the CAN data
bus.
Each control unit that is connected to the CAN data bus can read this signal and use it to calculate an input to
control an actuator.

Data bus system, block diagram GF54.00-P-0004-03A
Data bus system, advantages GF54.00-P-0004-04A
Data bus system, block diagram - GF54.00-P-0004-03A

Fig. 2: Data Bus System, Block Function Diagram
All control units are interlinked through the CAN data bus.
A control unit receives a measured value from a sensor, prepares a data telegram from this and places it on the
CAN data bus.
All other control units can then read and process this data packet.
Data bus system, advantages - GF54.00-P-0004-04A
With the former wiring of the individual electrical and electronic components (standard wiring) each control
unit is directly connected to all sensors and actuators, from which it obtains measured values or which it
actuates.
In some cases, this can result in long or redundant cable runs. The data bus system affords the following
advantages relative to conventional wiring:
DATA Bus System Advantages Notes

Lower cost of wiring Lines from sensors must only be lead to the nearest control unit
where the measured values are processed to form a data telegram
and are placed on the CAN data bus. Actuators can also receive
control signals from a different control unit which receives the
data telegram through the CAN bus and then uses this
information to calculate a control parameter for the actuator.
Improved electromagnetic
compatibility (EMC)
Fewer plug connections
Fewer pins on the control units
Weight saving
Fewer sensors Signals from one sensor (e. g ECT sensor) can be used several
times
Better diagnosis Since signals from one sensor can be received by several
receivers (e.g. vehicle speed signal), it can be assumed if a fault
is displayed by all systems which use a particular signal, that the
sensor is defective or that the control unit which processes the
signal is faulty.
If only one system displays a fault, even though the signal is
used several times, the fault is usually at the processing control
unit or at the actuator.
Fast transmission rates Up to 1 Mbit/s with a line length of max. 40 m (not currently in
use at Mercedes Benz).
Mercedes Benz uses transfer rates from 83 kbit/s up to 500
kbit/s.
Several messages can be transferred in
succession on the same line
CAN DATA BUS, FUNCTION - GF54.00-P-0005
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 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. 3: 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. 4: 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-0005AM
MODEL 215 with Engine 113.991

MODEL 220 with Engine 113.991
MODEL 230 with ENGINES 113.992 /995
Fig. 5: Identifying CAN Data Bus Function Diagram
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
 Improving the electromagnetic compatibility (EMC)
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 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) engine CAN data bus (CAN-C) for the
powerplant and chassis systems and the slower (83.3 kbit/s) body CAN data bus (CAN-B) structure for the
vehicle interior.
In addition for the vehicle diagnosis with STAR DIAGNOSIS there is a diagnosis CAN data bus (CAN-D) 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, electronic ignition switch control unit and the steering column module are connected
with both the body CAN data bus and the engine 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 is possible via a STAR DIAGNOSIS menu.
The international standardized network management "OSEK" (O pen systems and their Interfaces for
Electronics in motor vehicles) is used for all control units of the CAN data bus.
CAN data bus, function - GF54.00-P-0005F
MODEL 124 with ENGINE 104,111,119 (except 104.98)
MODEL 129 with ENGINE 104,112,113,119,120 (except 104.98)
MODEL 170 with ENGINE 111,112 (except, 112.96)
MODEL 202 with ENGINE 104, 111,112

MODEL 215 with ENGINE 113,137 (except 113.99)
MODEL 220 with ENGINE 112,113,137 (except, 113.99)
Shown on example of Controller Area Network bus class C (engine compartment) (CAN-C) in model 220
with engine 112, 113 and code (219) Distronic (DTR)
Fig. 6: Identifying CAN Data Bus Function
Task
 Data interchange between the individual control units

 Reducing the number of wires
 Improving the electromagnetic compatibility
Design
The data bus consists of a twisted, two-core data line which connects all the participants together in a parallel
circuit. The data line lines must not be mixed up (low or high level). The ME-SFI [ME] control unit (N3/10)
(except model 124 and model 140), the DAS [FBS] control unit (N73/1) (model 129), the DAS [FBS] radio
frequency/infrared control unit (N54/4) (model 129) and the DAS [FBS] radio frequency control unit (N54/3)
(model 170) are regarded as terminals as far as bus adaptation is concerned. A terminating resistor of 120 ohms
is fitted in each case. Exception: ME-SFI [ME] control unit (N3/10) with engine 120 (each fitted with 240
ohms).
When measuring the resistance on the data line (circuit 15 OFF), the various terminating resistors in the
terminals are connected in parallel.
Function
The data are transmitted digitally on the data bus at various intervals. The individual data blocks are defined in a
protocol and this also states which data are received or transmitted by a control unit. Each connected control
unit is able to transmit or receive data.
The total of the data blocks, the short pause between 2 transmission intervals and further properties of the data
bus are checked constantly. Any faults detected are stored.
Vehicles with EIS [EZS] control unit (N73)
In the vehicle a distinction is made between a fast Controller Area Network bus class C (engine compartment)
(CAN-C) and Controller Area Network bus class B (interior) (CAN-B) which is 6 times slower. The EIS [EZS]
control unit (N73) forms the interface (Gateway) for this. This does not apply to vehicles with a central gateway
control unit (N93) (except model 203).
Vehicles with central gateway control unit (N93)
The central gateway control unit forms the interface (Gateway) between the two data buses (N93) (except
model 203). The central gateway control unit (N93) serves as the interface for STAR DIAGNOSIS for all
model series.
The new control unit must be coded again when exchanging control unit. The control unit can be coded via a
menu in the handheld tester (up to 07/99) or via STAR DIAGNOSIS.
CAN data bus, GF54.00-P-0005A

function Model
Networking, general Model 202 as of 1.6.97 GF54.21-P-9611C
Model 210 as of 1.3.97 (except 210.081/281)
Model 210.081/281
Extended vehicle Model 215, 220 up to 31.8.03 GF00.19-P-0001S
networking (EVN),
function
Model 215, 220 as of 1.9.03 GF00.19-P-0001SX
Model 203 up to 23.4.04 GF00.19-P-0001PP
Model 203 as of 24.4.04 up to 30.11.04 except code GF00.19-P-0001PM
(494) USA version except code (498) Japanese version
Model 203 as of 1.12.04 except code (494) USA GF00.19-P-0001PN
version except code (498) Japanese version
Model 203 as of 24.4.04 up to 30.11.04 with code GF00.19-P-0001PMU
(494) USA version
Model 203 as of 1.12.04 with code (494) USA version GF00.19-P-0001PNU
Model 203 as of 24.4.04 up to 30.11.04 with code GF00.19-P-0001PMJ
(498) Japanese version
Model 203 as of 1.12.04 with code (498) Japanese GF00.19-P-0001PNJ
version
Model 209 up to 31.5.04 except code (491) USA GF00.19-P-0001Q
Model 209 as of 1.6.04 except code (494) USA version GF00.19-P-0001QM
except code (498) Japanese version
Model 209 up to 31.5.04 with code (498) Japanese GF00.19-P-0001QJ
version
Model 209 as of 1.6.04 with code (498) Japanese GF00.19-P-0001QMJ
version
Model 209 up to 31.5.04 with code (491) USA version GF00.19-P-0001QU
Model 209 as of 1.6.04 with code (494) USA version GF00.19-P-0001QMU
Model 230 up to 31.5.04 except code (494) USA GF00.19-P-0001R
Model 230 up to 30.6.04 with code (494) USA version
Model 230 as of 1.6.04 except code (494) USA version GF00.19-P-0001RM
Model 230 as of 1.7.04 with code (494) USA version
Model 211.0/2 GF00.19-P-0001T
CAN data bus, function - GF54.00-P-0005M
MODEL 215, 220 with ENGINE 275.950

Shown on model 215, 220
Fig. 7: Identifying CAN Data Bus Function Diagram - Shown On Model 215, 220
Data flow, model 216, 221

Fig. 8: CAN Data Flow, Model 216, 221
The tasks are:
 Data transfer between individual control units

 Reducing the number of electric cables
 Improving electromagnetic compatibility.
parallel.
The two lines of the data line must not be mixed up (LOW-/HIGH-level).
The data are transferred 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 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.
Model 215, 220, 230, 240
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 on model 215, 220 in the electronic ignition
switch control unit (N73), 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. The central gateway control unit (N93)
takes over these tasks in model 230 and 240.
Model 216, 221
Several CAN data bus systems are available in the vehicle. The central gateway control unit (N93) has the
following tasks:
 Controls the data traffic between the interior CAN, the diagnosis CAN, the chassis CAN and the central
CAN.
 Routing of all fault memories via the diagnosis CAN for data link connector diagnosis
 Memory for production data, global variant coding (series, country version) and maintenance computer.
The ME-SFI [ME] control unit is the gateway for the drive train CAN and chassis CAN.
This control unit coding is via a menu of the STAR DIAGNOSIS menu.
CAN data bus, see also wiring diagrams.
ME-SFI control unit, location/task/design/function GF07.61-P-5000M
CAN data bus, function - GF54.00-P-0005MA
Fig. 9: Identifying CAN Data Bus Function Diagram
The tasks are:
 Data interchange 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 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.
A distinction is made in the vehicle between a fast (500 kbit/s) CAN engine data bus (CLASS C) for the drive
and chassis systems and the slightly slower (83.3 kbit/s) CAN body data bus (CAN-B) structure for the vehicle
interior.
In addition to this the external vehicle diagnosis using STAR DIAGNOSIS also has a CAN data bus diagnosis
(CAN-D) with a speed of 500 kbits/s.
The interface between the three CAN data buses (Gateway) is located in the central gateway control unit (N93).
The instrument cluster (A1), electronic ignition switch control unit (N73) and steering column module (N80)
are connected both with the CAN data bus, body and with the CAN data bus, engine and exchange data with
both data bus systems.
However, they do not serve as an interface (gateway) between both data bus systems!
This control unit coding is possible via a STAR DIAGNOSIS menu.
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.
ME-SFI [ME] control unit component description N3/10 GF07.61-P-6000SM
CAN DATA BUS, CONTENTS, FUNCTION DESCRIPTION - GF54.00-P-0999ZZ
MODELS 124, 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463
Data bus system function GF54.00-P-0004A

Data bus system, block diagram GF54.00-P-0004-03A
Data bus system, advantages GF54.00-P-0004-04A
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
FUSE AND RELAY BOX AS-BUILT CONFIGURATION - GF54.15-P-0800
Fuse and relay box as-built configuration - GF54.15-P-0800I
MODEL 215, 220
Fuse assignment as-built configuration GF54.15-P-1256I

Relay assignment as-built configuration GF54.15-P-1257I
Fuse and relay box as-built configuration - GF54.15-P-0800MB
MODEL 220 with CODE (979) Special protection version with CODE (Z04) Light armoring with CODE
(Z07) Maximum protection
Fuse assignment as-built configuration GF54.15-P-1256MB

Relay assignment as-built configuration GF54.15-P-1257MB
FUSE ASSIGNMENT, AS-BUILT CONFIGURATION - GF54.15-P-1256
Fuse assignment, as-built configuration - GF54.15-P-1256I
MODEL 215, 220
GF54.15-P-1256-
Fuse assignment of rear fuse and relay box up to 31.8.02
01IH
as of 1.9.02 up to GF54.15-P-1256-
31.8.03 01JH
as of 1.9.03 up to GF54.15-P-1256-
31.5.04 01KH
GF54.15-P-1256-
as of 1.6.04
01LH
Fuse assignment of fuse and relay box in right engine GF54.15-P-1256-
up to 31.8.02
compartment 02IR
as of 1.9.02 up to GF54.15-P-1256-
31.5.04 02JR
GF54.15-P-1256-
as of 1.6.04
02KR
Fuse assignment of fuse and relay box in engine GF54.15-P-1256-
up to 31.8.02
compartment, left 03IL
as of 1.9.02 up to GF54.15-P-1256-
31.8.03 03JL
GF54.15-P-1256-
as of 1.9.03 03KL
Fuse assignment of fuse and relay box in right front of as of 1.9.02 up to GF54.15-P-1256-
engine compartment 31.8.03 10JM
GF54.15-P-1256-
as of 1.9.03
10KM
GF54.15-P-1256-
Fuse assignment of fuse box in cockpit as of 1.9.02
09JC
Fuse assignment of rear fuse and relay box - GF54.15-P-1256-01IH
Assignment of rear fuse and relay box
Fig. 10: Fuse Assignment Of Rear Fuse And Relay Box - Up To 31.8.02
Fuse circuit Color of Fused function Rating in

fused wire amperes (A)
50 - - Rear window roller blind relay (K40/5kQ) 10
51 - - Towing sensor relay (K40/5kR) 5
52 30 - Fuel pump relay (K40/5kT) 30
53 30 - Rear window defroster relay (K40/5kU) 50
54 15 2
rs/rt 0.75 mm Trailer recognition control module (N28/1) 10
55 30 rd/vi 2.5mm2 Trailer hitch socket (13-pin) (X58) 25
56 30 rd/ye 2.5 mm2 Trailer recognition control module (N28/1) 30
Valid for remote trunk locking (HDFS):
 Via circuit 30 connector sleeve (solder connector in

57 30 rd 2.5 mm2 harness) (Z7/26): 25
 Trunk lid open relay (K69/1)
 Trunk lid closed relay (K69/2)
Via circuit 30 connector sleeve fused, Keyless Go (Z7/19):

 Keyless Go control module (N69/5)
 Keyless Go left front door antenna (A2/38)
 Keyless Go left rear door antenna (A2/39)
 Keyless Go right front door antenna (A2/40)

gr/bk
58 30  Keyless Go right rear door antenna (A2/41) 7.5
0.75mm2
 Keyless Go left front door lift solenoid (L12)
 Keyless Go left rear door lift solenoid (L12/1)
 Keyless Go right front door lift solenoidL12/2)
 Keyless Go right rear door lift solenoid (L12/3)
rt/ws 2 2,5 Special vehicle multifunction control module (SVMCM)

59 30 30
mm 2 (N26/9), taxi only
60 15 - - -
61
30 Valid for radio (D2B): 15
rd/ye 1.5mm 2  via circuit 30 connector sleeve (Z4/3):

 Radio (A2)
rd/ye 0.75mm
2  Rear window antenna amplifier module (A2/12)
Valid for radio (D2B) with CD changer (code 819):

 via circuit 30 connector sleeve (Z4/3):
rd/ye 1.5mm2  Radio (A2)
rd/ye  Rear window antenna amplifier module (A2/12)
0.75mm2  CD player with changer (in K luggage
compartment) (A2/6)
Valid for Cockpit Management and Data System
(COMAND):
rd/ye 1.5mm2  COMAND operating, display and control module
rd/ye 1.5mm2 (A40/3)
rd/ye 0.5mm2  via connector sleeve, circuit 30 (Z4/3):
rd/ye
 Telephone circuit connector 15C (X39/40)
0.75mm2
 TV tuner (A2/10), Japan
rd/ye 0.5mm2
 Video decoder (A2/11)
rd/ye
 Relief relay, circuit 15 (K41)
0.75mm2
61 30 Valid for radio (D2B): 15
rd/ye 1.5mm2  via circuit 30 connector sleeve (Z4/3):
rd/ye  Radio (A2)
0.75mm2  Rear window antenna amplifier module (A2/12)

 via circuit 30 connector sleeve (Z4/3):
rd/ye 1.5mm2  Radio (A2)
rd/ye  Rear window antenna amplifier module (A2/12)
0.75mm2  CD player with changer (in K luggage
compartment) (A2/6)
(COMAND):
 COMAND operating, display and control module
(A40/3)
rd/ye 1.0 mm2  via circuit 30 connector sleeve (Z4/3):
 COMAND operating, display and control

rd/ye 1.5mm2 module (A40/3n1)
rd/ye
 Rear window antenna amplifier module (A2/12)
0.75mm2
 Navigation processor (A40/3n2)
 TV tuner (A2/42), ECE and USA

61 30 15
(COMAND) with traffic data recorder:
 COMAND operating, display and control module
(A40/3)
rd/ye 1.0 mm2  via circuit 30 connector sleeve (Z4/3):
 COMAND operating, display and control

rd/ye 1.5mm2 module (A40/3)
rd/ye
 Traffic data recorder (A2/43)
0.75mm2
 Navigation processor (A40/3n2)
 Rear window antenna amplifier module (A2/12)
Pneumatic system equipment with combined functions

62 30 rd/bk 1.5mm2 (A37) 20
Valid for telephone D2B (code 316):
 D2B interface for permanently installed telephone

(A59)
 CTEL transmitter / receiver (A35) if emergency call
system (TELE AID) fitted,
rd/bk
63 30  TELE AID control module (A35/8) 7.5
0.75mm2
or
Valid for telephone D2B (code 316) with voice control
system (813b):
 Via circuit 30 connector sleeve (solder connector in

harness) (Z7/26):
 D2B-Interface for fixed installation telephone
(A59)
 CTEL transmitter / receiver (A35)
 Voice control system control module (A35/11) if

rd/bk 0.5mm2 emergency call system (TELE AID) fitted,
 TELE AID control module (A35/8)
Valid for telephone D2B portable CTEL (code 317)

(preinstallation):
rd/bk
0.75mm2  Portable CTEL connector (X39/39)
 Traffic data recorder (A2/43)
64 rd/ye 0.75mm  COMAND operating, display and control module

30 2 (A40/3) 7.5
 Rear window antenna amplifier module (A2/12)
65 - - - -
Valid for radio (D2B) with sound system (code 810):
66 30 rd/ye 2.5 mm2 25
 Sound amplifier (A2/13)
67 30 rd/bl 2.5 mm2 Rear seats control module (N25/6) (not in the case of C215) 25
rd/wt 1.0mm2 via connector sleeve Kl.30 (Z7/40):
68 30 rd/wt 0.8mm2  Rear air conditioning control module (N22/4) 15

 Rear AC refrigerant shutoff valve (Y67)
rd/wt 0.5mm2  Delivery unit for rear heating system (A31/1)
rd/wt 0.5mm2  Circulation pump (A31/1m1)
 Left duovalve (A31/1y1)
rd/wt 0.8mm2  Right duovalve (A31/1y2)
Valid for rear air conditioning:

69 30 rd/bk 1.0mm2 Rear air conditioning control module (N22/4)
15
rd/bk
70 30 TPM [RDK] control module (N88) 10
0.75mm2
Left front seat adjustment control module with memory
71 30 rd/br 2.5mm2 (N32/1) 25
rd 2.5 mm2 Rear seats control module (N25/6), model 215, Left rear
72 30 40
rd/gn 4.0mm2 door control module (N69/3), model 220
Right front seat adjustment control module with memory
73 30 rd/vi 2.5mm2 (N32/2) 25
Rear seats control module (N25/6), model 215, Right rear

74 30 rd 4.0mm2 door control module (N69/4), model 220
40
rd/bl 4.0mm
22
With Parktronic system (code 220a):
75 15 bk/rd 1.5mm2 PTS control module (N62) 10
76 30 rd/bl 1.5mm2 Rear backrest refrigerator box (A39/1) 15
77 30 rd/bk 2.5 mm2 Roof operating unit control module (N70) 40
Fuse assignment of rear fuse and relay box - GF54.15-P-1256-01JH
Model 215, 220 as of 1.9.02 up to 31.8.03
Fig. 11: Fuse Assignment Of Rear Fuse And Relay Box - As Of 1.9.02 Up To 31.8.03
Fuse Terminal Color of Fused function Rating in

fused wire amperes
(A)
Valid for electric roller blind for rear window (code 540a):
F50 30 - 10
 Rear window roller blind relay (K40/5kQ)
Valid for towing sensor (code 882d):
F51 30 - 5
 Towing sensor relay (K40/5kR)
F52 30 - Fuel pump relay (K40/5kT) 30

F53 30 - Rear window defroster relay (K40/5kU) 50
pink/red Valid for trailer hitch (code 550):
F54 15 10
0.75 mm2  Trailer recognition control module (N28/1)
rd/vi Valid for trailer hitch (code 550):
F55 30 25
2.5mm2  Trailer coupling socket, 13-pin (X58)
Valid for trailer hitch (code 550):
rd/ye 2.5  Trailer recognition control module (N28/1)
F56 30 30
mm2
Valid for remote trunk closing (HDFS) (code 881b):
 Via terminal 87 connector sleeve (Z7/24):

F57 30 rd 2.5 mm2  Trunk lid open relay (K69/1)
25
 Remote trunk closing hydraulic pump (M51)
Valid for Keyless Go (code 889), model 215:
 fused via circuit 30 connector sleeve, Keyless Go (Z7/19):

 Keyless Go control unit (N69/5)
 Left door keyless go antenna (A2/38)
 Left rear Keyless Go antenna (A2/39)
 Right door keyless go antenna (A2/40)
 Right rear Keyless Go antenna (A2/41)
 Left door Keyless Go lift solenoid (L12)
 Right door Keyless Go lift solenoid (L12/2)
gr/bk  fused via circuit 30 connector sleeve, Keyless Go (Z7/19):

F58 30 7.5
0.75mm2  Keyless Go control unit (N69/5)
Keyless Go left front door antennaA2/38
Keyless Go antenna, left rear doorA2/39
Keyless go right front door antennaA2/40
Right rear door Keyless Go antennaA2/41
Left front door Keyless Go lifting magnetL12
Keyless Go left rear door lift solenoidL12/1
Right front door Keyless Go lifting magnetL12/2
Right rear door Keyless Go lifting magnetL12/3

Valid for taxi version (code 450), model 220 only:
rd/wt 2.5  Special vehicle multifunction control module (SVMCM)

mm2 (N26/9)
F59 30  Special vehicle multifunction control module (SVMCM) 30
(N26/9)
Via terminal 30 connector sleeve (Z4/3):
rd/ye
F60 30 7.5
0.75mm2  Antenna amplifier module Rear window (A2/12)
 Navigation processor (N41/1)
rd/ye
0.5mm2  VICS voltage supply separation point (X137/1)
rd/ye Valid for COMAND operating and display system (Code

352a): 7.5
0.75mm2 Rear window antenna amplifier module (A2/12)
Valid for hands-free system:
bk/ye
F61 30 7.5
0.75mm2  Via terminal 30 connector sleeve (Z4/3):
 Hands-free system control unit (A35/1)
Valid for voice control system (VCS) (code 813):

rd/bk
0.75mm2  Via terminal 30 connector sleeve (Z4/46):
 Voice control system control unit (A35/11)
Valid for telephone preinstallation network D-portable

rd/bk CTEL (code 273):
0.75mm2
 Portable CTEL connector (X39/39)
bk/ye Valid for Japanese version (code 498):
1.5mm2
bk/ye  Via terminal 30 connector sleeve (Z4/3):
0.75mm2  E-Call control unit (N112)
Valid for MB standard phone (code 853):

rd/bk 1.5
mm2  Telephone supply via connector sleeve (in wiring harness)
(Z28/30):
rd/bk  Telephone transmitter/receiver, D2B (A35/13)
 Selection switch for telephone handset, front and rear
0.75mm2
(A34/9), model 220 only
rd/bk 1.5 Valid for MB portable CTEL (code 854):
mm2  CTEL interface (A34/4)
rd/bk
 CTEL compensator (A28/3)
0.75mm2
Valid for MB portable CTEL (code 854) with
EMERGENCY CALL emergency call system (code 348a),
rd/bk 1.5 USA only:
mm2  via circuit 30 connector sleeve (solder connector in
harness) (Z7/26):
rd/bk
 E-Call control unit (A35/8)
0.5mm2
rd/bk  Telephone interface (A34/4)
0.75mm2  Voice control system control unit (A35/11)
Valid for TELE AID (code 855) with dynamic navigation
rd/bk 1.5 (code 815) model 220, taxi only:
mm2  Telephone supply via connector sleeve (in wiring harness)
(Z28/30):
 Telephone transmitter/receiver and TELE AID, D2B
rd/bk 0.5 (A35/17)
mm2  Selection switch for telephone handset, front and rear
(A34/9), model 220 only
bk/ye
F62 30 Pneumatic system equipment with combined functions (A37) 20
0.75mm2
Valid for left or right dynamic seat (code 433, 434), model
F63 30 rd 4.0mm2 220 only: 30
Pneumatic pump for dynamic seat control (M40/1)
rd/br
F64 30 Left front seat adjustment control module with memory (N32/1) 25
2.5mm2
F65 15 - - -
rd/vi Right front seat adjustment control module with memory
F66 30 25
2.5mm2 (N32/2)
Valid for electrically adjustable rear seat bench (code 223b)
and individual rear seats, electrically adjustable, with seat
rd/bl 2.5 ventilation, heated seats and memory package (code 224c):
F67 30 25
mm2
 Rear seats control unit (N25/6), model 220.0, standard on
model 220.1
rd/wt 1.0 Valid for air conditioning in rear (code 582), model 220:
F68 30 15
mm2  Via terminal 30 connector sleeve (Z7/40):
 Rear AC control unit (N22/4)
 Right duovalve (A31/1y2)
rd/wt 0.75
 Left duovalve (A31/1y1)
mm2
 Rear AC refrigerant shutoff valve (Y67)
 Circulation pump (A31/1m1)
rd/wt
0.5mm2  Circulation pump (A31/1m1)
rd/wt
0.5mm2
Valid for air conditioning in rear (code 582), model 220:
rd/bk
F69 30 15
1.0mm2  Electronic blower controller for rear air conditioning
(N29/2), standard on engine 275
rd/bk Valid for tire pressure monitor (code 475):
F70 30 10
0.75mm2 TPM [RDK] control module (N88)

2
rd 6.0 mm Via terminal 30 connector sleeve (Z4/3):
F71 30 40
rd 4.0mm2  Left front reversible emergency tensioning retractor (A76)
F 72 30 rd 2.5 mm2  Rear control unit (N22/6), model 215, 40
rd/gn
 Left rear door control unit (N69/3), model 220
4.0mm2
rd 6.0 mm2
F73 30 40
 Right front reversible emergency tensioning retractor
rd 4.0mm2 (A76/1)
F74 30 rd 4.0mm2  Rear control unit (N22/6), model 215, 40
rd/bl
 Right rear door control unit (N69/4), model 220
4.0mm2
bk/rd Valid for Parktronic system (PTS) (code 220a):
F75 15 10
1.5mm2  PTS control unit (N62)
Valid for cool compartment in center rear backrest (code
rd/bl 308):
F76 30 15
1.5mm2
 Rear backrest refrigerator box (A39/1)
rd/bk 2.5
F77 30 Roof operating unit control module (N70) 40
mm2
Fuse assignment of rear fuse and relay box - GF54.15-P-1256-01KH
Model 215, 220 as of 1.9.03 up to 31.5.04

Fig. 12: Fuse Assignment Of Rear Fuse And Relay Box - As Of 1.9.03 Up To 31.5.04

fused amperes
wire (A)
Valid for electric roller blind for rear window (code 540a):
F50 30 - 10
Valid for towing sensor (code 882a):

F51 30 - 5
F52 30 - Fuel pump relay (K40/5kT) 30

F53 30 - Heated rear window relay (K40/5kU) 50
rs/rt 0.75 Valid for trailer hitch (code 550):
F54 15 10
mm2  Trailer recognition control unit (N28/1)
rt/vi 2.5 Valid for trailer hitch (code 550):

F55 30 25
mm2  Trailer socket, 13-pin (X58)
rt/ge 2.5 Valid for trailer hitch (code 550):

F56 30 30
Valid for remote trunk closing (RTC) (code 881b):
rt 2.5  via connector sleeve circuit 87 (Z7/24):

F57 30 25
mm2  Trunk lid open relay (K69/1)
 RTC [HDFS] hydraulic pump (M51)
 Via circuit 30 connector sleeve fused, Keyless Go (Z7/19):

 Keyless Go control unit (N69/5)
 Left door Keyless Go antenna (A2/38)
 Left rear Keyless Go antenna (A2/39)
 Right door Keyless Go antenna (A2/40)
 Right rear Keyless Go antenna (A2/41)
 Left door Keyless Go lift solenoid (L12)
 Right door Keyless Go lift solenoid (L12/2)

gr/sw
F58 30 0.75  Via circuit 30 connector sleeve fused, Keyless Go (Z7/19): 7.5
mm2  Keyless Go control unit (N69/5)
 Left front door Keyless Go antenna (A2/38)
 Left rear door Keyless Go antenna (A2/39)
 Right front door Keyless Go antenna (A2/40)
 Right rear door Keyless Go antenna (A2/41)
 Left front door Keyless Go lift solenoid (L12)
 Left rear door Keyless Go lift solenoid (L12/1)
 Right front door Keyless Go lift solenoid (L12/2)
 Right rear door Keyless Go lift solenoid (L12/3)
Valid for taxi version (code 450), only model 220:

rt/ws 2.5
F59 30 30
mm2  Special vehicle multifunction control unit (SVMCU)
(N26/9)
Valid for TV tuner (code 860):

rt/ge
F60 30 0.75 7.5
mm2 Via terminal 30 connector sleeve (Z4/3):

 Navigation processor (N41/1)
rt/ge 0.5
 VICS voltage supply separation point (X137/1) H
mm2
sw/ge
F61 30 0.75 7.5
 Via terminal 30 connector sleeve (Z4/3):
mm2
 Handsfree system control unit (A35/1)
sw/ge
0.75 Valid for voice control system (VCS [SBS]) (code 813):
 Voice control system control unit (A35/11)
rt/sw Valid for D-network portable CTEL preinstallation (code 273):

0.75
mm2  Portable CTEL connector (X39/39)
sw/ge Valid for MB portable CTEL in armrest (code 382a):

1.5 mm2  Via terminal 30 connector sleeve (Z4/3):
sw/ge
0.75  Telecommunications control unit (N112)
mm2  Bluetooth module (A34/11)
sw/ge
 Rear telephone handset (A34/8), only model 220
0.5 mm2
rt/sw 1.5 Valid for MB portable CTEL in armrest (code 382a):
rt/sw
 Telephone interface (A34/4)
0.75
 E-net compensator (A28/3)
mm2
sw/ge Valid for Japanese version (code 498):
1.5 mm2  Via terminal 30 connector sleeve (Z4/3):
sw/ge
0.75  E-call control unit (N112)
mm2
sw/ge
Valid for USA version (code 491):
1.5 mm2
sw/ge  Via terminal 30 connector sleeve (Z4/3):
0.75  Telecommunications control unit (N112)
mm2  Portable CTEL antenna amplifier (A28/2)
Valid for TV tuner (code 860):

rt/ge
0.75  Via terminal 30 connector sleeve (Z4/3):
mm2  TV tuner (MOST) (A2/10)
 Operating and display unit display in rear (A40/2)
sw/ge
F62 30 0.75 PSE control unit (combined) (A37) 20
mm2
rt 4.0 Valid for left and right dynamic seat (code 433, 434), only
F63 30 model 220: 30
mm2 Pneumatic pump for dynamic seat control (M40/1)
rt/br 2.5
F64 30 mm2 Left front seat adjustment control unit with memory (N32/1) 25
F65 15 - - -
rt/vi 2.5
F66 30 Right front seat adjustment control unit with memory (N32/2) 25
mm2
Valid for electrically adjustable rear bench seat (code 223b)
and electrically adjustable individual rear seats with seat
rt/bl 2.5 ventilation, heated seats and memory package (code 224c):
F67 30 25
mm2
 Rear seats control unit (N25/6), model 220.0, standard on
model 220.1
rt/ws 1.0 Valid for rear air conditioning (code 582), model 220:
F68 30 15
mm2  via circuit 30 connector sleeve (Z7/40):
rt/ws  Rear AC control unit (N22/4)
0.75  Right duovalve (A31/1y2)
mm2  Left duovalve (A31/1y1)
rt/ws 0.5  Rear AC refrigerant shutoff valve (Y67)
mm2  Circulation pump (A31/1m1)
Valid for rear air conditioning (code 582), model 220:

rt/sw 1.0
F69 30 15
mm2  Rear air conditioning electronic blower controller (N29/2),
standard with engine 275
rt/sw Valid for tire pressure monitor (code 475):
F70 30 0.75 10
mm2  TPM [RDK] control unit (N88)
rt 6.0
mm2
F71 30 40
rt 4.0
 Left front reversible emergency tensioning retractor (A76)
mm2
rt 2.5
F 72 30  Rear control unit (N22/6), model 215, 40
mm2
rt/gn 4.0
 Left rear door control unit (N69/3), model 220
mm2
rt 6.0 Via terminal 30 connector sleeve (Z4/3):
mm 2
F73 30 40
rt 4.0  Right front reversible emergency tensioning retractor
mm 2 (A76/1)
rt 4.0
F74 30  Rear control unit (N22/6), model 215, 40
mm2
rt/bl 4.0
 Right rear door control unit (N69/4), model 220
mm2
sw/rt 1.5 Valid for Parktronic System (PTS) (code 220a):
F75 15 10
mm2  PTS control unit (N62)
rt/bl 1.5 Valid for refrigerator box in center rear backrest (code 308):
F76 30 15
mm2  Rear backrest refrigerator box (A39/1)
rt/sw 2.5
F77 30 Overhead control panel control unit (N70) 40
mm2
Fuse assignment of rear fuse and relay box - GF54.15-P-1256-01LH
Model 215, 220 as of 1.6.04
Fig. 13: Fuse Assignment Of Rear Fuse And Relay Box - As Of 1.6.04

fused amperes
wire (A)
Valid for code (540) Electric roller blind for rear window:
f50 30 - 10
Valid for code (882) Towing sensor:

f51 30 - 5
f52 30 -  Fuel pump relay (K40/5kT) 30

f53 30 -  Heated rear window relay (K40/5kU) 50
rs/rt 0.75 Valid for code (550) Trailer hitch:
f54 15 10
Valid for code (550) Trailer hitch:

rt/vi 2.5  Trailer socket, 13-pin (X58)
f55 30 25
mm2
rt/ge 2.5 Valid for code (550) Trailer hitch:
f56 30 30
Valid for code (881) Remote trunk closing (RTC):

rt 2.5  Trunk lid "open" relay (K69/1)
f57 30 25
mm2  trunk lid close relay (K69/2)
 RTC [HDFS] hydraulic pump (M51)
Valid for code (889) Keyless Go, on model 215:
 Keyless Go control unit (N69/5)

 Left door Keyless Go antenna (A2/38)
 Left rear Keyless Go antenna (A2/39)
 Right door Keyless Go antenna (A2/40)
 Right rear Keyless Go antenna (A2/41)
 Left door Keyless Go lift solenoid (L12)
 Right door Keyless Go lift solenoid (L12/2)
gr/sw
f58 30 0.75 Valid for model 220: 7.5
mm2
 Keyless Go control unit (N69/5)
 Left front door Keyless Go antenna (A2/38)
 Left rear door Keyless Go antenna (A2/39)
 Right front door Keyless Go antenna (A2/40)
 Right rear door Keyless Go antenna (A2/41)
 Left front door Keyless Go lift solenoid (L12)
 Left rear door Keyless Go lift solenoid (L12/1)
 Right front door Keyless Go lift solenoid (L12/2)
 Right rear door Keyless Go lift solenoid (L12/3)
Valid for code (450) Taxi version:

rt/ws 2.5
f59 30 30
mm2  Special vehicle multifunction control unit (SVMCU)
(N26/9)
Valid for code (860) TV tuner:

Valid except code (498) Japan version:
rt/ge  Navigation processor (N41/1)

f60 30 0.75 7.5
mm2 Valid for code (498) Japanese version:
 VICS power supply separation pointX137/1

 Hands-free system control unit (A35/1)

sw/ge
f61 30 0.75 7.5
mm2 Valid for code (813) Voice control system (VCS [SBS]), except
code (498) Japan version:
 Voice control system control unit (A35/11)

rt/sw Valid for code (380) Preinstallation for MB phone
0.75 "CTEL" (complete):
mm2  Portable CTEL connector (X39/39)
Valid for code (382) MB phone "CTEL" in armrest, except
code (498) Japan version, except code (491) USA version:
 Telecommunications control unit (N112)

sw/ge  Bluetooth module (A34/11)
1.5 mm2
Valid for model 220:
 Rear telephone handset (A34/8)
Valid for code (388) Universal Portable CTEL Interface

system, except code (491) USA version, except code (498)
Japan version:
 Universal Portable CTEL Interface (UPCI [UHI]) control

unit (N123/1/)
rt/sw 1.5
 Telephone interface (A34/4)
mm2
 E-net compensator (A28/3)
Valid for code (388) Universal Portable CTEL Interface

system, with code (491) USA version:
 Universal Portable CTEL Interface (UPCI [UHI]) control

unit (N123/1)
 Emergency call system control unit (N123/4)
sw/ge Valid for code (498) Japanese version:

1.0 mm2  GPS box control unit (N41/6)
Valid for code (860) TV tuner, except code (498) Japan
rt/ge version:
0.75
mm2  TV tuner (MOST) (A2/10)
 Operating and display unit display in rear (A40/2)
sw/ge
f62 30 0.75  PSE control unit (combined) (A37) 20
mm2
Valid for code (433) Left dynamic seat, incl. multicontour seat,
rt 4.0 and for code (434) Right dynamic seat, incl. multicontour seat,
f63 30 on model 220: 30
mm2
 Pneumatic pump for dynamic seat control (M40/1)
rt/br 2.5
f64 30  Left front seat adjustment control unit with memory (N32/1) 25
mm2
f65 15 - - -
rt/vi 2.5  Right front seat adjustment control unit with memory
f66 30 25
mm2 (N32/2)
Valid for code (223) Electrically adjustable rear bench seat,
and for code (224) Electrically adjustable individual rear seats
rt/bl 2.5 with seat ventilation, heated seats and memory package, on
f67 30 25
mm2 model 220:
 Rear seats control unit (N25/6)
Valid for code (582) Rear air conditioning, on model 220:

rt/ws 1.0 Rear AC control unit (N22/4)
f68 30 15
mm 2  Rear auxiliary heating system supply unit (A31/1)
 Rear AC refrigerant shutoff valve (Y67)
rt/sw 1.0 Valid for code (582) Rear air conditioning, on model 220:
f69 30 15
mm2  Rear air conditioning electronic blower controller (N29/2)
rt/sw Valid for code (475) tire pressure monitor:

f70 30 0.75 10
mm2  TPM [RDK] control unit (N88)
rt 6.0 Valid for model 220:
f71 30 40
mm2  Left front reversible emergency tensioning retractor (A76)
rt 2.5 Valid for model 215:
f72 30 40
mm2 Rear control unit (N22/6)
rt/gn 4.0 Valid for model 220:
mm2  Left rear door control unit (N69/3)

rt 6.0
f73 30 40
mm2 Right front reversible emergency tensioning retractor
(A76/1)
rt 4.0  Rear control unit (N22/6)

mm2
f74 30 40
rt/bl 4.0
mm2 Valid for model 220:
 Right rear door control unit (N69/4)
sw/rt 1.5 Valid for code (220) Parktronic system (PTS):

f75 15 10
mm2  PTS control unit (N62)
Valid for code (308) Refrigerator box in center rear backrest,

rt/bl 1.5 on model 220:
f76 30 15
mm2
 Rear backrest refrigerator box (A39/1)
rt/sw 2.5
f77 30  Overhead control panel control unit (N70) 40
mm2
Fuse assignment of fuse and relay box in right engine compartment - GF54.15-P-1256-02IR
Assignment in the fuse and relay box in the right engine compartment
Fig. 14: Fuse Assignment Of Fuse And Relay Box In Right Engine Compartment - Up To 31.8.02
28 30 - Fanfare horns relay (K40/7kP) 15
29 87 - Motor electronics/chassis relay (K40/7kK) 20
30 87 - Motor electronics/chassis relay (K40/7kK) 20
31 87 - Air pump relay (K40/7kN) 40
32 87 - Air compressor relay (K40/7kO) 40
rd/ye 4.0
33 30 Heating systems recirculation unit (A32) 40
mm2
rd/ye
34 87 Traction systems control module (N47) 5
0.5mm2
35 30 - - -
with Distronic (code 219a):
36 87 rd 0.5 mm2 DTR control module (N63/1)
7,5
Connector sleeve circuit 87 (Z7/5):
rd/ye
1.5mm2 Electronic selector lever module control module 15
37 87 
rd/ye (N15/5)
0.75mm2
 ETC control module (N15/3)
rd/bk
38 30 Luggage compartment interior button (KIT) 5
0.5mm2
rd/bk
39 30 Right front door control module (N69/2) 40
4.0mm2
With Xenon headlamps (code 612b):
40 15 rd 0.75mm2 Headlamp range adjustment control module (N71) 10
With stationary heater (code 228):
via circuit 30 connector sleeve (solder connector in
harness) (Z7/26):
41 30 rd 2.5 mm2 20
 STH heater unit or heater booster heater unit
(A6)
rd 0.75mm2  STH radio remote control receiver (A6/1)
bk/bl  via connector sleeve circuit 87 (Z7/24):
42 30 20
1.5mm2  Auxiliary air unit relay (K25)
Diesel engine only

43 87 rd/bl 4.0mm2 25
 via connector sleeve circuit 87D1 (Z7/47):
rd/bl 2.5  CDI control module (N3/9)
mm2  Starter relay (K40/kL), right front fuse and relay
rd/bl 0.5mm2 module (K40/7)
44 OM613 7.5
87 rd/gn Diesel engine only
1.5mm2  CDI control module (N3/9)
rd/gn  Intake manifold heating, right front fuse and
1.0mm2 relay module (K40/7)
rd/gn 2.5
via connector sleeve, circuit 87D2 (Z7/48)
mm2
OM628 rd/gn CDI control module (N3/9)
44  10
87 1.5mm2
rd/gn  Starter relay (K40/kL), right front fuse and relay
module (K40/7)
0.5mm2
rd/gn  Engine and AC electric suction fan with
integrated control (M4/7)
0.75mm2
 Charge fan circulation pump (M44)
45 - - - -
with Active-Body-Control (ABC):
 ABC control module (N51/2)

ws/ge 0.5
46 87 5
mm2
with air suspension:
 AIRmatic with ADS control module (N51)

bk/bl
47 15 AAC multifunction sensor (B31/1) 10
0.75mm2
bk/bl
Control module box blower motor (M2/2)
0.5mm2
AAC multifunction sensor (B31/1)
Actuation of auxiliary air unit relay (K25) via coolant
or transmission oil cooling connector (X22/3)
via blower/fan connector sleeve (Z5/1)
bk/bl
0.75mm2  AAC multifunction sensor (B31/1)
 Actuation of auxiliary fan unit relay (K25) via
coolant or transmission oil cooling connector
(X22/3)
 Control module box blower motor (M2/2)
bk/bl
0.5mm2
48 bk/vi
15 Suction-type fan control module (N65/2) 7,5
M112/113 0.5mm2
bk/vi Engine and AC electric suction fan with integrated
48 M137 15 7,5
0.5mm2 control (M4/7)
bk/ye
49 15 1.5mm2 Fused via circuit 15 connector sleeve (Z3/29) 15
bk/gn
 Ignition coil (T1/1) up to (T1/8)
1.5mm2
 Radio interference suppression capacitor (C4),
bk 1.0mm2 15
Japan USA
Fuse assignment of fuse and relay box in right engine compartment - GF54.15-P-1256-02JR
Model 215, 220 as of 1.9.02 up to 31.5.04
Assignment of fuse and relay box on right of engine compartment
Fig. 15: Fuse Assignment Of Fuse And Relay Box In Right Engine Compartment - As Of 1.9.02 Up To
31.5.04

F28 30 - FAN relay module (K40/7kP) 15
F29 87 - Motor electronics/chassis relay (K40/7kK) 20
F30 87 - Motor electronics/chassis relay (K40/7kK) 20
F31 87 - Air pump relay (K40/7kN) 40
F32 87 - Air compressor relay (K40/7kO) 40
rt/ge 4.0
F33 30 Heating systems recirculation unit (A32) 40
mm2
rt/ge 0.5
F34 87 ESP, SPS [PML] and BAS control unit (N47-5) 10
mm2
Valid for steering wheel heater (code 443):
F 35 30 rt 1.5 mm2 DC/DC converter control unit (N99) 15
Valid for Distronic (DTR) (code 219a):
F 36 87 rt 0.5 mm2 DTR control unit (N63/1) 7.5
rt/ge 1.5 Via connector sleeve circuit 87 (Z7/5):

mm2  VGS electric control unit (Y3/8)
rt/ge 1.0  Electronic selector lever module control unit (N15/5),
F37 87 mm2 only AMG 15
rt/ge 0.75  ETC [EGS] control unit (N15/3)
mm2
rt/ws 0.5
F38 30 Trunk lid emergency release switch (S88/10) 5
mm2
rt/sw 4.0 Right front door control unit (N69/2), model 220

F39 30 40
mm2  Right door control unit (N69/2), model 215
Valid for Bi-Xenon headlamp (code 614) , standard on

F 40 15 rt 1.0 mm2 model 215 and xenon headlamp unit (code 612b): 10
 via AHRA [ALWR] circuit 15 connector sleeve

rt 0.75 mm2 (Z3/50):
 Headlamp range adjustment control unit (N71)
Valid for stationary heater (code 228):

via circuit 30 connector sleeve (solder connector in harness)
(Z7/26):
F41 30 rt 2.5 mm2
 STH heater unit (A6), model 215
 STH or HB heater unit (A6), model 220
 STH radio remote control receiver (A6/1)
rt 0.75 mm2
Valid for stationary heater (code 228), only model 220
with engine 613, 628:
rt 2.5 mm2 20
 STH heater unit or heater booster heater unit (A6)
sw/bl 1.5
F42 30 Auxiliary air unit relay (K25) 20
mm2
Diesel engine 613:
via circuit 87 connector sleeveD1 (Z7/47):
rt/bl 2,5
F43 87 25
mm2  CDI control unit (N3/9)
 CDI relay (K40/7kM)
rt/bl 4,0 Diesel engine 628, 648:

mm2 via circuit 87 connector sleeveD1 (Z7/47):
rt/bl 2,5
 CDI control unit (N3/9)
mm2
 CDI relay (K40/7kM)
rt/bl 1,5
 Fuel pump relay (K 40/5kT), only engine 648
mm2
 Starter relay (K 40/7kL)
Diesel engine 613:
rt/gn 1,0  CDI relay (K40/7kM)
F44 87 7.5
mm
rt/gn 1,5
mm2
rt/gn 2,5 Diesel engine 628:
10
mm2 via connector sleeve circuit 87D2 (Z7/48):
rt/gn 1,5  AAC with integrated control additional fan motor
mm2 (M4/7)
 Charge air cooler circulation pump (M44)
rt/gn 2,5 Diesel engine 648:

mm2 via connector sleeve circuit 87D2 (Z7/48):
rt/gn 1,5
mm2
rt/gn 0,75  CDI relay (K40/7kM)
mm2  AAC with integrated control additional fan motor
(M4/7)
F45 87 - - -
Valid for Active Body Control (ABC) (code 487a):
 ABC control unit (N51/2) standard for model 215

ws/ge 0.5
F46 87 5
mm2
with air suspension:
 AIRmatic with ADS control unit (N51)

 AAC multifunction sensor (B31/1)
sw/bl 0.75
 Control unit box blower motor (M2/2)
mm2
sw/bl 0.5
F47 15 10
mm2 Via blower/fan connector sleeve (Z5/1):
sw/bl 0.75
mm2  AAC [KLA] multifunction sensor (B31/1), valid for
right-hand drive vehicles
sw/bl 0.5
 Coolant temperature switch (100° C) (A27/1s1)
mm
F 48 - - - -
sw/ge 1.5
mm2
F49 15 Via circuit 15 connector sleeve (fused) 15 (Z3/29): 15
sw/ge 1.0
mm2
 Cylinder 1 ignition coil (T1/1)
sw/gn 0.75
mm2
sw 1.0 mm2  Right radio interference suppression capacitor (C4)
sw/ge 1.5
mm2
Via circuit 15 connector sleeve (fused) (Z3/29):
sw/ge 1.0
mm2
sw/ge 0.75
mm2
 Cylinder 7 ignition coil (T1/7), only engine 113
 Cylinder 8 ignition coil (T1/8), only engine 113
sw 1.0 mm2  Left radio interference suppression capacitor (C4)
Fuse assignment of fuse and relay box in right engine compartment - GF54.15-P-1256-02KR
Model 215, 220 as of 1.6.04
Assignment of fuse and relay box on right of engine compartment
Fig. 16: Fuse Assignment Of Fuse And Relay Box In Right Engine Compartment - As Of 1.6.04

f28 30 -  FAN relay module (K40/7kP) 15
Valid for engine 112, 113
f29 87 - 20
 Motor electronics/chassis relay (K40/7kK)
Valid for engine 112, 113

f30 87 -  Motor electronics/chassis relay (K40/7kK) 20
f31 87 -  Air pump relay (K40/7kN) 40
f32 87 -  Air compressor relay (K40/7kO) 40
rt/ge 4.0
f33 30  Heating systems recirculation unit (A32) 40
mm2
rt/ge 0.5
f34 87  ESP, SPS [PML] and BAS control unit (N47-5) 10
mm2
Valid for code (443) steering wheel heater:
f35 30 rt 1.5 mm2 15
 DC/DC converter control unit (N99)
Valid for code (219) Distronic (DTR):
f36 87 rt 0.5 mm2 7.5
 DTR control unit (N63/1)
 ETC [EGS] control unit (N15/3)
rt/ge 1.5
f37 87  Electronic selector lever module control unit (N15/5) 15
mm2
 VGS electric control unit (Y3/8)
rt/ws 0.5 Valid for code (494) USA version:

f38 30 5
mm2  Trunk lid emergency release switch (S88/10)
 Right front door control unit (N69/2)

rt/sw 4.0
f39 30 40
mm2
Right door control unit (N69/2)

Valid for model 220, with code (612) xenon headlamp
unit, with code(614) Bi-Xenon headlamp:
f40 15 rt 1.0 mm2 10
 Headlamp range adjustment control unit (N71)
Valid for code (228) Stationary heater:
 STH radio remote control receiver (A6/1)
f41 30 rt 2.5 mm2 Valid for model 215: 20
 STH heater unit (A6)
Valid for model 220

 STH heater unit or heater booster heater unit (A6)
sw/bl 1.5 Valid for engine 131, 628:
f42 30 20
mm2  Auxiliary air unit relay (K25)
Valid for engine 628, 648:

rt/bl 4.0  Starter relay (K40/7kl)
f43 87 25
mm2
Valid for engine 648:
 Fuel pump relay (K40/5kT)

Valid for engine 628, 648:

 Right front fuse and relay module (K40/7)
rt/gn 2.5  AAC with integrated control additional fan motor
F44 87 (M4/7) 10
mm2

f45 87 - - -
Valid for code (487) Active Body Control (ABC):
 ABC control unit (N51/2)

ws/ge 0.5
f46 87 5
mm2 Valid for model 220, with code (489) Airmatic (semi-
active air suspension):
 AIRmatic with ADS control unit (N51)
 AAC multifunction sensor (B31/1)
sw/bl 0.75
f47 15 Valid for right-hand drive vehicles: 10
mm2
 Control unit box blower motor (M2/2)

 Coolant temperature switch (100° C) (A27/1s1)
f48 - - - -
Valid for engines 112, 113:
 Radio interference suppression capacitor (C4)

sw/ge 1.5  Cylinder 4 ignition coil (T1/4)
f49 15 15
mm2  Cylinder 5 ignition coil (T1/5)

Fuse assignment of fuse and relay box in engine compartment, left - GF54.15-P-1256-03IL
Assignment of fuse and relay box in engine compartment, left
Fig. 17: Fuse Assignment Of Fuse And Relay Box In Engine Compartment, Left - Up To 31.8.02

1 87 - Wiper park heater relay (K40/6kA) 40
2 87 - High pressure and return pump relay (K40/6kF) 50
3 30 - 15
Steering wheel adjustment, horizontal:
 S relay 1, jacket tube longitudinal adjustment (K40/6kD)
 S relay 2, jacket tube longitudinal adjustment (K40/6kE)
Steering wheel adjustment, vertical:

4 30 - S relay 1, jacket tube, height adjustment (K40/6kI) 15
 S relay 2, jacket tube height adjustment (K40/6kJ)
5 15R - Wiper On and Off relay (K40/6kH) 40

bk/vi
6 15 Heater booster switch (S4/3) 7,5
0.75mm2
7 15 - - -
8 30 - - -
Valid for air suspension:

rd/wt
9 30 30
1.5mm2
Valid for Active-Body-Control (ABC):
 ABC control module (N51/2)

bk/bl
10 15  Windshield wiper water pump (M5/1) 15
0.75mm2
bk/gr
11 15R Front cigar lighter with ashtray illumination (R3) 15
1.5mm2
pk/gn
12 15R Sensor for vehicle-sensitive seat belt lock (A60) 7,5
0.5mm2
rd/bk
13 30 Left front door control module (N69/1) 40
4.0mm2
14 15R - - -
15 30 - - -
bk/bl
16 15R Stop light switch (S9/1) 7,5
0.5mm2
17 - - - -
Valid for D-net portable CTEL (D2B) (preinstallation)
(code 317):
bk/ye  Portable CTEL connector (X39/39)

18 15R 5
0.75mm2
Valid for MB D-net telephone (D2B) (code 316):
 D2B interface for permanently installed telephone (A59)
Valid for MB D-net telephone (D2B) (code 316) with Tele

Aid emergency call system (code 347):
 TELE AID control module (A35/8)
bk/ye Valid for MB D-net telephone (D2B) (code 316) with E-call
0.5mm2 emergency call system (code 349) via connector sleeve
circuit 15R (Z3/12):
 D2B-Interface fixed installation (A59)

 Frequency selector control module (N96)
 Emergency call control module (A35/8)
19 15 - - -
bk/gn Instrument cluster (A1)
20 15 5
0.5mm2 Datalink connector (X11/4)
bk/ye
21 15R Instrument cluster (A1) 5
0.5mm2
rd/ye
22 30 Instrument cluster (A1) 5
0.75mm2
rd/wt
1.5mm2 via circuit 30 connector sleeve, climate control (Z7/21):
rd/wt
0.75mm2  AAC [KLA] control and operating module (N22)
23 30 Circulation pump (A31/1m1) 10
rd/wt 
0.5mm2  Left duovalve (A31/1y1)

rd/wt  Right duovalve (A31/1y2)
0.75mm2
rd/bl
24 30 Diagnostic connector (X11/4) 10
0.75mm2
25 30 - - -
rd/bk
26 30 Upper control panel control module (N72/1) 10
0.75mm2
27 30 - - -
Fuse assignment of fuse and relay box in engine compartment, left - GF54.15-P-1256-03JL
Model 215, 220 as of 1.9.02 up to 31.8.03

Fig. 18: Fuse Assignment Of Fuse And Relay Box In Engine Compartment, Left - As Of 1.9.02 Up To
31.8.03

F1 87 - Wiper park heater relay (K40/6kA) 40
F2 87 - High pressure and return pump relay (K40/6kF) 50
Steering wheel adjustment, horizontal:
 Steering column forward/back adjustment relay 1

F3 30 - (K40/6kD) 15
(K40/6kE)
Steering wheel adjustment, vertical:
F4 30 -  Steering column height adjustment relay 1 (K40/6kI) 15
 Steering column height adjustment relay 2 (K40/6kJ)
F5 15R - Wiper On and Off relay (K40/6kH) 40

F6 - - - -
F7 - - - -
F8 - - - -
Valid for air suspension:

rd/wt 1.5
F9 30 30
mm2
Valid for Active Body Control (ABC) (Code 487a):
 ABC control unit (N51/2), standard on model 215

bk/bl
F10 15 Windshield washer fluid pump (M5/1) 15
0.75mm2
bk/ye
F11 15R Separation point for VICS voltage supply (X137/1), 5
0.5mm2
F12 15R - - -
rd/bk 4.0  Left front door control unit (N69/1), model 220
F13 30 40
mm2  Left door control unit (N69/1), model 215
F14 15R - - 10
F15 30 - - 30
F16 15R bk/bl 0.5mm2 Stop light switch (S9/1) 7.5
pk/gn
F17 15R Vehicle-sensitive seatbelt lock sensor (A60), model 215 7.5
0.5mm2
Valid for telephone preinstallation network D-portable
bk/ye CTEL (code 273):
F18 15R 2 5
0.75mm
Valid for MB standard telephone (code 853):
 Cellular telephone transmitter and receiver unit,

D2B (A35/13)
Valid for TELE AID (code 855):
bk/ye  Telephone and TELE AID transmitter and receiver

0.5mm2 unit, D2B (A35/17)
Valid for EMERGENCY CALL emergency call system

(code 348a), USA only:
 via circuit 15R (Z3/12) connector sleeve

 E-Call control unit (A35/8)
 Telephone interface (A34/4)
 Left front reversible emergency tensioning retractor

(A76) model 220
F19 15 rd/ye 0.5mm2 5
 Right front reversible emergency tensioning
retractor (A76/1) model 220
F20 15 - - -
F21 15R - - -
Valid for COMAND operating and display system
rd/ye 2.5 (Code 352a):
F22 30 15
mm2  COMAND operating, display and control module
(A40/3)
Valid for TV tuner (code 860) and COMAND operating
and display system (code 352a):
 TV tuner (A2/42)
Valid for COMAND operating and display system

(code 352a) and Japanese version (code 498):
rd/ye  Via terminal 30 connector sleeve (Z4/3):
F23 30 7.5
0.75mm2  Operating and display unit rear screen (A40/2)
Valid for CD changer (code 819) and Japanese version

(code 498):
 via circuit 30 connector sleeve (Z4/3)

 CD player with changer (in luggage
compartment) (A2/6)
rd/ye 2.5
F24 30 Audio gateway control module (N93/1) 20
mm2
rd/ye 2.5 Valid for sound system (code 810):
F25 30 25
mm2  Sound amplifier (A2/13), standard on model 215
F26 - - - -
F27 30 - - -
Fuse assignment of fuse and relay box in engine compartment, left - GF54.15-P-1256-03KL
Model 215, 220 as of 1.9.03

Fig. 19: Fuse Assignment Of Fuse And Relay Box In Engine Compartment, Left - As Of 1.9.03

fused amperes (A)
wire
f1 87 -  Wiper park heater relay (K40/6kA) 40
f2 87 -  High pressure and return pump relay (K40/6kF) 50
(K40/6kD)
f3 30 - 15
(K40/6kE)
 Steering column height adjustment relay 1 (K40/6kI)
f4 30 - 15
 Steering column height adjustment relay 2 (K40/6kJ)
f5 15R -  Wiper On and Off relay (K40/6kH) 40
f6 - - - -
f7 - - - -
f8 - - - -
Valid for model 220, with code (489) Airmatic (semi-active
air suspension):
rt/ws 1.5  AIRmatic with ADS control unit (N51)

f9 30 20
mm2
Valid for code (487) Active Body Control (ABC):
 ABC control unit (N51/2)

sw/bl 0.75
f10 15  Windshield washer fluid pump (M5/1) 15
mm2
Valid for code (352) COMAND operating and display
sw/ge 0.5 system, for code (498) Japan version, for code (813) Voice
f11 15R control system (VCS [SBS]): 5
mm2
 VICS power supply separation pointX137/1
f12 15R - - -
 Left front door control unit (N69/1)

rt/sw 4.0
f13 30 40
mm2
 Left door control unit (N69/1)

f14 15R - - -
f15 30 - - -
sw/bl 0.5
f16 15R  Stop light switch (S9/1) 7.5
mm2
rs/gn 0.5 Valid for model 215:
f17 15R 7.5
mm2  Vehicle-sensitive seat belt lock sensor (A60)
Valid for code (380) Preinstallation for MB phone
sw/ge 0.75 "CTEL" (complete):
f18 15R 5
mm2
gn/rt 0.5 Valid for code (494) USA version:

mm2  Emergency call system control unit (N123/4)
rt/ge 0.5  Left front reversible emergency tensioning retractor

f19 15 5
mm2 (A76)
 Right front reversible emergency tensioning retractor
(A76/1)
f20 15 - - -
f21 15R - - -
Valid for code (352) COMAND operating and display
rt/ge 0.75 system, except code (498) Japan version:
f22 30 7.5
mm2
rt/ge 2.5 Valid with code (498) Japan version:

15
mm2  COMAND operating, display and control unit (A40/3)
Valid for code (819) CD changer (6 CDs):
 CD player with changer (in trunk) (A2/6)
rt/ge 0.75
f23 30 7.5
mm2 Valid for code (352) COMAND operating and display
system, for code (498) Japan version, for code (861) Rear
TV screen:
 Operating and display unit display in rear (A40/2)

rt/ge 2.5
f24 30  Audio gateway control unit (N93/1) 20
mm2
rt/ge 2.5 Valid for code (810) sound system:
f25 30 25
mm2  Sound amplifier (A2/13)
f26 - - - -
f27 30 - - -
Fuse assignment of fuse box in cockpit - GF54.15-P-1256-09JC
Model 215, 220 as of 1.9.02
Assignment of fuse box in interior
Fig. 20: Fuse Assignment Of Fuse Box In Interior - Cockpit
Fuse Terminal Color of fused Fused function Rating in amperes

wire (A)
 Alarm signal horn with additional battery
(H3/1)
f78 30z rt 4.0 mm2  Steering column module (N80) 7.5
 EIS control unit (N73)
 ME-SFI control unit (N3/10)
f79 30 rt/ge 0.5 mm2  Instrument cluster (A1) 5
f80 30 rt/sw 0.75 mm2  Upper control panel control unit (N72/1) 10
f81 30 rt/bl 0.75 mm2  Data link connector (X11/4) 10
 AAC [KLA] control and operating unit
f82 30 rt/ws 1.5 mm2 (N22) 10
 Heating system delivery unit (A31)
f83 30 rt/vi 0.75 mm2  Central gateway control unit (N93) 10
 Instrument cluster (A1)

f84 15 sw/gn 0.5 mm2  Data link connector (X11/4) 5
f85 15R sw/ge 0.5 mm2  Instrument cluster (A1) 5
 Front cigar lighter with ashtray
f86 15R sw/gr 1.5 mm2 15
illumination (R3)
Fuse assignment of fuse and relay box in right front of engine compartment - GF54.15-P-1256-10JM
Model 215, 220 as of 1.9.02 up to 31.8.03
Assignment of engine fuse and relay box
Fig. 21: Fuse Assignment Of Fuse And Relay Box In Right Front Of Engine Compartment - As Of 1.9.02
Up To 31.8.03
Fuse Terminal Color of fused Fused function Rating in amperes

wire (A)
Motronic relay (K40/8kV), M275/M113/E55
F87 87 - 20
AMG
Motronic relay (K40/8kV), M275/M113/E55
F88 87 - 20
AMG
F89 87 - - -
Charge air relay (K40/8kW), M275/M113/E55
F90 87 - 10
AMG
F91 87 - - -
Fuse assignment of fuse and relay box in right front of engine compartment - GF54.15-P-1256-10KM
Model 215, 220 as of 1.9.03
Assignment of engine fuse and relay box

Fig. 22: Fuse Assignment Of Fuse And Relay Box In Right Front Of Engine Compartment - As Of 1.9.03

Valid for engine 112, 113, 275, on model 220 S 65 AMG,
on model 215, CL 65 AMG:
f87 87 - 20
 Motronic relay (K40/8kV)
Valid for engine 112, 113, 275, on model 220 S 65 AMG,
on model 215, CL 65 AMG:
f88 87 - 20
 Motronic relay (K40/8kV)
f89 87 - - -
Valid for engine 113, 275, on model 220 S 65 AMG, on
model 215, CL 65 AMG:
f90 87 - 10
Valid for model 220, for engine S55AMG, S65AMG, for
model 215 for engine CL 55 AMG, CL 65 AMG:
f91 87 - 10
 Intank fuel pump (M3/1)
Fuse assignment as-built configuration - GF54.15-P-1256MB
MODEL 220 with CODE (979) Special protection version with CODE (Z04) Light armoring with CODE
(Z07) Maximum protection
Fuse assignment of fuse and relay box in rear GF54.15-P-1256-01MB

Fuse assignment in fuse and relay box in engine compartment on right GF54.15-P-1256-02MB
Fuse assignment of fuse and relay box in engine compartment on left GF54.15-P-1256-03MB
Fuse assignment of fuse and relay box in rear - GF54.15-P-1256-01MB

Assignment of fuse and relay box in rear
Fig. 23: Fuse Assignment Of Fuse And Relay Box In Rear
Fuse Terminal Color of fused Fused function Rating in

wire amperes (A)
50 - - Rear sun blind relay (K40/5kQ) 10
51 - - Anti-towing sensor relay (K40/5kR) 5
52 - - Fuel pump relay (K40/5kT) 30
53 - - Relay for rear window defroster (K40/5kQ) 50
black/yellow
54 15 Automatic fire warning and extinguishing system 10
(sw/ge) 0.5 mm2
red/green (rt/gn)
55 30 PAS and special signal system 30
4.0 mm2
56 30 - Hydraulic window lift mechanism 40
57 - - - -
red/yellow (rt/ge)
58 30 Automatic fire warning and extinguishing system 7.5
0.75 mm2
59 - - PAS MCS 30
60 - - - -
61 30 Valid for radio (D2B): 10
red/yellow (rt/ge)  via sleeve connector c. 30 (Z4/3)
1.5 mm2  Radio (A2)
red/yellow (rt/ge)  Antenna amplifier module on rear window
0.75 mm2 (A2/12)
 via sleeve connector c. 30 (Z4/3)
red/yellow (rt/ge)  Radio (A2)

0.75 mm2  Antenna amplifier module on 2 rear window
(A2/12)
CD player with changer (in trunk) (A2/6)
Valid for cockpit management and data system
15
(COMAND):
red/ yellow (rt/ge)  COMAND operating, display and control module
1.0 mm2 (A40/3n1)
red/yellow (rt/ge)  via sleeve connector c. 30 (Z4/3) COMAND
1.5 mm2 operating, display and control module (A40/3n1)
Antenna amplifier module on rear window
red/yellow (rt/ge) (A2/12)
0.75 mm2  Navigation processor (A40/3n2)
 TV tuner (Europe, USA) (A2/42)
Valid for cockpit management and data system

15
(COMAND) with traffic data memory:
red/yellow (rt/ge)  COMAND operating, display and control module
1.0 mm2 (A40/3n1)
red/yellow (rt/ge)  via sleeve connector c. 30 (Z4/3) COMAND
1.5 mm2 operating, display and control module (A40/3n1)
Traffic data memory (A2/43)

red/yellow (rt/ge)  Navigation processor (A40/3n2)
0.75 mm2  Antenna amplifier module on rear window
(A2/12) 43 of 346
black/yellow PSE control module (A37)
62 30 20
(sw/ge) 0.75 mm2 ATA inclination sensor (B33)
Valid for D2B telephone (code 316):
red/black (rt/sw)
63 30 5
0.75 mm2  D2B interface for permanently installed
telephone (A59)
 Telephone transmitter/receiver (A35) if with TELE
emergency call (TELE AID) is present, AID 7.5
 Emergency call control module (TELE AID)
(A35/8)
7.5
or
valid for D2B telephone (code 316) with voice

control system (813b):
 via sleeve connector c. 30 (Z7/26) 5

 D2B interface for permanently installed
telephone (A59) Telephone
transmitter/receiver (A35)
 Voice control system control module
(A35/11) if emergency call (TELE AID) is
present,
with TELE
 Emergency call control module (TELE AID) AID
(A35/8) 7.5
Valid for D2B portable cellular telephone (code 317)
(preequipment): 5
Portable cellular telephone connector (X39/39)
Valid for optional portable cellular telephone:
 D2B interface for permanently installed

telephone (A59)
red/black (rt/sw)
64 30 5
0.5 mm2 Valid for D2B portable cellular telephone (code 317)
(preequipment):
 D2B interface for portable cellular telephone

(A59/1)
red/black (rt/sw)
65 30 D2B interface for portable cellular telephone (A59/1) 5
0.5 mm2
66 30 - Interior lamp with universal joint 7.5
red/blue (rt/bl) 2.5
67 30 Rear HS control module (N25/6) 25
mm2
via sleeve connector c. 30 (Z7/40):
 Rear AC control module (N22/4)

 Rear AC refrigerant shut-off valve (Y67)
red/white (rt/ws)
68 30 15
1.5 mm2  Heating system delivery unit (A31/1)
 Coolant circulation pump (A31/1-m1)
 Left duo valve (A31/1-y1)
 Right duo valve (A31/1-y2)
red/black (rt/sw) Valid for rear air conditioning:

69 30 15
1.0 mm2 Rear AC pushbutton control module (N22/3)
red/black (rt/sw)
70 30 Tire pressure monitor control module (N88) 10
0.75 mm2
red/brown (rt/br) Left front seat adjustment control module with memory
71 30 25
2.5 mm2 (N32/1)
red/green (rt/gn)
72 30 Left rear door control module (N69/3) 40
4.0 mm2
73 30 red/violet (rt/vi) Right front seat adjustment door control module with 25
2.5 mm2 memory (N32/2)
74 30 Right rear door control module (N69/4) 40
mm2
black/red (sw/rt) with Parktronic system (code 220a):
75 15 10
1.5 mm2 PTS control module (N62)
76 30 Refrigerator box in rear armrest (A39/1) 15
mm2
red/black (rt/sw)
77 30 Overhead control panel control module (N70) 40
2.5 mm2
Fuse assignment in fuse and relay box in engine compartment on right - GF54.15-P-1256-02MB
Assignment for fuse and relay box in engine compartment on right
Fig. 24: Fuse Assignment In Fuse And Relay Box In Engine Compartment On Right
Fuse Clamp Color of fused Fused function Rating in

wire amperes (A)
28 - - Fanfare horns relay (K40/7KP) 15
29 - - Engine electronics/chassis relay (K40/7kK) 10
30 - - Engine electronics/chassis relay (K40/7kK) 20
31 - - Secondary air pump relay (K40/7kN) 40
32 - - Air compressor relay (K40/7kO) 40
33 - - Electric suction-type fan 60
Traction system control module:
red/yellow (rt/ge)
34 87 Control module for ESP, SPS and BAS (N47-5) 5
0.5 mm2 (electronic stability program (ESP), speed sensitive
power steering (SPS), brake assist (BAS))
Heating systems recirculation unit (A32)
35 30 40
red/yellow (rt/ge)  Blower regulator (A32n1)
4.0 mm2 Blower motor (A32m1)
with Distronic (code 219a):
36 30 red (rt) 0.5 mm2 DTR control module (N63/1) 7.5
red/yellow (rt/ge) Connector sleeve c.87 (Z7/5):
1.5 mm2
37 87  Electronic selector level control module (N15/5)
15
red/yellow (rt/ge)
1.5 mm 2  ETC control module (N15/3)
38 - - - -
red/black (rt/sw)
39 30 Right front door control module (N69/2) 40
4.0 mm2
With xenon headlamp (code 612b):
40 15 red (rt) 0.75 mm2 Headlamp range adjustment control module (N71) 10
with stationary heater (code 228):
via sleeve connector c. 30 (Z7/26)
41 30 red (rt) 2.5 mm2  Stationary heater or heater booster (A6) 20
 Receiver for stationary heater radio remote control
(A6/1)
 via sleeve connector c. 87 (Z7/24):
 Transmission oil fan motor relay (K25)
black/blue
42 30 20
(sw/bl) 1.5 mm2  Engine oil fan unit (A27/1):
Temperature switch (100 °C) (A27/1s1)

43 - - - -
44 - - - -
45 - - - -
white/yellow
46 87 ADS, suspension control module (N51) 5
(ws/ge) 0.5 mm2
black/blue
47 15 Multi-function sensor (B31/1) 7.5
(sw/bl) 0.5 mm2
black/violet
48 15 Suction fan control module (N65/2) 7.5
(sw/vi) 0.5 mm2
black/violet
49 15 Suction fan control module (N65/2) 7.5
(sw/vi) 0.5 mm2
Fuse assignment of fuse and relay box in engine compartment on left - GF54.15-P-1256-03MB
Assignment for fuse and relay box in engine compartment on left

Fig. 25: Fuse Assignment Of Fuse And Relay Box In Engine Compartment On Left
Fuse Terminal Color of fused wire Fused function Rating in

amperes (A)
1 - - - -
2 - - High pressure and return pump relay (K40/6kF) 50
Jacket tube horizontal adjustment relay 1
3 - - 15
(K40/6kD)
Jacket tube vertical adjustment relay 2
4 - - 15
(K40/6kJ)
5 - - Wiper on and off relay (K40/6kH) 40
6 - - Hydraulic brake 5
7 - 2nd three-phase alternator 7.5
9 30 red/white (rt/ws) 1.5 mm2  ADS, suspension control module (N51) 30
black/blue (sw/bl) 0.75
10 15  Windshield washer water pump (M5/1) 15
mm2
black/yellow (sw/ge) 1.5  Circuit 15 connector sleeve (fused)
mm 2
(Z3/29)
black/green (sw/gn)1.5
 Ignition coils
mm / black/yellow
 Ignition coils
(sw/ge) 1.5 mm2
gray/black (gr/sw) 1.5 Cigarette lighter illuminated (R3):
11 15R 15
mm2  Heating element (R3-r1)
Sensor for left side airbag and window airbag

black/blue (sw/bl) 0.5 (A53/1)
12 15R 7.5
mm2 Sensor for right side airbag and window airbag
(A54/1)
13 30 red/black (rt/sw) 4.0 mm2 Left front door control module (N69/1) 40
black/blue (sw/bl) 0.5
16 15R Stop lamp switch (S9/1) 7.5
mm2
17 - - - -
Valid for D2B portable cellular telephone
(code 317) (preequipment):
 Portable cellular telephone connector

(X39/39)
Valid for D2B telephone (code 316):
 - D2B interface for permanently installed

telephone (A59)
Telephone transmitter/receiver (A35)

black/yellow (sw/ge) 0.75
18 15R Valid for D2B telephone (code 316) with voice 5
mm2 control system (813b):

telephone (A59)
Telephone transmitter/receiver (A35)
Valid for D2B telephone (code 316) with

TELE AID emergency call system (code 347):

telephone (A59)
 Telephone transmitter/receiver (A35)
black/yellow (sw/ge) 0.5  Emergency call control module (TELE
mm2 AID) (A35/8)
black/red (sw/rt) 0.75
19 15 Instrument cluster (A1) 7.5
mm2
 Diagnostic cables connector sleeve
(Z6/33):
Instrument cluster (A1)
Data link connector (X11/4)
 Separation point
Compact wiring harness/diagnosis
module II, cockpit (X35/66)
 Intermediate connector
black/green (sw/gn) 2.5
20 15 7.5
mm2 Diagnosis/taillamp wiring harness
16-pin (X11/15)
 Measuring connector (X11/19)
black/green (sw/gn) 0.5

 Data link connector (X11/4)
mm2
black/yellow (sw/ge) 0.75
21 15R Instrument cluster (A1) 7.5
mm2
red/yellow (rt/ge) 0.75
22 30 Instrument cluster (A1) 7.5
mm2
via connector sleeve c. 30 fused (Z7/21):
 Automatic air conditioning (AAC)

pushbutton control module (N22)
23 30 red/white (rt/ws) 1.5 mm2  Heating system delivery unit (A31) 10
 Coolant circulation pump (A31/-
m1)
 Left duo valve (A31/-y1)
 Right duo valve (A31/-y2)
 via diagnostic cable connector sleeve

(Z6/33):
 Instrument cluster (A1)
 Data link connector (X11/4)
 Separation point
Compact wiring harness/diagnosis

24 30 red/blue (rt/bl) 2.5 mm2 module II, cockpit (X35/66)
10
 Intermediate connector
Diagnosis/taillamp wiring harness

16-pin (X11/15)
 Measuring connector (X11/19)

red/blue (rt/bl) 0.5 mm2  Data link connector (X11/4)
red/yellow (rt/ge) 0.75
25 30 Jacket tube module (N80) 10
mm2
red/black (rt/sw) 0.75
26 30 Upper control panel control module (N72/1) 10
mm2
27 - - - -
RELAY ASSIGNMENT - GF54.15-P-1257
Relay assignment, production details - GF54.15-P-1257I
Models 215, 220
GF54.15-P-1257-
Relay assignment of rear fuse and relay box
01IH
GF54.15-P-1257-
Relay assignment of fuse and relay box in right engine compartment
02IR
GF54.15-P-1257-
Relay assignment of fuse and relay box in engine compartment, left
03IL
Relay assignment of fuse and relay box in right front of engine As of GF54.15-P-1257-
compartment 1.9.02. 05IM
Relay assignment of rear fuse and relay box - GF54.15-P-1257-01IH
Fig. 26: Relay Assignment Of Rear Fuse And Relay Box
Bay Designation
Q Rear window roller blind relay (K40/5kQ)
R Towing sensor relay (K40/5kR)
S Circuit 15 relay (K40/5kS)
T Fuel pump relay (K40/5kT)
U Rear window defroster relay (K40/5kU)
Relay assignment of fuse and relay box in right engine compartment - GF54.15-P-1257-02IR
Fuse and relay box in right of engine compartment
Fig. 27: Relay Assignment Of Fuse And Relay Box In Right Engine Compartment
Bay Designation
K Motor electronics/chassis relay (K40/7kK)
L Starter relay (K40/7kl)
Only valid for diesel:
M
CDI relay (K40/7kM)
N Air pump relay (K40/7kN)
O Air compressor relay (K40/7kO)
P Fanfare horns relay (K40/7kP)
Relay assignment of fuse and relay box in engine compartment, left - GF54.15-P-1257-03IL
Fuse and relay box in left of engine compartment
Fig. 28: Relay Assignment Of Fuse And Relay Box In Left Of Engine Compartment
Bay Designation
A Wiper park heater relay (K40/6kA)
B Circuit 15 relay (k40/6kB)
C Circuit relay 15R (K40/6kC)
D Steering column forward/back adjustment relay 1 (K40/6kD)
E Steering column forward/back adjustment relay 2 (K40/6kE)
F High pressure and return pump relay (K40/6kF)
G Wiper stage 1 and 2 relay (K40/6kG)
H Wiper On and Off relay (K40/6kH)
I Steering column height adjustment relay 1 (K40/6kI)
J Steering column height adjustment relay 2 (K40/6kJ)
Relay assignment of fuse and relay box in right front of engine compartment - GF54.15-P-1257-05IM
Model 215, 220 as of 1.9.02
Assignment of fuse and relay box in right front of engine compartment
Fig. 29: Relay Assignment Of Fuse And Relay Box In Right Front Of Engine Compartment
Bay Designation
V Motronic relay (K40/8kV)
W Charge air relay (K40/8kw)
X Intank fuel pump relay (K40/8kX), AMG only
Relay assignment as-built configuration - GF54.15-P-1257MB
MODEL 220 with CODE (979) Special protection version with CODE (Z07) Maximum protection
Fuse assignment of fuse and relay box in rear GF54.15-P-1257-01IH

Fuse assignment in fuse and relay box in engine compartment on right GF54.15-P-1257-02MB
Relay assignment of fuse and relay box in engine compartment on left GF54.15-P-1257-03MB
Fuse assignment in fuse and relay box in engine compartment on right - GF54.15-P-1257-02MB
Assignment for fuse and relay box in engine compartment on right
Fig. 30: Assignment For Fuse And Relay Box In Engine Compartment On Right
Plug location Designation

K Engine electronics/chassis relay (K40/7kK)
L Starter relay (K40/7kL)
M -
N Secondary air pump relay (K40/7kN)
O Air compressor relay (K40/7kO)
P Fanfare horns relay (K40/7KP)
V Brake booster hydraulic unit relay (K37)
E Brake booster hydraulic unit safety relay (K37/1)
Relay assignment of fuse and relay box in engine compartment on left - GF54.15-P-1257-03MB
Assignment for fuse and relay box in engine compartment on left

Fig. 31: Relay Assignment Of Fuse And Relay Box In Engine Compartment On Left
Bay Designation
A -
B Relay for c.15 (K40/6kB)
C Relay for c.15R (K40/6kC)
D Jacket tube horizontal adjustment relay 1 (K40/6kD)
E Jacket tube horizontal adjustment relay 2 (K40/6kD)
F High pressure and return pump relay (K40/6kF)
G Wiper position 1 and 2 relay (K40/6kG)
H Wiper on and off relay (K40/6kH)
I Jacket tube vertical adjustment relay 1 (K40/6kJ)
J Jacket tube vertical adjustment relay 2 (K40/6kI)
V Brake booster hydraulic unit relay (K37)
E Brake booster hydraulic unit safety relay (K37/1)
Fuse and relay assignment of fuse and relay holder in luggage compartment - GF54.15-P-1257-10M
Shown on model 220

Fig. 32: Identifying Fuse And Relay Holder, Fuse 52 And Fuel Pump Relay - Shown On Model 220
Fuse Terminal Cable ID (fused line) Fused function Rating in amperes (A)
K40/5f52 30 RD 10.0  Fuel pump (M3) 30
Relay Designation
K40/5kT  Fuel pump relay
FUEL PUMP RELAY, LOCATION/TASK/DESIGN/FUNCTION - GF54.15-P-4105
Fuel pump relay, location/task/design/function - GF54.15-P-4105AM
MODEL 230 with ENGINE 113.992 /995

Fig. 33: Identifying Fuel Pump Relay
Fuel pump relay, GF54.15-P-4105-

Model 211, 219
location 01TA
GF54.15-P-4105-
Model 215, 220
01AM
GF54.15-P-4105-
Model 230
01RA
GF54.15-P-4105-
Model 463
01GM
Fuel pump relay, The fuel pump relay actuates the fuel pump (M3) or the fuel
task pump control unit (N118).
Fuel pump relay,
The fuel pump relay is a 4-pin plug-in relay.
design
function 02AM
Fuel pump relay position - GF54.15-P-4105-01AM
Model 215, 220
Shown on MODEL 220
The fuel pump relay is located on the rear fuse and relay module (socket T).
Fig. 34: Identifying Fuel Pump Relay (Plug Position T) - Models 215, 220
Fuel pump relay, function - GF54.15-P-4105-02AM

If the relay is actuated by the ME-SFI [ME] control unit (N3/10) by a ground signal at "circuit 86", it closes its
power contact. When the power contact is closed the fuel pump control unit (N118) and the Fuel pump(s) (M3)
are connected via "circuit 87" with voltage from "circuit 30".
The two fuel pumps are connected in parallel on model 211, 219.
Fig. 35: Identifying Fuel Pump Relay With Circuit Diagram
Fuel pump relay position / task / design / function - GF54.15-P-4105L
ENGINE 104 (except 104.98) in MODEL 129,140, 202, 210
ENGINE 111 in MODEL 163, 170, 202, 203, 208, 210
ENGINE 112 (except 112.96) in MODEL 163, 170, 202, 203, 208, 209, 210, 211, 220, 230
ENGINE 113 (except 113.99) in MODEL 129, 163, 208, 209, 210, 211, 215, 220, 230
ENGINE 119 (except 119.96) in MODEL 129,140, 210

The brief designation relay differs for the various models.
Fig. 36: Identifying Fuel Pump Relay Module
Fuel pump relay position Model 129 GF54.15-P-4105-01D

Model 140 GF54.15-P-4105-01S
Model 163 with engine 111, GF54.15-P-4105-01GH
112, 113 up to 31.08.01
Model 163 with engines 111, GF54.15-P-4105-01GA
112, 113 as of 01.09.01
Model 170: integrated in relay GF54.15-P-4105-01A
module
Model 202, 208 GF54.15-P-4105-01L
Model 203, 209 GF54.15-P-4105-01P
Model 210 as of 3/97 GF54.15-P-4105-01F
Model Series 210 up to 2/97:
integrated in relay module
Model 211 with engine GF54.15-P-4105-01T
112.91/94/95, 113.96
Model 215, 220 GF54.15-P-4105-01M
Model 230 GF54.15-P-4105-01R
Fuel pump relay, task Actuates the fuel pump.
Fuel pump relay, design The fuel pump relay is a 4-pin
plug-in relay.
Fuel pump relay function GF54.15-P-4105-02L
Fuel pump relay position - GF54.15-P-4105-01M
Fuel pump relay function - GF54.15-P-4105-02L
Shown on model 140
Fig. 38: Identifying Fuel Pump Relay Module - Shown On Model 140
The fuel pump relay (K27) is switched by a ground signal from the control unit at terminal 86. If the contact is
closed, the fuel pump (M3) is connected to terminal 30 (B+) via terminal 87. Circuit 30 is protected by a 30 A
fuse.
With models 129, 140, 202, 208, the fuse is attached to the relay.
On vehicles with two fuel pumps, the pumps are connected in parallel.
Fuel pump relay, location/task/design/function - GF54.15-P-4105M
MODEL 215, 220 with ENGINE 275.950 /980

MODEL 230 with ENGINE 275.951 /954 /981
MODEL 240 with ENGINE 285.950 /980
Fig. 39: Identifying Fuel Pump Relay

Model 215, 220
location 01MM
Model 230 GF54.15-P-4105-01RM
Model 240 GF54.15-P-4105-01MA
To supply the fuel pump control unit (N118) with
Fuel pump relay, task
voltage.
Fuel pump relay, design 4-pin plug-type relay with an N.O. contact.
Fuel pump relay,
GF54.15-P-4105-02M
function
Fuel pump relay, location - GF54.15-P-4105-01MM
Fuel pump relay, function - GF54.15-P-4105-02M
When actuated by the motor electronics control unit, with a ground signal at circuit 86, the relay closes its
power contact. When the contact is closed the fuel pump control unit (N118) is connected to circuit 30 (B+) via
circuit 87. The voltage supply to circuit 30 is fused.
Fig. 41: Identifying Fuel Pump Relay With Circuit Diagram
LEFT SIGNAL ACQUISITION AND ACTUATION MODULE,

Models 215, 220
Left signal
acquisition and GF54.21-P-
actuation module, 4101-01I
location
Left signal
actuation module, 4101-03S
task
GF54.21-P-
Models 215, 220 in combination with automatic air conditioning
4101-03I
Left signal The left front SAM control unit (N10/6) is contained in a sturdy
acquisition and plastic housing. Power semiconductors are used to control smaller
actuation module, consumers directly. Five connectors are used to provide the
design necessary electrical connections.
Left signal
The left front SAM control unit (N10/6) detects incoming electrical
acquisition and
signals, evaluates the signals and controls the relevant components
actuation module,
as necessary.
function
Left signal acquisition and actuation module, location - GF54.21-P-4101-01I
Shown on model 220

The left front SAM control unit (N10/6) is located on the rear left of the engine compartment and is pushed onto
the left front fuse and relay module (K40/6) from underneath.
Fig. 42: Identifying Left Front SAM Control Unit And Fuse And Relay Module
Left signal acquisition and actuation module, task - GF54.21-P-4101-03I
Task
There are two types of input signals in the case of the left front SAM control module (N10/6):
 Digital signals
 Analog signals
Reading in digital signals:
Depending on how quickly the processor has to react to signal changes, the signals are read in in shorter or
longer intervals.
So that the system does not react to short-term faults, the left front SAM control module (N10/6) only takes
over signal changes when the new level value has been read in three times in succession.
Reading in analog signals:
The power supply to the switches and sensors depends on the present battery voltage. Before reading in a
switch/sensor, the processor first reads the unfiltered battery voltage. If the voltage is within the valid range, the
switch can be read in. This voltage is then set in proportion to the switch voltage. So that the system does not
react to short-term faults, the left front SAM control module (N10/6) only takes over changes when the new
level value has been read in three times in succession Sensor values are transmitted as physical values.
Reading in following sensors
 Refrigerant temperature
The refrigerant temperature sensor (B12/1) is supplied with 5V.
The sensor ground is to be selected jointly for the refrigerant temperature sensor (B12/1) and refrigerant
pressure sensor (B12). The temperature and pressure must also be measured at the same time.
 Refrigerant pressure
The refrigerant pressure sensor (B12) is supplied with 5 V stabilized. The sensor ground is to be selected
jointly for the refrigerant temperature sensor (B12/1) and refrigerant pressure sensor (B12). The
temperature and pressure must also be measured at the same time.
 Outside temperature
Output of the following information on the interior CAN (CAN B):
 Refrigerant compressor ON
 Refrigerant compressor actuating signal
Actuating the refrigerant compressor
The output of the refrigerant compressor (A9) is controlled continuously.
In order to switch on the refrigerant compressor (A9) the AAC control and operating module (N22) transmits
the via CAN B the switch-on request and the specified value (0 - 100%) to the left front SAM control module
(N10/6). The refrigerant compressor (A9) is current-controlled (100% corresponds to 1A). At the same time the
torque expected from the refrigerant compressor (A9) is conveyed via the electronic ignition switch control
module (N73) to the motor electronics control module (N3/10) and the ETC [EGS] control module (N15/3).
The left front SAM control module (N10/6) transmits load increase signals via the electronic ignition switch
control module (N73) to the motor electronics control module (N3/10) and switches the refrigerant compressor
ON after a defined time delay (approx. t=450 ms) (A9)
In order to switch the refrigerant compressor (A9) Off, the AAC control and operating module (N22) transmits
via Can B the switch-off request and the specified value = 0% to the left front SAM control module (N10/6).
Simultaneously the refrigerant compressor torque is set to the value of 0 and via the electronic ignition switch
control module (N73) conveyed to the motor electronics control module (N3/10) and the ETC [EGS] control
module (N15/3). The left front SAM control module (N10/6) transmits the erased load increase signal via the
electronic ignition switch control module (N73) to the motor electronics control module (N3/10) and switches
off the refrigerant compressor (A9) after a defined delay.
Under brisk acceleration the refrigerant compressor (A9) is regulated at the request of the motor electronics
control module (N3/10) for a defined time (max. t=10 s) by the left front SAM control module (N10/6) directly
to half the request from the AAC control and operating module (N22). The AAC control and operating module
(N22) receives the acceleration signal as information. If the engine fan is defective and there is a cooling
problem at the same time (engine temperature too high) the motor electronics control module (N3/10) requests
an emergency shutoff of the refrigerant compressor (A9) from the AAC control and operating module (N22) or
from the left front SAM control module (N10/6).
Left signal acquisition and actuation module, task - GF54.21-P-4101-03S
Model 215
MODEL 220
The left front SAM control module (N10/6) has the following tasks:
Actuating:
 the wiper system,

 the headlamp cleaning system,
 the steering column adjustment,
 exterior lights,
 the A/C compressor,
 the anti-theft alarm system,
 of the wake-up signal of the air suspension (model 220 only).
Scanning the following switches:
 exterior lamp switch (S1),

 brake fluid indicator switch (S11),
 parking brake indicator switch (S12),
 HCS [SRA] switch (S1s1),
 steering column driving position microswitch (M20s1).
 coolant temperature sensor (B11/4),

 outside temperature display temperature sensor (B14),
 refrigerant pressure sensor (B12),
 Hall sensor of fore/aft longitudinal adjustment motor (M20m1) and height adjustment up/down motor
(M20m2),
 Left front brake pad contact sensor (S10/1).
Scanning the following signals:

 Circuit 15,
 Circuit 15R,
 Wiper motor cam control.
Switching of consumers:
 Lamps of exterior lights,

 Wiper motor (M6/1),
 Steering column adjustment motor group (M20),
 Alarm signal horn with additional battery (H3/1).
Switching the following relays:
 Wiper park position heater relay (K40/6kA),

 Circuit 15 relay(K40/6kB),
 Circuit relay 15R (K40/6kC),
 Jacket tube longitudinal adjustment relay 1(K40/6kD),
 Jacket tube longitudinal adjustment relay 2 (K40/6kE),
 Wiper stage 1 and 2 relay (K40/6kG),
 Wiper On and Off relay(K40/6kH),
 Jacket tube height adjustment relay 1 (K40/6kI),
 Jacket tube height adjustment relay 2 (K40/6kJ).
The left front SAM control module (N10/6) is connected to the interior CAN for the exchange of data.
RIGHT SIGNAL ACQUISITION AND ACTUATION MODULE,

Models 215, 220
Right signal
Model 220
actuation module, 4102-01I
location
Right signal
task
GF54.21-P-
Model 215 in combination with automatic air conditioning
4102-03N
GF54.21-P-
Model 220 in combination with automatic air conditioning
4102-03I
Right signal The right front SAM control unit (N10/7) is contained in a sturdy
acquisition and plastic housing. Power semiconductors are used to control smaller
actuation module, consumers directly. Five connectors are used to provide the
design necessary electrical connections.
Right signal
The left front SAM control unit (N10/7) detects incoming electrical
acquisition and
signals, evaluates the signals and controls the relevant components
actuation module,
as necessary.
function
Right signal acquisition and actuation module, location - GF54.21-P-4102-01I
The right front SAM control module (N10/7) is located in the right rear of the engine compartment and is
plugged into the right front fuse and relay module from underneath (K40/7).
Fig. 43: Identifying Right Front SAM Control Module And Fuse And Relay Module
Right signal acquisition and actuation module task - GF54.21-P-4102-03I
Task
Actuation of coolant circulation pump
The front coolant circulation pump is actuated by the right signal-acquisition and actuation module (SAM) at
the request of the AAC pushbutton control module. The right SAM reports back the status to the AAC
pushbutton control module. Switching on the coolant circulation pump is requested by the AAC pushbutton
control module under certain operating conditions and also when the ignition is switched off (e.g. residual
engine heat utilization).
NOTE: On vehicles with rear air conditioning the rear coolant circulation pump is
actuated directly by the rear AC control module in contrast to the concept for
automatic air conditioning.
Right signal acquisition and actuation module, task - GF54.21-P-4102-03N
task
Actuating the heater water circulation pump
The front coolant circulation pump is actuated by the right front SAM control module upon request from the
AAC control and operating module (N22) (N10/7). The right front SAM control module (N10/7) reports back
the status to the AAC control and operating module (N22). Under certain operating conditions switching on the
coolant circulation pump is requested by the AAC control and operating module(N22) even when the ignition is
switched off (e. g. engine residual heat utilization).
Right signal acquisition and actuation module, task - GF54.21-P-4102-03S
MODELS 215, 220
The right front SAM control module (N10/7) has the following tasks:
Actuation:
 of headlamp cleaning system,

 the interior lighting,
 the washer fluid hose heater,
 the auxiliary water pumps.
 coolant level indicator switch (S41),

 washer fluid level check of windshield washer system (S42),
 glove compartment illumination with switch (E13/2)
 ATA [EDW] hood switch (S62),
 ATA switch for glove box.
 Right front brake pad contact sensor (S10/2).
 Circuit 61 (reading in generator voltage).


 Lamps of interior lights,
 Washer nozzle heater (R2/1),
 Washer nozzle hose heater (R2/11),
 Windshield washer fluid pump (M5/1),
 HCS [SRA] pump (M5/2).
 Motor electronics/chassis relay (K40/7kK),

 Fanfare horn relay (K40/7kP),
 Transmission oil cooler relay (external relay),
 CDI relay (K40/7kM).
The right front SAM control module (N10/7) is connected to the interior CAN for the exchange of data.
REAR SIGNAL ACQUISITION AND ACTUATION MODULE,

Models 215, 220
Rear signal
location
Rear signal
task
Rear signal The rear SAM control module (N10/8) is contained in a sturdy
acquisition and plastic housing. In the control module are located power
actuation module, semiconductors which actuate the smaller consumers directly. The
design electrical connection takes place via five connectors.
Function
Electric sun blind for
MODELS 215, 220 with electric roller blind for rear window CODE GF68.50-P-
rear window,
540a 0001S
function
Heated rear window, GF67.29-P-
function 0003S
Instrument cluster GF54.30-P-
(KI) function 0002S
Central locking (CL GF80.20-P-
[ZV]) function 0005S
Interior lighting (IL GF82.20-P-
Model 220.
[IBL]), function 0002S
Exterior lights, Model 215 left hand steering vehicle. Models GF82.10-P-
function 220.02 /06 /07 /12 /16 /17 left hand steering vehicle. 0003B
Seat belt wearing
GF91.40-P-
convenience,
2000S
function
Rear signal acquisition and actuation module, location - GF54.21-P-4103-01S
Model 215
MODEL 220
The rear SAM control module (N10/8) is located below the right rear seat.
Shown on model 220
Fig. 44: Identifying Rear SAM Control Module And Rear Fuse And Relay Module - Shown On Model
220
Rear signal acquisition and actuation module, task - GF54.21-P-4103-03S
Model 215
MODEL 220
The SAM control unit in the rear (N10/8) has the following tasks:
Actuating:
 seat belt wearing convenience,
 rear window heater,
 rear roller blind.
 contact sensor for right rear brake linings (S10/4),

 fuel level sensor (B4).
 left front door contact switch (S17/3),

 right front door contact switch (S17/4),
 left rear door contact switch (S17/5) model 220 only,
 right rear door contact switch (S17/6) model 220 only,
 trunk lid power closing locking eye microswitch (S88/3),
 seat belt buckle switch and left rear seat belt comfort-fit, rear left (S68/11) and right (S68/12),
 ATA luggage compartment contact switch
 ATA fuel filler flap switch
 ATA rear bench seat switch.
 Stop lamp switch signal (circuit 54).
This signal does not come direct from the stop lamp switch (S9/1), but via a separate line from the traction
systems control module (N47), which reads in the stop lamp switch (S9/1) directly.

 Lamps of trunk lighting,
 Heated rear window (R1),
 Solenoids for seat belt comfort-fit, rear left (K18/6) and rear right (K18/7) model 220 only.
 Heated rear window relay (K40/5kU),

 Rear window roller blind relay(K40/5kQ),
 Towing sensor relay (K40/5kR),
 Circuit 15 relay (K40/5kS),
 Fuel pump relay (K40/5kT).
Over/Under voltage shutoff
In the event of over/undervoltage switching off occurs to protect consumers. As a data basis for the current
voltage level the CAN message from the electronic ignition switch control module (N73) and the locally
measured voltage circuit 30 at the rear SAM control module (N10/8) is used.
The SAM control unit in the rear (N10/8) is connected to the passenger compartment CAN for the exchange
of data.
CASING TUBE MODULE POSITION/TASK/DESIGN/FUNCTION - GF54.21-P-4104S
MODEL 215, 220
Jacket tube model, location GF54.21-P-4104-01S

Jacket tube model, task GF54.21-P-4104-02S
Jacket tube model, design GF54.21-P-4104-03S
Jacket tube model, function GF54.21-P-4104-04S
Casing tube module position - GF54.21-P-4104-01S
Model 215
Model 220
Shown on model 220

Fig. 45: Identifying Jacket Tube Module - Shown On Model 220
Casing tube module, task - GF54.21-P-4104-02S
Model 215, model 220
The steering column module (N80) has the following tasks:
 Reading in the pushbuttons on the multi-function steering wheel :
Left multi-function steering wheel pushbutton group (S110), scroll forward/back pushbutton (S110s1),
model 215 only: system selection pushbutton (S110s3), model 220 up to 31.5.00 only: system selection
and VCS pushbutton (S110s3), fanfare horns' pushbutton (S110s5),
Right multi-function steering wheel pushbutton group (S111) pushbutton + and a, setting of specific
functions and volume control (S111s1), accept/terminate phone call pushbutton (S111s3), fanfare horns'
pushbutton (S111s5),
 Reading in the combination switch (S4) ,

 Reading in the steering column adjustment and entrance/exit aid switch group (S59/1) ,
 Reading in switch for cruise control with variable speed limiter (S40/4) ,
 Model 215 as of production start-up and model 220 as of 1.6.00: reading in the voice control system
switch (VCS, S93/2) ; this switch together with (S40/4) has been integrated into a single housing
 Reading in and initialization of the steering angle sensor (N49)
 Transmission of the ignition and test currents via the fanfare horns and airbag clock spring contact
(A45) for the driver airbag ignition squib (AB) (R12/3).
The steering column module (N80) is connected to the engine-compartment CAN and the interior CAN.
The steering column module (N80) however does not act as an interface (Gateway) between the two bus
systems: The steering column module (N80) is not used to exchange data between the two bus systems.
Casing tube module design - GF54.21-P-4104-03S
Fig. 46: Identifying Casing Tube Module Design
Casing tube module function - GF54.21-P-4104-04S
With the exception of the switch for cruise control with variable speed limiter (S40/4) all switches and
pushbuttons that can be read in from the steering column module (N80) are read in as coded voltages .
This procedure has the following advantages:
 the number of plug connections is greatly reduced,

 the design can be distinctly smaller on account of smaller plug connections,
 contacting problems are minimized.
Voltage-coded reading in of pushbuttons on steering column module's multi-function steering wheel:
Several particularities must be observed when voltage coding the multi-function steering wheel's pushbuttons:
 All the multi-function steering wheel's pushbutton contacts are read in by the steering column module
(N80) via 2lines only. (The 3rd line is for the pushbutton-unit illumination.)
If the voltage coding took place solely by way of different resistors in corresponding graduations, then an
appropriately high interference resistance could no longer be guaranteed. For this reason the pushbuttons
are read in as follows:
The steering column module (N80) generates a voltage which constantly changes its polarity for the
purpose of testing the pushbuttons.
The pushbuttons on the multi-function steering column are split up into two groups (left and right multi-
function steering wheel pushbutton groups (S110, S111) with the respective pushbuttons for the fanfare
horns).
These pushbutton groups have one diode each connected in series, with a different polarity for each
group.
The right or left pushbutton group is alternately queried, depending upon the polarity of the test voltage
from the steering column module (N80). The pushbutton contact query "switches" back and forth
between the two switching groups . The actual voltage coding is conducted solely within one of the
pushbutton groups.
 If within one of the pushbutton groups for the multifunction steering wheel several pushbuttons are
actuated simultaneously, the steering column module (N80) always issues a message for one function to
the CAN interior! This results in different valances for the various functions within a single pushbutton
group. The pushbutton with the lowest resistance value has the highest valence .
 Valences for the pushbutton functions within the right multi-function steering wheel pushbutton
group (S111) :
1. "Fanfare horns" pushbutton function
2. "Terminate phone call" pushbutton function
3. "Accept phone call" pushbutton function
4. "a" pushbutton function
5. "+" pushbutton function
Example:
If the "terminate phone call" pushbutton and the "a" pushbutton are pressed simultaneously, only the
"terminate phone call" pushbutton operation is forwarded to the CAN!
 Valences for the multi-function steering wheel pushbutton functions within the left-hand
pushbutton group (S110) :
1. "Fanfare horns" pushbutton function
2. model 220 up to 31.5.00: pushbutton function "voice control system"
2. Model 215 and as of 1.6.00 model 220: "System selection, scroll backwards" pushbutton
3. "System selection, scroll forwards" pushbutton
4. "Scroll backwards" pushbutton
5. "Scroll forwards" pushbutton
UPPER CONTROL PANEL CONTROL MODULE LOCATION/TASK/DESIGN/FUNCTION -
GF54.21-P-4105S
MODELS 215, 220
Upper control panel control module location GF54.21-P-4105-01S

Upper control panel control module purpose GF54.21-P-4105-02S
Upper control panel control module design GF54.21-P-4105-03S
Function
Hazard warning flasher actuation function GF82.10-P-3009A
Antitheft alarm system (ATA), function GF80.50-P-0001S
Rear head restraint adjustment (KAF) function GF91.16-P-0002S
Electric sun blind for rear window, function GF68.50-P-0001S
Upper control panel control module location - GF54.21-P-4105-01S
Models 215, 220
Shown on model 220
Fig. 47: Identifying Upper Control Panel Control Module - Shown On Model 220
Upper control panel control module task - GF54.21-P-4105-02S
Models 215, 220
The upper control panel control module (N72/1) is connected to the CAN (interior compartment) and has the
following tasks:
Reading in the switches:
 ESP OFFswitch (N72/1s1)

 Level control switch (N72/1s3)
 Comfort and sport switch (N72/1s3)
 Hazard warning system switch (N72/1s5)
 Interior central locking switch (N72/1s6),
 TS/IMS switch (N72/1s7) and ATA function display (interior motion sensor with code 882 only) and
depending on the equipment variant:
 PTS OFF switch (N72/1s8)
 Rear head restraints switch (N72/1s4)
 Rear blind switch (N72/1s9)
Actuation of the indicator lamps of various switches.
Reading in components of the lower control panel:
 DTR switch block (S46/8)
.All the switches are equipped with search illumination.
Upper control panel control module design - GF54.21-P-4105-03S
Models 215, 220
The special equipment block (right switch group on vehicles with left-hand steering, left switch group on
vehicles with right-hand steering) can be disconnected from the control module.
Fig. 48: Identifying Upper Control Panel Control Module Switches
RAIN/LIGHT SENSOR LOCATION/TASK/FUNCTION - GF54.21-P-4123Q
MODEL 209.3 /4, 211.0 /2, 215, 220 as of 1.9.02

Fig. 49: Identifying Rain/Light Sensor - Shown On Model 209.3
Rain/light The rain/light sensor (B38/2) is stuck onto the inside of the windshield
sensor location below the overhead control panel control module.
The rain sensor (B38/2) measures the quantity of moisture on the
Rain/light windshield and controls the intermittent time of the wiper system. At the
sensor task same time it also records the intensity of the daylight and through this
controls the automatic functions of exterior lights and interior lights.
Rain
GF54.21-P-
sensor/light
4123-04Q
sensor, function
Rain sensor/light sensor, function - GF54.21-P-4123-04Q
Presentation of function overview of rain/light sensor

Fig. 50: Identifying Infrared Transmitter And IR Receiver
Function principle
 Circuit 15R ON
Function principle
Infrared light is radiated from the IR transmitter unit (2) and guided to the windshield (4) via the lens (1). The
intensity of the light reflected at the windshield (4) is measured by the IR-receiver unit (3) which is located at
the other end of the lens (1)
 The windshield (4) is dry (Fig. A)
If the windshield is dry in the area of the rain/light sensor, the light is almost completely reflected: the IR
receiver unit (3) measures a high light intensity.
 Windshield (4) is wet (Fig.B)
If there is moisture on the windshield (4) in the area of the reflection surface, part of the light is diffused
from the glass on to the windshield (4). As a result the intensity of the reflected light reduces: the IR
receiver unit (3) measures a lower light intensity.
The light intensity measured by the IR receiver (3) is a measure for the quantity of water on the
windshield (4) The smaller the measured intensity the larger the quantity of water on the windshield (4).
Reading out via the rain/light sensor

The rain/light is connected with the interior CAN via the overhead control panel control module as interface
The front SAM control module with fuse and relay module (model 209) or driver-side SAM control module
with fuse and relay module (model 211) or left front SAM control module (models 215, 220) transmits a request
to the rain/light sensor via the interior CAN, this then conveys the instantaneous degree of wetting for each
request.
The automatic driving light actuation actuates the low beam in the following cases:
 Dusk
 Darkness
 Driving through tunnels
and in the case of a detected sensor failure.
The above-mentioned switch-on conditions are considered separately and the driving lights are switched on
when at least one of the conditions is met.
A detection of fog is not recognized. In fog the driving lights must continue to be switched on manually
Measurement and compensation
Via the serial interface the rain/light sensor receives information as to which wiper system it should actuate
(reversing wiper system or two-stage), or whether the driving light should be switched on and emits the signals
necessary for actuation
LIGHT SWITCH MODULE POSITION/TASK/DESIGN - GF54.25-P-4103M
MODELS 215, 220 as of 1.7.00
Shown on model 215

Fig. 51: Identifying Lamp Switch Module - Shown On Model 215
The control elements in the light switch module (S1) the:
 manual headlamp leveling system,
Light switch module,  headlamp cleaning system
task
and
 and exterior mirror adjustment are combined in a

single control unit.
Light switch module, GF54.25-P-4103-
design 01M
Light switch module design - GF54.25-P-4103-01M
Shown on model 215
Fig. 52: Identifying Light Switch Module And Exterior Lamp Switch - Shown On Model 215
INSTRUMENT CLUSTER (IC), FUNCTION - GF54.30-P-0002S
Model 215, 220
Illustration showing instrument cluster during lamp check, valid up to 31.8.02 on Model 220
Fig. 53: Overview Of Instrument Cluster - Valid Up To 31.8.02 On Model 220
Illustration showing instrument cluster (A1) during lamp check, valid as of 01.9.02 on Model 220
Fig. 54: Overview Of Instrument Cluster - Valid As Of 01.9.02 On Model 220
General information
The instrument cluster (A1) has the following functions:
 Information about important vehicle operating conditions (e.g. speed, amount of fuel ...)
 Provides warnings of critical operating conditions
 Display of various systems (e.g. audio, trip computer ...)
 Functions as computer and display for the "Active Service System" (ASSYST)
 Functions as a trip computer
To perform these functions, the instrument cluster (A1) is equipped with the multifunction display (A1p13),
various meters and gauges, warning and malfunction indicator lamps as well as an acoustic transmitter. The
instrument cluster (A1) also generates various signals (such as "Speed", "Terminal.58d" ...) for transmission to
the engine compartment CAN and/or interior compartment CAN.
Except for the signal for the airbag indicator and warning lamp (A1e15), all of the required information from
the various control units is transmitted to the instrument cluster (A1) via the engine compartment CAN or the
interior compartment CAN.
Only a few wires are required to connect the instrument cluster to the rest of the vehicle. The instrument cluster
(A1) is equipped, therefore, with just one connector.
The instrument cluster contains a microprocessor to process the incoming data. The program and necessary data
are stored in an electronic memory chip. The program is operated using the system selection button (S110s3),
the scroll forward/back button (S110s1) on the multifunction steering wheel and the two buttons on the
instrument cluster (A1).
Diagnosis is performed with the STAR DIAGNOSIS TOOL.
GF54.30-P-
Instrument cluster (IC), operating information
0002-05S
GF54.30-P-
Instrument cluster (IC) component network
0002-06S
GF54.30-P-
Activating instrument cluster, function
2006S
GF54.30-P-
Instrument cluster illumination function
2007S
GF54.30-P-
Setting switch and controls illumination, function
2010S
GF54.30-P-
Indicator and warning messages via indicator lamps
2011S
Displaying check/warning messages by means of GF54.30-P-
multifunction display, function 2012S
Model 220 as of 1.9.99, GF54.30-P-
Outputting acoustic warning messages, function
Model 215 2013A
GF54.30-P-
Model 220 up to 31.8.99
2013S
Function to test malfunction indication lights and engine GF54.30-P-
running detection 2014S
GF54.30-P-
Fuel quantity display function
3018S
GF54.30-P-
Displaying outside temperature, function
3019S
GF54.30-P-
Displaying coolant temperature, function
3020S
GF54.30-P-
Engine rpm display function
3021S
GF54.30-P-
Displaying distance, function
3022S
GF54.30-P-
Displaying transmission information, function
3023S
GF54.30-P-
Displaying time, function
3024S
GF54.30-P-
Displaying speed, function
3025S
Displaying vehicle speed ranges with segment tachometer, GF54.30-P-
function 3026S
GF54.30-P-
Coolant/washer fluid level voltage coding, function
4001S
Instrument cluster (IC), operating information - GF54.30-P-0002-05S
Shown on instrument cluster, valid up to 31.8.02
Model 220
Shown on instrument cluster during lamp check, valid as of 01.9.02

Controls of multi-function steering wheel, Model 220 up to 31.5.00
Fig. 58: Identifying Controls Of Multi-Function Steering Wheel, Model 220 Up To 31.5.00
multifunction steering wheel controls Model 215 and Model 220 as of 1.6.00
Fig. 59: Identifying Multifunction Steering Wheel Controls (Model 215 And Model 220 As Of 1.6.00)
Operating multifunction display (A1p13):
 Calling up display of different systems

 Browsing within a system
 Example: Displaying engine oil level
Individual settings:
Changing settings
 Example: Changing temperature display from Celsius to Fahrenheit

 Restoring the factory settings
 Calling up stored error and warning messages
 Acknowledging error and warning messages on the multifunction display (A1p13)
 Setting illumination brightness
If the instrument cluster (A1) is activated by opening the driver's door, for instance, the main screen of the
base system (trip and total mileage) always appears on the multifunction display (A1p13).
Calling up display of different systems:
 Terminal 15R ON
The driver can switch the multifunction display (A1p13) to the main screen of the next system or to the
"Settings" function by pressing 109 of 346 the system selection button on the multifunction steering wheel.
Example: Changing temperature display from The duration of actuation is of no importance. The display jumps
on one system each time the button is pressed. After running through all the systems, the display returns to the
main screen of the base function and then begins running through the systems again from the beginning.
System selection using system selection button on multifunction steering wheel
Fig. 60: Function Of System Selection Button
When the system selection button is pressed, the display jumps clockwise (arrow) to the next system.
It is not possible to jump counterclockwise with Model 220 up to 31.5.00.
Browsing within a system:
 Terminal 15R ON
In addition to the main screen, most systems also feature other screens.
The scroll forward/back button (S110s1) is used for browsing within a system. The function of the scroll
forward/back button is shown below using the main screen as an example. The display jumps one screen further
each time the driver presses the scroll forward/back button (S110s1).
The direction of browsing depends on which segment of the button (?, ?) is pressed.
Only systems and functions with which the vehicle is equipped are displayed. If a system is not present, it is
skipped when the system selection button is pressed.
The driver can jump to another system from any screen by pressing the system selection button.
With the exception of the trip computer, the main screen of the relevant system now appears. When changing
from the previous system to the trip computer system, the display always shows the most recently displayed
screen in the trip computer system.
Function of the scroll forward/back button to display the engine oil level
up to 31.08.2003
Fig. 61: Function Of Scroll Forward/Back Button To Display Engine Oil Level - Up To 31.08.2003
Function of the scroll forward/back button to display the engine oil level
as of 01.09.2003
Fig. 62: Function Of Scroll Forward/Back Button To Display Engine Oil Level - As Of 01.09.2003
Displaying engine oil level with "Terminal 15 ON":
 Press the system selection button repeatedly until the base function (trip and total mileage) is displayed.
 Press the scroll forward (?) button twice or
 Press the scroll back button (?) once up to 31.08.2003, or four times as of 01.09.2003
This displays the engine oil level in the multifunction display (A1p13).
Individual settings (second level):
 Terminal 15R ON
 Up to 31.5.01, speed less than 5 kph
 As of 01.6.01 (except ): Also possible while driving.
The "Settings" function allows the driver to change various presets. The following settings can be selected for
the instrument cluster (A1):
Set time (hours)
 Only on vehicles without COMAND operating and display system (Code 352a)
Set time (minutes)
 Only on vehicles without COMAND operating and display system (Code 352a)
Temperature indication
 The outside temperature can be changed from degrees Celsius to degrees Fahrenheit and vice versa. The
instrument cluster (A1) also sends a message for the air conditioning on the interior compartment CAN.
Speedometer (only adjustable when stationary)
 This can be switched between miles and kilometers per hour.
This changeover also affects the display on the trip computer integrated in the instrument cluster (A1). The
instrument cluster (A1) also sends an appropriate message over the engine compartment CAN.
Text/language
 The language in which the texts appear in the instrument cluster (A1) can be selected here. The
instrument cluster (A1) also relays an appropriate message onto the interior compartment CAN.
As of 01.6.01, two English-language versions are available ( and ). The language setting on the
COMAND system has no effect on the language setting in the instrument cluster (A1).
The following settings are also possible:
 Auto door locks (ON or OFF)

 Up to 31.5.00: Driving lights (manual, automatic, always-on)
 As of 1.6.01, the "automatic" function can be selected at the exterior lamp switch 111 of 346
Changing the driving lights from "always on" to "manual" is only possible when the vehicle is stationary.
 Speed limiter for winter tires (210 kph or Off). This setting can only be changed when the vehicle is
stationary.
 As of 1.9.02, the speed limiter for winter tires can also be set while the vehicle is in motion (setting in 10
km steps from 160 kph to 210 kph or in 10 mile steps from 100 mph to 150 mph).
 Headlamp switch-off delay
 Interior light courtesy delay
Further information on these settings can be found in the functional description for the respective systems.
Changing settings
Fig. 63: Overview And Sequence Of Possible Settings
Changing settings:
 Press the system selection button repeatedly until the "Settings" function appears on the multifunction
display (A1p13).
 Press the scroll forward (?) or scroll back (?) button repeatedly until the display for the setting to be
changed appears in the multifunction display (A1p13).
 Press the + and a button for setting specific functions and volume control (S111s1) in the + or a direction
until the arrow in the display is on the desired value.
 The setting becomes effective immediately.
Additional settings are possible as of 01.6.00:

 Tire pressure monitor
 Locator lighting (the locator lighting is part of the Night Security Illumination (NSI) together with the
headlamp switch-off delay).
Up to 31.5.01: The settings can only be selected when the vehicle is moving at less than 5 kph. If the speed
exceeds 10 kph while the setting is being made, the display jumps back to the main "Settings" screen. The
display only returns to the previously displayed screen when the vehicle speed falls below 5 kph.
As of 01.6.01 (except ), settings can also be made at speeds over 5 kph.
This does not include:
 Kilometers/miles switchover
 Driving lights
 Winter tire coding (vehicle speed limit)
As of 1.9.02, the speed limiter for winter tires can be set in steps and activated/deactivated while the vehicle
is in motion.
Example:
Example: Changing temperature display from Celsius to Fahrenheit:
display (A1p13).
 Press the scroll forward (?) or scroll back button (?) repeatedly until the "TEMPERATURE" display
appears on the multifunction display (A1p13).
 Press the button a on the right-hand side of the steering wheel; the arrow on the display now points to
(degrees or Fahrenheit).
 The setting becomes effective immediately.
Resetting the factory settings
A reset cancels all the settings that can be made here and restores the default factory settings.
Carry out reset:
display (A1p13).
 Press the reset button (R) and hold down for at least 3 seconds.
 The multifunction display (A1p13) shows the message: "DO YOU WANT TO RESET TO THE
FACTORY SETTINGS?".
 Press the reset button a second time within 5 seconds to reset all the settings to the default factory
settings.
If the reset button is not pressed within this 5 second period, the display switches back to the main screen.
The settings are then not reset.
As of 1.6.01 (except ): If restoration of the factory settings is performed when driving, the message:
"NOT COMPLETELY RESET TO FACTORY SETTINGS WHEN DRIVING" is displayed in connection with
the subjects of the instrument cluster, the lights and the vehicle. If reset in the configuration image, the system
jumps to the base image of the configuration.
Call stored fault and warning messages
When the instrument cluster (A1) is activated, the stored messages can be browsed:
 Press the system selection button repeatedly until "-- ERRORS" appears on the multifunction display
(A1p13).
 Scroll through the fault messages using the scroll forward/back button (S110s1). The messages are
displayed in the order in which they were acknowledged.
Acknowledging fault and warning messages on multifunction display (A1p13)
These messages are divided into 3 categories according to their priority. Messages of categories 2 and 3 on the
multifunction display (A1p13) can be reset by pressing the reset key (R).
Messages belonging to category 1 (highest priority) cannot be acknowledged. Fault or warning lights that light
up in parallel cannot be acknowledged.
Modification as of 1.6.01:
Warning messages in taxi vehicles ("Terminal 30") are displayed once per driving cycle for 2 minutes and can
be acknowledged. The interior compartment CAN is wakened in the event of a taxi emergency call without the
Set brightness of lighting
The brightness of illumination of the instrument cluster (A1) and the switch and controls illumination can be
adapted to individual requirements with the dimmer for instrument, switch and controls illumination (A1r1):
 Tap the dimmer for instrument, switch and controls illumination (A1r1) and the regulator extends.
 Clockwise rotation of the regulator increases the brightness; counterclockwise rotation decreases the
brightness.
Switching on ESP rolling test:
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:
 Set the standard display (basic state with current mileage reading).
 Depending on the version, press and hold down the reset button for approx. 20 s to 30 s or press and hold
down the reset button 3 times for 2.5 s until a beep can be heard.
 Press the scroll forward/back button (S110s1) once in ? direction. The roller dynamometer test mode
display appears
 Switch on the rolling test with the + and a button, specific function setting and volume control (S111s1).
The rolling test remains active (even when "Term.15R ON" has been switched off in between) until it is
switched off with the + and a button, specific function setting and volume control (S111s1).
Instrument cluster (IC), networking of components - GF54.30-P-0002-06S
The instrument cluster (A1) is networked with the engine compartment CAN and the interior CAN. Data is
exchanged with both bus systems and with practically all the control units of the two bus systems.
Valid up to 31.8.02
The instrument cluster (A1) does not, however, act as an interface (gateway) between the two bus systems. This
function is reserved for the EIS [EZS] control unit (N73).
Valid as of 01.9.02
The interface between the interior CAN and the engine compartment CAN is provided by the central gateway
control unit (N93).
Below is a list of the CAN messages that are important for the functions of the instrument cluster (A1)
including trip computer and ASSYST.
The connections of the instrument cluster (A1) are described in the last section.
Received messages for display instruments and internal processing:
 Four wheel speeds:
over engine compartment CAN from chassis control unit (N47)
 Engine speed signal:
over engine compartment CAN from ME-SFI [ME] control unit (N3/10) or CDI control unit (N3/9)
 Shift range, shift lever position, transmission mode:
over engine compartment CAN from ETC [EGS] control unit (N15/3)
 Fuel tank level:
over interior CAN from rear SAM control unit (N10/8)
 Coolant temperature:
 Fuel-consumption signal:
 Oil level:
 Oil temperature:
 Outside temperature signal:
over interior CAN from left front SAM control unit (N10/6)
 Standing lamp ON/OFF:
over interior CAN from left front SAM control unit (N10/6)
 Coolant and washer fluid level:
over interior CAN from right front SAM control unit (N10/7)
 In vehicles with COMAND:
the time is read in from the COMAND operating, display and control unit (A40/3) over the interior CAN.
 Status of "circuit 15" and "key in ignition":
over interior CAN from electronic ignition switch control unit (N73)
 Signals from multifunction steering wheel buttons:
see separate section
Received messages for indicator and warning lamps:

 Signal for left turn signal indicator lamp (A1e1) and right turn signal indicator lamp (A1e2):
For turn signals from steering column module (N80) over interior CAN
For hazard warning flashers from upper control panel control unit (N72/1) over interior CAN
For anti-theft alarm system from left front SAM control unit (N10/6) over interior CAN
With special functions from special vehicle multifunction control unit (SVMCU [MSS]) (N26/9) over
interior CAN
 Signal for high beam indicator lamp (A1e3):
from left front SAM control unit (N10/6) or from special vehicle multifunction control unit (SVMCU
[MSS]) (N26/9) with model 220 over interior CAN
 Signal for brake fluid level and parking brake (A1e7): over interior CAN from left front SAM control unit
(N10/6)
 Signal for preglow indicator lamp (A1e16):
over engine compartment CAN from CDI control unit (N3/9)
 Signal for ESP warning lamp (A1e41) and ESP indicator lamp (A1e42):
over engine compartment CAN from chassis control unit (N47)
 Signal for seat belt warning lamp (A1e9):
over interior CAN from left front seat adjustment control unit with memory (N32/1) or from right front
seat adjustment control unit with memory (N32/2)
 Signal for engine diagnosis indicator lamp (A1e58) or "CHECK ENGINE" MIL (A1e26):
 Signal for DTR warning lamp (A1e59):
via engine compartment CAN from DTR control unit (N63/1)
 Signal for tire pressure monitor warning lamp (A1e66), via interior CAN from TPM [RDK] control unit
(N88)
The airbag indicator and warning lamp (A1e15) is actuated by a discrete line not via the CAN bus.
Received messages for the multifunction display (A1p13)

 All signals for the messages in the multifunction display (A1p13) are received over 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.
Messages sent by the instrument cluster (A1):
 Displayed speed:
to interior CAN
 Current time:
to interior CAN
 Temperature units (degrees Celsius and degrees Fahrenheit):
to interior CAN
 Automatic driving light actuation (ON/OFF):
to interior CAN
 Interior light courtesy delay:
to interior CAN
 Headlamp switch-off delay:
to interior CAN
 Outside temperature signal:
to engine compartment CAN
 Circuit 58 d:
to engine compartment CAN and interior CAN
 Circuit 61 e:
 Engine off time:

 Winter tires maximum speed:
 Signals from multifunction steering wheel buttons:
see section below
CAN data of multifunction steering wheel buttons Since the buttons on the multifunction steering wheel each
have several functions, the data from these buttons must be processed 114 of 346 accordingly:
 All the buttons in the left multifunction steering wheel button group (S110) and the right multifunction
steering wheel button group (S111) are voltage-coded and are read by the steering column module (N80).
 The steering column module (N80) puts the relevant messages onto the interior CAN.
 This CAN data is received by the instrument cluster (A1).
 The instrument cluster (A1) interprets this data in combination with the systems currently displayed on
the multifunction display (A1p13) and passes this interpreted data again on the interior CAN.
This interpretation is necessary because the operation of the some of buttons depends on the current
content of the multifunction display (A1p13).
Example:
If the driver presses the + and -button, setting specific functions and volume control (S111s1) on the
multifunction steering wheel, the volume of the sound system is usually increased.
However, if the multifunction display (A1p13) is currently displaying another setting such as the interior light
courtesy delay, this setting is changed when the driver presses the "+" button. The volume stays the same.
Connections:
The linking of the instrument cluster (A1) with the engine compartment CAN and the interior CAN has reduced
the number of inputs and outputs (including voltage supply) to the following connections:
 CAN-C Low = engine compartment CAN

 CAN-C High = engine compartment CAN
 CAN-B Low = interior CAN
 CAN-B High = interior CAN
 Circuit 31 Ground
 Circuit 30 Battery positive Supplies the instrument cluster (A1) with power.
 Circuit 15R Switched positive
Used for the airbag indicator and warning lamp (A1e15) and for the diagnostic interface of the instrument
cluster (A1) as a voltage supply.
 K-line
This line is connection to the data link connector (X11/4). Data is transferred from the instrument cluster
(A1) when carrying out diagnosis with the STAR DIAGNOSIS TOOL.
 Input for airbag indicator and warning lamp (A1e15)
This input is connected directly to the relevant output of the restraint systems control unit (N2/7).
TABLE OF CONTENTS, FUNCTION DESCRIPTION, INSTRUMENT CLUSTER - GF54.30-P-0997S
Models 215, 220
GF54.30-P-
Instrument cluster (IC), function
0002S
GF54.30-P-
Instrument cluster (IC), operating instructions
0002-05S
GF54.30-P-
Instrument cluster (KI) component network
0002-06S
GF54.30-P-
Instrument cluster activation function
2006S
GF54.30-P-
Instrument cluster module illumination function
2007S
GF54.30-P-
Setting pushbutton unit illumination, function
2010S
Function to display malfunction/warning indication via GF54.30-P-
indication lights 2011S
Function for displaying check/warning messages by means of GF54.30-P-
multifunction display 2012S
Model 215, model 220 GF54.30-P-
Outputting audible warning messages, function
as of 1.9.99 2013A
Model 220 up to GF54.30-P-
31.8.99 2013S
GF54.30-P-
Indicator lamp test and engine running recognition, function
2014S
GF54.30-P-
Displaying fuel level, function
3018S
GF54.30-P-
Outside temperature display function
3019S
GF54.30-P-
Displaying coolant temperature, function
3020S
GF54.30-P-
Displaying engine speed, function 3021S
GF54.30-P-
Distance display function
3022S
GF54.30-P-
Displaying transmission information, function
3023S
GF54.30-P-
Displaying time, function
3024S
GF54.30-P-
Speed display function
3025S
Displaying vehicle speed ranges with segment tachometer, GF54.30-P-
function 3026S
GF54.30-P-
Battery charge/generator indicator, function
3027S
GF54.30-P-
Coolant/washer fluid level voltage coding, function
4001S
Survey of system components for instrument cluster, GF54.30-P-
location/task/design/function 9997S
ACTIVATING INSTRUMENT CLUSTER, FUNCTION - GF54.30-P-2006S
Model 215, 220
Networking of components shown on Model 220
Fig. 64: Activating Instrument Cluster Networking Of Components - Shown On Model 220
Activation of instrument cluster:
Owing to the 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.
When the instrument cluster (A1) is activated:
 the current contents appear on the displays,

 the instrument cluster lighting (A1) is switched on,
 the fuel reserve indicator lamp (A1e4) comes on.
Switching on "Terminal 115R" activates the instrument cluster (A1). When "Terminal 115R" is switched off,
the instrument cluster (A1) remains active for an additional 30 s after any warning messages have been
processed.
With "Terminal 15R OFF", the instrument cluster (A1) is activated under the following circumstances:
 if the reset button is pressed (right-hand button) (instrument cluster (A1) activated for 30 seconds),
 if the driver's door is opened or closed (instrument cluster (A1) activated for 30 seconds),
 if the standing lamps or driving lights are switched on (the instrument cluster (A1) is active for as long as
the standing lamps remain switched on).
If one of the circumstances mentioned above occurs while the instrument cluster (A1) is already active, the
instrument cluster remains active for an additional 30 seconds. It is not possible to activate the instrument
cluster (A1) using the keys on the multifunction steering wheel.
Networking:
 The rear SAM control unit (N10/8) monitors the status of the door contact switch and relays the
corresponding data to the interior compartment CAN.
 The status of the standing lamps (ON/OFF)is sent on the interior compartment CAN by the left front
SAM control unit (N10/6).
The instrument cluster (A1) receives these messages and is activated if necessary.
INSTRUMENT CLUSTER ILLUMINATION FUNCTION - GF54.30-P-2007S
Model 215, 220
Diagram showing illumination regulation

Fig. 65: Brightness Of Instrument Cluster Illumination
Illumination of instrument cluster:
The instrument cluster (A1) illumination is switched on automatically when the instrument cluster is activated.
Owing to the "black-screen" technology, details on the instrument cluster (A1) (displays, gauges, etc.) do not
become clearly visible until the unit is illuminated. The instrument cluster is activated by opening the driver's
door, for example, or by pressing the reset button.
The brightness of the lighting depends on:
 the ambient brightness

 the setting of the instrument, switch and controls illumination dimmer (A1r1)
The diagram shows the dependency of the instrument cluster lighting brightness on the ambient brightness and
the setting of the instrument, switch and controls illumination dimmer (A1r1):
 With curve (a), the instrument, switch and controls illumination dimmer (A1r1) is set all the way to the
right (maximum). As the ambient brightness increases, so does the brightness of the instrument cluster
lighting. The possible brightness ranges from (a-min) to the maximum value (max).
 With curve (b), the instrument, switch and controls illumination dimmer (A1r1) is set all the way to the
left (minimum). As the ambient brightness increases, so does the brightness of the instrument cluster
lighting. The possible brightness ranges from (b-min) to the maximum value (max). The maximum value
(max.), however, is only reached when the ambient brightness is greater.
When the instrument cluster (A1) is activated, the illumination is always set to at least the minimum level (b-
min). Lower levels of illumination are not available.
As is evident from the diagram, changing the dimmer for instrument, switch and controls illumination (A1r1)
also changes the minimum value from (a-min) to (b-min) or vice versa.
Photo transistor
The instrument cluster (A1) is equipped with a phototransistor to allow the lighting to be adapted automatically
according to the ambient brightness. It is located under the fuel level and reserve gauge (A1p2).
SETTING SWITCH AND CONTROLS ILLUMINATION, FUNCTION - GF54.30-P-2010S
Model 215, 220
Diagram showing signal flow for terminal 58d
Fig. 66: Showing Signal Flow For Terminal 58d
The brightness of the switch and controls illumination can be adjusted using the instrument, switch and controls
illumination dimmer (A1r1) of the instrument cluster (A1). Control is adjusted based on the pulse-duty factor at
"Terminal 58d" (refer to separate section).
Signal flow:
 If the standing lamps are switched on, the left front SAM control unit (N10/6) relays the message
"standing lamps ON" on the interior compartment CAN.
 The instrument cluster (A1) receives this message and relays the message "duty cycle term. 58d" on both
the interior compartment CAN and on the engine compartment CAN.
 Various control units receive this message and supply the lamps of the switch and controls illumination
with the square-wave voltage U58d .
Representation of the on/off ratio

Fig. 67: Representation Of On/Off Ratio
Pulse-duty factor Terminal 58d
The lamps of the switch and controls illuminations are supplied with a square-wave voltage U 58d :
 The lamps are energized during the time (t1) which is then followed by a pause. After the pause the lamps
are energized again 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 higher the on/off ratio (i.e. the longer the power flow duration t1) ), the greater the average power and
therefore the brighter the lamps.
The diagram shows the voltage characteristic U58d as applied to the outputs "term. 58d" of the various control
units. The upper and lower diagrams illustrate a duty cycle of 80 % and 40 %, respectively.
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 brightness adjustment:
 Considerably more efficient

 The brightness of the lamps remains independent of the number of lamps
 Each control unit that is connected to the interior compartment CAN or engine compartment CAN can
actuate the lamps with the brightness specified by the instrument cluster (A1).
When the standing lamps are OFF, the instrument cluster (A1) sends the message "duty cycle, term. 58d = 0
%".
When the standing lamps are ON, the sent duty cycle can be adjusted from 12 - 100 % using the instrument,
switch and controls illumination dimmer (A1r1).
DISPLAY MONITORING/WARNING MESSAGES VIA INDICATOR LAMPS, FUNCTION -

GF54.30-P-2011S
MODELS 215, 220
Illustration shows instrument cluster during lamp check (valid up to 31.8.02) on model 220
Illustration shows instrument cluster during lamp check (as of 01.9.02) on model 220
Left turn signal indicator lamp (A1e1), right turn signal indicator lamp (A1e2)
These are activated differently according to function:
 During operation as directional indicators only one of the indicator lamps is triggered.
The lamp activation signal is transmitted via the interior CAN from the column jacket module (N80).
If one of the turn signal lamps fails, the indicator lamps are triggered at twice the normal frequency. The
instrument cluster (A1) receives the information about the defective turn signal lamp from the control unit
responsible for activating that particular lamp unit.
 When the hazard warning flashers are operated both indicator lamps are triggered. The signal for
actuating the lamps comes over the interior CAN from the upper control panel control unit (N72/1).
 When the flashers are triggered for the anti-theft alarm system both indicator lamps always flash. The
trigger signal for the lamps is received from the left front SAM control unit (N10/6) via the interior CAN.
 Both indicator lamps always flash when the lamps are triggered for special functions. The trigger signal
for the lamps is received from the special vehicle multifunction control unit (SVMCU [MSS]) (N26/9)
via the interior CAN.
While turn indication is only possible with "circuit 15 ON", the other types of flashing 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:
 Flashing for special functions (highest priority)

 Flashing for anti-theft alarm system
 Hazard warning flashing
 Direction indicators (lowest priority)
High beam indicator lamp (A1e3):
This lamp is activated differently according to function:
 For high beam ON and the headlamp flasher, the left front SAM control unit (N10/6) sends the signal to
switch on the steady light via the interior CAN.
 For special functions, such as the emergency alarm, the special vehicle multifunction control unit
(SVMCU [MSS]) (N26/9) sends the trigger signal for the lights to flash on and off via the interior CAN.
If different requests to turn on the high beam occur at the same time, the special vehicle multifunction control
unit (SVMCU [MSS]) (N26/9) request has the highest priority.
Fuel reserve warning lamp (A1e4):
This warning lamp comes on as soon as the reserve level is reached. Control of this lamp is linked to the fuel
level and reserve indicator (A1p2).
For more information, see document "Display fuel level, function"
Brake fluid level and parking brake warning lamp (A1e7):
This lamp is actuated when the parking brake is not released while driving or if the brake fluid drops below the
minimum level.
The left front SAM control unit (N10/6) sends the trigger signal for the lamp via the interior CAN.
Seat belt warning lamp (A1e9) valid up to 31.8.02:
This indicator lamp is not provided in all national markets.
The lamp comes on when the engine is running if one of the front seat belt buckles is not fastened when the seat
is occupied. A warning tone (model 220) or gong (model 215) also sounds.
The left front seat adjustment control unit with memory (N32/1) or right front seat adjustment control unit with
memory (N32/2) sends the signal to switch on the lamp via the interior CAN.
Seat belt warning lamp (A1e9) valid as of 01.9.02:
The seat belt warning lamp (A1e9) operates in the same way as in vehicles valid up to 31.8.02 except that a
gong sounds in both vehicle models.
Airbag indicator and warning lamp (A1e15):
This lamp is triggered to signal malfunctions in the supplemental restraint system (SRS).
It is triggered directly by the restraint systems control unit (N2/7).
Preglow indicator lamp (A1e16) :
This indicator lamp is only fitted in vehicles with a diesel engine.
The lamp comes on with "circuit 15 ON" as long as the preheat time is running. The signal to activate the lamp
is sent by the CDI control unit (N3/9) via the engine compartment CAN.
If there is a fault with the preglow indicator lamp (A1e16), an error bit is set in the instrument cluster (A1) and a
corresponding message is sent to the CDI control unit (N3/9) via the engine compartment CAN. There is,
however, no fault message in the multifunction display (A1p13)!
ABS indicator lamp (A1e17):
This lamp is actuated when there is a fault in the ABS system.
The signal to activate the lamp is sent by the traction system control unit (N47) via the engine compartment
CAN.
ESP warning lamp (A1e41) and ESP indicator lamp (A1e42) valid as of 01.9.02:
The ESP warning lamp (A1e41) is actuated whenever the system intervenes in the driving situation.
The ESP indicator lamp (A1e42) is triggered when there is a fault in the system.
The signal to activate the relevant lamp is sent by the traction system control unit (N47) via the engine
compartment CAN.
Engine diagnosis indicator lamp (A1e58) or CHECK ENGINE (A1e26):
The vehicles vary according to national version, and are equipped with either an engine diagnosis indicator
lamp (A1e58) or a CHECK ENGINE indicator lamp (A1e26).
The lamp is activated if there is a fault in the injection system, the ignition system or the exhaust system.
The signal for actuating the lamp comes is sent by the CDI control unit (N3/9) or the ME-SFI [ME] control unit
(N3/10) via the engine compartment CAN.
DTR warning lamp (A1e59):
This lamp is present only on vehicles equipped with Distronic (DTR) (Code 219a).
It is activated if the vehicle gets too close to the vehicle in front. An acoustic signal also sounds.
The signal to activate the lamp is sent via the engine compartment CAN from the DTR control unit (N63/1).
Tire pressure monitor warning lamp (A1e66)
This lamp is present only on vehicles equipped with tire pressure monitor (Code 475). The lamp lights up
yellow in addition to the multifunction display (A1p13) when the system detects rapid pressure loss of > or =
0.2 bar/min.
The signal to activate the lamp is sent by the TPM [RDK] control unit (N88) via the interior CAN.
Light sources
Bulbs are used for the following indicator lamps:
 Left turn signal indicator lamp (A1e1)

 Right turn signal indicator lamp (A1e2)
 High beam indicator lamp (A1e3)
 Airbag indicator and warning lamp (A1e15)
 Preglow indicator lamp (A1e16)
All other indicator and warning lamps in the instrument cluster (A1) are equipped with light emitting diodes
(LED).
In addition to the operation scenarios described above, all of the indicator and warning lamps with the
exception of the

are also triggered during the lamp test.
Triggering and illumination of some indicator and warning lamps, such as the engine diagnosis indicator
lamp (A1e58), is accompanied by the appearance of a malfunction message in the multifunction display
(A1p15). 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!
Instrument cluster (IC), location/task GF54.30-P-3039S
DISPLAYING CHECK/WARNING MESSAGES BY MEANS OF MULTIFUNCTION DISPLAY,

MODEL 215, 220
Multifunction display (A1p13), valid up to 31.8.02:
Various pieces of driver information are displayed in the multifunction display (A1p13).
In addition to displaying the total and trip mileage (main screen), information for the following systems can also
be selected and displayed on the multifunction display (A1p13):
 Audio
 Telephone (special equipment)
 Navigation (special equipment)
 Distronic (special equipment)
 Trip computer
Modification valid as of 01.6.01:
 Digital speedometer in multifunction display (A1p13)

 In taxi vehicles "Terminal 30", warning messages are displayed once per driving cycle for 2 minutes and
can be acknowledged. The interior compartment CAN is wakened in the event of a taxi emergency call
without the instrument cluster (A1).
In addition, various fault and warning messages can be displayed on the multifunction display (A1p13)) if the
driver so wishes.
Multifunction display (A1p13), valid as of 01.9.02:
Various driver information is presented in the multifunction display (A1p13).
Starting from the main screen, the following displays can be called up using the system selection button
(S110s3) and scroll forward/back button (S110s1):
 Digital speedometer
 Service indicator
 Service scope as of 01.09.03
 Tire pressure
 Engine oil level scan
Starting from the described "driving mode" screen, it is possible to scroll through various setting and
information menus on the multifunction display (A1p13) by changing the display level using the system
selection button on the multifunction steering wheel.
Only systems and functions with which the vehicle is equipped are displayed:
 Audio displays
 Radio
 CD
 CC
 TV tuner (special equipment)
 Navigation (special equipment)
 Distronic (adaptive cruise control) (special equipment)
 Vehicle configuration
 Telephone display (special equipment)
 Taxi functions (special equipment)
 Telematics/Tele Aid (USA)
 Trip computer
 Fault and warning messages
Classification of fault and warning messages into categories, valid up to 31.8.02:
The messages are divided into three categories according to their priority.
 Messages of the highest priority belong to category 1. These messages cannot be acknowledged. A short
warning chime also sounds when these messages are displayed. Any errors of categories 2 and 3 are
hidden.
 Messages of medium priority belong to category 2. These messages can be acknowledged by pressing the
reset button (r). A short warning chime also sounds when these messages are displayed. Any errors of
category 3 are hidden.
 Messages of the lowest priority belong to category 3. These messages can be acknowledged by pressing
the reset button (r). A warning chime does not sound.
If no other malfunctions are present, the display will revert to the previous mask when the error status message
is acknowledged.
Classification of fault and warning messages into categories, valid as of 01.9.02:
The messages are divided into three categories according to their priority.
 Category 1:
Warning messages with the same priority are displayed immediately and hide menu levels. Any warning
messages of category 2 are also hidden. The messages disappear if the reason for their appearance no
longer exists. If there is more than one message, each one is displayed in turn for 5 seconds. The
messages cannot be acknowledged.
 Category 2:
Warning messages are only displayed if there are no priority 1 messages. New priority 2 messages are
displayed for at least 2 seconds; if there is more than one message, each one is displayed in turn for 5
seconds. Other properties such as color, warning chime, acknowledgment capability and so on are
specified in the properties of each message. Additionally, the priority 2 messages are divided into 3
classes.
Class 2A: After acknowledgment, the errors are written to the diagnostic trouble code memory and are no
longer displayed for this driving cycle.
Class 2B: After acknowledgment, the errors are not written to the diagnostic trouble code memory and are no
longer displayed for this driving cycle.
Class 2C: After acknowledgment, the errors are not written to the diagnostic trouble code memory. If the
message has been acknowledged, it is released for display again if it was inactive for longer than 2 seconds.
Warning chime:
The warning chime mentioned above is a warning gong in Model 220 and Model 220 as of 01.0.99 and is a
warning buzzer in Model 220 up to 31.8.99.
Some messages are accompanied by a warning or indicator lamp for the duration of the fault. This applies
even if the corresponding message was acknowledged.
Storage of messages, valid up to 31.8.02:
Messages of category 1 are not stored. Most fault messages of category 2 and 3 are, however, stored in a cyclic
memory in the instrument cluster (A1) after they have been acknowledged.
Fault messages of category 2 and 3 that have not been acknowledged are sent automatically to the cyclic
memory when terminal 15R is switched OFF. A maximum of 16 fault messages can be stored. If another fault
occurs, the oldest fault message is overwritten.
Storing messages, valid as of 01.9.02:
Messages of category 1 are not stored and cannot be acknowledged since the display disappears immediately as
soon as the reason for its appearance no longer exists.
The messages of category 2 are divided into 3 classes (2A, 2B, 2C), as described above. Only the messages of
class 2A and 2B are stored.
Display of fault and warning messages:

With very few exceptions (e.g. lights warning, key in ignition), fault messages are only displayed when the
engine is running.
Current fault messages, valid up to 31.8.02:
 Displayed immediately. If the fault exists for just a short time, messages of category 2 and 3 are displayed
for at least 2 seconds. Messages of category 1 are displayed for as long as the fault remains.
Current fault messages, valid as of 01.9.02:
 Displayed immediately and hide the menu levels. Messages of category 1 are displayed for as long as the
error remains. Messages of category 2 are also displayed immediately for at least 2 seconds, but cannot
hide messages of category 1.
Several current fault messages:
 If several fault messages of different priority are present at the same time, the message with the highest
priority is displayed.
 New fault messages of the same or higher priority category hide the previously displayed message.
 If several faults of the same category occur at the same time, the messages are displayed in turn for 5
seconds.
Reminder of acknowledged messages:
If the driver acknowledges messages while driving, these messages are displayed again as a reminder after
"Terminal 15R OFF". In this case, current messages, e.g. lights warning, hide this reminder function.
 If there were no messages, the main screen appears when terminal 15R is switched OFF.
Displaying stored fault messages:
The driver can scroll through the stored messages when the instrument cluster (A1) is activated:
 Press the system selection button (S111s3) repeatedly until "-- FAULTS" appears in the multifunction
display (A1p13).
Example, valid up to 31.8.02:
Four of the approximately 200 possible messages can be found below accompanied by a short description.
The order in which the messages are displayed if several errors occur at the same time can be explained using
an example:
 The windshield washer fluid level has fallen below the minimum mark. The following message of
category 3 appears on the multifunction display (A1p13). "CHECK WASHER FLUID LEVEL" (Figure
1).
 If another fault occurs at the alternator, the category 2 message "BATTERY/ALTERNATOR CHECK -
VISIT WORKSHOP!" is displayed (Figure 2). This message hides the first message because it has a
higher priority.
 If the coolant level then also drops below its minimum mark, the category 2 message "CHECK
COOLANT LEVEL!" is displayed (Figure 3). The display now alternates every 5 seconds between this
message and the message "BATTERY/ALTERNATOR CHECK - VISIT WORKSHOP!" (Figure 2)
because there are now two messages with the same priority.
The example assumes that none of the messages were acknowledged by the driver.
Illustration showing warning message of category 3, valid up to 31.8.02
Figure 1
Fig. 70: Identifying Check Wiper Fluid Message
Figure 2
Fig. 71: Identifying Check Battery/Generator Message
Figure 3
Fig. 72: Identifying Check Coolant Level Message
Figure 4
Fig. 73: Identifying Display Defective Message
Figure 1:
Warning message of category 3:
This category 3 message is displayed when the level of washer fluid for the windshield and headlamp cleaning
system drops below the minimum.
This information comes from the right front SAM control unit (N10/7) via the interior compartment CAN.
For more information, see document:
"Coolant/washer reservoir fluid level voltage code entry, function"
Figure 2:
This category 2 message is displayed if the alternator is not functioning correctly, but the engine speed is higher
than 200 rpm. For more information, see document:
"Battery charge and alternator check, function".
Figure 3:
This category 2 message appears when the coolant drops below the minimum level.
This information is sent on the interior compartment CAN by the right front SAM control unit (N10/7).
For more information, see document:
"Coolant/washer reservoir fluid level voltage code entry function"
Figure 4:
This category 2 message appears when a malfunction in the interior and/or engine compartment CAN occurs,
affecting communications with several control units.
If communications with only one control unit are affected, the symbol for the affected system appears at
position (2).
Displaying stored fault messages:
The driver can scroll through the stored messages when the instrument cluster (A1) is activated:
 Press the system selection button repeatedly until "--FAULTS" appears on the multifunction display
(A1p13).
Example, valid as of 01.9.02
Four of the approximately 200 possible messages can be found below accompanied by a short description.
The order in which the messages are displayed if several errors occur at the same time can be explained using
an example:
 The filler cap is open. In the multifunction display (A1p13), the priority 2 / class 2 C message "CHECK
FILLER CAP!" is displayed (Figure 1).
 A loss of tire pressure occurs. In the multifunction display (A1p13), the priority 2 / class 2 B message
"CHECK TIRES!" is displayed (Figure 2).
 If another fault occurs at the alternator, the priority 2 / class 2 A message "BATTERY/ALTERNATOR"
"VISIT WORKSHOP!" is displayed (Figure 3).
Three priority 2 messages now exist and are displayed; since the messages have the same priority, they
are each displayed alternately for 5 seconds.
 The driver has forgotten to release the parking brake. The priority 1 message is displayed in the
multifunction display (A1p13); the priority of this message means that it hides all other messages. If the
parking brake is released again, the display disappears and the other messages are displayed alternately
until the faults have been rectified.
This only applies if the error messages have not been acknowledged.
Illustration showing warning message of priority 2 / class 2C, valid as of 01.9.02
Figure 1
Fig. 74: Identifying Warning Message Of Fuel Pump
Illustration showing warning message of priority 2 / class 2B, valid as of 01.9.02
Figure 2
Fig. 75: Identifying Warning Message Of Tire
Illustration showing warning message of priority 2 / class 2A, valid as of 01.9.02
Figure 3
Illustration showing warning message of priority 1, valid as of 01.9.02
Figure 4
Fig. 77: Identifying Warning Message Of Parking Brake
OUTPUTTING ACOUSTIC WARNING MESSAGES, FUNCTION - GF54.30-P-2013
Outputting acoustic warning messages, function - GF54.30-P-2013A
MODEL 215,
220 as of 1.9.99
Function of acoustic warning:
The acoustic turn signal indicator (A1h2) is integrated in the instrument cluster (A1). This is a contactless relay.
The turn signal flasher is always accompanied by an acoustic clicking sound generated in the same rhythm. The
acoustic turn signal/flasher function varies according to the type of signal:
Turn signal flashing:
The trigger signal for the acoustic turn signal function (A1h2) comes the steering column module (N80) via the
interior compartment CAN. If one of the turn signals fails, the acoustic turn signal indicator (A1h2) operates at
twice the usual frequency. The instrument cluster (A1) receives the information via the interior compartment
CAN after the signal is originally generated by the control unit governing operations within the circuit in which
the issue arises.
Hazard warning flashing:
The trigger signal for the acoustic turn signal indicator (A1h2) function comes from the upper control panel
control unit (N72/1) via the interior compartment CAN.
Anti-theft alarm system flashing:
The trigger signal for the acoustic turn signal indicator (A1h2) function comes from the left front SAM control
unit (N10/6) via the interior compartment CAN.
Special functions flashing:
The trigger signal for the acoustic turn signal indicator (A1h2) function comes from the special vehicle
multifunction control unit (SVMCU) (N26/9) via the interior compartment CAN.
Warning chime:
The instrument cluster (A1) has a speaker which outputs an acoustic signal (gong or short buzzer tone) in the
case of various faults and operating conditions. This acoustic signal is usually output once only. In some cases,
however, the signal is output repeatedly.
The gong sounds:
When fault and warning messages of medium and top priority occur (in addition to the message that appears in
the multifunction display panel (A1p13)).
 When the seat belt warning lamp (A1e9) lights up. This indicator lamp is not available in all country
variants. The trigger signal for the lamp comes via the interior compartment CAN from the left front seat
adjustment control unit with memory (N32/1) and/or from the right front seat adjustment control unit with
memory (N32/2).
 The brake fluid level and parking brake warning lamp (A1e7) lights up when the vehicle starts to move
before the parking brake is released. The gong sounds until the parking brake is released or the engine is
switched off. The trigger signal comes via the interior compartment CAN from the left front SAM control
unit (N10/6).
 When the ignition key remains in the electronic ignition switch (EIS) control unit (N73) with the ignition
off and the door is opened. The "ignition key status information" and the ignition OFF signal come via the
interior compartment CAN from the EIS control unit (N73), and the door contact signal comes from the
rear SAM control unit (N10/8).
 When the standing lamps are on, the ignition key is withdrawn and the driver's door is open (lights
warning). The "ignition key status information" comes via the interior compartment CAN from the EIS
control unit (N73), the door contact switch signal from the rear SAM control unit (N10/8) and the
standing lamp signal from left front SAM control unit (N10/6).
 If the child safety lock is unlocked. The trigger signal is transferred from the pneumatic control unit
(combined) (A37) to the interior compartment CAN.
 When specially protected vehicles exceed a speed of 210 kph. The gong is canceled as soon as the speed
drops back below 207 kph. The speed on the electronic speedometer (A1p8) is used.
 When the vehicle speed exceeds 120 kph (Gulf states only). The gong is canceled as soon as the speed
drops back below 117 kph.
 When the speed set at the variable speed limiter is exceeded owing to inertial acceleration (e.g. when
driving downhill).
 The displayed speed is used. The set maximum speed comes via the engine compartment CAN from the
motor electronics control unit (N3/10) or from the CDI control unit (N3/9).
 If the selector lever in vehicles with "keyless go" is not set to "P" and one or more doors are open. The
selector lever position signal comes from the ETC control unit (N15/3) via the engine compartment CAN.
The door contact signal is transferred from the rear SAM control unit (N10/8) to the interior compartment
CAN.
The buzzer tone sounds:
When the DTR warning lamp (A1e59) lights up. This lamp is actuated when the distance to the preceding
vehicle falls below the defined safety margin. The signal comes via the engine compartment CAN from the
DTR control unit (N63/1).
Outputting acoustic warning messages, function - GF54.30-P-2013S
MODEL 220 up to 31.8.99
Acoustic turn signal indicator (A1h2):
The acoustic turn signal indicator (A1h2) is integrated in the instrument cluster (A1). This is a contactless relay.
The turn signal flasher is always accompanied by an acoustic clicking sound generated in the same rhythm. The
acoustic turn signal/flasher function varies according to the type of signal:
 Turn signal flashing:
The trigger signal for the acoustic turn signal indicator (A1h2) comes via the interior compartment CAN
from the steering column module (N80).
If one of the turn signals fails, the acoustic turn signal indicator (A1h2) operates at twice the usual
frequency. The instrument cluster (A1) receives the information through the interior compartment CAN
after the signal is originally generated by the control unit governing operations within the circuit in which
the issue arises.
 Hazard warning flashing:
The trigger signal for the acoustic turn signal indicator (A1h2) function comes via the interior
compartment CAN from the upper control panel control unit (N72/1).
 Anti-theft alarm system flashing:
compartment CAN from the left front SAM control unit (N10/6).
 Special functions flashing:
compartment CAN from the special vehicle multifunction control unit.
Warning chime:
The instrument cluster (A1) is equipped with a speaker that can respond to various malfunctions and operating
conditions by generating an acoustic warning signal at a frequency of approximately 2000 Hz with a duration of
roughly 0.2 seconds.
An acoustic warning is given:
 When fault and warning messages of medium and top priority occur (in addition to the message that
appears in the multifunction display panel (A1p13)).
Further information is given in the documentation for the system concerned.
 When the seat belt warning lamp (A1e9) lights up. This indicator lamp is not available on all national
versions.
The trigger signal comes via the interior compartment CAN from the left front seat adjustment control
unit with memory (N32/1) and/or from the right front seat adjustment control unit with memory (N32/2).
 The brake fluid level and parking brake warning lamp (A1e7) lights up when the vehicle starts to move
before the parking brake is released. The trigger signal comes via the interior compartment CAN from the
left front SAM control unit (N10/6).
 When the DTR warning lamp (A1e59) lights up.
This lamp is triggered when the distance to the preceding vehicle falls below the defined safety margin.
The actuating signal comes over the engine compartment CAN from the DTR control unit (N63/1).
 When the ignition key remains in the electronic ignition switch (EIS) control unit (N73) with the ignition
off and the door is opened.
The "ignition key status information" and the ignition OFF signal come via the interior compartment
CAN from the EIS control unit (N73), and the door contact signal comes from the rear SAM control unit
(N10/8).
 When the standing lamps are on, the ignition key is withdrawn and the driver's door is open (lights
warning).
The "ignition key status information" comes via the interior compartment CAN from the EIS control unit
(N73), the door contact signal comes from the rear SAM control unit (N10/8) and the standing lamp
signal from the left front SAM control unit (N10/6).
 If the child safety lock is unlocked.
The trigger signal comes via the interior compartment CAN from the pneumatic control unit (combined)
(A37).
 When specially protected vehicles exceed a speed of 210 kph. The acoustic warning signal is canceled as
soon as the speed drops back below 207 kph.
The speed displayed on the electronic speedometer (A1p8) is used.
 When the vehicle speed exceeds 120 kph (Gulf states only). The acoustic warning signal is canceled as
soon as the speed drops back below 117 kph.
 When the speed set at the variable speed limiter is exceeded, e.g. owing to inertial acceleration.
The displayed speed is used. The set maximum speed comes via the engine compartment CAN from the
motor electronics control unit (N3/10) or from the CDI control unit (N3/9).
Displaying check/warning messages by means of indicator lamps, function GF54.30-P-2011S

Displaying check/warning messages by means of multifunction display, function GF54.30-P-2012S
Displaying speed, function GF54.30-P-3025S
FUNCTION TO TEST MALFUNCTION INDICATION LIGHTS AND ENGINE RUNNING

DETECTION - GF54.30-P-2014S
Model 215, 220
Fig. 78: Networking Of Components For Malfunction Indication Lights And Engine Running Detection
Lamp test:
A lamp test is performed when term. 15 is ON. During this test, all of the indicator and warning lamps present
on a particular vehicle (as defined by individual options as well as national version) are checked, with the
exception of:
are actuated.
The lamp test continues only for as long as Terminal 61 is at low level (Terminal 61 < 9V) (alternator not yet in
operation) and the engine speed remains below 200 rpm.
If no malfunctions are present the lamps will go out as soon as the engine starts to run.
The DTR warning lamp (A1e59) is tested during the indicator lamp test even if the vehicle is not equipped
with Distronic.
Engine running detection, terminal 61e, valid up to 31.8.02:
The instrument cluster (A1) links the CAN messages "Terminal 61" and "engine speed" to a CAN message at
"Terminal 61e" (engine running detection).
"Term. 61e" is, for example, required by the motor electronics control unit (N3/10) or by the CDI control unit
(N3/9) and traction systems control unit (N47).
This signal can have either a "high" or "low" status.
It is low when "Term. 61" is low and the engine speed is less than 200 rpm. In all other cases the signal status is
"high".
The "Term. 61e" signal is transferred by the instrument cluster (A1) to the engine compartment CAN where it is
then available to the control units.
Networking (see diagram above).
Engine running detection, terminal 61e, valid up as of 01.9.02:
The instrument cluster (A1) links the CAN messages "Terminal 61" and "engine speed" to a CAN message at
"Terminal 61e" (engine running detection).
"Term. 61e" is, for example, required by the motor electronics control unit (N3/10) or by the CDI control unit
(N3/9) and traction systems control unit (N47). This signal can have either a "high" or "low" status.
It is low when "Term. 61" is low and the engine speed is less than 200 rpm. In all other cases the signal status is
"high".
The "Term. 61e" signal is transferred by the instrument cluster (A1) to the engine compartment CAN where it is
then available to the control units.
Networking (see diagram above).
The following CAN data is required:
 Term. 61 alternator check
The "Term. 61" signal from the alternator (G2) (alternator check) is read in by the right front SAM
control unit (N10/7). The right front SAM control unit (N10/7) then passes the message "Term. 61
High" (alternator functioning) or "Term. 61 Low" (alternator not functioning) onto the interior
compartment CAN.
 Engine speed
The pulses from the crankshaft position sensor (L5) are read in by the motor electronics control unit
(N3/10) or by the CDI control unit (N3/9). The motor electronics control unit (N3/10) (gasoline models)
or the CDI control unit (N3/9) transfers the engine speed message (in rpm) to the engine compartment
CAN.
The instrument cluster (A1) receives these messages and evaluates them as described above.
The same CAN message is used for the charge indicator warning message "BATTERY/ALTERNATOR
VISIT WORKSHOP". This message appears on the multifunction display (A1p13) if "Term. 61" is "low" and
the engine speed is greater than 200 rpm.
The following chart recapitulates the interrelationships portrayed in the above section.
Notice regarding the chart
The CAN message "Terminal 61" can assume the states "High" and "Low". This status depends on the actual
voltage at the input of the right front SAM control unit (N10/7). It becomes "High" when this voltage exceeds 9
V. It becomes "low" when the voltage drops back below 4.5 V.
Terminal 61 Engine speed Terminal 61e Instrument cluster (A1)

low (< 4.5 V) too low low Indicator lamp test
low (< 4.5 V) o.k. high "BATTERY/ALTERNATOR VISIT WORKSHOP"
high (> 9 V) too low high -
high (> 9 V) o.k. high -
low (< 4.5 V) Signal error low Indicator lamp test
high (> 9 V) Signal error high -
STEPPER MOTOR, LOCATION/DESIGN/FUNCTION - GF54.30-P-3009A
MODEL 129,140 as of 1.6.96, 163, 168, 170, 202 as of 1.8.96, 208, 210 as of 1.6.96, 215, 220
General
Stepper motors are motors which, like most electric motors, consist of a fixed stator and a moveable rotor. The
rotary motion is not continuous, rather the rotor turns in steps, a certain angle at a time, for example 90°.
Design
The illustration shows the basic design of a stepper motor with 1 pole pair and 2 phases. The stator is made of
magnetically soft iron and holds the windings. Opposite windings belong together and form a phase (in this
case, a and b). The rotor consists of a permanent magnet. In the illustration the rotor has 1 pole pair.
Function
The rotor is turned by applying current through phase a or b (see illustration). The magnetism in the stator
changes according to the polarization (I) of the phases.
Fig. 79: Identifying Stepper Motor Design
The rotor will turn so that its south pole (S) is at the north pole (N) of the stator and its north pole (N) is at the
south pole (S) of the stator. The illustration shows a full rotation of the rotor. The rotor moves in steps of 90°
from positions 1 through 4 and back to its starting position.
Unlike normal electric motors, the motor can stop in each of these positions with a certain holding torque. This
type of motor is therefore particularly suitable for use as a servomotor for exact positioning.
The size of the steps can be reduced considerably by increasing the number of pole pairs and phases.
Theoretically, it is even possible to make the steps infinitely small with just a few poles and phases by using
complicated electronic phase control (sine-cosine control).
Stepper motors (with sine-cosine control) are used, for example, for pointing instruments in the instrument
cluster (A1).
LIQUID CRYSTAL DISPLAY (LCD), LOCATION/TASK/FUNCTION - GF54.30-P-3015A
MODEL 129, 140 as of 1.6.96, 163, 168, 170, 202 as of 1.8.96, 208, 210 as of 1.6.96, 215,220
Task
The liquid crystal displays (LCDs) can display numbers, letters and other symbols. They are therefore used as
the output devices of electronic systems. They are increasingly used as a replacement for the conventional
analog indicating instruments and indicator lamps.
Operating principle
The operating principle of the liquid crystal display is explained using a seven-segment display as an example
(see illustration).
A spacer frame (d) which surrounds a thin layer of liquid crystal (e) is sandwiched between the glass plates (a)
and (f). Transparent electrodes (segments) are attached to glass plate (a) in the shape of the desired characters.
Fig. 80: Identifying Liquid Crystal Display
The transparent counter-electrode (h) is on glass plate (f). If a voltage is applied between the contact (g) of the
counter-electrode (h) and one or more contacts (b) of the segmented electrodes (c), the optical properties of the
liquid crystal between the counter-electrode (h) and the energized electrodes (c) change. If the LCD is viewed in
the direction of the arrow, the energized electrodes (c) appear dark and are thus visible. By actuating the
appropriate electrodes (c) it is possible to display any number.
The liquid crystal display also has 2 polarization filters (i). These types of display have a better contrast and
require a lower supply voltage (approx. 1.5 - 5 V).
Other characters can also be displayed if the appropriate electrode layout or shape is selected. Strip-type
electrodes are usually used in the multifunction display (A1 p13). Here strip-type electrodes are attached to both
of the glass plates (a) and (f). The strips on glass plate (a) are arranged vertically to the strips on glass plate (f).
This arrangement allows individual dots (pixels) to be actuated. If different dots are actuated repeatedly in
sequence at a sufficiently high speed, it is possible to produce almost any "image".
PHOTODIODE AND PHOTOTRANSISTOR, LOCATION / TASK / FUNCTION - GF54.30-P-3016A
MODEL 202 as of 1.8.96, 208, 210 as of 1.6.96, 215, 220
Task:
Photodiodes and phototransistors are used to measure light intensity so that electrical equipment can then be
controlled using the measured signal.
In the instrument cluster (A1), a phototransistor is used in order to adapt the illumination or display brightness
to the ambient brightness.
Semiconductors (general information):
Photodiodes are semiconductor elements. The conductivity of semiconductors (e.g. silicon) is between that of
metals and nonconductors. The conductivity of semiconductors is largely dependent on
 temperature,
 light exposure and
 any contamination by foreign atoms.
Conductivity can therefore be influenced by deliberate contamination (doping). A distinction is made between
two types of doping:
 N-doping
The material is contaminated with foreign atoms which produce an excess of electrons. Since electrons
have a negative charge, the term "N-type conduction" is used.
 P-doping
The material is contaminated with foreign atoms which produce a lack of electrons ("holes"). This results
in positive charge carriers and the term "P-type conduction" is used.
Bringing together a P and N-doped layer produces a diode (block layer).
Owing to the displacement of electrons and holes, the conductivity of this array depends heavily on the polarity
of the applied voltage.
The conductivity is very high when the N-material is connected to the negative pole and the P-material is
connected to the positive pole (conducting direction).
If the polarity is different, the conductivity is very low (non-conducting direction).
Photodiode:
In a diode, additional electrons and holes are produced when it is exposed to light. The conductivity of a diode
connected in non-conducting direction therefore increases in proportion to the light intensity. Photodiodes are
manufactured in such a way that this effect is especially pronounced.
Owing to the linear correlation between light intensity and conductivity, photodiodes are ideal for measuring
purposes.
Phototransistor:
A transistor is produced if 3 doped layers are combined in an NPN or PNP arrangement.
A transistor therefore has 3 contacts (emitter, base = control input, collector). Transistors can be used to amplify
and switch electrical signals.
Here the NP or PN arrangement has the same effect as the photodiode. The correlation with respect to the
conductivity of the transistor between the two outer layers (emitter and collector) is, however, greater owing to
the transistor effect. The transistor therefore reacts even more sensitively to light than photodiodes.
Special phototransistors are usually manufactured without the base contact since no control input is required.
QUARTZ, LOCATION/TASK/FUNCTION - GF54.30-P-3017A
MODEL 129,140 as of 1.6.96, 163, 168, 170, 202 as of 1.8.96, 208, 210 as of 1.6.96, 215, 220
Piezo-electric effect:
A thin quartz plate (c) is coated on two opposing sides with a conductive material (a), (b) (see illustration). If a
tensile or compressive load is applied to the array, an electrical voltage "U" is produced between the points (d)
and (e). The polarity of the generated voltage depends on the direction of load (compression/tension).
Reversed piezo-electric effect:
If, however, a voltage is applied to the points (d) and (e), the quartz plate increases or decreases in length.
Task:
Mechanical vibrations can be converted into electrical oscillations using the piezo-electric effect. For example,
for microphones, knock sensors, pressure sensors.
Electrical oscillations can be converted into mechanical vibrations or motion using the reversed piezo-electric
effect: piezo-electric speakers, actuators.
Both effects are combined in the quartz resonator: If an AC voltage whose frequency is roughly equal to the
mechanical resonant frequency (fundamental or harmonic component) of the quartz plate is applied to the points
(d) and (e), the quartz is stimulated to generate resonant vibrations which stabilize the frequency of the
electrical oscillations. For this reason, quartz resonators are often used where a high degree of frequency
stability is required (e.g. in clock generators (oscillators) for electronic clocks and microprocessors).
Fig. 81: Identifying Piezoelectric Loudspeaker (Quartz), Function
FUEL QUANTITY DISPLAY FUNCTION - GF54.30-P-3018S
Model 215, 220
Fig. 82: Networking Of Components For Displaying Fuel Quantity
Networking:
 The fuel level sensor (B4) changes its resistance according to the fuel level in the tank. The fuller the
tank, the lower the resistance.
 The resistance of the fuel level sensor (B4) is read in by the rear SAM control unit (N10/8).
 The rear SAM control unit (N10/8) converts the resistance values from the fuel level sensor (B4) into a
percentage (a full tank corresponds to 100 %).
 This percentage is transferred by the rear SAM control unit (N10/8) to the interior compartment CAN.
 The instrument cluster (A1) reads in this percentage from the interior compartment CAN and uses this
information as the basis for controlling the fuel level and low fuel gauge (A1p2) as well as the fuel
reserve indicator lamp (A1e4) as required.
 The fuel level and reserve gauge (A1p2) is controlled by a stepper motor.
Display of fuel level, valid up to 31.8.02:
 If "Term. 15" is ON, the current tank level is indicated in the fuel level and reserve gauge (A1p2).
 If the tank is filled while "Term. 15" is ON, detection of refilling (updating of the display) only takes
place after a refill quantity of at least 5 liters.
 The display is updated as soon as the ignition is switched on again. There is always a delay before the
display is updated. This suppresses fluctuations in the display, e.g. due to cornering.
Reserve range, valid up to 31.8.02:
 The reserve range extends from "0" to "R". This corresponds to a quantity of 0 to approx. 12 liters with
the standard tank and of 0 to approx. 10 liters with the ski bag version.
 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 to prevent the lamp flickering.
Display of fuel level, valid as of 01.9.02:
 When "Term. 15" is ON, the indicator moves to the display reading within 1 second. The time constant is
then increased to 8 seconds.
 When the engine starts, a time constant of 0.25 seconds is selected for 4 seconds in order to obtain a
display reading with the full on-board voltage.
 Once these 4 seconds have elapsed or the vehicle moves, the time constant for display updating is set to
30 seconds.
 If the tank is filled while "Term. 15" is ON, detection of refilling (updating of the display) only takes
place after a refill quantity of at least 5 liters.
Reserve range, valid as of 01.9.02:
 The reserve range extends from "0" to "R". This corresponds to a quantity of 0 to approx. 11 liters with
the standard tank and of 0 to approx. 10 liters with the ski bag version.
 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 to prevent the lamp flickering.
Tank type code, valid up to 31.8.02:
Coding for the tank type is not necessary. The fuel level sensors (B4) are designed so that a certain resistance
corresponds to the same percentage for both tank variants.
Tank type code, valid as of 01.9.02:
Two characteristics which are set by means of the variant coding are available for determining the display
reading. The upper tank value and tank reserve value can be selected independently of the respective tank
characteristic.
Fuel level sensor seizure detection, valid as of 01.9.02
If seizure of the fuel level sensor is detected, this is stored in the diagnostic trouble code memory and can be
read out using the STAR DIAGNOSIS TOOL.
In the case of a fault, the pointer of the fuel level and reserve gauge (A1p2) moves to the left stop. The fuel
reserve indicator lamp (A1e4) does not light up. This information is valid for all vehicles.
DISPLAYING OUTSIDE TEMPERATURE, FUNCTION - GF54.30-P-3019S
Model 215, 220
Networking of components Shown on Model 220
Fig. 83: Networking Of Components For Displaying Outside Temperature - Shown On Model 220
Basic requirements
Basic requirements for display of outside temperature:

 Outside temperature
 Vehicle speed signal
 Engine running time
Displaying outside temperature
The instrument cluster (A1) processes these data as the basis for generating the display. The fact that the outside
temperature indicator (A1p4) 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:
 When the instrument cluster (A1) is activated, the current outside temperature is always displayed.
Coolant temperature equal to or greater than 60 °C:
 When the ignition is switched off, the last measured temperature value is stored and displayed.
 When the instrument cluster (A1) is activated, the stored temperature is displayed.
If the measured outside temperature falls below the stored value, the current measured temperature is displayed
after 8 seconds.
If the measured outside temperature rises above the stored value, the current measured temperature is displayed
after the following delay periods:
 When the engine is switched off, the current outside temperature is displayed after six times the engine
running time. This is based on the previous engine running time.
Example:
 Previous engine running time was 5 minutes; the delay time is 6 x 5 minutes. The current temperature is
therefore displayed after a delay of 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 therefore 60 minutes.
When the vehicle is moving, the delay periods depend on the ground speed.
 At speeds in excess of 45 kph, increasing outside temperatures are displayed after a delay of 1 1/2
minutes.
 At speeds of 20 to 45 kph, increasing outside temperatures are displayed after a delay of 3 minutes.
 If the speed falls below 20 kph (from higher values), the display is only changed if the measured value
falls.
Reading range:
The reading range is -38 to +58 degrees Celsius or -36 to +136 degrees Fahrenheit. Temperatures are graduated
in steps of 0.5 degrees Celsius or 1 degree Fahrenheit.
Changing from degrees Celsius to degrees Fahrenheit
The driver can switch between degrees Celsius and degrees Fahrenheit using the "Settings" function on the
Reading in required data for displaying outside temperature:
 The outside temperature display 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.)
 This resistance value from the outside temperature display temperature sensor (B14) is read in by the left
front SAM control unit (N10/6).
 The left front SAM control unit (N10/6) converts the resistance value from the outside temperature
display temperature sensor (B14) into a temperature value.
 This temperature value is sent by the left front SAM control unit (N10/6) to the interior compartment
CAN.
Vehicle speed signal:
 The four wheel speed signals are read in by the wheel speed sensors of the traction systems control unit
(N47).
 The traction systems control unit (N47) sends the four wheel speed signals to the engine compartment
CAN.
 The instrument cluster (A1) uses the signals to determine the vehicle speed (see also the document
"Displaying speed, function").
Coolant temperature:
 The coolant temperature sensor (B11/4) changes its resistance according to the coolant temperature. (The
sensor is an NTC resistor, i.e. its resistance decreases as the temperature rises.)
Reading in coolant temperature:
 The resistance of the coolant temperature sensor (B11/4) is read in by the motor electronics control unit
(N3/10) or by the CDI control unit (N3/9) and the resistance value from the coolant temperature sensor
(B11/4) is converted into a temperature value.
 This temperature value is then sent to the engine compartment CAN.
Engine running time:

 The engine running time is determined internally in the instrument cluster (A1) using the integrated timer
(z).
The instrument cluster (A1) processes this data and actuates the display accordingly.
Notes on diagnosis
If the display shows the lowest temperature value of -38 °Cor36°F when the outside temperature is obviously
higher, the sensor may be faulty or there may be an open circuit.
If the highest temperature, 58 °C or 136 °F, appears on the display when the outside temperature is obviously
lower, there may be a short circuit in the sensor or the wire.
DISPLAYING COOLANT TEMPERATURE, FUNCTION - GF54.30-P-3020S
Model 215, 220
Fig. 84: Networking Of Components For Displaying Coolant Temperature
Signal flow, valid up to 31.8.02:
 The coolant temperature sensor (B11/4) 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 of the coolant temperature sensor (B11/4) is read in by the motor electronics control unit
(N3/9) or the CDI control unit (N3/10).
 The motor electronics control unit (N3/10) or the CDI control unit (N3/9) converts the resistance values
of the coolant temperature sensor (B11/4) into a temperature value.
 This temperature value is transferred by the motor electronics control unit (N3/10) or CDI control unit
(N3/9) to the engine compartment CAN.
 The instrument cluster (A1) reads in this temperature from the engine compartment CAN and actuates the
coolant temperature gauge (A1p1) accordingly. If necessary, a warning message also appears on the
The coolant temperature gauge (A1p1) is driven by a step motor.
Display of coolant temperature:
 This display is a plateau display.
That is to say, at temperatures between 95 °C and 115 °C the indicator remains at 95 °C. Temperatures
within this temperature range are not critical. The correct temperature is only displayed once the
temperature reaches 116 ° C. This avoids the driver being worried unnecessarily by the display, e.g. at
high outside temperatures.
 The warning range begins at 128 °C. At temperatures in excess of 128 °C, the coolant temperature
symbol and the warning message "COOLANT - STOP - ENGINE OFF!" is displayed in the
multifunction display (A1p13). A warning signal also sounds.
If the engine fan fails, the plateau display disappears and the values between 95 °C and 115 °C are displayed.
ENGINE RPM DISPLAY FUNCTION - GF54.30-P-3021S
Model 215, 220
Fig. 85: Networking Of Components For Engine RPM Display
Networking, valid as of 01.9.02:
 Engine speed is registered by the crankshaft position sensor (L5). The signals from the crankshaft
position sensor (L5) are read in by the motor electronics control unit (N3/10) or the CDI control unit
(N3/9) and are transferred to the engine compartment CAN as a message (in rpm). The instrument cluster
(A1) receives this message and actuates the stepper motor of the tachometer (A1p5) relative to the engine
speed.
Adaptation to number of cylinders

It is not necessary to adapt the tachometer (A1p5) to the number of cylinders in the engine.
If implausible CAN values occur, the pointer of the tachometer (A1p5) is moved to the left-hand end of the
scale. An error bit is also stored in the fault memory.
Warning range:
The warning range (marked red on the scale) commences at Vehicles with
 gasoline engines at 6000 rpm,

 diesel engines at 4600 rpm.
DISPLAYING DISTANCE, FUNCTION - GF54.30-P-3022S
Model 215, 220
Networking
Fig. 86: Networking Of Components For Displaying Distance
Calculating the distance:
The distance is calculated in the instrument cluster (A1) using the vehicle speed (integration according to time).
 The computer in the instrument cluster (A1) calculates the distance and the vehicle speed using the wheel
speeds measured by the four wheel speed sensors. The instrument cluster (A1) receives the wheel speeds
in "rpm" from the traction system control unit (N47) on the engine compartment CAN.
 The system also includes tire size in its calculations of distance and speed. The tire size code is entered
using the STAR diagnosis tool.
Refer to the document entitled "Displaying Speed, Function" for evaluation of the wheel speed signals.
Displaying the total mileage:
 The total mileage is displayed as a 6-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 total mileage odometer is from 0 to 999999 kilometers or miles.
If the maximum mileage is reached, the counter is not reset to 0. It is then necessary to replace the
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 odometer:
The trip odometer is reset to 0 by pressing the trip odometer reset button (right-hand button on the
instrument cluster (A1)). Prerequisites:
 The instrument cluster (A1) is activated and

 the multifunction display (A1p13) is displayed in the main screen (total and trip mileage).
Switching between kilometers and miles:
The mileage display can be switched over from kilometers to miles by means of the Settings function.
If implausible wheel speed signal values are received on the CAN, the total and trip mileage odometer
"freezes" and an error bit is stored in the memory.
The current reading on the total mileage odometer is also relayed onto the interior compartment CAN by the
Storage of data:
If the battery is removed, the total mileage is stored for at least 5 years.
The trip mileage is also protected against data loss if the battery is removed for a short period of time.
Activating instrument cluster, function GF54.30-P-2006S

Displaying speed, function GF54.30-P-3025S
Instrument cluster (IC), operating information GF54.30-P-0002-05S
Liquid crystal display (LCD), location/task/ function GF54.30-P-3015A
DISPLAYING TRANSMISSION INFORMATION, FUNCTION - GF54.30-P-3023S

Model 215, 220
Gear indicator (A1p12), up to 08.09.2002
 The gear indicator (A1p1) is a liquid crystal display.

 It displays the selected shift range (1-4) or the selector lever position (D-P) and the selected transmission
mode (W or S). It may take up to one minute for the displayed transmission mode to be updated.
 The required data comes from the ETC control unit (N15/3) via the engine compartment CAN.
The display panel remains dark if there are errors in the CAN signals.
Fig. 87: Identifying Instrument Cluster And Gear Indicator - Up To 08.09.2002
Gear indicator (A1p12), as of 09.09.2002
 The gear indicator (A1p1) is a liquid crystal display.

 It displays the selected shift range (1-4) or the selector lever position (D-P) and the selected transmission
mode (C, S or A). It may take up to one minute for the displayed transmission mode to be updated.
 The required data comes from the ETC control unit (N15/3) via the engine compartment CAN.
The display panel remains dark if there are errors in the CAN signals.
Fig. 88: Identifying Instrument Cluster And Gear Indicator - As Of 09.09.2002
Liquid crystal display (LCD), location/task/function GF54.30-P-3015A
DISPLAYING TIME, FUNCTION - GF54.30-P-3024S
Model 215, 220
Networking of components:
Fig. 89: Networking Of Components For Displaying Time
General:
Time measurement (clock) requires a periodic process with a cycle duration of high accuracy (e.g. earth
rotation, pendulum oscillation).
Likewise, an electronic clock (A1p6) requires an electric clock signal with high frequency accuracy. This clock
signal is usually derived from the extremely constant mechanical oscillations of an oscillator crystal. A quartz
with a very high frequency (several MHz) is normally used. This frequency is then scaled down to the required
frequency of 1 Hz using an electronic frequency scaler. The display thus receives an electrical pulse to switch
the display every second.
Displaying time on vehicles without Command:
The electronic clock (A1p6) works according to the principle described above.
Electronics are also required to set the clock.
The driver can set the clock in the "Settings" menu using the buttons on the multi-function steering wheel:

 System selection button (S110s3)
 + and - button, specific function setting and volume control (S111s1)
The signals from these buttons are registered by the steering column module (N80) and relayed to the
instrument cluster (A1) via the interior compartment CAN.
(For further information see Operating Instructions)
Displaying time on vehicles with Command:
On vehicles with COMAND, the instrument cluster (A1) uses the time information from the COMAND control
unit. The current time is received via the GPS antenna (A2/49a2) and passed on to the COMAND control unit.
The time information is transferred from the COMAND control unit to the interior compartment CAN every
minute as a message.
If the COMAND variant is coded in the instrument cluster (A1), the instrument cluster adopts this time
information.
If GPS signals are received from the telephone and GPS roof antenna (A2/49), these signals can be used to
switch automatically between summer and winter time.
Adjustments for different time zones are also automatic. COMAND system receives local information via GPS.
The components indicated by the broken lines in the networking diagrams are only relevant for vehicles with
the COMAND operating and display system (Code 352a).
The instrument cluster (A1) also outputs the current time as a message via the interior compartment CAN.
DISPLAYING SPEED, FUNCTION - GF54.30-P-3025S

Model 215, 220
Fig. 90: Networking Of Components For Displaying Speed
The electronic speedometer (A1p8) is used to display the vehicle speed.
Determining the vehicle speed:
This display is furnished as the distance covered in one hour in either miles or kilometers.
To calculate the vehicle speed, the processor in the instrument cluster (A1) evaluates the wheel speed signals
from the four wheel speed sensors:
 Left front wheel speed sensor (L6/1)

 Right front wheel speed sensor (L6/2)
 Left rear wheel speed sensor (L6/3)
 Right rear wheel speed sensor (L6/4)
The instrument cluster (A1) receives the wheel speeds in "rpm" from the traction systems control unit (N47) via
the engine compartment CAN.
 The system also includes tire size in its speed calculations. The tire size code is entered using the STAR
DIAGNOSIS TOOL.
The determined vehicle speed is displayed on the electronic speedometer (A1p8).
The speedometer is driven by a stepper motor.
Evaluating the wheel speed signals:
Since the wheels do not always rotate at the same speed, all four 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 exist between the individual wheel speed signals, the vehicle speed is determined using the
rotational speed of the left front wheel.
If the individual wheel speed signals vary substantially, the speed signals may be faulty or the vehicle may be
cornering:
 If the computer detects, by means of suitable comparisons (comparing the two sides of the vehicle), that
the vehicle is cornering, the vehicle speed is calculated from the mean value of the front wheel speeds.
 On the other hand, if the comparisons tend to suggest one or more faulty wheel speed signals, the vehicle
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 bit is stored in the memory.
If error messages are received for all wheels speeds, the speed is displayed as "0" (indicator points to the left
side of the scale). This evaluation of the wheel speed signals also applies for evaluating the distance traveled
since the distance is calculated from the vehicle speed.
Depending on the national version, the electronic speedometer (A1p8) is calibrated either in kilometers per
hour, or in miles per hour with a secondary scale for kilometers per hour.
DISPLAYING VEHICLE SPEED RANGES WITH SEGMENT SPEEDOMETER, FUNCTION -

GF54.30-P-3026S
Models 215, 220
Segment speedometer
The electronic speedometer (A1p8) can display brighter segments on the outer scale.
This feature is used in the "winter tires speed limit", the "variable speed limit" and the "Distronic" functions.
Segment speedometer-speed limit for winter tires
If the winter tires speed limit is switched on, the first 21 segments are displayed (from 0 to 210 km/h). This
clearly indicates the active vehicle speed range.
Segment speedometer with variable speed limit and Distronic valid up to 31.8.02
The "variable speed limit" and "Distronic" systems make use of the segment speedometer in the following way:
If the adjusted speed is in a scale segment, the associated scale segment is displayed brighter. If it is between
two scale segments, the two adjacent scale segments are displayed brighter.
Examples:
The adjusted speed is 85 km/h (value is in one segment), then:
 The 0 -80 km/h segments are--> DARK
 The 80 -90 km/h segment is--> BRIGHT

The adjusted speed is 89 - 91 km/h (value is between two segments), then:
 The 0 -80 km/h segments are> DARK

 The 80 -100 km/h segments are> BRIGHT
 Die 100 -260 km/h segments are> DARK
If the speedometer needle leaves the lit range, other scale segments are lit according to the movement of the
needle. This clearly alerts the driver to variations from the set speed.
Segment speedometer with variable speed limit and Distronic valid as of 01.9.02
The function of these systems is shown to the driver via 2 separate displays. The permanent display with an
activated function takes place via the segments in the speedometer. With this display it is possible to darken
individual partial areas of the speedometer scale. Supplemental information is displayed to the driver on the
multifunction display for a limited periodA1p13).
This display takes place when the driver intervenes such as speed changes or activation attempts. If a condition
occurs in which a driver should intervene a warning appears on the display
Segment speedometer with variable speed limit
With the variable speed limit all segments of the useable vehicle speed range are actuated bright and the
remaining segments are actuated dark. With an adjusted variable speed limit which is not a multiple of 10 km/h
or 5 mph, rounding up takes place to the next highest multiple of 10 km/h or 5 mph.
Example 1 :
 The 0 -90 km/h segments are--> BRIGHT

Example 2:
 The 0 -70 km/h segments are--> BRIGHT

If the speedometer segments flash, this means that the variable speed limit can no longer brake the vehicle
(driving downhill). The bright phase is t =600 ms, the dark phase is t = 400 ms.
Segment speedometer with Distronic
With the cruise control display the segment, in which the adjusted speed is located, is switched bright. If the
speed of the vehicle deviates from the adjusted speed, the segments up to the target speed are switched bright.
Example 1:
With an adjusted speed of 80 km/h (value is in one segment), then:
 The 60 -70 km/h segment --> actuated bright
Example 2: (for +/- 1km/h)
With an adjusted speed of, for example, 81 km/h and a target speed of 55 km/h:
 The 50 -90 km/h segment is--> actuated bright
CAN data for segment speedometer
The instrument cluster receives the data for the "speed limit for winter tires" and "variable speed limit" from the
traction systems control module via the engine compartment CAN (A1)(N47).
The instrument cluster receives the data for "Distronic" (A1) from the DTR control module via the engine
compartment CAN (N63/1).
BATTERY CHARGE/ALTERNATOR MONITORING FUNCTION - GF54.30-P-3027S
Model 215, 220
Warning message in multifunction display

Fig. 92: Networking Of Components
Battery charge/alternator check, valid up to 31.8.02:
The message "BATTERY/ALTERNATOR CHECK" "VISIT WORKSHOP!"
which appears in the multifunction display (A1p13) replaces the previously used alternator charge
indicator/warning lamp (this message is a Category 2 message). It appears if the alternator is not functioning
correctly "Term. 61" and the engine speed exceeds 200 rpm.
Battery charge/alternator check, valid as of 01.9.02:
The message "BATTERY/ALTERNATOR"
"VISIT WORKSHOP!"
which appears in the multifunction display (A1p13) replaces the previously used alternator charge
indicator/warning lamp (this message has Class 2 priority 2A).
It appears if the alternator is not functioning correctly "Term. 61" and the engine speed exceeds 200 rpm.
Networking:
The following CAN data is required:
"Term. 61" alternator check The "Term. 61 (= D+)" signal from the alternator (G2) is read in by the right front
SAM control unit (N10/7). The right front SAM control unit (N10/7) then transfers the message "Term. 61
High" (voltage at Term. 61 > 9 V) or "Term. 61 Low" (alternator not functioning correctly) to the interior
compartment CAN.
Engine speed:
The pulses from the crankshaft position sensor (L5) are read in by the motor electronics control unit (N3/10) or
the CDI control unit (N3/9). This control unit transfers the message "engine speed" (in rpm) to the engine
compartment CAN.
The instrument cluster (A1) receives these messages and evaluates them as described above.
Terminal 61 (= D+) alternator check
The CAN message "Terminal 61" can assume the states "High" and "Low". This status depends on the actual
voltage at the input of the right front SAM control unit (N10/7).
It becomes "High" when this voltage exceeds 9 V. It is "low" when the voltage again drops below 4.5 volts.
Excitation current for the alternator
The excitation winding is supplied with the pre-excitation current via a resistor located in the wiring harness.
When the ignition is ON, the voltage at "Term. 61" is low, as the excitation winding virtually 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.
This battery charge/alternator check function is closely associated with the indicator lamp test and engine
running detection functions ("Term. 61e").
INSTRUMENT CLUSTER (IC), LOCATION/TASK - GF54.30-P-3039S
Models 215, 220
Location of component
Fig. 93: Identifying Instrument Cluster
Instrument cluster (KI), The instrument cluster (A1) is located in the

location instrument panel
Task of the instrument cluster GF54.30-P-3039-
(KI) 02S
Task of the instrument cluster (KI) - GF54.30-P-3039-02S
The instrument cluster (A1) has the task of presenting the dynamic and static condition of the vehicle visually.
5 displays form the basis of driver information:
 The electronic speedometer (A1p8)

 Tachometer (A1p5)
 Fuel level and reserve gage (A1p2)
 Multifunction display (A1p13)
 Engine coolant temperature gauge (A1p1)
The instrument cluster (A1) provides the driver with further information on the following display components:
 Electronic clock (A1p6)

 Gear indicator (A1p12)
 Outside temperature indicator (A1p4)
The various functions of the multifunction steering wheel are also displayed via the instrument cluster (A1).
COOLANT/WASHER FLUID LEVEL VOLTAGE CODING, FUNCTION - GF54.30-P-4001S
Models 215, 220
The circuit shown in the figure is used to determine the level of the coolant and windshield washer fluid.
The coolant level indicator switch (S41) and the windshield washer fluid level indicator switch (S42) are
connected in series. Both switches are read in via two lines by the right front SAM control unit (N10/7).
The figure illustrates the status of the switches when the coolant and washer fluid are at the correct levels.
Fig. 94: Circuit Diagram For Determine Level Of Coolant And Windshield Washer Fluid
Voltage coding:
For voltage coding the resistors r1 and r2 are connected in parallel with the switches s1 and s2 . (The values from
r1 and r2 must be different.) When the switches are open, these resistors, together with r3 of the right front SAM
control unit (N10/7), form a voltage divider which is supplied with the constant voltage U const .
The voltage Ue at the input of the right front SAM control unit (N10/7) 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 results in a different value for voltage Ue at the input of the right front SAM control
unit (N10/7).
Evaluation
The voltage Ue is applied at the input of the ADC (analog-to-digital converter) of the right front SAM control
unit (N10/7). The ADC (analog-to-digital converter) converts the analog voltage into a digital value.
This is necessary since the processor of the right front SAM control unit (N10/7) can only work with digital
values.
The processor compares the values to the threshold values stored in memory and if necessary, passes an
appropriate message (coolant and/or washer fluid level too low) on the CAN (passenger compartment).
The instrument cluster (A1) reads this message and controls the multifunction display (A1p13) accordingly.
If the resistance values and the voltage Uconst are known, Ue can be calculated using the following formula:
Ue = Uconst * (r1 + r2 )/(r1 + r2 + r3 )
Assignment of switch status/warning messages:
The following table shows the warning messages which appear according to the status of the switches.
These messages can be acknowledged by pressing the reset button on the instrument cluster (A1).
If there is an open circuit in the wiring or if a sensor fails, no message appears on the multifunction display
(A1p13). A fault is stored, however, in the fault memory of the right front SAM control unit (N10/7).
Status Status Washer Warning on the multifunction display

Coolant fluid
open closed No message
open open "CHECK WASHER FLUID LEVEL"
closed closed "CHECK COOLANT LEVEL"
"CHECK COOLANT LEVEL" (The message "CHECK WASHER
closed open
FLUID LEVEL" has a lower priority.)
Instrument cluster (IC), function GF54.30-P-0002S

Windshield washer, function GF82.35-P-3002S
"CHECK ENGINE" MIL, LOCATION/TASK/FUNCTION - GF54.30-P-4101
"CHECK ENGINE" MIL, location/task/function - GF54.30-P-4101AM
MODEL 211, 219 with ENGINE 113.990 with CODE (494) USA version
MODEL 230 with ENGINES 113.992 /995 with CODE (494) USA version
MODEL 463 with ENGINE 113.993 with CODE (491) USA version
Shown on MODEL 211, 219

Fig. 95: Identifying Check Engine Malfunction Indicator Lamp - Shown On Model 211, 219
"CHECK ENGINE"
malfunction indicator The indicator lamp is located in the instrument cluster (A1).
lamp, location
"CHECK ENGINE"
malfunction indicator The indicator lamp signals faults relevant to exhaust emissions to the driver.
lamp, task
The indicator lamp is actuated by the ME-SFI [ME] control unit (N3/10) at the
"CHECK ENGINE" ground end when the engine is started. If there is no fault, the motor electronics
malfunction indicator control unit interrupts the actuation and the indicator lamp goes out. To check
lamp, function the bulb function it lights up for approx. 1 second when the ignition is switched
"ON".
"CHECK ENGINE" indicator lamp, location/task/function - GF54.30-P-4101M
Shown on the instrument cluster of model 220

Fig. 96: Identifying Check Engine MIL - Model 215, 220
CHECK
ENGINE
The CHECK ENGINE indicator lamp is located in the instrument cluster.
indicator lamp,
location
CHECK
ENGINE
To indicate faults in the fuel injection system
indicator lamp,
task
CHECK The indicator lamp is actuated by the instrument cluster via a CAN message from
ENGINE the engine control unit. As a check of the function it lights up when the ignition is
indicator lamp, ON and for approx. 1 second as of an engine speed of approx. 500 rpm. The
function indicator lamp goes out if there is no fault present.
ENGINE DIAGNOSIS MALFUNCTION INDICATOR LAMP, LOCATION/TASK/ FUNCTION -

GF54.30-P-4102A
MODELS 129 with ENGINE 112, 113 with CODE (925) low emission EURO3 with CODE (926) low
emission EURO4 or EURO3/EURO4 fitted as standard (without code)
MODELS 170 with ENGINE 111.983,112 (except, 112.96) with CODE (925) low emission EURO3 with
CODE (926) low emission EURO4 or EURO3/EURO4 fitted as standard (without code)
MODELS 203 with ENGINE 112 (except 112.96) with CODE (925) low emission EURO3 with CODE
(926) low emission EURO4 or EURO3/EURO4 fitted as standard (without code)
MODELS 210 with ENGINE 111, 112, 113 with CODE (925) low emission EURO3 with CODE (926) low
MODELS 211 with ENGINE 112,113 (except, 113.99) with CODE (925) low emission EURO3 with
MODELS 215 with ENGINE 113,137 (except 113.99) with CODE (925) low emission EURO3 with CODE
(926) low emission EURO4 or EURO3/EURO4 fitted as standard (without code)
MODELS 220 with ENGINE 112,113,137 (except, 113.99) with CODE (925) low emission EURO3 with
MODELS 230 with ENGINE 112,113 (except, 113.99) with CODE (925) low emission EURO3 with
Shows model 220
Fig. 97: Identifying Engine Diagnosis Indicator Lamp Location - Shows Model 220
Engine diagnosis indicator In instrument cluster

lamp, location
Model 129 with engine 112, 113 GF54.30-P-4102-01A
Model 163 with engine 112, 113 GF54.30-P-4102-01GH
Model 170 with engine 111.983, 112 GF54.30-P-4102-01G
EURO3/ EURO4
Model 202, 208 with engine 111.95/98, 112, GF54.30-P-4102-01E
113EURO3/EURO4
Models 203, 209 with engines 111, 112 GF54.30-P-4102-01P
Model 210 with engine 111, 112, 113 GF54.30-P-4102-01F
EURO3/ EURO4
Model 211 with engine 112, 113 GF54.30-P-4102-01T
Model 215, 220 with engine 112, 113, 137 GF54.30-P-4102-01M
EURO3/EURO4
Model 230 with engine 112, 113 GF54.30-P-4102-01R
Engine diagnosis indicator Display of fault in injection system.
lamp, task
Engine diagnosis indicator The engine diagnosis indicator lamp (with
lamp, function engine symbol) is actuated by the motor
electronics control unit at the ground end.
To check the bulb function it lights up for
approx. 1 second when the ignition is
switched "ON". If there is no fault, the
motor electronics control unit interrupts the
actuation and the indicator lamp goes out.
Engine diagnosis indicator lamp location - GF54.30-P-4102-01M
Fig. 98: Identifying Engine Diagnosis Indicator Lamp
"CHECK ENGINE" MIL COMPONENT DESCRIPTION - GF54.30-P-5011SM
Type 171
Fig. 99: Identifying Check Engine MIL - Type 171

Model 203
Fig. 100: Identifying Check Engine MIL - Model 203
Model 209
Fig. 101: Identifying Check Engine MIL - Model 209
Model 215, 220
Fig. 102: Identifying Check Engine MIL - Model 215, 220
Task
The "CHECK ENGINE" MIL notifies the driver of any exhaust-gas relevant faults.
Function
The "CHECK ENGINE" MIL is actuated at the ground end by the MESFI [ME] control unit (N3/10).
To check the bulb function it lights up for approx. 1 second when the ignition is switched "ON".
If there is no fault, the motor electronics control unit interrupts the actuation and the indicator lamp goes out.
SURVEY OF SYSTEM COMPONENTS FOR INSTRUMENT CLUSTER,

Models 215, 220

Table of contents, function description, instrument cluster GF54.30-P-0997S
FANFARE HORNS, FUNCTION - GF54.35-P-0001S
MODEL 215, 220
 Circuit 15: ON
Function:
 When the impact absorber on the multifunction steering wheel is pressed, one or more buttons for the
fanfare horns (S110s5, S111s5) are actuated.
 The status of these buttons is read in by the steering column module (N80).
 The steering column module (N80) sends a corresponding message on the (interior) CAN.
 This message is received by the right front SAM control unit (N10/7).
 The right front SAM control unit (N10/7) actuates the relay for the fanfare horns (K40/7kP). This relay is
located on the right front fuse and relay module (K40/7).
 The relay for the fanfare horns (K40/7kP) connects the two fanfare horns (H2) to circuit 30.
 The signal sounds as soon as at least one of the buttons (S110s5, S111s5) is actuated.
Actuation of the fanfare horns (H2)
One line of the fanfare horns (H2) is always connected to ground, actuation is therefore accomplished by
connecting to circuit 30 (via K40/7kP).
Control of the relay for the fanfare horns (K40/7kP) The relay coil for the fanfare horns (K40/7kP) is
permanently connected to circuit 15; when the fanfare horns (H2) are actuated, the other connection is
connected to ground via the right front SAM control unit (N10/7).
Buttons for the fanfare horns (S110s5, S111s5) Four buttons for the fanfare horns are located on a circuit
board below the impact absorber of the multifunction steering wheel. This ensures that the fanfare horns can be
actuated from any point on the impact absorber. The two right and the two left buttons are each connected in
parallel. They are read in voltage-coded by the steering column module (N80) together with the buttons of the
left and right multifunction steering wheel button groups (S110, S111).
See also applicable wiring diagrams.
GF54.35-P-
Fanfare horns, location of components
0001-01S
GF54.35-P-
Fanfare horns, networking of components
0001-02S
GF54.21-P-
Steering column module, location/task/design/function
4104S
Right signal acquisition and actuation module (SAM), GF54.21-P-
Model 215 up to 31.8.03
except CODE (494) USA
GF82.90-P-
Multifunction steering wheel, function version
0001N
except CODE (498)
Japanese version
Model 220 up to 31.8.03
with CODE (494) USA
GF82.90-P-
version
0001A
with CODE (498) Japan
version
Model 220 up to 31.8.03
GF82.90-P-
version
0001I
except CODE (498)
Japan version
Model 220.0 /1, 215.3 as GF82.90-P-
of 1.9.03 0001SM
Fanfare horns arrangement of components - GF54.35-P-0001-01S
Models 215, 220
Shown on model 220

Fig. 103: Identifying Fanfare Horns Components - Shown On Model 220
Fanfare horns interlinking of components - GF54.35-P-0001-02S
Models 215, 220
Fig. 104: Identifying Fanfare Horns Interlinking Of Components
TABLE OF CONTENTS, FUNCTION DESCRIPTION, FANFARE HORNS - GF54.35-P-0999SZ
MODEL 215, 220

GF54.35-P-
Fanfare horns, function
0001S
GF54.35-P-
Fanfare horns, location of components
0001-01S
GF54.35-P-
Fanfare horns, networking of components
0001-02S
GF54.21-P-
Steering column module, location/task/design/ function
4104S
Right signal acquisition and actuation module (SAM), GF54.21-P-
Model 215 up to 31.8.03
GF82.90-P-
Multifunction steering wheel, function version
0001N
except CODE (498)
Japanese version
Model 220 up to 31.8.03
with CODE (494) USA
GF82.90-P-
version
0001A
with CODE (498) Japan
version
Model 220 up to 31.8.03
GF82.90-P-
version
0001I
except CODE (498)
Japan version
Model 220.0 /1, 215.3 as GF82.90-P-
of 1.9.03 0001SM
FUNCTION OF TRIP COMPUTER (TRIP) - GF54.50-P-0001R
MODELS 203 up to 30.6.02, 208 as of 1.8.99, 210 as of 1.7.99, 215, 220 with CODE (494a) USA version
The trip computer is integrated in the instrument cluster (A1). The display takes place via the multifunction
display (A1p13) of the instrument cluster (A1).
On 2 different data memories it is possible to access:
The contents of the short-distance memory are shown in the display "since start", the contents of the long-
distance memory are shown in the display "since reset".
The following functions are provided by the trip computer:
 Display and calculation of the estimated range

 Display of the tank content
 Display and calculation of average fuel consumption
 Display of distance traveled
 Display of trip time
The data for average fuel consumption, travel time and mileage are stored separately in the short-distance
memory and long-distance memory.
In a further display screen the tank contents and the provisional range are displayed together.
When the trip computer is called up, the most recent display appears.
Operation
The trip computer functions are operated via the multifunction steering wheel and the button for resetting
(Reset) the instrument cluster (A1).
In models 203, 215 and 220, the instrument cluster (A1) receives all the information required for the trip
computer functions over CAN.
In models 208 and 210, the fuel gauge sensor (B4/1, B4/2 or B4) is polled directly by the instrument cluster
(A1).
Further details can be found in the documents listed in the table below.
Most of the documents on the sub-functions include illustrations of the displays on the multifunction display
(A1p13). In the process the presentation always takes place for models 208, 210, 215 and 220. The displays of
model 203 differ slightly from this.
Trip computer (TRIP), Model 203 GF54.50-P-0001-02PP

networking of components
Models 208, 210 GF54.50-P-0001-02A
Model 215, 220 GF54.50-P-0001-02S
Instrument cluster (IC), Model 203.0/2 GF54.30-P-0002-05PP
operating information
Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
Instrument cluster (IC), Model 203 GF54.30-P-0002-06PP
Kilometer / miles GF54.50-P-2002R
switchover, function
Travel time, function GF54.50-P-2004R
Range, function GF54.50-P-2006R
Fuel consumption, GF54.50-P-2007R
function
Distance, function GF54.50-P-2008R
Average speed, function GF54.50-P-2009R
Reset, function GF54.50-P-2010R
Trip computer (TRIP) Networking of components - GF54.50-P-0001-02S
Models 215, 220
Networking
Fig. 105: Trip Computer (TRIP) Networking Of Components
TABLE OF CONTENTS, FUNCTION DESCRIPTION OF TRIP COMPUTER - GF54.50-P-0999RZ
Trip computer (TRIP), function GF54.50-P-0001R

Trip computer (TRIP), networking of GF54.50-P-0001-
components 02S
Kilometer/miles switchover, function GF54.50-P-2002R
Also contains information on "tank
contents"
Fuel consumption, function GF54.50-P-2007R
Model 220 up to 31.8.03
Multifunction steering wheel, function with CODE (494) USA version GF82.90-P-0001A
with CODE (498) Japan version
GF82.90-P-
Model 220.0 /1, 215.3 as of 1.9.03
0001SM
Instrument cluster (IC), operating GF54.30-P-0002-
Model 220
information 05S
KILOMETER / MILES SWITCHOVER, FUNCTION - GF54.50-P-2002R
No particular switchover of the dimensional units is to be performed for the trip computer as it takes over the
adjustments and codings of the instrument cluster (A1).
The dimensional units (kilometers/miles) of the instrument cluster (A1) are switched over via the selection
"Adjustments" in the instrument cluster (A1).
The only requirement is to preset the unit of measurement used to monitor the distance (kilometers or miles).
The other units required by the trip computer are then converted automatically.
UK gallons/US gallons are coded via the national version using STAR DIAGNOSIS.

Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
function
TRAVEL TIME, FUNCTION - GF54.50-P-2004R
The trip computer allows the travel time to be displayed
 "SINCE START" (short-distance memory) and

 "SINCE RESET" (long-distance memory)
The function is similar to that of a stopwatch.
Travel time "SINCE START" (short-distance memory), function

 Activate the "SINCE START" display screen via the system selection button (S110s3) and scroll
forward/back button (S110s1) of the multifunction steering wheel.
 The driving time elapsed since the last reset of the short-distance memory (circuit 15 ON), as well as the
distance traveled, the average journey speed and fuel consumption.
Fig. 106: Travel Time Display Screen - Since Start (Short-Distance Memory)
Travel time "SINCE RESET" (long-distance memory), function
 Activate the "SINCE RESET" display screen via the system selection button (S110s3) and scroll
 The display shows the travel time elapsed (circuit 15 ON) since the last reset of the long-distance
memory, as well as the mileage traveled, the average speed and fuel consumption.
Fig. 107: Travel Time Display Screen - Since Reset (Long-Distance Memory)
As the travel time is only counted with terminal 15 ON, the instrument cluster (A1) needs the information
about the status of circuit 15. This information is placed on the CAN interior by the electronic ignition switch
control unit (N73) and read by the instrument cluster (A1). The travel time is calculated internally in the
If the display of travel time or travel distance exceeds the maximum display value (99:59 h or 65.535 km
(40.959 miles), the travel time and travel distance of the respective memory are automatically reset This
preserves the relationship between travel time and mileage.

Instrument cluster (IC) Model 203 GF54.30-P-0002PP
function
Models 208, 210 GF54.30-P-0002B
Model 215, 220 GF54.30-P-0002S
Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
RANGE, FUNCTION - GF54.50-P-2006R
Figure 1
The fuel tank content (this function is not integrated in model 203; only the estimated range is displayed) and
the estimated range are displayed on a common display screen on the multifunction display (A1p13).
Tank content, function
The tank contents are displayed in US gallons (picture 1) or in liters (picture 2).
It can also be displayed in UK gallons. This is done by using the Star Diagnosis tool to code the appropriate
national variant.
Fig. 108: Tank Content Display Screen - Gallon
Figure 2
The trip computer of the instrument cluster (A1) needs the following information to determine the tank
contents:
 The fill level in the fuel tank:

In model 203, the fuel gauge sensors for the left and right halves of the tank (B4/1 and B4/2) are polled
by the rear SAM control unit with fuse and relay module (N10/2) and the appropriate message is
transmitted over the interior CAN.
The instrument cluster (A1) receives this message, assesses it and displays the corresponding fuel level.
In models 208 and 210, the fuel gauge sensor (B4/1, B4/2 or B4) is polled directly by the instrument
cluster (A1).
Fig. 109: Tank Content Display Screen - Liters
In models 215 and 220, the fuel gauge sensor B4 is polled by the rear SAM control unit (N10/8) and the
appropriate message is transmitted over the interior CAN.
The instrument cluster (A1) receives this message, evaluates it and displays the corresponding value as the tank
content.
The tank contents are displayed in steps of 1 l or 0.2 gallons. No coding is necessary for the type of fuel tank
(normal tank or ski bag). This is taken care of by the different designs of fuel gauge sensor.
Range, function (except 203)
The estimated range is displayed in miles (Figure 1) or in kilometers (Figure 2).
The range is calculated by taking the quotient of the fuel tank content and the average fuel consumption
("SINCE START").
The following information is therefore required to calculate the range:
 The current fuel tank content (see above)

 The average fuel consumption, using the data from the short- distance memory ("SINCE START")
The range is displayed in increments of one kilometer or one mile.1 1 The range is updated more
frequently when the fuel level in the tank is in the reserve range. The reserve range used as a basis for this
may differ slightly from the reserve range of the fuel level and reserve gauge (A1p2) of the instrument
cluster (A1).
function
Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
FUEL CONSUMPTION, FUNCTION - GF54.50-P-2007R
The trip computer allows the average fuel consumption to be displayed:

Figure 1
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 (Figure 1),

 Liters per 100 km (Figure 2) or
 Kilometers per liter (only if national variant Japan is coded).
Fig. 110: Fuel Consumption Display Screen - Miles Per Gallon
Figure 2
Fuel consumption "SINCE START" (short-distance memory), function

 Activate the "SINCE START" display screen via the system selection button (S110s3) and scroll
 The display shows the fuel consumption calculated since the last reset of the short-distance memory, as
well as the mileage traveled, the average speed and travel time.
Fuel consumption "SINCE RESET" (long-distance memory), function
 Activate the "SINCE RESET" display screen via the system selection button (S110s3) and scroll
 The display shows the fuel consumption calculated since the last reset of the long-distance memory, as
well as the mileage traveled, the average speed and travel time.
Fig. 111: Fuel Consumption Display Screen - Liters Per 100 Km
The trip computer calculates the average fuel consumption figures from the mileage traveled and the
consumption signal.
The fuel consumption signal uses information on the amount of fuel injected within a specific period.
The instrument cluster (A1) receives this data in the following way:
 The consumption signal is generated by the ME-SFI/CDI control unit (N3/10, N3/9) and transmitted as a
message over the engine compartment CAN.
 The distance traveled is determined from the 4 wheel speeds. The signals come from the traction systems
control unit (N47) over the engine compartment CAN.
After resetting it may take up to 3 km or up to 2 minutes until sufficient data is available in order to calculate
and display the consumptions correctly. During this time, depending on the unit setting (kilometers/miles) and
the national variant coding of the instrument cluster (A1), the display shows 5.8 MPG, 40 L/100 km or 2.5
km/L.
It is completely 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).
Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
DISTANCE, FUNCTION - GF54.50-P-2008R
The trip computer allows the mileage traveled to be displayed

Mileage "SINCE START" (short-distance memory), function
 Activate the "SINCE START" display screen (short-distance memory) via the system selection button
(S110s3) and scroll forward/back (S110s1) of the multifunction steering wheel.
 The display shows the mileage traveled since the last reset of the short-distance memory, as well as the
travel time, the average speed and fuel consumption.
Fig. 112: Mileage Display Screen - Since Start (Short-Distance Memory)
Mileage "SINCE RESET" (long-distance memory), function
 Activate the "SINCE RESET" display screen (long-distance memory) via the system selection button
(S110s3) and scroll forward/back button (S110s1) of the multifunction steering wheel
 The display shows the mileage traveled since the last reset of the long-distance memory, as well as the
travel time, the average speed and fuel consumption.
The mileage is displayed in miles or in kilometers in the range from 0 - 40.959 miles (or 0 to 65.535 km)1 1
with a resolution of one mile or one kilometer.
After reset the first value change occurs after 1 km or 1 mile.
Fig. 113: Mileage Display Screen - Since Reset (Long-Distance Memory)
The 4 wheel speed signals are evaluated for the travel distance. They are sent in the form of a message of the
CAN engine compartment from the control unit for traction systems (N47) to the instrument cluster (A1). The
travel distance is counted in parallel with the counting of the travel distance counter function of the instrument
cluster (A1).
If the display of travel time or travel distance exceeds the maximum display value (99:59 h or 65.535 km
(40.959 miles), the travel time and travel distance of the respective memory are automatically reset This
preserves the relationship between travel time and mileage.

Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
Displaying distance, Model 203 GF54.30-P-3022PP
function
Models 208, 210 GF54.30-P-3022B
Models 215, 220 GF54.30-P-3022S
AVERAGE SPEED, FUNCTION - GF54.50-P-2009R

The trip computer allows the average vehicle speed to be displayed:

Figure 1
The average speed is displayed in miles per hour (picture 1) or kilometers per hour (picture 2)
 The display resolution is one mile per hour or one kilometer per hour.
 The display range extends from 0 to 160 mph or 0 to 260 km/h.
 The value is updated once per second.
To calculate the average speed, the ratio is formed from the distance traveled and the travel time since the last
time the short-distance memory or long-distance memory was reset.
Fig. 114: Average Speed Display Screen - Miles Per Hour
Figure 2
Average speed "SINCE START" (short-distance memory), function
 Activate the "SINCE START" (short-distance memory) via the system selection button (S110s3) and
scroll forward/back button (S110s1) of the multifunction steering wheel.
 The display shows the average speed calculated since the last reset of the short-distance memory, as well
as the travel distance, the fuel consumption figure and travel time.
Fig. 115: Average Speed Display Screen - Kilometers Per Hour
Average speed "SINCE RESET" (long-distance memory), function
 Activate the "SINCE RESET" (long-distance memory) via the system selection button (S110s3) and
scroll forward/back button (S110s1) of the multifunction steering wheel.
 The display shows the average speed calculated since the last reset of the long-distance memory, as well
as the mileage traveled, the average fuel consumption and travel time.
The following information is required:
 Travel time: is calculated internally in the instrument cluster (A1).

 Travel distance: is determined from the 4 wheel speeds. The wheel speeds are sent in the form of a
message of the CAN engine compartment from the control unit for traction system (N47) to the
It is completely 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). If initial values are defective the following
appears in the display field: "- - -".

Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
Displaying speed, Model 203 GF54.30-P-3025PP
function
Models 208, 210 GF54.30-P-3025B
Model 215, 220 GF54.30-P-3025S
RESET, FUNCTION - GF54.50-P-2010R
The contents of the long-distance memory and short distance memory can be reset with the reset button (right-
hand button) of the instrument cluster (A1):
Resetting the long-distance memory ("SINCE RESET")
 Circuit 15 ON
 Using the system selection button (S110s3) and scroll forward/back button (S110s1) of the multifunction
steering wheel, select the "SINCE RESET" display screen
 Operate the reset button for 1 second
 The display is reset (see figure)
The diagram shows the "SINCE RESET" display screen (long-distance memory) after a reset.
The display screen for "SINCE START" (transient memory) resets in the same way.
Manually resetting the short-distance memory ("SINCE START")
 Terminal 15 ON
 Using the system selection button (S110s3) and scroll forward/back button (S110s1) of P54.50-2027-01
the multifunction steering wheel, select the "SINCE START" display screen (short-distance memory)
 Operate the reset button for 1 second
 The display is reset
Fig. 116: Resetting Long-Distance Memory Display Screen - Since Reset
Automatically resetting the short-distance memory ("SINCE START")
As the "SINCE START" display (short-distance memory) is considered for the data of one driving cycle, the
contents of the "SINCE START" display (short-distance memory) are normally reset automatically.
 On model 203 resetting takes place as soon as the instrument cluster (A1) has not been activated for 4 h.
 In models 208, 210, 215 and 220, the reset occurs when the engine is started.
Incorporation of the data from the previous driving cycle in the short-distance memory (except model
203)
In many cases it can however be meaningful to incorporate the data from the previous driving cycle in the short-
distance memory, because, for example, the data for filling the tank during a holiday trip should also be
recorded during any interruptions to the trip. The data for the entire trip can then be stored in the long-distance
memory ("since reset").
The procedure for this is as follows:
 Using the system selection button and scroll forward/back button, select the "SINCE START" display
screen (short-distance memory)
 Start engine
 The "SINCE START" display (short-distance memory) flashes for up to 2 miles or 2 minutes after engine
start
 When the display flashes operate the reset button for 1 second
 The values of the previous driving cycle are incorporated in the short-distance memory
If the display of travel time or travel distance exceeds the maximum display value (99:59 h or 65.535
km (40.959 miles), the travel time and travel distance of the respective memory are automatically reset
This preserves the relationship between travel time and mileage.
After a reset it may take as much as 3 km or 2 min until the trip computer has enough data to display
the fuel consumption figures correctly. During this time, depending on the unit setting (kilometers/miles)
and the national variant coding of the instrument cluster (A1), the display shows 5.8 MPG, 40 L/100 km
or 2.5 km/L.

function
Model 203.7 GF54.30-P-0002-05PC
Models 208, 210 GF54.30-P-0002-05B
Model 215, 220 GF54.30-P-0002-05S
TAXIMETER, LOCATION/TASK/DESIGN - GF54.61-P-4107S
MODEL 220 with CODE (450) taxi version
Fig. 117: Identifying Taximeter Control Module, Interior Rearview Mirror Unit And Microphone
Taximeter, task GF54.61-P-4107-01S

Taximeter, design GF54.61-P-4107-02S
Taximeter, task - GF54.61-P-4107-01S
The tasks of the taximeter control module (A67n1) are as follows:
 Switch the roof sign lamp on/off automatically or via a discrete switch (with status display in interior
mirror)
 Store the journey information in journey memory (storage capacity: information on approx. 800 journeys)
 Record the distance covered via the integrated odometer
 Receipt of the DCF time signal via the time signal receiver in the taximeter
 Read out the journey information via a serial data interface (HALE-CEY system, special equipment)
 Connect a printer via an RS485 interface
System test mode (also refer to Taxi Owner's Manual)
The following tests/checks can be carried out in the taximeter's system test mode:
 DCF time signal test (display: "dCF")

 Vehicle speed test (display: "SPd") or
 Check the trackage with distance pulse display
 Display brightness test
 Temperature test
 Display test
 Seat contact test
 Check calibration checksums
 Check system time with date and year
The wheel speed signal used by the taximeter control module originates from the traction systems control
module (N47). This control module reads in the sensor signal from the left front vehicle speed sensor (L6/1) for
this.
If the ambient temperature at the taximeter rises above 85°C, the display is switched off automatically. If the
temperature then drops below the limit value again, the display is switched on automatically.
Taximeter automatic shutoff
The following options can be programmed with the Star diagnosis tool:
Taximeter automatic shutoff when ignition/starter key is in position "0":
 YES/NO
 YES after a time delay of up to 255 minutes
Taximeter design - GF54.61-P-4107-02S
The taximeter operated with pushbuttons (1-4) is located in the housing of the interior rearview mirror unit
(A67). The associated function display is integrated in the left half of the mirror surface. The brightness of the
display is dimmed automatically by the taximeter depending on the ambient light and interior light (CAN
messages from the overhead control panel control module (N70)).
Fig. 118: Identifying Taximeter Design
PARKTRONIC SYSTEM (PTS), FUNCTION - GF54.65-P-0001A
MODELS 140,163,168, 202, 208, 210, 215, 220 with CODE (220a) Parktronic System (PTS)
Fig. 119: Identifying Rear And Front Monitoring Area Of Parktronic System - Model 140
Shown on model 168
Fig. 120: Identifying Rear And Front Monitoring Area Of Parktronic System - Model 168
General information
The Parktronic system (PTS) is an ultrasonic measurement system for detecting the range to an obstruction in
critical situations. It assists the driver when parking and in maneuvering situations at speeds of > or = 15 km/h.
The sensors in the front and rear bumpers emit ultrasound signals which are reflected by an obstacle in the
detection range. The echoed ultrasound signals are received by the sensors and their journey time is measured.
The Parktronic control unit (N62) calculates the distance between the vehicle and the obstacle from the runtime
of the echo and actuates the warning indicators.
The distance between the vehicle and the obstacle is indicated to the driver visually and acoustically.
In the process the brightness of the warning indicators can be adapted to the brightness of the surroundings
automatically or manually depending on the model series.
The Parktronic system (PTS) is activated when the ignition is switched on.
The system is active even if it was manually deactivated during the last journey.
The Parktronic system can be switched on or off by a switch.
On models 215, 220 as of 01.07.02 the lower limit of speed at vu > or = is 15 km/h and the upper limit of
speed at vo > or = a is 18 km/h.
Parktronic system (PTS) block Model 140,202,208,210 GF54.65-P-0001-01A

diagram
Model 163 GF54.65-P-0001-01E
Model 168 GF54.65-P-0001-01B
Model 215, 220 GF54.65-P-0001-01C
Parktronic system (PTS), Model 140 GF54.65-P-0001-02A
Model 163 GF54.65-P-0001-02I
Model 168 GF54.65-P-0001-02E
Model 202 GF54.65-P-0001-02D
Model 208 GF54.65-P-0001-02C
Model 210 GF54.65-P-0001-02B
Model 215 GF54.65-P-0001-02G
Model 220 GF54.65-P-0001-02F
Self-test, function GF54.65-P-2000A
Operation, function GF54.65-P-3000A
Parktronic system (PTS), block diagram - GF54.65-P-0001-01C
Models 215, 220 with code 220a Parktronic system (PTS)

Fig. 121: Parktronic System (PTS) Block Diagram
Parktronic system (PTS), location of components - GF54.65-P-0001-02F
Model 220 with code 220a Parktronic system (PTS)

Fig. 122: Identifying Parktronic System (PTS) Components
Parktronic system (PTS), location of components - GF54.65-P-0001-02G
Model 215 with code 220a Parktronic system (PTS)

Fig. 123: Identifying Parktronic System (PTS) Components
CONTENTS, FUNCTION DESCRIPTION, PARKTRONIC SYSTEM (PTS) - GF54.65-P-0999A
Parktronic system (PTS), function GF54.65-P-0001A

Parktronic system (PTS), block Model 140,202,208,210 GF54.65-P-0001-01A
diagram
Model 163 GF54.65-P-0001-01E
Model 168 GF54.65-P-0001-01B
Model 215, 220 GF54.65-P-0001-01C
Parktronic system (PTS), location of Model 140 GF54.65-P-0001-02A
components
Model 163 GF54.65-P-0001-02I
Model 168 GF54.65-P-0001-02E
Model 202 GF54.65-P-0001-02D
Model 208 GF54.65-P-0001-02C
Model 210 GF54.65-P-0001-02B
Model 215 GF54.65-P-0001-02G
Model 220 GF54.65-P-0001-02F
Self-test, function GF54.65-P-2000A
Operation, function GF54.65-P-3000A
Forward travel, function GF54.65-P-4000A
Reversing, function GF54.65-P-4001A
Fault analysis, function GF54.65-P-4004A
Survey of system components, GF54.65-P-9999A
Parktronic system (PTS), location /
task / design / function
SELF-TEST, FUNCTION - GF54.65-P-2000A
Procedure
The Parktronic control unit (N62) carries out a self-test after the ignition is switched on.
The Parktronic control unit (N62), sensors and lines to the sensors are checked.
After the self-test all the active warning indicators are actuated fully for approx. t=2 seconds, as a result all the
segments and the frames of the active warning indicators light up.
System o.k.
Model 168, 202, 208, 210, 215, 220
 The frames of the active warning indicators light up.
Model 163
 The first elements of the active warning displays light up at half brightness.
Malfunction
Model 168, 202, 208, 210, 215, 220
 All the red segments and the red parts of the frames on the active warning indicators light up.
Model 163
 All the red segments of the active warning displays light up.
If a warning indicator does not receive any valid signals within t=0.5 seconds after the ignition is switched on,
the two red segments of the corresponding warning indicator light up. Thereupon a warning chime follows for
approx. t=3 seconds and after t=20 seconds the warning indicator is switched off.
In operation the Parktronic control unit (N62) carries out system tests at regular intervals, in which parts of the
Parktronic system (PTS) are checked.

PTS control unit, location / task GF54.65-P-4100A
Sensors, location/task/function GF54.65-P-4102A
Warning display, location / task / design / function GF54.65-P-4104A
OPERATION, FUNCTION - GF54.65-P-3000A
Function
The complete Parktronic system (PTS) is only active at speeds below < or = 15 km/h.
If a speed of > or = 15 km/h is exceeded the Parktronic control unit (N62) goes into standby mode. The
background illumination of the displays is deactivated by the Parktronic control unit (N62). The sensors remain
activated, depending on the direction of travel (driving forwards or reversing).
If a speed of 40 km/h is exceeded the complete Parktronic system (PTS) is switched off by the Parktronic
control unit (N62).
If the speed is reduced below the specified speeds, the Parktronic system (PTS) is activated vice versa as
described.
The Parktronic system (PTS) can be switched on or off manually by operating the PTS ON/OFF switch (S95).
On vehicles with automatic transmission all the sensors are activated in selector lever position "P".
Models 163, 215, 220
If the selector lever is in position "P", the warning elements and sensors are deactivated.
On model 215, 220 as of 01.07.02 the lower speed limit at vu < or = is 15 km/h and the upper speed limit at
vo > or = is 18 km/h.
Forward travel, function GF54.65-P-4000A

Reversing, function GF54.65-P-4001A
PTS switch, location/task GF54.65-P-4101A
FORWARD TRAVEL, FUNCTION - GF54.65-P-4000A
Monitoring range
Fig. 124: Identifying Monitoring Range - Shows On Model 140
 Circuit 15 ON,
 If the speed drops below = 40 km/h (standby mode),
 The lower speed limit is dropped below (Parktronic system (PTS) activated),
 The Parktronic system (PTS) is not deactivated manually via the PTS ON/OFF switch (S95).
Function
When driving forwards, only the front sensors and the front warning indicators are active.
Monitoring range
Vehicle center: approx. 100 cm
Outside of vehicle: approx. 60 cm (model 168: approx. 80 cm)
An obstacle is no longer detected at a distance below approx. 20 cm in the vehicle center and approx. 15cm
(model 168: approx. 20 cm) at the outside of the vehicle.
The monitoring range is subdivided into a left and right sector with 3 sensors respectively (model 168: 2
sensors) and one optical/acoustic warning indicator.
By means of the side sensors obstacles to the side of the vehicle, such as high curbs, walls, bushes, masts and
signs are also detected. Therefore there may be a display although there is no obstacle in front of the vehicle.

REVERSING, FUNCTION - GF54.65-P-4001A
 Circuit 15 ON,
 Selector lever position in "R" or "N"(with code (420) automatic transmission, center shifter console),
 The lower speed limit is dropped below,
 No trailer operation (with code (550) trailer hitch),
 The Parktronic system (PTS) is not deactivated manually via the PTS ON/OFF switch (S95).
Detection of vehicle movement:
Reversing is detected
in vehicles with manual transmission:
 via the backup lamp switch (S16/2),
in vehicles with automatic transmission:
 starter lock-out and back-up lamp switch (S16/1),

 starter lock-out and back-up lamp switch/detection of selector lever position (S16/3),
 gear recognition switch (S16/10).
The rear sensors and warning indicators are only active when reversing without trailer.
The front sensors and warning indicators are active irrespective of the trailer so that obstacles in the front swivel
range of the vehicle are also detected when reversing.
When reversing with a trailer, the rear sensors and warning indicators are not active because otherwise the
trailer would always be identified as an obstruction.
The trailer is detected by a trailer recognition microswitch (X58s1) in the power outlet for the trailer hitch with
code (550) trailer hitch.
If an adapter (7/13 pin) is used for trailer operation, it must be removed after operating the trailer, because
otherwise the system continues to detect a trailer and allows the rear sensors and warning indicators to be
switched off.
Trailer recognition by the trailer recognition microswitch (X58s1) is not applicable on models 215 and 220
as of 1.5.99. Here the trailer is recognized by the trailer recognition control unit (N28/1). Trailer recognition is
conveyed to the Parktronic control unit (<>) via the Controller Area Network bus class B (interior) (CAN-B)
(N62).
Monitoring area (vehicle rear):
Vehicle center: approx. 120 cm
Outside of vehicle: approx. 80 cm
An obstacle is no longer detected at a distance below approx. 20 cm.
The detection range is divided into a left-hand and a right-hand sector, each with two sensors and one visual
warning display. The acoustic signal is combined for the two rear warning indicators.
Variant coding can be carried out for the Parktronic control unit (N62) using STAR DIAGNOSIS. On
vehicles without a detachable trailer hitch (models 163, 168) or with a spare wheel on the vehicle rear (model
163), this makes possible an extension of the warning range of the sensors.
Variant coding makes it possible to adjust the warning range of the sensors to changes in the overall length of
the vehicle.

FAULT ANALYSIS, FUNCTION - GF54.65-P-4004A
The Parktronic system (PTS) distinguishes between a malfunction and a fault.
 Circuit 15 ON,
 Sensors active.
Operational problem
If a malfunction occurs during operation, it is indicated by the lighting of the red segments and the frames of all
the active warning indicators. There is no warning tone.
A malfunction can be caused by a defect in the sensors, the warning indicator, by the Parktronic control unit
(N62), via a line discontinuity or a brief malfunction from outside (e.g. compressed-air hammer on a
construction site, steam cleaner or an induction loop at a traffic light).
If a malfunction lasts less than t=2 minutes then it is not detected as a fault and is not stored in the fault
memory.
Fault
If a fault is detected during a function test while driving, the next time the lower speed limit is dropped below
the red bar graphs of the warning indicator are actuated and a warning chime is emitted for t=3 seconds.
If a malfunction exists for longer than t=2 minutes (for t=20 seconds when diagnosis is connected), then it is
detected as a fault and stored in the fault memory of the Parktronic control unit (N62).
The fault is displayed by the lighting up of the red segments of all the active warning indicators in conjunction
with a warning chime for t=3seconds. After a fault display for t=20 s the warning displays are switched dark.
Fault in the data transfer to the warning indicator
The warning indicators and the corresponding lines cannot be checked by the Parktronic control unit (N62), as
the data transfer only runs towards the warning indicators (no entry in the fault memory).
If a warning indicator does not receive any valid signals within t=0.5 seconds after switching on the ignition, the
two red segments of the appropriate warning indicator light up, a warning chime is switched on for a duration of
t=3 seconds and the warning indicator is switched off after t=20 seconds.
If errors occur during operation, then the last display is preserved until valid signals are received again.

PTS CONTROL UNIT, LOCATION / TASK - GF54.65-P-4100A

Fig. 125: Locating PTS Control Unit - Shows On Model 140
PTS control unit, On model 140 the Parktronic

location control unit (N62) is located under
the rear bench seat.
Model 202, 208 GF54.65-P-4100-01A
Model 210 as of 01.07.99
Model 215, 220 GF54.65-P-4100-01AB
Model 210 up to 30.06.99 GF54.65-P-4100-01AD
Model 168 GF54.65-P-4100-01GC
Model 163 GF54.65-P-4100-01GH
PTS control unit, task GF54.65-P-4100-02A
PTS control module, location - GF54.65-P-4100-01AB
Models 215, 220 with code (220a) Parktronic system (PTS)
Shown on Model 220
Fig. 126: Identifying PTS Control Module Location - Shown On Model 220
PTS control unit, task - GF54.65-P-4100-02A
The Parktronic control unit (N62) performs the following tasks:
 Voltage supply of sensors and warning indicators,

 Processing the ambient signals (reverse gear recognition, lights, vehicle speed signal and Parktronic
system switch, trailer recognition (with code (550) trailer hitch)),
 Actuation of sensors,
 Evaluation of echo travel times,
 Production of the data of data telegrams for the warning indicators,
 Self-test of Parktronic system (PTS),
 Storage of system faults in the diagnostic trouble code memory.
The Parktronic control unit (N62) is connected with the other control units for data exchange via the Controller
Area Network bus class B (interior) (CAN-B).
PTS SWITCH, LOCATION/TASK - GF54.65-P-4101A
Location in models 140,168, 202, 208, 210
Shown on model 208
Fig. 127: Identifying Centre Console And PTS On/Off Switch
PTS switch, location On models 140, 168, 202, 208 and 210
the PTS ON/OFF switch (S95) is fitted
in the lower part of the center console.
Model 215, 220 up to 30.06.02 GF54.65-P-4101-01A
Model 215, 220 as of 01.07.02 GF54.65-P-4101-01AC
Model 163 GF54.65-P-4101-01GH
PTS switch, task To switch the Parktronic system (PTS)
off/on manually by operating the PTS
ON/OFF switch (S95) on models 140,
168, 202, 208 and 210. The light
emitting diode in the PTS ON/OFF
switch (S95) lights up when the
Parktronic system (PTS) is switched
off and goes out when the Parktronic
system (PTS) is switched off.
Model 215, 220 as of 01.07.02 GF54.65-P-4101-02A
PTS switch, location - GF54.65-P-4101-01A
The PTS OFF switch (N72/1s8) is located below the center nozzle.
Fig. 128: Identifying PTS OFF Switch - Illustrated On Model 220
PTS switch, location - GF54.65-P-4101-01AC
Models 215, 220 as of 01.07.02 with code (220a) Parktronic system (PTS)

Fig. 129: Identifying Upper Control Panel Control Module And PTS OFF Switch - Illustrated On Model
220
PTS switch, task - GF54.65-P-4101-02A
Models 215, 220 as of 01.07.02 with code (220a) Parktronic system (PTS)
As of 01.07.02 the PTS OFF switch (N72/1s8) is no longer a rocker switch, but a push-push button is used.
Using the PTS OFF switch (N72/1s8) the Parktronic system can be switched on or off manually.
If the Parktronic system is switched off, this is displayed by the illuminating LED in the PTS OFF switch
(N72/1s8).
The control status is read in by the upper control panel control module (N72/1) and passed on as a CAN
message via the interior CAN to the Parktronic control module (N62)
SENSORS, FUNCTION - GF54.65-P-4102-03A
The sensor actuated by the Parktronic control unit (N62) transmits an ultrasonic signal and is ready to receive
after a brief delay (time for the diaphragm movement to decay).
Each sensor receives the echoes of its own ultrasound signals and the echoes of ultrasound signals from
adjacent sensors. The distance to the obstacle is calculated from the journey time of the echoes. Detection angle:
horizontal: 120°
vertical: 60 °
There are several versions of the sensors depending on vehicle model/model year. Different versions of
sensors must not be installed together. Faulty seat or mechanical damage to the sensors or the wrong version of
a sensor, can cause malfunctions or incorrect displays.
SENSORS, LOCATION/TASK/FUNCTION - GF54.65-P-4102A
Fig. 130: Identifying Sensors Location - Shown On Model 220 Up To 30.06.02
Shown on model 220 up to 30.06.02
Sensors, location The sensors (A42b1, A42b2, A42b3, A42b4, A42b5 and
A42b6) are integrated in the front bumper and the
sensors (A43b7, A43b8, A43b9 and A43b10) are
integrated in the rear bumper.
Sensors, task The sensors (A42b1, A42b2, A42b3, A42b4, A42b5,
A42b6, A43b7, A43b8, A43b9 and A43b10) are used as
a transmitter and as a receiver for ultrasonic sensors for
measuring the distance to an obstacle.
Sensors, function GF54.65-P-4102-03A
WARNING DISPLAY, LOCATION / TASK / DESIGN / FUNCTION - GF54.65-P-4104A

Fig. 131: Identifying Warning Display, Location - Shows On Model 140
Warning display, The warning indicators for the Parktronic system (PTS) on
location model 140 are located in the instrument panel on the driver-
side, center instrument panel and in the vehicle rear in the
rear dome lamp.
Model 202, 208 GF54.65-P-4104-02A
Model 210 up to 30.6.99
Model 215, 220
Model 163, 168,203 GF54.65-P-4104-02AC
Model 210 as of 1.7.99 GF54.65-P-4104-02AD
Warning display, Displays the distance to an obstacle within the front and rear
task detection ranges.
Emit a warning signal when a minimum distance is not
reached.
Warning display, GF54.65-P-4104-03A
design
Warning display, GF54.65-P-4104-01A
function
Warning display, function - GF54.65-P-4104-01A
Function
On all models, except model 163 the function readiness of the Parktronic system (PTS) is signaled by the bright
frame of the LCD warning indicator.
In model 163 this is indicated by the first yellow segment of the LED warning display lighting up at half
brightness (approximately 50% of maximum possible brightness).
When an obstacle is approached, one or more segments of the warning indicator light up depending on the
distance.
An intermittent warning tone sounds when the first red segment lights up. At the second red segment the
intermittent tone becomes a continuous signal.
The warning tones from the front and rear warning displays are different.
The brightness of the warning indicators (background illumination) changes if:
 on vehicles without automatic light switch daylight sensor the lighting is switched on with the exterior
lamp switch.
 on vehicles with automatic light switch daylight sensor the ambient conditions such as darkness, twilight
or passing through a tunnel are recognized.
In both cases the brightness is reduced to 30% of maximum brightness.
In countries with daylight driving lamp circuit, the brightness does not change, but remains constant at 60% of
the maximum possible brightness.
In models 140, 168, 202, 208, 210, 211 the function of the daytime running lamps can be activated via the
corresponding diagnosis tool (STAR-DIAGNOSIS).
ACTUATION OF SEGMENTS: MODEL 140, 163, 202, 208, 209.3, 210, 211, 215, 220
Rear sensors
Segment Display Warning signal Front sensors (cm)
Center (cm) Corner (cm)
1. (yellow) optical - <100 - <120
2nd (yellow) - <80 - <100
3rd (yellow) - <70 - <80
4th (yellow) - < 60 < 60 <65
5th (yellow) - <50 <50 <50
6th (yellow) - <40 <40 <40
7th (red) visual and intermittent <30 <30 <30
acoustic approx. 3 s
8. (red) continuous <20 <15 <20
approx. 3 s
ACTUATION OF SEGMENTS: MODEL 168

Rear sensors
Segment Display Warning signal Front sensors (cm)
Center (cm) Corner (cm)
1. (yellow) optical - <100 - <120
2nd (yellow) - <80 <80 <100
3rd (yellow) - <70 <70 <80
4th (yellow) - < 60 < 60 <65
5th (yellow) - <50 <50 <50
- <40 <40 <40
6th (yellow)
7th (red) visual and intermittent <30 <30 <30
acoustic approx. 3 s
8. (red) continuous <20 <15 <20
approx. 3s
Warning indicator, location - GF54.65-P-4104-02A
Models 202, 208, 210 up to 30.6.99, 215, 220 with code (220a) Parktronic system (PTS)
Shown on model 210 up to 30.6.99
Fig. 132: Identifying Warning Indicator Location - Shown On Model 210 Up To 30.6.99
Warning display, design - GF54.65-P-4104-03A
Shown on models 168, 202, 208, 210, 215, 220

Fig. 133: Identifying Warning Display Design - Shown On Models 168, 202, 208, 210, 215, 220
Fig. 134: Identifying Warning Display Design - Shown Models 140
On models 140, 168, 202, 208, 210, 215, 220 the warning indicators consist of LCD bar displays with 6 yellow
segments (2) and 2 red segments (3) and the frame (1).
The frame (1) is yellow in the area of the yellow segments (2) and red in the area of the red segments (3).
On model 163 the warning indicators consist of LED displays with 6 yellow and 2 red light emitting diodes, the
source of sound and the microprocessor which the control unit data telegram evaluates and converts.
OVERVIEW OF SYSTEM COMPONENTS OF PARKTRONIC SYSTEM (PTS),

LOCATION/TASK/DESIGN/FUNCTION - GF54.65-P-9999A
MODEL 140,163,168, 202, 208, 210, 215, 220 with CODE (220a) Parktronic System (PTS)
PTS control module, location/task GF54.65-P-4100A

Warning indicator, location/task/design/ function GF54.65-P-4104A
Parktronic system (PTS), contents, function description GF54.65-P-0999A
ENGINE COOLING
Electric Cooling Fans - 215, 220 & 230 Chassis (Except 215.376/378, 220.176/178 & 230.476)
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.
NOTE: When the battery is disconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle.
NOTE: The following table identifies models applicable to this article.
Model (Year) Chassis Number Engine Number
CL500 Coupe (2001-04) 215.375 113.960
CL55 Coupe (2001-02) 215.373 113.982
CL55 Coupe (2003-04) 215.374 113.991
S430 Sedan (2001) 220.070 113.941
S430 Sedan (2001-04) 220.170 113.941
S430 Sedan (2003-04) 220.183 113.948
S500 Sedan (2001-04) 220.175 113.960
S500 Sedan (2003-04) 220.184 113.966
S55 AMG Sedan (2001-02) 220.173 113.982
S55 AMG Sedan (2003-04) 220.174 113.991
SL500 Roadster (2003-04) 230.475 113.963
SL55 AMG Roadster (2003-04) 230.474 113.992

Vehicles are equipped with a cooling fan module mounted to radiator. Cooling fan assembly includes an electric
motor and one-piece fan shroud. The cooling fan assembly is attached to radiator by screws and retaining clips.
Cooling fan operation is controlled by an input signal from Powertrain Control Module (PCM). PCM enables
cooling fan through fan control circuits via DATA-bus communication system. In addition, A/C control module
can request that PCM activate cooling fan control circuit, when A/C high side pressure reaches a specified level.
TESTING
No testing available at this time from vehicle manufacturer.
TROUBLE SHOOTING
COOLING FAN
Disconnect harness plug connector from cooling fan. Spin fan wheel by hand several times and check for
imbalance or grinding noises, if imbalance or grinding noise is found, replace cooling fan motor. See
COOLING FAN MOTOR & SHROUD under REMOVAL & INSTALLATION.
ELECTRIC RADIATOR FAN DOES NOT RUN
Some possible causes of radiator fan not running include, faulty fan motor, fan relay, PCM, engine coolant
temperature sensor, A/C pressure transducer, fuse or wiring faults.

COOLING FAN MOTOR & SHROUD
CAUTION: Risk of injury to skin and eyes from scalding from hot coolant. Do not
open cooling system until coolant temperature has dropped below 193°F
(90°C). Wear protective clothing and eye protection.
NOTE: During procedure number(s) and letter(s) in parentheses correspond to number

(s) and letter(s) inside the illustration(s).
Removal
1. With engine cooled, cover radiator cap with shop towels, open cap slowly to relieve pressure and then
remove.
2. Raise vehicle, remove necessary guards to gain access to coolant drain plug (3), drain coolant into proper
container. See Fig. 1 .
3. Remove left air intake tube from air cleaner housing.
4. Remove bolts from retaining tabs (3) on from shroud. See Fig. 2 .
5. Disconnect harness plug connector from cooling fan.
6. Disconnect coolant line of expansion reservoir tank to coolant line thermostat housing to radiator.
7. Disconnect lower radiator hose (2) from radiator. See Fig. 2 .
8. Dismount fastening shackle (arrow) for automatic transmission oil line (at bottom of fan shroud).
9. Remove fan shroud, pull fan shroud out of retaining lugs on radiator. Take care not to break off tabs (4).
See Fig. 2 .
Fig. 1: Draining Coolant (Chassis 215 Shown, Others Similar)
Fig. 2: Removing & Installing Cooling Fan Motor With Shroud (Chassis 220 Shown, Others Similar)
Installation
1. Install in reverse order, install fan shroud, connect harness plug to cooling fan and install all hoses. See
TORQUE SPECIFICATIONS .
2. Fill and bleed cooling system. Turn interior car heater on at full heat. Start and let engine run and warm
up, continuously adding coolant to system until the coolant level reaches the markings on the on radiator
filler neck or the coolant expansion tank. At coolant temperature of about 140-193°F (60-90°C) install the
radiator cap or expansion tank cap. Check coolant level when engine has completely cooled. See Fig. 3
and Fig. 4 . Top off coolant if needed.
3. Check for coolant leaks.
Fig. 3: Identifying Coolant Level With Engine Cold (Chassis 215 & 220)
Fig. 4: Identifying Coolant level With Engine Cold (Chassis 230)
Application INCH Lbs. (N.m
Fan Shroud Bolts 70 (8)
Hose Clamps 88 (10)
WIRING DIAGRAMS
NOTE: See COOLING FANS in appropriate SYSTEMS WIRING DIAGRAMS article in

ELECTRICAL.
ENGINE
Engine Cooling System - 215 & 220 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
GENERAL INFORMATION ON THE COOLANT PREHEATER - AH20.00-P-1001-01A
General information
An electric coolant preheater can be retrofitted in the motor water circuit to keep the engine coolant warm or to
warm it up in order to prevent the engine cooling out completely at low ambient temperatures.
The electrical coolant preheater can be built into the water circuit of the engine subsequently or can be
retrofitted.
The engine coolant preheater can be connected to the local mains supply using the plug provided on the device.
It has a power consumption of 500 W at a voltage of 230 V or 115 V.
For retrofitting:
The spare parts are listed in Group 20 of the ET documentation for the corresponding engine.
NOTES ON COOLANT LEVEL - AH20.00-P-1142-01V
Engine 112, 113, 137, 156, 271, 272, 273, 275, 285, 612, 628, 629, 642
When the engine is cold, the engine coolant level must reach up to the marking "MIN" on the coolant expansion
reservoir (arrow).
When coolant is warm: approx. 1 cm above this scribe mark.
Fig. 1: Locating Coolant Expansion Reservoir

Models 215, 220 with engines 113, 137
Model 215, 220 with engine 275, main circuit
Model 463 with engine 112, 113, 628, 642
When engine is cold, the engine coolant level must reach up to the marking (arrow) at the coolant expansion
reservoir.
Fig. 2: Locating Coolant Level - Model 220,215,220,461,463

reservoir.
Fig. 3: Locating Coolant Level - Model 210 With Engine 112, 113
Model 202, 208 with engine 112, 113
reservoir.
Fig. 4: Locating Coolant Level - Model 202, 208 With Engine 112, 113
Model 129 with engines 112, 113
reservoir.
Fig. 5: Locating Coolant Level - Model 129 With Engines 112, 113
Model 230 engine 112, 113, 272, 273
Model 230 with engine 275, main circuit
reservoir.
Fig. 6: Locating Coolant Level - Model 230 Engine 112, 113, 272, 273,275
Model 211 with engine 112, 113, 156, 271, 272, 273
Model 219 with engine 113, 156, 272, 273
When the engine is cold, the engine coolant level must reach up to the marking (arrow) in the coolant expansion
reservoir.
Fig. 7: Locating Coolant Expansion Reservoir - Model 211,219

Model 216 with engine 156, 273,
Model 221 with engine 156, 272, 273, 629, 642
Model 216, 221 with engine 275, main circuit
reservoir.
Fig. 8: Locating Coolant Expansion Reservoir - Model 216,221

Model 240 with Engine 285, main circuit
reservoir.
Fig. 9: Locating Coolant Expansion Reservoir - Model 240

Model 215, 216, 220, 221, 230 with engine 275, low temperature circuit
Model 240 with engine 285, low temperature circuit
The engine coolant level must be placed, when coolant is warm or cold, in the cross-hatched illustrated area of
filler neck.
Fig. 10: Locating Coolant Expansion Reservoir - Model 215,216,220,221,230,240
GENERAL NOTES: PASSENGER CARS: ENGINE COOLING SYSTEM - AH20.00-Z-9999AZ
MODEL all
Notes on coolant level ENGINE 271, 272, 646 AH20.00-P-1142-01CW

in MODEL 204
Notes on coolant level ENGINE 266.9, 640.9 in AH20.00-P-1142-01AK
MODEL 169.0/3, 245.2
Notes on coolant level ENGINE 113, 156, 272, AH20.00-P-1142-01GZB
629, 642 in MODEL 164
ENGINE 113, 156, 272,
642 in MODEL 251
Notes on coolant level ENGINE 272, 642 in AH20.00-P-1142-01PI
MODEL 203 ENGINE
156, 272, 273, 642 in
MODEL 209
Notes on coolant ENGINE all AH20.00-N-2080-01A
General information on ENGINE 111, 112, 113, AH20.00-P-1001-01A
the coolant preheater 119, 166, 271, 602, 603,
604, 605, 606, 611, 612,
613, 668 ...
Notes on coolant level MODEL 124, 129, 140, AH20.00-P-1142-01A
163, 168, 170, 202, 208,
210, 211, 219, 220 ...
Notes on engine coolant ENGINE 111, 112, 113 AH20.00-P-1142-01GH
level in MODEL 163
Notes on coolant level ENGINE 642.940 in AH20.00-P-1142-01GZD
MODEL 164.120/122
Notes on coolant level ENGINE 111, 112, 113, AH20.00-P-1142-01P
271, 272, 273, 611, 612,
646...
Notes on coolant level ENGINE 642 in MODEL AH20.00-P-1142-01TI
211
Notes on coolant level ENGINE 629 in MODEL AH20.00-P-1142-01TJ
211
Notes on viscous fan ENGINE 120 AH20.40-P-0001-01AO
clutch
Notes on coolant level ENGINE 155 in MODEL AH20.00-P-1142-01SLR
199
Notes on coolant level ENGINE 642, 629 in AH20.00-P-1142-01SXI
MODEL 221
Notes on coolant level ENGINE 112, 113, 137, AH20.00-P-1142-01V
156, 271, 272, 273, 275,
285, 612, 628, 629, 642...
Notes on application of ENGINE 113... AH20.10-P-0001-
sealant to coolant pump 02RVK
housing
NOTES ON APPLICATION OF SEALANT TO COOLANT PUMP HOUSING - AH20.10-P-0001-

02RVK
Engine 113.990/991/992/993/995
Application of sealant to timing case cover
The sealing surface must be cleaned. The sealant must only be applied on the timing case cover to the
specified surfaces in the form of a sealing compound bead 2.0 mm(± 0.5 mm) diameter. The sealing compound
must be applied within 10 min. The sealing compound bead must not be spread. Only the sealing compound
listed in the Repair Products may be used.
Fig. 11: Identifying Sealant Area Of Timing Case Cover
BASIC KNOWLEDGE
COOLANT CIRCUIT AS-BUILT CONDITION - GF20.00-P-0800
Coolant circuit as-built condition - GF20.00-P-0800AA
ENGINE 137.970
Coolant circuit diagram model 220, 215 with engine 137
Fig. 12: Coolant Circuit Diagram Model (220, 215) With Engine (137)
Engine cooling
All the components positioned in direction of travel ahead of the engine are combined in a cooling module.
The cooling module includes:
 a 16 mm flat tube condenser with integrated steering oil cooler in the upper half
 a coolant cooler with integrated transmission oil heat exchanger
 an electric suction fan
 Radiator area sealing
 an ABC (active body control) oil cooler
An additional coolant cooler is housed in the front right wheelhousing.
The coolant hoses between cooling module and engine are connected with a quick-coupling system.
The overflow tank, fitted previously for avoiding a loss of coolant when the engine is switched off, is
discontinued as the loss of coolant as a result of the formation of vapor bubbles during reheating, is avoided by
means of a two-stage pressure valve in the coolant system cap.
The engine fan with viscous clutch, and the electric additional fan, used previously are replaced on engine 137
with a new design of EC (electrically commutated, brushless or carbonless) suction fan with a large blower
wheel of 520 mm Ø The fan speed of the EC suction fan is steplessly electronically controlled in line with
demand by the engine control module, on the bases of the coolant temperature and the air conditioning system
Coolant circuit as-built configuration - GF20.00-P-0800C
ENGINE 112
Fig. 13: Coolant Circuit Diagram - Model 210 With Engine 112
Coolant circuit as-built condition - GF20.00-P-0800D
ENGINE 113
Diagram of coolant circuit engine 113
All except engine 113.944

Fig. 14: Coolant Circuit Diagram - All Except Engine 113.944
Coolant circuit diagram model
202.033/093 with engine 113.944

Fig. 15: Coolant Circuit Diagram - Model 202.033/093 With Engine 113.944
RESERVOIR CAP, LOCATION/DESIGN/FUNCTION - GF20.30-P-1000A
ENGINE 606.912 /962 in MODEL 210
ENGINE 112 in MODEL 129, 170, 202, 203, 208, 210, 220
ENGINE 113 in MODEL 129, 202, 208, 209, 210, 220
ENGINE 111.951 in MODEL 203.035 /235 /735
ENGINE 111.955 in MODEL 203.045 /245 /745
ENGINE 112.912 in MODEL 203.061 /261
ENGINE 112.946 in MODEL 203.064/264
ENGINE 611.962 in MODELS 203.004 /006 /204 /206 /706
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 611.960
ENGINE 611.961
ENGINE 612.961
ENGINE 612.965
ENGINE 612.963
ENGINE 613.960
ENGINE 613.961
ENGINE 612.966
ENGINE 113.968 in MODEL 209.375 /475

ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342
ENGINE 271.946 in MODEL 203.046 /246 /746
ENGINE 271.948 in MODEL 203.040 /740
ENGINE 612.962
ENGINE 271.941 in MODEL 211.042 /242
ENGINE 271.942 in MODEL 203.043 /243 /743, 209.343 /443
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 612.990 in MODEL 203.018 /218 /718
ENGINE 646.962 in MODEL 203.007 /207 /707
ENGINE 646.963 in MODEL 203.008 /208 /708

Fig. 16: Identifying Expansion Reservoir Cap
Cap location The cap (2) is screwed

onto the expansion
reservoir in the engine
compartment.
Cap task During the engine off
heating phase (after
switching off the engine)
the pressure in the cooling
system may rise.
So that no coolant escapes,
the cap (2) is additionally
built-in with a
compression stage.
Cap function GF20.30-P-1000-01A
Reservoir cap, function - GF20.30-P-1000-01A
Fig. 17: Identifying Expansion Reservoir, Vacuum Valve And Cap

The cap (2) has two opening pressures.
1st stage
If the pressure in the cooling system exceeds the first compression stage, the valve opens and allows the
pressure to escape into the upper part of the cap (2)
2nd stage
If the pressure continues to rise, the pressure relief valve of the 2nd stage (4) opens and allows the pressure to
escape through several ventilation bores (a) mounted at the cap of the expansion reservoir (1), along the annular
port (b) into the outlet nipple (c) and a hose extension to atmosphere.
The 2nd stage cap (2) eliminates the need for the overflow tank.
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.
SAFETY INFORMATION: ENGINE COOLING SYSTEM - AS20.00-Z-9999ZZ

MODEL all
Risk of injury to skin and ENGINE all AS20.00-Z-0001-01A

eyes suffering scalding
from contact with hot
coolant spray.
Risk of poisoning from
swallowing coolant.
TROUBLE DIAGNOSIS
ENGINE OVERHEATED - AF20.20-P-6100A
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 220, 461, 463
MODIFICATION NOTES
29.9.99 Supersedes SI20/50 from Remove SI 20/50 from
08.03.94 your binder.

50 001 F7 Radiator Convert cooling
clogged with system to KFM type
corrosion 30 ?
products
Risk of injury Do not open cooling AS20.00-Z-
to skin and system unless coolant 0001-01A
eyes suffering temperature is below
scalding from 90 °C. Open cap
contact with slowly and release the
hot coolant pressure. Do not pour
spray. coolant into beverage
Risk of bottles.
poisoning Wear protective
from gloves, protective
swallowing clothing and safety
coolant. glasses.
1 Drain coolant from
engine block and
radiator.
Flush residual
corrosion products out
of cooling/heating
system so that new
radiator cannot be
clogged
Do not flush
cooling/heating
system with citric
acid, only with clear
water.
2 Disconnect hot
water hose from
engine to heater feed
line
3 Carefully blow out
or flush heat
exchanger
Do not work with
full air pressure
available Ensure that
the coolant is
completely drained
from the heater.
4
Remove/install/replace
radiator
5 Mix antifreeze, type
30, with water outside
of cooling system and
fill into cooling
system.
Mixing ratio 50 :
50. BB00.40-P-
Coolant specifications 0310-01A
6 Remove sticker from
5 l container and apply
to expansion reservoir
Service Information SI20.00-P-
on coolant 0001A
7 Dispose of drained
coolant properly
Pay attention to
legal provisions and
local wastewater
regulations.
Notes on All engines AH20.00-N-
coolant 2080-01A

000 989 16 25 11 Antifreeze, type 30 (5 l container) 1
TESTING & REPAIR
INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010
Inspect cooling system for leaks - AR20.00-P-1010HA
ENGINE 111
ENGINE 112 (except 112.961 /946 /953 /947 /960 /916 /955 /912)
ENGINE 112.945
ENGINE 113.962
ENGINE 113 (except 113.992 /987 /988 /968 /991 /990 /963 /995)
ENGINE 120
ENGINE 137
ENGINE 601
ENGINE 602
ENGINE 602.931
ENGINE 603
ENGINE 603.931
ENGINE 603.972
ENGINE 604
ENGINE 605
ENGINE 606
ENGINE 606.964
ENGINE 611
ENGINE 612
ENGINE 612.965
ENGINE 613
ENGINE 628
ENGINE 628.962
ENGINE 628.963
ENGINE 646.951
ENGINE 646.961
ENGINE 647.961
ENGINE 648.960/ 961
ENGINE 285.950
ENGINE 612.966
ENGINE 113.982
ENGINE 271.941/ 943
ENGINE 275 / (except 275.953 /982)
ENGINE 285.980
Fig. 18: Identifying Expansion Reservoir
Remove/install
Risk of injury Do not open cooling system AS20.00-Z-
1 to skin and unless coolant temperature 0001-01A
eyes caused by is below 90°C. Open cap
scalding from slowly and release the
contact with pressure. Do not pour
hot coolant coolant into beverage
spray. containers.
Risk of Wear protective gloves,
poisoning protective clothing and
caused by safety glasses.
swallowing When closing cover with
coolant. detent (2): rotate closing
Open cap with cover with detent carefully
detent (2) or 2- up to first detent, release
stage cap (2a) pressure relief, then
at expansion unscrew closing cover with
reservoir (1) or detent (2).
radiator. For model 163 with 2-
stage cap (2a) or 1-stage
cap: Rotate cap half a
revolution in
counterclockwise direction,
release pressure, then
unscrew 2-stage cap (2a) or
1-stage cap.
2 Set heating All model except model
switches to 163. Model 163 does not
maximum have any pulsed valve; the
heating heater heat exchanger has
capacity coolant permanently
flowing through it.
Checking
3 Check coolant Replace coolant against
level, if a separate order if the
required adjust antifreeze protection is
correctly. insufficient:
4 Fit test cap (3) Model 124, 126, Fig. 20
on expansion 129, 140, 170, 201, 202,
reservoir or 210,
radiator Model 463.209 /232 /233
with engine 112.945,
Model 463.304 /324 /325
with engine 602.931
Model 463.307 /327 /328
with engine 603.931
Model 463.300 /320 /321
with engine 603.972
Model 463.308 /330 /331
with engine 606.964
Model 170, 202, Fig. 22
203, 208, 209, 210, 211
Model 215,
Model 220 with engine 137,
275, 628,
Model 230 with engine 112,
113, 275,
Model
461.302 /331 /332 /342 /345
Model 463.243 /246 with
engine 113.982,
Model 463.244 /245 /250
Model
463.247 /248 /249 /254 with
engine 113.962,
Model 463.322 /323 with
engine 612.965,
Model 463.309/ 332/ 333
with engine 628.962
Model 163 with Fig. 21
engine 111, 112, 113, 612,
628
5 Connect Fig. 19
pressure pump
(4).
6 Apply pressure *BE20.30-P-
to cooling 1005-01A
system and
check
leaktightness of
cooling system
7 Inspect cooling
and heating
hoses as well
as their
connection
points for
proper
condition and
loss of coolant;
replace coolant
hoses, if
necessary
8 Check hose If necessary, retighten
clamps for hose clamps and replace if
condition and required.
seating *WH58.30-Z-
1001-06A
*WH58.30-Z-
1002-06A
*WH58.30-Z-
1019-02A
9 Install in the
reverse order
RADIATOR OR EXPANSION RESERVOIR CAP

Number Designation Cap 2-stage cap
BE20.30-P-1005- Test pressure for bar gage 1.4 1.4
01A pressure-testing
cooling system
Fig. 19: Identifying Pressure Pump (124 589 24 21 00)

Fig. 20: Identifying Test Cap (124 589 00 91 00)

Number Designation
WH58.30-Z-1019-02A Hose clamp pliers (length 210 mm, clamping range
80 mm)
Inspect cooling system for leaks - AR20.00-P-1010HN
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Low-temperature circuit
ENGINE 285 in MODEL 240 Low temperature circuit
Shown on engine 285
Fig. 23: Inspecting Cooling System For Leaks - Shown On Engine 285
Remove/install
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
manufacturer.
AR01.10-P-
1 Remove engine trim panel. Engine 275.95, 285
2405LA
AR01.10-P-
Engine 275.98
2405IM
Only open cap (1) at a coolant

temperature below 40°C otherwise
coolant can flow out.
2 Remove cap (1) of filler neck (2) If coolant has flown out, the low
temperature circuit must be bled: ?
AR20.00-P-
Bleed low temperature circuit
1145H
Checking
Check engine coolant level and antifreeze
*BF20.00-
3 content of coolant in the low temperature
P-1001-04A
circuit, correct if required
AH20.00-N-
Notes on coolant
2080-01A
AH20.00-P-
Notes on coolant level
1142-01V
In case of inadequate antifreeze
content:
Replace coolant of low
temperature circuit: ?
Drain/fill in coolant
AR20.00-P-
Model 215, 216, 220, 221, 230
1142HM
AR20.00-P-
Model 240
1142HN
4 Mount test cap (01) on filler neck (2) Fig. 20
5 Connect testing unit (02) at test cap (01) Fig. 19
6 Apply pressure to low temperature circuit Test pressure approx. 1.4 bar.
Check condition and coolant loss of coolant
7 lines and hoses as well as connecting points; In the engine compartment.
replace coolant lines and hoses if required
Check condition and seating of the clamps;
8 remove clamp with hose clamp pliers if
necessary and replace
AR61.20-P-
9 Remove bottom engine compartment paneling Model 215, 220
1105M
Model 216, model 221 without top AR61.20-P-
protection 1105SX
Model 221 with code Z07 Top AR61.20-P-
protection 1105SXS
AR61.20-P-
Model 230
1105R
AR61.20-P-
Model 240
1105H
Check condition and coolant loss of low

10 temperature circuit radiator, coolant lines and If vehicle is raised.
hoses as well as connecting points; replace
low temperature circuit radiator, as well as
coolant lines and hoses if required
Check condition and seating of the clamps;
If no water loss can be determined
11 remove clamp with hose clamp pliers if
from outside: ?
necessary and replace
Remove engine induction air ducts
AR09.41-P-
from left and right-side charge air
8623H
coolers.
Check left and right charge air
cooler at air inlet using a flexible
endoscope, cylinder illumination AR09.41-P-
unit and inspection mirror for inner 6800-01H
leaktightness.
In the event of leaks: ?
Replace left and/or right-side
charge air cooler. AR09.41-P-
If no water loss is determined at 6817HH
the side of the air inlet: ?
Leaving coolant lines connected,
AR09.41-P-
remove left and right-side charge
6817HH
air coolers from engine.
Check left and right charge air
cooler at air outlet using a flexible
endoscope, cylinder illumination AR09.41-P-
unit and inspection mirror for inner 6800-01HH
leaktightness.
In the event of leaks: ?
Replace left and/or right-side AR09.41-P-
charge air cooler. 6817HH
13 Pour in coolant After installation of new parts
AR20.00-P-
14 Bleed low temperature circuit After installation of new parts
1145H
MIXTURE RATIO FOR COOLANT

Number Designation ENGINE all
Up to -37°
50/50
C
Antifreeze/water
Up to -45°
55/45
BF20.00-P-1001- Mixture ratio for C
04A coolant BB00.40-P-0310-
Sheet
Specifications for service 01A
products BB00.40-P-0325-
Sheet
00A
Inspect cooling system for leaks - AR20.00-P-1010RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 220.074 /174
ENGINE 112.961 in MODELS 203.065 /265
ENGINE 113.993 in MODELS 463.270 /271
Shown on model 220

Fig. 26: Inspecting Cooling System For Leaks (Shown On Model 220)
Remove/install
Risk of injury to skin and Do not open cooling system AS20.00-Z-0001-01A
eyes caused by scalding unless coolant temperature
from contact with hot is below 90°C. Open cap
coolant spray. Risk of slowly and release the
poisoning from pressure. Do not pour
swallowing coolant. coolant into beverage
containers. Wear protective
gloves, protective clothing
and safety glasses.
1 Open 2-stage cap (2) Rotate 2-stage cap (2)
half a revolution in
counterclockwise direction,
release overpressure, then
unscrew 2-stage cap (2).
2 Set heater control to
maximum heat output
Checking
3 Check coolant level, if If antifreeze protection
required adjust correctly. is insufficient, replace as a
separate repair order:
?
Engine 113.992 in model AR20.00-P-1142RVK
230.474
230.472
Engine 113.990 in models
211.076/276
215.374
220.074/174
230.475
170.466
203.065/265
Engine 113.993 in models AR20.00-P-1142GX
463.270/271
Notes on coolant level Engine 113.992 in model AH20.00-P-1142-01V
230.474
230.472
211.076 /276
215.374
220.074/ 174
230.475
463.270/ 271
Notes on coolant level Engine 112.960 in model AH20.00-P-1142-01P
170.466
203.065/ 265
4 Mount test cap (3) on Test cap Fig. 22
expansion reservoir (1)
5 Connect tester (4) Discharge cooling system
with a test pressure of
approx. 1,4 bar.
Pressure pump Fig. 19
6 Check tightness of cooling Check cooling and
system. heating hoses as well as
their connection points for
proper condition and loss of
coolant; replace cooling
and heating hoses if
necessary
7 Inspect condition and 6 mm socket hexagon *WH58.30-Z-1001-06A
installation at hose clamps;
retighten or replace if
necessary
7 mm socket hexagon *WH58.30-Z-1002-06A

Number Designation
DRAIN/FILL IN COOLANT - AR20.00-P-1142
Drain/fill in coolant - AR20.00-P-1142H
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Main circuit
ENGINE 285 in MODEL 240 Main circuit

Fig. 29: Identifying Coolant Compensation Tank, Cooling System Cap And Drain Hose - Model (240)
Fig. 30: Identifying Drain Plug And Drain Screw - Show On Engine (285.950)
Shown on engine 285.950

Fig. 31: Identifying Drain Screw (Model 215,216,220,221)
Drain
temperature is below 90°C. Open cap
caused by scalding from contact with
slowly and release the pressure. Do not pour AS20.00-Z-
hot coolant spray.
coolant into beverage containers. 0001-01A
Risk of poisoning caused by
Wear protective gloves, protective clothing
swallowing coolant.
and safety glasses.
AH20.00-N-
Notes on coolant
2080-01A
Only when draining coolant at crankcase,
Detach ground line(s) from battery right.
1
(ies) Do not connect quiescent current
retention unit.
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
Model 216, 221
0003SX
AR54.10-P-
Model 230
0003R
AR54.10-P-
Model 240
0003H
Turn cooling system cap (1) 1/2 one
Unscrew cooling system cap (1) at
2 revolution until the pressure is releases then
coolant expansion reservoir (2)
unscrew cooling system cap (1).
Remove lower engine compartment Only the front and center engine
3 paneling compartment paneling.
AR61.20-P-
Model 215, 220
1105M
Model 216, Model 221 without top AR61.20-P-
protection 1105SX
AR61.20-P-
Model 221 with code Z07 Top protection
1105SXS
AR61.20-P-
Model 230
1105R
AR61.20-P-
Model 240
1105H
Drain coolant from radiator
Push siphon hose (3) onto left fitting
4
(4) at radiator
Slacken siphon hose (5) at radiator
5 Catch coolant in a suitable vessel.
and drain coolant
Tighten drain plug (5) and detach
6
drain hose (3) from fitting (4)
Drain coolant at crankcase, right
Detach drain plug (6) near alternator
7 and slide drain hose (3) onto drain Model 230, 240
plug (6)
Open drain plug (6) and drain off Model 230, 240
8
coolant Catch coolant in a suitable vessel.
Detach drain hose (3) and tighten
9 Model 230, 240
drain plug (6)
*BA20.00-P-
1002-02D
Detach drain plug (8) and slide drain
10 Model 215, 216, 220, 221
hose (3) onto drain plug (8)
Open drain plug (8) and drain off Model 215, 216, 220, 221
11
12 Model 215, 216, 220, 221
drain plug (8)
*BA20.00-P-
1001-02D
Drain coolant at crankcase. left
Detach drain plug (7) and place drain
13 Model 216, 220, 221, 240
hose (3) on drain plug (7)
Open drain plug (7) and drain off Model 216, 220, 221, 240
14
15 Model 216, 220, 221, 240
drain plug (7)
*BA20.00-P-
1001-02D
16 Lower vehicle
Filling
Pour in coolant and bleed cooling AR20.00-P-
17 Use clean coolant again.
system 1142-04A
Fig. 22
Fig. 36
BB00.40-P-
Coolant specifications Sheet 310.1
0310-01A
Anticorrosion/antifreeze agents BB00.40-P-
Sheet 325.0
(Sheet 325.0) 0325-00A
AH20.00-P-
1142-01V
*BF20.00-P-
1001-04A
AR20.00-P-
18 Inspecting cooling system for leaks Model 215, 220, 230, 240
1010HA
AR20.00-P-
Model 216, 221
1010SX
Install lower engine compartment AR61.20-P-
19 Model 215, 220
paneling 1105M
Model 216, AR61.20-P-
Model 221 without top protection 1105SX
AR61.20-P-
1105SXS
AR61.20-P-
Model 230
1105R
AR61.20-P-
Model 240
1105H
Only when coolant has been drained at
20 Attach ground line(s) to battery(ies)
crankcase on the right.
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
Model 216, 221
0003SX
AR54.10-P-
Model 230
0003R
AR54.10-P-
Model 240
0003H
Connect up STAR DIAGNOSIS,
Only if ground line(a) on the battery(ies)
21 read and erase diagnostic trouble
were removed.
code memory
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
ENGINE COOLING, GENERAL
Number Designation Engine 275.950/951/ Engine 275.953/954/ 982,
952/980/981, 285.950 285.980
BA20.00-P- Coolant drain plug to
Nm 14 14
1001-02D crankcase
Nm 12 -
1002-02D alternator

Up to -37°
50/50
C
Antifreeze/water
Up to -45°
55/45
BF20.00-P-1001- Mixture ratio for C
04A coolant BB00.40-P-0310-
Sheet
Sheet
00A
Fig. 33: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Pour in coolant and bleed cooling system - AR20.00-P-1142-04A

Fig. 34: Identifying Tester Cap (169 589 00 91 00)
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 the control unit (3) to the test cap (2) .
3. Attach the venturi nozzle (9) to the control unit (3).
4. Close the drain valve (8) and the feed valve (7).
Shown on model 171 with engine 272
Fig. 37: Identifying Cooling System Bleeding Procedure - Shown On Model 171 With Engine 272
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 the 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 the 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-1142HA
ENGINE 230.467 112 in MODEL 129, 163, 202, 208, 210, 211.061 /065 /261 /265 /080 /280 /082 /282, 220,
230.467
ENGINE 113 in MODEL 129, 163, 202, 208, 210, 211.070 /270 /083 /283, 215, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.982 in MODEL 463.241 /243 /246
Fig. 38: Identifying Cooling System Components - Model 202
Shown on model 215 with engine 137

Fig. 39: Identifying Cooling Compensation Tank Components - Shown On Model 215 With Engine 137
MODIFICATION NOTES
12.10.04 Fill coolant using vacuum Step 16
method added
Drain
Risk of death caused by Align vehicle between columns of AS00.00-Z-0010-
vehicle slipping or toppling vehicle lift and position four support 01A
off the lifting platform. plates at vehicle lift support points
specified by vehicle manufacturer.
Risk of injury to skin and Do not open cooling system unless AS20.00-Z-0001-
eyes caused by scalding coolant temperature is below 90°C. 01A
from contact with hot Open cap slowly and release the
coolant spray. pressure. Do not pour coolant into
Risk of poisoning caused beverage containers.
by swallowing coolant. Wear protective gloves, protective
clothing and safety glasses.
Notes on coolant AH20.00-N-
2080-01A
1 Open engine hood
2 Disconnect ground cable of Only when draining coolant at
battery crankcase, right.
Do not connect quiescent current
retention unit.
Model 129, 163,202,208,210 AR54.10-P-
0003A
Model 211.0 AR54.10-P-
0003T
Model 211.2 AR54.10-P-
0003TA
Model 215, 220 AR54.10-P-
0003I
0003R
Model 463 without special protection AR54.10-P-
0003G
Model 463.241 with special protection, AR54.10-P-
code 979 0003PV
code 979 0003PM
3 Open cooling system cap (2) Observe the different versions.
at coolant expansion Cooling system cap (2) with detent:
reservoir (1) Rotate cooling system cap with detent
(2) carefully to first predetent, release
pressure, then unscrew cooling system
cap with detent (2).
1-stage and 2-stage cooling system cap
(2): turn cooling system cap (2) 1/2
revolution counterclockwise, release
pressure, then remove cooling system
cap (2).
4 Raise vehicle
5.1 Remove lower engine Model 129,202,208,210 AR61.20-P-
compartment paneling 1105AB
Model 163 with engine 113 AR61.20-P-
1105GH
1105T
Model 215, 220 AR61.20-P-
1105M
1105R
5.2 Remove under-ride guard Model 463
6 Remove air deflector shield Model 163 with engine 113.942
Drain coolant from
radiator
7 Push siphon hose (3a) onto Model 129, 202, 208, 210, 211, 215,
radiator drain plug (3) 220, 230, 463
8 Open radiator drain plug (3) Model 129, 202, 208, 210, 211, 215,
and drain coolant 220, 230, 463
Catch coolant in a suitable vessel.
9 Tighten radiator drain plug Model 129, 202, 208, 210, 211, 215,
(3) and detach drain hose 220, 230, 463
(3a) from radiator drain plug
(3)
10 Detach lower coolant hose Model 163
from radiator or coolant Catch coolant in a suitable vessel.
pump and drain coolant
11 Attach lower coolant hose to Model 163
radiator or coolant pump Installation: Replace hose clamp. *BA20.20-P-
1004-01A
Drain coolant at crankcase
12 Push siphon hose (4a) onto Model 129, 202, 208, 210, 211, 215,
crankcase drain plug (4) 220, 230, 463
13 Open crankcase drain plug Model 129, 202, 208, 210, 211, 215,
(4) and drain coolant 220, 230, 463
Catch coolant in a suitable vessel.
14 Tighten crankcase drain Model 129, 202, 208, 210, 211, 215,
plug (4) and detach drain 220, 230, 463
hose (4a) from crankcase *BA01.40-P-
drain plug (4) 1003-01C
*BA20.00-P-
1001-02B
15 Lower vehicle
Filling
16 Pour in coolant and bleed Reuse clean coolant. AR20.00-P-
cooling system 1142-04A
Fig. 22
Fig. 36
Coolant specifications Sheet 310.1 BB00.40-P-0310-
01A
Anticorrosion/antifreeze Sheet 325.0 BB00.40-P-0325-
agents (Sheet 325.0) 00A
Engine 112, 113 *BF20.00-P-
1001-02K
Engine 137 *BF20.00-P-
1001-02M
Notes on coolant level Engine 112, 113, 137 AH20.00-P-
1142-01V
Notes on coolant level Model 163 with engine 112, 113 AH20.00-P-1142-
01GH
17 Inspect cooling system for AR20.00-P-
leaks 1010HA
18 Fit air deflector Model 163 with engine 113.942
19.1 Install under-ride guard Model 463
19.2 Install lower engine Model 129,202,208,210 AR61.20-P-
compartment paneling 1105AB
Model 163 with engine 113 AR61.20-P-
1105GH
1105T
Model 215, 220 AR61.20-P-
1105M
1105R
20 Lower vehicle
21 Connect ground cable to Only when coolant has been drained at
battery crankcase on the right.
Model 129, 163, 202, 208, 210 AR54.10-P-
0003A
Model 211.0 AR54.10-P-
0003T
Model 211.2 AR54.10-P-
0003TA
Model 215, 220 AR54.10-P-
0003I
0003R
Model 463 without special protection AR54.10-P-
0003G
code 979 0003PM
code 979 0003PV
22 Perform basic programming Only if ground line for battery has
been disconnected.
0200A
0200GH
Model 202, 208 AR00.19-P-
0200C
0200D
0200T
Model 215, 220 AR00.19-P-
0200M
0200R
Model 463 except AR00.19-P-
463.206 /209 /232 /233 /240 /241 0200P
Model 463.206/ 209/ 232/ 233/ 240/
241
23 Read out and erase the fault Only if the ground line of the battery
memory using STAR has been disconnected.
DIAGNOSIS.

Number Designation Engine 113.940/941/ Engine 137
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995
BA01.40-P-1003- Outlet connection Nm 12 12
01C for crankcase

113.940/941/
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-1001-02B Coolant drain plug to Nm 12
crankcase
RADIATOR, COOLANT HOSES

Number Designation Engine 112.942/970,
113.942/965/981
BA20.20-P-1004-01A Hose clamp Nm 3
COOLING SYSTEM
112.910/920 112.911/921/941 in 112.922/944/972 in
in Model 202, model 210 model 220
112.940 in
Model 208
BF20.00- Cooling Total filling Liters approx.9.5 approx.10.0 approx.10.5
P-1001- system capacity
02K Capacity of Liters approx.4.75 approx.5.0 approx.5.0
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity Liters approx.5.25 approx.5.5 approx.5.5
of anticorrosion/
antifreeze down
to -45°C
Specifications Sheet BB00.40-P- BB00.40-P-0310- BB00.40-P-0310-
for Operating 0310-01A 01A 01A
Fluids Sheet BB00.40-P- BB00.40-P-0325- BB00.40-P-0325-
0325-00A 00A 00A
COOLING SYSTEM
Number Designation Engine Engine 112.945 in Model Engine
112.923/943 463.209/232/233/244 /245/250 112.942 in
in model Model 163,
129 113.940/980
in Model
210,
113.943/984
in Model
208,
113.944 in
Model 202
BF20.00- Cooling Total filling capacity Liters approx.11.75 approx.11.5 approx.11.0
P-1001- system Capacity of Liters approx.6.0 approx.5.8 approx.5.5
02K anticorrosion/antifreeze
agent down to -37°C
Filling capacity of Liters approx.6.5 approx.6.4 approx.6.0
anticorrosion/antifreeze
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P-0310-01A BB00.40-P-
Sheet BB00.40-P- BB00.40-P-0325-00A BB00.40-P-
0325-00A 0325-00A
COOLING SYSTEM
Engine
112.913/917/ Engine
949/954 in Model 113.967/969 in
Number Designation 211 model 211
BF20.00-P- Cooling Total filling Liters approx.9.5 approx.10.75
1001-02K system capacity
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.5.25 approx.6.0
anticorrosion/
antifreeze down to -
45°C
Sheet BB00.40-P-0325- BB00.40-P-0325-
00A 00A
COOLING SYSTEM
Number Designation Engine Engine Engine 113.962 in
113.941/960 113.941/9601 in Model 463.206/
in model 220 model 129 240/241 /247/248
249/254
BF20.00- Cooling Total filling Liters approx.11.5 approx.12.75 approx.12
P-1001- system capacity
02K Capacity of Liters approx.5.75 approx.6.25 approx.6
anticorrosion/
antifreeze agent
down to -37°C
of anticorrosion/
antifreeze down
to -45°C
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-0310-
for Operating 0310-01A 0310-01A 01A
Fluids Sheet BB00.40-P- BB00.40-P- BB00.40-P-0325-
0325-00A 0325-00A 00A
COOLING SYSTEM
Engine Engine Engine
113.991 in 113.960/ 986 in 113.960 /
Number Designation model 215 model 215 model 230.467
BF20.00-P- Cooling Total filling Liters approx.14.5 approx.11.5 approx.10.8
Capacity of Liters approx.7.3 approx.5.75 approx.5.4
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.8 approx.6.25 approx.6
anticorrosion/
antifreeze 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 0310-01A
COOLING SYSTEM
Number Designation Engine Engine Engine 113.982 in
112.970 113.942/981 in model
113.965 in model 163 463.241/243/246
Model 163
Capacity of Liters approx.6.0 approx.5.75 approx.5.95
anticorrosion/
antifreeze agent
down to -37°C
of anticorrosion/
antifreeze down
to -45°C
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-0310-
for Operating 0310-01A 0310-01A 01A
Fluids Sheet BB00.40-P- BB00.40-P- BB00.40-P-0325-
0325-00A 0325-00A 00A
COOLING SYSTEM
113.986/991 in 113.948/966 in 112.975 in
Model 220 model 220 model 220
Capacity of Liters approx.6.8 approx.5.8 approx.5,2
anticorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.7.4 6.4 approx.5.7
anticorrosion/
antifreeze down to
-45°C
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0310-01A
COOLING SYSTEM
BF20.00-P-1001- Cooling system Total filling capacity Liters approx.12
02M Filling capacity of Liters approx.6
anticorrosion/
37°C
Filling capacity of Liters approx.6,6
anticorrosion/
45°C
Specifications for Sheet BB00.40-P-0310-
Operating Fluids 01A
Sheet BB00.40-P-0325-
00A
Bleed cooling system - AR20.00-P-1142-06GA

1. Engines 605, 606 in model 210: open drain plug at cylinder head at the front left, pour in coolant, close
drain plug when the coolant flows out.
2. Switch vehicle heating to maximum heating capacity and allow engine to warm up at average engine
speed.
3. Refill the coolant continuously until the coolant level reaches the marking on the radiator filler opening or
the coolant expansion reservoir.
4. At coolant temperature of about 60 to 70°C, close the filler opening on the radiator or coolant expansion
reservoir with the plug.
Drain/fill in coolant - AR20.00-P-1142HM
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Low-temperature circuit
Fig. 42: Identifying Charge Air Cooler Circulation Pump, Coolant Hose And Cap - Model 215
Drain
temperature is below 90°C. Open cap slowly and
caused by scalding from contact
release the pressure. Do not pour coolant into AS20.00-Z-
with hot coolant spray.
beverage containers. 0001-01A
Wear protective gloves, protective clothing and
swallowing coolant.
safety glasses.
AH20.00-N-
Notes on coolant
2080-01A
AR01.10-P-
1 Remove engine trim panel Engine 275.95
2405LA
AR01.10-P-
Engine 275.98
2405IM
Unscrew cap (1) slowly and until excess pressure
2 Unscrew cap (1).
escapes.
Remove lower engine Model 230: Only remove right engine
3
compartment paneling compartment paneling under bumper.
AR61.20-P-
Model 215, 220
1105M
AR61.20-P-
Model 216, Model 221 without top protection
1105SX
AR61.20-P-
1105SXS
AR61.20-P-
Model 230
1105R
Remove coolant hose (2) to
Collect coolant in a container.
4 charge air cooler circulation
pump (M44) Follow regulations for disposal of coolant.
Filling
Connect coolant hose (2) to
Check coolant hose (2) and hose clamp for
5 charge air cooler circulation
damage, replace if required.
pump (M44)
*BF20.00-P-
6 Pour in coolant
1001-04A
AR20.00-P-
7 Bleed low temperature circuit
1145H
Inspecting cooling system for AR20.00-P-
8
leaks 1010HN
Install lower engine compartment AR61.20-P-
9 Model 215, 220
paneling 1105M
AR61.20-P-
Model 216, model 221 without Top protection
1105SX
AR61.20-P-
1105SXS
AR61.20-P-
Model 230
1105R

Up to -37°
50/50
C
Antifreeze/water
BF20.00-P-1001- Mixture ratio for Up to -45°
55/45
04A coolant C
BB00.40-P-0310-
Sheet
Sheet
00A
Drain/fill in coolant - AR20.00-P-1142RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074 /174
ENGINE 112.961 in MODELS 203.065 /265
Shown on model 220
Fig. 43: Identifying Coolant Drain/Fill Components (Shown On Model 220)
MODIFICATION NOTES
14.10.04 Fill coolant using vacuum Step 10
method added
Drain
eyes caused by scalding from system unless coolant
contact with hot coolant spray.temperature is below 90°
Risk of poisoning from C. Open cap slowly and
swallowing coolant. release pressure. Do not
pour coolant into
safety glasses.
1 Open engine hood Model 170 AR88.40-P-1000G
Model 203 AR88.40-P-1000P
Model 215, 220 AR88.40-P-1000M
Model 211 AR88.40-P-1000T
Model 230 AR88.40-P-1000R
2.1 Detach ground line(s) at Only when draining
battery(ies) coolant at crankcase, on
the right, in models 170,
203, 215, 220, 230.
Do not connect
quiescent current
retention device.
Model 170 AR54.10-P-0003A
Model 203 AR54.10-P-0003P
Model 215, 220 AR54.10-P-0003I
Model 230 AR54.10-P-0003R
3 Open cooling system cap (1) Pay attention to
at coolant expansion reservoir different versions.
(2) Cooling system cap (1)
with notch:
Turn cooling system cap
(1) carefully to first
predetent, release
pressure, then unscrew
cooling system cap (1).
1-stage and 2-stage
cooling system cap (1):
turn cooling system cap
(1) 1/2 revolution
anticlockwise, release
pressure and then
unscrew cooling system
cap (1).
Model 203 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
Drain coolant from radiator
5 Push drain hose (3a) onto Catch coolant with
engine radiator (3) drain plug suitable vessel.
(arrow), engine radiator (3)
open drain plug and drain
coolant
6 Close engine radiator (3) drain
plug and detach coolant (3a)
drain hose at fitting (arrow)
Drain coolant at crankcase
7.1 Slide drain hose onto Models 170, 203, 215,
crankcase drain plug (4), open 220, 230
crankcase drain plug (4) and Catch coolant with
drain coolant suitable vessel.
8.1 Detach drain hose on Model 170, 203, 215,
crankcase drain plug (4) and 220, 230
screw crankcase drain plug (4)
tight
*BA20.00-P-1001-02B
9 Lower vehicle
Filling
10 Pour in coolant and bleed Reuse clean coolant. AR20.00-P-1142-04A
cooling system
Coolant specifications Sheet 310.1 BB00.40-P-0310-01A
Anticorrosion/antifreeze Sheet 325.0 BB00.40-P-0325-00A
agents (Sheet 325.0)
*BF20.00-P-1001-02K
Notes on coolant level Model 211, 215, 220, 230 AH20.00-P-1142-01V
with engine 113
Notes on coolant level Models 170, 203 with AH20.00-P-1142-01P
engine 112
leaks
12 Install lower engine Model 170 AR61.20-P-1105A
Model 203 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
13.1 Connect up ground line(s) at Only when coolant has
battery(ies) been drained at crankcase
on the right.
Model 170 AR54.10-P-0003A
Model 203 AR54.10-P-0003P
Model 215, 220 AR54.10-P-0003I
Model 230 AR54.10-P-0003R
14.1 Perform basic programming Only if ground line(s) on
battery(ies) were
disconnected.
Model 170 AR00.19-P-0200B
Model 203 AR00.19-P-0200P
Model 215, 220 AR00.19-P-0200M
Model 230 AR00.19-P-0200R
15.1 Connect up STAR Only if ground line(s) on
DIAGNOSIS, read and erase battery(ies) were
diagnostic trouble code disconnected.
memory
Connect up STAR AD00.00-P-2000-04A
fault memory
16 Close engine hood Model 170 AR88.40-P-1000G
Model 203 AR88.40-P-1000P
Model 215, 220 AR88.40-P-1000M
Model 211 AR88.40-P-1000T
Model 230 AR88.40-P-1000R

Number Designation Engines 112,
113.940/941/942/943/944/945/946/948/960/961/963/964/965/966/967/968/971/980/981
BA20.00- Coolant Nm 12
P-1001- drain
02B plug on
crankcase
COOLING SYSTEM
113.990 113.991 in 113.992/995 in
model 215 model 230
BF20.00-P- Cooling Total filling capacity Liters approx. 13.2 approx. 14.5 approx. 13.0
1001-02K system Capacity of Liters approx. 6.6 approx. 7.3 approx. 6.5
Filling capacity of Liters approx. 7.3 approx. 8 approx. 7.3
down to -45°C
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine Engine Engine 112
113.963 in 112.961 in in model 170
model model
230.475 203.065/265
AMG
BF20.00-P- Cooling Total filling capacity Liters approx. 11.5 approx. 10.5 approx. 8
1001-02K system Capacity of Liters approx. 5.8 - approx. 4
Filling capacity of Liters approx. 6.5 - approx. 4.5
down to -45°C
Specifications for Sheet BB00.40-P- - BB00.40-P-
Sheet BB00.40-P- - BB00.40-P-
0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine 113.986/991
in Model 220
BF20.00-P-1001- Cooling system Total filling capacity Liters approx. 13.5
02K Capacity of anticorrosion/antifreeze Liters approx. 6.8
Filling capacity of Liters approx. 7.4
anticorrosion/antifreeze down to -
45°C
Specifications for Operating Fluids Sheet BB00.40-P-0310-
01A
Sheet BB00.40-P-0325-
00A
VENTING AIR FROM LOW TEMPERATURE CIRCUIT - AR20.00-P-1145
Venting air from low temperature circuit - AR20.00-P-1145H

ENGINE 275, 285
Fig. 44: Venting Air From Low Temperature Circuit
Vacuum-type cooling system filler with low-temperature circuit (NTKL) adaptation
Fig. 45: Identifying Vacuum-Type Cooling System Filler With Low-Temperature Circuit (NTKL)
Prepare for bleeding: line routing Illustrated on model 230

Fig. 46: Identifying Control Unit, Coolant Bottle And Venturi Nozzle Connection
Perform bleeding: line routing Illustrated on model 230
Fig. 47: Identifying Vacuum Box, Control Unit And Venturi Nozzle

Risk of injury to skin and eyes temperature is below 90°C. Open cap slowly and
caused by scalding from contact release the pressure. Do not pour coolant into
with hot coolant spray. Risk of beverage containers. AS20.00-Z-
poisoning caused by swallowing Wear protective gloves, protective clothing and 0001-01A
coolant. safety glasses.
AH20.00-
Notes on coolant All engines N-2080-
01A
Only conduct ventilation
procedure on a cold engine
Vacuum-type cooling system
Fig. 36
filler
NTKL adapter Fig. 52
Attach STAR DIAGNOSIS in
order to actuate the circulation
1.1 Model 216, 221
pump for the low-temperature
circuit
AD00.00-
Connect STAR DIAGNOSIS and
P-2000-
read out fault memory
04A
Preparing for actuation of the AR20.00-
1.2 circulation pump on the low Model 215, 220 P-1145-
temperature circuit 01M
AR20.00-P-
Model 230
1145-01R
AR20.00-P-
Model 240
1145-01H
The venturi nozzle (6) will lose its function if
used without the pressure tube (7). The venturi
nozzle (6) does not generate a vacuum but creates
Screw on connection (M) at excess pressure at connection (U) if the
2 pressure tube (7) of the venturi compressed air is connected without the pressure
nozzle (6) tube (7).
When first assembling the venturi nozzle (6)
connection (M) on the workshop equipment
compressed air system must be closed.
Fill coolant reservoir (4) with
3 20 liter
coolant
Open low temperature circuit at
4 Tester cap Fig. 20
filler neck and screw on test cap
5 Empty vacuum box (1)
AR20.00-
Prepare low temperature circuit
6 P-1145-
for bleeding and check for leaks
02R
7 Bleed low temperature circuit AR20.00-

using circulation pump and P-1145-
vacuum 03R
Close cooler vacuum filling Close connections (A, B) and close diagnostic
8
device sockets for low temperature circuit.
Screw on test cap and close low
9
temperature circuit
Replace switch (2) for manual
10 actuation of the circulation pump
against a relay
Fig. 49: Identifying Vacuum-type Cooling System Filler (285 589 00 21 00)
Fig. 50: Identifying NTKL Adapter (285 589 01 21 00)
Actuate circulation pump - AR20.00-P-1145-01M
Fig. 51: Identifying Cooler Vacuum Filling Device (285 589 00 21 00)
Fig. 52: Identifying NTKL Adapter (285 589 01 21 00)
1. Open the engine fuse and relay box (K40/8).

2. Remove the charge air relay (K40/8kW) from the engine fuse and relay box (K40/8).
3. Plug in the switch (included with the delivery of the cooler vacuum filling device ) in the
plug position of the charge air relay (K40/8kW).
Activate the switch to actuate the circulation pump . A lamp will light up on the switch when
the circulation pump is actuated .
Fig. 53: Identifying Charge Air Relay (K40/8kW) And Relay Box (K40/8)
Prepare the low temperature circuit for the bleeding process - AR20.00-P-1145-02R
1. Connect the connections (A, B) to the service connections of the charge air cooler.
Fig. 54: Identifying Service Connections Of Charge Air Cooler
2. Close all the valves (C, D, H, HA, O, P) on the control unit, the Y-fitting and the vacuum box.
Fig. 55: Identifying Valves On Control Unit
All the connections described in steps 3 to 5 will be maintained throughout the bleeding process.
Interchanging the hoses (E, J, S) will damage the bleeding devices.
3. Connect the coolant feed (J) to connection (N).

4. Connect the coolant drain (E) to connection (F).
5. Lay down the waste air hose (S) in the receptacle.
Fig. 56: Connection Of Coolant Feed And Coolant Drain

Fig. 57: Connection Of Control Unit And Venturi Nozzle
6. Connect the control unit (5) to the test connection (L) to the test connection.
7. Connect the venturi nozzle (6) to the control unit (5) - connection (U) to connection (T).
8. Connect the compressed air (Z) to the venturi nozzle (6) - compressed air (Z) to connection (M).
An audible air discharge is normal.
9. Generate a vacuum in the control unit (5) - open valve (P).

10. By regulating the valve (O) (arrow), draw in the coolant up to the control unit (5) by suction. Then again
close valve (O).
Fig. 58: Locating Control Unit - Open And Close Valve
11. Test the low temperature circuit for leaks - close valve (P).
The unchanged display (arrow) of the pressure gauge shows that the vacuum has been maintained,
thereby indicating the leak tightness of the low temperature circuit.
Fig. 59: Identifying Low Temperature Circuit For Leaks - Close Valve
Fig. 60: Identifying Venturi Nozzle From Control Unit
12. Detach the venturi nozzle (6) from the control unit (5).
The display of the pressure gauge (arrow) must continue to show a vacuum even after the preparatory
tasks have been completed.
Carrying out the bleeding process for the low temperature circuit - AR20.00-P-1145-03R
Fig. 61: Carrying Out Bleeding Process For Low Temperature Circuit
1. Connect venturi nozzle (6) with vacuum box (1) connection (U) to connection (G).
2. Generate vacuum in vacuum box (1) - open valve (H).
3.1 Model 215, 220, 230, 240:
Actuate circulation pump for low-temperature circuit. Switch on switch on relay slot.
3.2 Model 216, 221:
Actuate circulation pump for low temperature circuit via STAR DIAGNOSIS.
4 Generate vacuum in low temperature circuit - open valves (C, D) and wait for 15 seconds.
5 Start venting process - open valve (O) for at least 5 minutes.
The air in the coolant is removed by flushing the low temperature circuit.
6 Observe coolant flow in the area of the Y-fitting (arrow) during the flushing process. If the coolant is
flowing free of bubbles after 5 minutes then the low temperature circuit has been bled.
Fig. 62: Identifying Generate Vacuum In Low Temperature Circuit - Open Valves
7 Stop coolant flow by first closing valve (O), switching off the switch for the circulation pump, actuating
STAR DIAGNOSIS and then closing valves (C, D).
8 Remove vacuum - disconnect compressed air (Z) from venturi nozzle (6) connection (M).
Fig. 63: Identifying Venturi Nozzle Connection
9 Decouple connection (L) to test cap.
Venting air from the low temperature circuit - AR20.00-P-1145RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 220.074 /174
ENGINE 112.961 in MODELS 203.065 /265
Fig. 64: Identifying Venting Air From Low Temperature Circuit
Remove/install
Risk of injury to skin and Do not open cooling system AS20.00-Z-0001-01A
eyes caused by scalding unless coolant temperature
from contact with hot is below 90°C. Open cap
coolant spray. Risk of slowly and release pressure.
poisoning from Do not pour coolant into
swallowing coolant. beverage containers.
safety glasses.
1 Open cap at coolant Cap with detent:
expansion reservoir (2) Carefully turn cap as far as
first detent, release
pressure, and then unscrew
cap.
2-stage and 1-stage cap:
Rotate cap half a revolution
counterclockwise, release
pressure relief and then
unscrew cap.
Notes on coolant All engines AH20.00-N-2080-01A
2 Pour in coolant Fill coolant up to AR20.00-P-1142RVK
prescribed marking in
coolant expansion reservoir
(2).
3 Close coolant drain line
(4) with pliers
4 Detach coolant line from
fitting (3)
5 Attach additional Route vent hose to
ventilation hose to fitting coolant expansion tank (2).
(3)
Risk of injury caused by No parts of the body or AS00.00-Z-0009-01A
moving parts that can limbs should be within the
pinch, crush or , in operating range of the
extreme cases even sever mechanism when
extremities. components are in motion.
6 Venting air from the low The electric fan runs up
temperature circuit to 50% during the
ventilation procedure.
Purging: Actuate charge
air cooler circulation pump
(M44) using STAR
DIAGNOSIS. Let charge
air cooler circulation pump
(M44) run until coolant
flows out of fitting (3) free
of bubbles.
diagnosis system
leaks

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact 6511 1801 00
Passenger Car
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM - AR20.00-Z-
9112AB
ENGINE 112
ENGINE 111, 112, 113, 120, 137, 271, 275, 285,

AR20.00-P-
Inspect cooling system for leaks 601, 602, 603, 604, 605, 606, 611, 612, 613, 628,
1010HA
646, 647, 648...
AR20.00-P-
Inspect cooling system for leaks ENGINE 111, 112, 113, 271, 611, 612, 646...
1010P
AR20.00-P-
Inspect cooling system for leaks ENGINE 112, 113...
1010RVK
AR20.00-P-
Drain/fill in coolant ENGINE 112, 113, 137...
1142HA
AR20.00-P-
Drain/fill in coolant ENGINE 112, 113...
1142PV
AR20.00-P-
1142RVK
ENGINE 112.947 in MODEL 170.465 ENGINE AR20.00-P-
112.960 in MODEL 170.466 1142SV
Venting air from the low AR20.00-P-
ENGINE 112, 113...
temperature circuit 1145RVK
AR20.10-P-
Remove/install coolant pump ENGINE 112, 113...
1271B
AR20.10-P-
1271R
AR20.10-P-
Testing coolant thermostat ENGINE 112, 113...
2455AV
AR20.10-P-
Remove/install coolant thermostat ENGINE 112, 113...
2460B
Removing/installing coolant AR20.10-P-
thermostat 2460R
AR20.20-P-
Remove/install radiator ENGINE 112, 113... 3865AB
AR20.20-P-
Remove/install radiator ENGINES 112, 113 in MODEL 129
3865AV
AR20.20-P-
Remove/install the radiator ENGINE 112, 113...
3865HC
ENGINE 112 in MODELS 210, 208, 202 AR20.20-P-
Remove/install radiator
ENGINE 113 in MODELS 210, 208, 202 3865HD
AR20.20-P-
Removing/installing the radiator ENGINE 112, 113...
3865PV
AR20.20-P-
Remove/install radiator ENGINE 112, 113, 275...
3865R
AR20.20-P-
Remove, install radiator ENGINE 112...
3865SV
AR20.20-P-
3865TV
Install/uninstall AIR management ENGINE 112.913 in MODEL 211.061/261 AR20.20-P-
control system ENGINE 112.949 in MODEL 211.065/265 3880T
AR20.30-P-
Test cooling system cap ENGINE 112, 113...
4300FV
ENGINE 111, 112, 113, 271, 611, 612, 613, 628, AR20.30-P-
Check cooling system cap
642... 4300P
AR20.30-P-
Test coolant gage ENGINE 111, 112, 113, 156...
4460A
AR20.40-P-
Remove/install electric fan ENGINE 112, 113...
5000PV
Removing, installing electric fan
112.960 in MODEL 170.466 5000SV
AR20.40-P-
Remove/install electric fan ENGINE 112, 113, 646, 647, 648...
5000T
AR20.40-P-
Disassemble/reassemble fan ENGINE 111, 112, 113, 271, 611, 612, 646...
5100PQ
AR20.40-P-
Remove/install viscous fan clutch ENGINE 112, 113...
5660C
AR20.40-P-
Remove/install fan shroud ENGINE 112, 113...
6800AB
AR20.40-P-
6800TB
9113AB
ENGINE 113
Inspect cooling system for AR20.00-P-

leaks ENGINES 113, 272, 273 in MODEL 164 1010GZ
ENGINE 111, 112, 113, 120, 137, 271, 275, 285, 601,
602, 603, 604, 605, 606, 611, 612, 613, 628, 646, 647,
leaks 1010HA
648...
ENGINE 111, 112, 113, 271, 611, 612, 646...
leaks 1010P
Inspecting the cooling system ENGINE 272.967 in MODELS 251.065 /165 AR20.00-P-
for leaks ENGINE 113.971 in MODELS 251.075/175 1010RT
ENGINE 112, 113...
leaks 1010RVK
ENGINE 272.964 in MODEL 219.356 ENGINE
113.967 in MODEL 219.375 ENGINE 113.990 in
leaks 1010TX
MODEL 219.376
AR20.00-P-
Drain/fill in coolant ENGINE 113, 272, 273 in MODEL 164
1142GZ
AR20.00-P-
Drain/fill in coolant ENGINE 112, 113, 137...
1142HA
AR20.00-P-
1142PV
ENGINE 272.967 in MODELS 251.065 /165 AR20.00-P-
ENGINE 113.971 in MODELS 251.075/175 1142RT
AR20.00-P-
1142RVK
113.990 in MODEL 219.376 1142TY
Venting air from the low AR20.00-P-
ENGINE 112, 113...
temperature circuit 1145RVK
AR20.10-P-
1271B
AR20.10-P-
Remove/install coolant pump ENGINE 113.964 in MODEL 164.175
1271GZ
AR20.10-P-
1271R
AR20.10-P-
Remove/install coolant pump ENGINE 113.971 in MODELS 251.075 /175
1271RT
AR20.10-P-
Remove/install coolant pump ENGINE 113...
1271RVK
AR20.10-P-
Remove/install coolant pump ENGINE 113.967 in MODEL 219.375
1271TY
AR20.10-P-
Remove, install coolant pump ENGINE 113.990 in MODEL 219.376
1271TZ
AR20.10-P-
Testing coolant thermostat ENGINE 112, 113...
2455AV
AR20.10-P-
Test coolant thermostat ENGINE 113.964 in MODEL 164.175 2455GZ
AR20.10-P-
Test coolant thermostat ENGINE 113.971 in MODEL 251.075/175
2455RT
AR20.10-P-
Testing coolant thermostat ENGINE 113.995 in MODEL 230.472
2455RVK
Test coolant thermostat
113.990 in MODEL 219.376 2455TY
AR20.10-P-
Test coolant thermostat ENGINE 113.989 in MODEL 171.473
2455VT
Remove/install coolant AR20.10-P-
ENGINE 112, 113...
thermostat 2460B
thermostat 2460GZ
ENGINE 113.971 in MODEL 251.075/175
thermostat 2460RT
ENGINE 113...
thermostat 2460RVK
thermostat 2460TY
thermostat 2460TZ
AR20.20-P-
Remove/install radiator ENGINE 112, 113...
3865AB
AR20.20-P-
Remove/install radiator ENGINES 112, 113 in MODEL 129
3865AV
AR20.20-P-
Remove/install radiator ENGINE 113.964 in MODEL 164.175
3865GZ
AR20.20-P-
Remove/install the radiator ENGINE 112, 113...
3865HC
ENGINE 112 in MODELS 210, 208, 202 AR20.20-P-
ENGINE 113 in MODELS 210, 208, 202 3865HD
Removing/installing the AR20.20-P-
ENGINE 112, 113...
radiator 3865PV
AR20.20-P-
3865R
ENGINE 272.967 in MODEL 251.065/165 AR20.20-P-
ENGINE 113.971 in MODEL 251.075/175 3865RT
AR20.20-P-
3865TV
113.990 in MODEL 219.376 3865TY
AR20.30-P-
Test cooling system cap ENGINE 112, 113...
4300FV
Testing the cooling system cap 272.967 in MODEL 164.186 4300GZ
AR20.30-P-
Check cooling system cap ENGINE 111, 112, 113, 271, 611, 612, 613, 628, 642...
4300P
ENGINE 272.967 in MODELS 251.065 /165 AR20.30-P-
Testing the cooling system cap
ENGINE 113.971 in MODELS 251.075/175 4300RT
AR20.30-P-
Test coolant gage ENGINE 111, 112, 113, 156...
4460A
Testing the coolant gage
272.967 in MODEL 164.186 4460GZ
AR20.30-P-
Test coolant gage ENGINE 113.971 in MODEL 251.075/175
4460RT
Remove/install expansion AR20.30-P-
ENGINES 113, 272, 273 in MODEL 164
reservoir 4950GZ
ENGINE 113, 156, 272, 642 in MODEL 251
reservoir 4950RT
ENGINE 113.967 in MODEL 219.375 ENGINE
113.990 in MODEL 219.376 ENGINE 156.983 in
reservoir 4950TY
MODEL 219.377
ENGINE 113.988 in MODELS 203.076 /276 with AR20.40-P-
Remove/install electric fan
TRANSMISSION 722.636 5000AC
113.981 in MODEL 163.174 5000GH
AR20.40-P-
Remove/install electric fan ENGINE 113.964 in MODEL 164.175
5000GZ
AR20.40-P-
Remove/install electric fan ENGINE 112, 113...
5000PV
AR20.40-P-
Remove/install electric fan ENGINE 113.971 in MODEL 251.075/175
5000RT
AR20.40-P-
Remove/install electric fan ENGINE 112, 113, 646, 647, 648...
5000T
113.990 in MODEL 219.376 5000TY
AR20.40-P-
Remove/install electric fan ENGINE 113, 271, 272...
5000V
AR20.40-P-
Disassemble/reassemble fan ENGINE 111, 112, 113, 271, 611, 612, 646...
5100PQ
Disassemble fan and ENGINE 113.967 in MODEL 219.375 ENGINE AR20.40-P-
reassemble 113.990 in MODEL 219.376 5100TY
Remove/install viscous fan AR20.40-P-
ENGINE 112, 113...
clutch 5660C
AR20.40-P-
6800AB
AR20.40-P-
6800TB
ENGINE 113.990 in MODEL 211.076/276 AR20.40-P-
Remove, install fan shroud
ENGINE 156.983 in MODEL 211.077/277 6800TC
Removing and installing the fan AR20.40-P-
shroud 6800TY
Remove/install fan shroud
156.983 in MODEL 219.377 6800TZ
AR20.40-P-
Remove/install fan shroud ENGINE 113.989 in MODEL 171.473
6800VT
9137AB
ENGINE 137
Inspect cooling system ENGINE 111, 112, 113, 120, 137, 271, 275, 285, 601, 602, AR20.00-P-
for leaks 603, 604, 605, 606, 611, 612, 613, 628, 646, 647, 648 ... 1010HA
AR20.00-P-
Drain/fill in coolant ENGINE 112, 113, 137 ...
1142HA
ENGINE 137.970 in MODELS 215.378, 220.178
pump 1271L
thermostat 2460L
ENGINE 275.950 in MODEL 220.176 ENGINE 137.970 in AR20.20-P-
MODEL 215.378, 220.178 /878 3865MC
Remove/install fan AR20.40-P-
ENGINE 137, 275 ...
shroud 6800AC
9275AB
ENGINE 275
ENGINE 111, 112, 113, 120, 137, 271, 275, 285, 601,
602, 603, 604, 605, 606, 611, 612, 613, 628, 646, 647,
leaks 1010HA
648 ...
ENGINE 275, 285 ...
leaks 1010HN
Inspect cooling system for ENGINE 156, 272, 273, 275, 642 in MODEL 221 AR20.00-P-
leaks ENGINE 156, 273, 275 in MODEL 216 1010SX
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Main AR20.00-P-
circuit ENGINE 285 in MODEL 240 Main circuit 1142H
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Low- AR20.00-P-
temperature circuit 1142HM
Venting air from low ENGINE 275, 285 AR20.00-P-

temperature circuit 1145H
AR20.10-P-
Remove/install coolant pump ENGINE 275 in MODEL 215, 216, 220, 221, 230
1271MC
Remove/install coolant ENGINE 275 in MODEL 215, 216, 220, 221, 230 AR20.10-P-
thermostat ENGINE 285 in MODEL 240 2460H
Remove, install coolant AR20.10-P-
ENGINE 275 in MODEL 215, 216, 220, 221, 230
thermostat housing 2710M
ENGINE 275.980 in MODEL 215.379, 220.179
radiator 3865IM
ENGINE 275.950 in MODEL 220.176 ENGINE 137.970 AR20.20-P-
in MODEL 215.378, 220.178 /878 3865MC
AR20.20-P-
Remove/install radiator ENGINE 112, 113, 275 ...
3865R
AR20.20-P-
Remove/install radiator ENGINE 275.981 in MODEL 230.479
3865RM
AR20.20-P-
Remove/install radiator ENGINE 275.982 in MODEL 216.379, 221.179
3865SXM
AR20.20-P-
Remove/install radiator ENGINE 275 (except 275.982) in MODEL 216, 221
3865SZ
Removing/installing AR20.20-P-
Engine 275.980 in model 215.379 up to 29.2.04, 220.179
additional radiator 3866IM
Remove/install additional AR20.20-P-
ENGINE 275.982 in MODEL 221.179, 216.379
radiator 3866SX
AR20.20-P-
Remove/install radiator unit ENGINE 275.980 in MODEL 215.379, 220.179
3871IM
Remove/install coolant level ENGINE 272, 273, 275, 642, 629 in MODEL 221 AR20.30-P-
switch ENGINE 275 in MODEL 216 4392SXI
Remove/install expansion ENGINE 156, 272, 273, 275 in MODEL 221 ENGINE AR20.30-P-
reservoir 156, 273, 275 in MODEL 216 4950SX
AR20.40-P-
Remove/install fan shroud ENGINE 137, 275 ...
6800AC
AR20.40-P-
Remove/install fan shroud ENGINE 275.980 in MODEL 215.379, 220.179
6800IM
AR20.40-P-
Remove/install fan shroud ENGINE 275.982 in MODEL 216.379, 221.179
6800SXM
AR20.40-P-
Remove/install fan shroud ENGINE 275 (except 275.982) in MODEL 216, 221
6800SZ
REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271
Remove/install coolant pump - AR20.10-P-1271B
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250

ENGINE 112 in MODELS 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 220
ENGINE 113.982 in MODELS 463.243 /246
Shown on engine 112
Fig. 65: Identifying Coolant Pump Components - Shown On Engine 112
MODIFICATION NOTES
16.12.03 Value changed Value in BA20.10-P-1002-01M modified on *BA20.10-P-1002-
from 10 Nm to 9 engine 112.910/911/912/913/914/915/916/ 01M
Nm 917/920/921 /922/923/940/941 /942/
943/944/945/946/947/949/953/954/
955/960/961 /970/972/973/975
Remove/install
Risk of death Align vehicle between the columns of the AS00.00-Z-0010-
caused by vehicle and position the four support plates below 01A
slipping or toppling the lifting platform support points specified
off the lifting by the vehicle manufacturer.
platform.
1 Lift/jack up vehicle Models 129, 170, 202, 208, 210, 220
1000GH
Model 171 AR00.60-P-1000V
Models 203, 209 AR00.60-P-1000P
Model 463 AR00.60-P-1000G
Risk of injury When moving components, ensure that no AS00.00-Z-0011-
caused by fingers body parts or limbs are within the 01A
being jammed or operating range of moving parts.
pinched when
removing, installing
or aligning hoods,
doors, trunk lid/
rear-end door or
sliding roof.
2 Open engine hood Model 129
Model 163.154/172 up to VINA145272 AR88.40-P-
1000GH
Model 163.154/172 up to
VINX708318154/172
Model 163.154/172 from VINA145273 AR88.40-P-1000GI
Model 163.154/172 from VINX708319
Models 163.157/174/175
Model 170 AR88.40-P-1000G
Model 171.4 AR88.40-P-1000V
Model 202 AR88.40-P-1000E
Model 203 AR88.40-P-1000P
Models 208/210 AR88.40-P-1000F
Model 209 AR88.40-P-1000Q
Model 220 AR88.40-P-1000M
1000GG
3.1 Unclip cover on Only model 220.
front side of engine
4.1 Remove engine All except models 170.466, 171.473,
cover or air filter 203.065 /265, 203.076 /276, 209.376 /476
from 24.4.04.
5.1 Partially remove air Engine 112.960 in model 170.466 AR09.10-P-
filter housing 1150SVK
Engine 112.961 in models 203.065/ 265
Engine 113.987 in models 209.376 /476 as AR09.10-P-
of 24.4.04 1150AC
ENGINE 113.988 in Models 203.076/276
6.1 Remove viscous fan All except models 163.174/175, 170, AR20.40-P-5660C
(1) 171.473, 203, 208.365 /465, 209, 220
Right-hand thread!
7.1 Remove fan shroud On vehicles fitted with suction fan,
(3) separate the plug connection of the suction
fan before removing the fan shroud.
6800VT
Model 463 with engines 112.945, AR20.40-P-6800V
113.962/982
Model 220 with engines 112, 113 AR20.40-P-
6800AB
8.1 Remove electric fan Model 163 with engines 113.965/981 AR20.40-P-
5000GH
Model 170 with engines 112.947/ 960 AR20.40-P-
5000SV
Model 171.473 with engine 113.989 AR20.40-P-5000V
Model 203.076/ 276 AR20.40-P-
5000AC
Model 203 with engines 112.912/916/ AR20.40-P-
946/953/961 5000PV
Model 209 with engines 112.912 /955,
113.968 /987.
Models 208.365/ 465
Risk of injury to Do not open cooling system unless coolant AS20.00-Z-0001-
skin and eyes temperature is below 90°C. Open cap 01A
caused by scalding slowly and release the pressure. Do not
from contact with pour coolant into beverage containers.
hot coolant spray. Wear protective gloves, protective clothing
Risk of poisoning and safety glasses.
from swallowing
coolant.
9 Drain coolant from Model 163: For draining coolant,
radiator detach bottom coolant line at radiator or at
coolant pump.
Installation: On model 163 replace
radiator connection of hose clamps to
coolant hose, otherwise this can cause a
damage to the bolt/ thread.
Hose clamp *BA20.20-P-1004-
Collect coolant 01A
Disposal of coolants: observe legal
regulations or local wastewater
requirements! Refer to Environmental
Protection Catalog issued by MBVD/PWU
for locations in Germany.
Models 129, 163, 202, 208, 210, 220 with AR20.00-P-
engine 112 1142HA
Models 220, 210, 208, 202, 163, 129 with
engine 113
Model 463.206 /240 /241 /247 /248 /
249 /254 with engine 113.962.
Model 463.209 /232 /233 /244 /245 /250
with engine 112.945.
Models 463.243 /246 with Engine 113.982
Model 170.466 with engine 112.960 1142SV
Models 203.061 /261 with Engine 112.912 1142PV
Models 203.064 /264 /764 with Engine
112.946
10 Remove poly-V-belt Lock tensioning pulley with drift or pin
(2) (diameter 5 mm).
Model 463.209 /232 /233 /244 /245 /250 AR13.22-P-1202B
with engine 112.945.
Model 463.206 /240 /241 /247 /248 /
249 /254 with engine 113.962.
Models 129, 163 with engine 112
Models 129, 202, 208.370 /470, 210 with
engine 113
Model 163 with engine 113 except
113.965/981
Models 202, 208, 210, 220 with engine AR13.22-P-
112 1202BA
220.074/174
MODELS 208.374 /474 with Engine 113
Models 220.074/174 AR13.22-P-1202R
1202SV
1202SVK
MODELS 203.065 /265 with ENGINE
112.961
Models 203.061 /261 with Engine 112.912 1202PV
Models 203.064 /264 /764 with Engine
112.946
11.1 Remove shock Models 210, 203, 209, 202, 170, 129 with
absorber (10) manual transmission
12 Remove poly-V-belt Model 463.209 /232 /233 /244 /245 /250 AR13.25-P-3200B
tensioning device with engine 112.945.
Model 463.206 /240 /241 /247 /248 /
249 /254 with engine 113.962.
Models 129, 163 with engine 112
Models 129, 202, 208, 210 with engine
113
113.965/981
Model 163.174 with engine113.981 AR13.25-P-
Model 163.175 with engine 113.965 3200BA
Models 170, 202, 203, 208, 209, 210, 220
with engine 112
Models 203, 209, 220 with engine 113
13 Disconnect coolant Check condition of coolant hoses and
hose (4, 5) hose clamps, replace if necessary.
14.1 Disconnect coolant All except model 171.473.
hose (6) at oil-water Check condition of coolant hose and
heat exchanger hose clamp, replace if necessary.
15.1 Remove bolts from Only model 171.473.
oil lines on oil filter
Bolt of oil line to oil filter housing *BA18.20-P-1003-
01D
16.1 Remove bolts from Only model 171.473. *BA18.20-P-1004-
oil lines brackets 01D
and lay oil lines Bolt, oil line bracket
with brackets to one
side
17.1 Remove bracket Only model 171.473
with switchover
valve and pressure
sensor and place to
one side
18 Take off belt pulley Engine 112: ?
of coolant pump (7) Belt pulley to coolant pump *BA20.10-P-1002-
01M
Engine 113, except 113.987 /988 /
989 /991: ?
Belt pulley to coolant pump *BA20.10-P-1002-
01C
Engines 113.987 /988/989 /991: ?
Belt pulley to coolant pump *BA20.10-P-1002-
01L
Engine 113.989: ?
Counterholder Fig. 67
19 Remove coolant Installation: Replace gasket of coolant
pump (8) pump (9).
Engine 112: ?
Self-tapping screw, coolant pump to *BA20.10-P-1001-
timing case 01M
Engine 113 except 113.987 /988 /
989 /991: ?
Self-tapping screw, coolant pump to *BA20.10-P-1001-
timing case 01C
Engines 113.987 /988/989 /991: ?
Bolt, coolant pump to timing case *BA20.10-P-1001-
01L
Engine 112, 113: ?
Alternator screw *BA15.40-P-1003-
01A
External Torx set Fig. 66
order
21 Inspect cooling All except models 170, 171.473, 203, AR20.00-P-
system for leaks 209, 220.074/174 1010HA
Models 170, 171.473, 203, 209 AR20.00-P-1010P
Models 220.074/174 AR20.00-P-
1010RVK
ALTERNATOR
Number Designation Engines Engine 113.991 in
112.91/92/94/ models 215, 220
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1003- Bolt for alternator Nm 42 -
01A
OIL FILTER
BA18.20-P-1003-01D Bolt, oil line to oil filter Nm 9
housing
BA18.20-P-1004-01D Bolt for oil line bracket Nm -
COOLANT PUMP, COOLANT THERMOSTAT

112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975
BA20.10-P- Self-tapping Thread not pre- M6 Nm 14
1001-01M screw, coolant tapped
pump to timing Thread not pre- M8 Nm 35
case tapped
Thread pre- M6 Nm 10
tapped
tapped
BA20.10-P- Belt pulley to coolant pump Nm 9
1002-01M
Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
Number Designation 993/995
BA20.10-P- Self-tapping Thread not pre- M6 Nm 14
1001-01C screw, coolant tapped
pump to timing Thread not pre- M8 Nm 35
case tapped
tapped
tapped
BA20.10-P- Belt pulley to coolant pump Nm 10
1002-01C

Engine
113.987/988/
Number Designation 990/991 Engine 113.989
BA20.10-P- Bolt, coolant M6 Nm 14 14
1001-01L pump to timing
case M8 Nm 20 20
BA20.10-P- Belt pulley to coolant pump Nm 9 9
1002-01L

Engines 112.942/ 970,
Number Designation 113.942/ 965/981

Remove/install coolant pump - AR20.10-P-1271L
ENGINE 137.970 in MODELS 215.378, 220.178
Fig. 68: Identifying Coolant Pump Remove/Install Components
MODIFICATION NOTES
Value modified from 14 Value modified in BA20.10-P-1001-01C, line 1 *BA20.10-P-1001-
25.7.02
Nm to Nm on engine 137, 275 01C
25.7.02
25.7.02
25.7.02
Nm to Nm on engines 137, 275 01C
Figure modified from 10 Value modified in BA20.10-P-1002-01C on *BA20.10-P-1002-
25.7.02
Nm to 8 Nm engines 137, 275 01C
Remove/install
Torx bit set Fig. 70

External Torx set Fig. 66
*WH58.30-
Z-1001-06A
*WH58.30-
Z-1002-06A
Risk of injury to skin and eyes caused by coolant temperature is below 90°C.
scalding from contact with hot coolant Open cap slowly and release the
AS20.00-Z-
spray. pressure. Do not pour coolant into
0001-01A
Risk of poisoning from swallowing beverage containers.
coolant. Wear protective gloves, protective
clothing and safety glasses
AR20.00-P-
1 Drain coolant from radiator
1142HA
*BF20.00-P-
1001-02M
AR09.10-P-
2 Remove air filter
1050L
AR20.40-P-
3 Remove fan shroud (1)
6800AC
Lock tensioning pulley with drift AR13.22-P-
4 Remove poly V-belt (2)
or pin (diameter 5 mm). 1202L
*BA01.40-P-
5 Remove guide pulley (3)
1006-01C
*BA01.30-P-
6 Remove pulley (4)
1002-01G
AR03.30-P-
7 Remove belt pulley / vibration damper (5)
1600L
*BA03.30-P-
1001-01D
Unscrew coolant pump belt pulley (6) at
8
coolant pump (7)
*BA20.10-P-
1002-01C
Inspect condition of coolant
Detach coolant hoses (8, 9) at coolant pump
9 hoses and hose clamps, replace if
(7)
necessary.
Installation:
Replace seal of coolant pump (7a).
10 Remove coolant pump (7) Installation: Observe length of
bolts and tightening sequence: ?
AR20.10-P-
Bolt diagram for coolant pump
1271-03L
*BA20.10-P-
1001-01C
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
near the running engine Do not grasp hot or rotating parts.
12 Run engine and inspect for leaks
AR20.00-P-
13 Inspect cooling system for leaks
1010HA
Connect up STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
CYLINDER HEAD
BA01.30-P-1002-01G Bolt, guide pulley to front cover on right M8 Nm 30

BA01.40-P-1006-01C Bolt, pulley to timing case cover Nm 30

Stage 1 Nm 200
BA03.30-P-1001-01D Central bolt on vibration damper
Stage 2 Angle° 90

Number Designation Engines 137,
275
Thread not
M6 Nm -
pretapped
BA20.10-P-1001- Self-tapping screw, coolant pump to Thread not
M8 Nm -
01C timing case pretapped
Thread pre-tapped M6 Nm -
Thread pre-tapped M8 Nm -
BA20.10-P-1002-
01C Belt pulley to coolant pump Nm 8
COOLING SYSTEM
Total filling capacity Liters approx. 12
Filling capacity of anticorrosion/antifreeze
Liters approx. 6
down to -37°C
BF20.00-P-1001- Cooling Liters approx. 6.6
down to -45°C
02M system
BB00.40-P-0310-
Sheet
01A
Specifications for Operating Fluids
BB00.40-P-0325-
Sheet
00A

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive
Bolt diagram of coolant pump - AR20.10-P-1271-03L

Number Designation Engines 137, 275 Engine 285
BA20.10-P-1004-01C Coolant pump at the timing case M7 Nm 14 14
1 to 9: Bolts for fastening coolant pump at timing case cover and simultaneously fastening timing case cover
to crankcase. 10 and 11: Bolts for fastening coolant pump to timing case cover.
1. Screw in bolts according to the tightening sequence.
Item number corresponding to tightening sequence.
Fig. 71: Bolt Diagram Of Coolant Pump
Remove/install coolant pump - AR20.10-P-1271MC
ENGINE 275 in MODEL 215, 216, 220, 221, 230

Fig. 72: Identifying Coolant Pump Remove/Install Components - Engine 275 In Model 215.216
Remove/install
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 spray. AS20.00-Z-
pressure. Do not pour coolant into
coolant.
AR20.00-P-
1 Drain coolant at radiator
1142H
AH20.00-N-
Notes on coolant
2080-01A
Model 216, 221 except 216.379, AR20.40-P-
2 Remove fan shroud
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
AR20.40-P-
Model 215.376, 220.176, 230
6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
Slacken bolts (1) for belt pulley (2) at *BA20.10-
3
coolant pump (3) P-1002-01C
AR13.22-P-
4 Remove poly-V belt Model 215, 220, 230
1202L
Model 216, 221 AR13.20-P-
0001SZ
Detach the belt pulley (2) from coolant pump
5
(3)
Inspect condition of coolant
Remove coolant hoses (4, 5) from coolant hoses (4, 5) and hose clamps.
6
pump (3) Installation: Replace if
required.
AR03.30-P-
7 Remove belt pulley/vibration damper (9)
1600L
*BA01.30-
8 Detach guide pulley (6) from front cover.
P-1002-01G
*BA01.40-
9 Dismount guide pulley (10)
P-1006-01C
Installation: Replace gasket (8).
Unscrew bolts (7) and take off coolant pump
10 Installation: Observe length of
(3)
bolts and tightening sequence:
AR20.10-P-
Bolt plan for coolant pump
1271-03L
*BA20.10-
P-1004-01C
AS00.00-Z-
0005-01A
near the engine as it is running Do not touch hot or rotating parts.
AR20.00-P-
12 Inspecting cooling system for leaks Model 215, 220, 230
1010HA
AR20.00-P-
Model 216, 221
1010SX
CYLINDER HEAD
BA01.30-P-1002-01G Bolt, guide pulley to front cover on right M8 Nm 35

BA01.40-P-1006-01C Bolt, pulley to timing case cover Nm 35

BA20.10-P-1002-01C Belt pulley on coolant pump Nm 8
BA20.10-P-1004-01C Coolant pump at the timing case M7 Nm 14
Remove/install coolant pump - AR20.10-P-1271RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074
Fig. 73: Identifying Coolant Pump Remove/Install Components - Engine 113.990 In Models 211.076
Bolt assignment of coolant pump

Fig. 74: Identifying Bolt Assignment Of Coolant Pump
MODIFICATION NOTES
Text modified from "thread pretapped to Text modified to BA20.10-P- *BA20.10-P-
17.7.02
thread not pretapped". 1001-01C in line 2 1001-01C
Text modified from "thread not pretapped Text modified to BA20.10-P- *BA20.10-P-
17.7.02
to thread pretapped". 1001-01C in line 3 1001-01C
Remove/install
Risk of injury to skin and Do not open cooling system unless coolant
eyes caused by scalding from temperature is below 90°C. Open cap slowly and
contact with hot coolant release pressure. Do not pour coolant into AS20.00-Z-
spray. beverage containers. 0001-01A
Risk of poisoning from Wear protective gloves, protective clothing and
swallowing coolant. safety glasses.
AR20.00-P-
1142RVK
AH20.00-N-
Notes on coolant
2080-01A
Remove front engine
2
Remove poly-V-belt of AR13.21-P-
3
supercharger 1202RVK
AR13.22-P-
4 Remove poly-V-belt (4) Model 215.374, 220.074, 230.472 /474
1202R
AR13.22-P-
Model 211.076 / 276
1202RV
Unscrew bolts of belt pulley Installation: Tighten bolts for belt pulley (1)
5
(1) at coolant pump (3) fully.
*BA20.10-P-
Engines 113.992/ 995 1002-01C
*BA20.10-P-
Engines 113.990/ 991 1002-01L
Take off belt pulley of Installation: Screw in bolts only by hand, do
6
coolant pump (2) not tighten.
Carefully lever off cap with a slotted
Remove cap of compressor
7 screwdriver in order to avoid damaging guide
poly-V-belt guide pulley
pulley.
Unscrew bolt for compressor *BA13.25-P-
8
poly-V-belt guide pulley 1008-01D
Take off compressor poly-V-
9
belt guide pulley
Installation: The threads for mounting
tensioning device of compressor are not pretapped
Unscrew bolts for tensioning on a new timing case cover. For this reason a new
10 pulley for compressor poly- timing case cover requires new self-cutting bolts
V-belt to be used.
If timing case cover was not replaced, observe
torque when threads are pre-tapped.
*BA13.25-P-
1006-01D
Take off tensioning pulley
11 for compressor poly-V-belt
(5)
Disconnect coolant hose (6) Check condition of coolant hoses and hose
12 clamps. Install new parts if necessary in order to
and coolant hose (7)
avoid a loss of coolant.
Installation: The threads for mounting
alternator are not pre-tapped on a new timing case
cover.
Loosen bolt M10x110 (4g)
13 For this reason a new timing case cover requires
on alternator
new self-cutting bolts to be used.
*BA15.40-P-
1005-01A
Installation: The threads for mounting coolant

14
Unbolt coolant pump (3) at pump are not pre-tapped on a new timing case
timing case cover and cover.
remove For this reason a new timing case cover requires
new self-cutting bolts to be used.
Notes on application of
AH20.10-P-
sealant to coolant pump
0001-02RVK
housing
*BA20.10-P-
Engines 113.992/ 995 1001-01C
*BA20.10-P-
Engines 113.990/ 991 1001-01L
*BR00.45-Z-
Loctite sealant
1013-01A
16
leaks 1010RVK

Number Designation Engine 113.940/941/ 942/943/944/
945/946/948/ 960/961/962/ 963/965/966/
967/968/969/ 980/981/982/ 984/986/992
993/995
Thread not
M6 Nm 14
pretapped
Thread not
Self-tapping screw pretapped M8 Nm 35
BA20.10-P-
for coolant pump to
1001-01C Thread pre-
timing case M6 Nm 10
tapped
Thread pre-
M8 Nm 25
tapped
BA20.10-P-
Belt pulley to coolant pump Nm 10
1002-01C

Number Designation Engine 113.987/988/ 990/991
M6 Nm 14
BA20.10-P-1001-01L Bolt, coolant pump to timing case
M8 Nm 20
BA20.10-P-1002-01L Belt pulley on coolant pump Nm 9
BELT TENSIONING DEVICE

Number Designation Engine 113.990/
991/992/ 993/995
Nm 35
Thread not
pretapped
BA13.25-P- Self-tapping bolt, compressor belt tensioner to
1006-01D timing case cover Thread
Nm 25
pretapped
BA13.25-P- Bolt, guide pulley for compressor and major
M8x78 Nm 68
1008-01D assembly belts to timing case cover
ALTERNATOR
Number Designation Engine 113.991 Engine 113.992/ Engine
in models 215, 995 in model 113.990 in
220 230 model 211
Thread not
Self-grooving screw pre-tapped Nm 57 57 57
BA15.40-P-
Alternator on timing
1005-01A Thread pre-
case Nm 45 45 45
tapped
REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
TESTING COOLANT THERMOSTAT - AR20.10-P-2455AV
ENGINE 112
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
ENGINE 113 (except 113.995) in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 75: Coolant Thermostat Test
Remove/install
skin and eyes temperature is below 90°C. Open cap slowly 01A
caused by and release pressure. Do not pour coolant into
scalding from beverage containers.
contact with hot Wear protective gloves, protective clothing and
coolant spray. safety glasses.
Risk of poisoning
from swallowing
coolant.
1 Remove coolant Installation:
thermostat (1)
 Install new sealing ring.
 The coolant thermostat (1) must not be
removed from housing. Otherwise it will
be destroyed. The housing is supplied
together with a coolant thermostat (1) for
repair purposes.
Engine 112 in models 170, 203,
211.080/280 /082/282/261/265,
Engine 113 in models 211.083/283/270,
215.373/375
Engine 112 in models 211.061/065, 220, 129, AR20.10-P-
209.361/461, 163, 202, 208, 209.365/465, 210, 2460B
463.245/233/209 /250/244/232,
Engine 113 in models 209, 210, 129, 208,
211.070, 220, 230.475, 163, 202,
463.254/206/248 /240/247/241/249,
Engine 113.982 in models 463.246/243
Engine 113.990 in models 211.076/276, AR20.10-P-
Engine 113.991 in models 215.374, 220.074, 2460RVK
Engine 112.973 in model 230.467 AR20.10-P-
2460R
Checking
2 Heat coolant Suspend coolant thermostat (1) from a wire
thermostat (1) in a vessel filled with water and heat water.
For heating up under no circumstance use a
welding torch or a soldering torch, otherwise
sudden heat penetration modifies the metal
structure!
3 Measure The heating-up rate should be not more than
temperature of 1°C to 2°C/minute from about 8°C below start
water of opening of coolant thermostat (1).
*WH58.30-Z-
1002-08A
4 Warm up water to If the check values are not achieved, replace
full opening coolant thermostat (1).
temperature of Check values for engine 113.969:
valve (2) and then Start of opening
measure hub of Minimum stroke
valve (2) Check values engine 112, 113 except 113.969:
Start of opening *BE20.10-P-
1001-02A
Minimum stroke *BE20.10-P-
1002-02A
5 Install in the
reverse order
6 Inspect cooling
system for leaks Engine 112.946 in model 209.764
Engine 112 (except AR20.00-P-
112.961/946/953/947 /960/916/955/912), 1010HA
Engine 113 (except
113.992/987/968/991 /990/963)
Engine 113.963/990/991/992 AR20.00-P-
1010RVK
Engine 112.912/916/947/953/955/960/961, AR20.00-P-
Engine 112.946 except in model 209.764, 1010P
Engine 113.968/987
COOLANT THERMOSTAT
Number Designation Engine 112, 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/ 995
BE20.10-P-1001-02A Start of opening °C 85 to 89
BE20.10-P-1002-02A Minimum stroke °C 102
mm 8
BE20.10-P-1003-02A Thermostat bypass valve mm -
dia.

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-2460B
ENGINE 112 in MODEL 129, 163, 202, 208, 209.361 /365 /461 /465, 210, 211.061 /261 /065 /265, 220
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113 in MODEL 129, 163, 202, 203, 208, 209, 210, 211.070 /270, 220, 230.475
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
Fig. 76: Identifying Coolant Thermostat Components - Shown On Engine 112
MODIFICATION NOTES
1.9.04 Value changed Value in row 1003 changed for engine *BA20.10-P-
from 10 Nm to 14 112.910/911/912/913/914/915/916/917/ 1003-01M
Nm 920/921/922/923/940/941/942/943/944/
945/946/947/949/953/954/955/960/961 /
970/972/973/975
Remove/install
Risk of injury Keep body parts and limbs well clear of moving AS00.00-Z-
caused by fingers parts. 0011-01A
being pinched or
crushed when
removing,
installing or
aligning hoods,
doors, trunk lids,
tailgates or
sliding roof.
1 Open engine
hood
Risk of injury to Do not open cooling system unless coolant AS20.00-Z-
skin and eyes temperature is below 90°C. Open cap slowly and 0001-01A
caused by release the pressure. Do not pour coolant into
scalding from beverage containers.
contact with hot Wear protective gloves, protective clothing and
coolant spray. safety glasses.
Risk of
poisoning caused
by swallowing
coolant.
2 Drain coolant at Model 163: For draining coolant, detach
radiator (6) bottom coolant line at radiator or at coolant pump.
Installation: On model 163 replace radiator
connection of hose clamps to coolant hose,
otherwise this can cause a damage to the bolt/
thread.
Model 163 *BA20.20-P-
Collect coolant 1004-01A
Disposal of coolants: observe legal regulations
or local wastewater requirements! Refer to
Environmental Protection Catalog issued by
MBVD/PWU for locations in Germany.
Engine 112 in model 220, 208, 211, 163, 210, AR20.00-P-
129, 202 1142HA
Engine 113 in model 211, 163, 208, 202, 210,
220, 129
463.240 /241 /248 /254 /206 /247 /249
463.233 /244 /209 /232 /245 /250
Engine 113.982 in model 463.246 /243
Engine 113.963 in model 230.475 AR20.00-P-
1142RVK
Engine 112.912 in model 209.361 /461 AR20.00-P-
Engine 112.955 in model 209.365 /465 1142PV
Engine 113.968 in model 209.375 /475
Engine 113.987 in MODEL 209.376/ 476
Engine 113.988 in model 203.076/ 276
Notes on coolant AH20.00-N-
2080-01A
3 Unclip cover on Model 211, 220
front side of
engine
4 Remove engine Except model 211, 230
cover with Model 171.473 AR09.10-P-
integrated air Model 203.076/ 276 1150AC
filter Model 209.376/ 476 as of 24.4.04
For model 463, 220, 210.074 /274,
208.370 /374 /470,
209.361 /365 /375 /376 /461 /465 /475 /476,
202.033 /093, 129, the air filter is integrated in the
engine cover. Remove engine cover or air filter by
pulling it vertically up and off the cylinder head
covers.
5 Detach coolant Inspect condition of coolant hose (5) and hose
hose (5) clamp (4), replace if necessary.
6 Remove poly-V Model 171.473 with engine 113.989 AR13.22-P-
belt from guide 1202PV
pulley
7 Unscrew bolts The coolant thermostat must not be removed
(3), remove from the housing. Otherwise it will be destroyed.
coolant Re-installation is not possible. The housing is
thermostat supplied together with the coolant thermostat for
housing (1) with repair purposes.
coolant Installation: Install new sealing ring (2).
thermostat *BA20.10-P-
Engine 112
1003-01M
Engine 113 except 113.987 /988/989 /991 *BA20.10-P-
1003-01C
Engine 113.987 /988/989 /991 *BA20.10-P-
1003-01L
8 Install in the
reverse order
9 Inspect cooling Model 129, 163, 202, 208, 210, 211, 463 AR20.00-P-
system for leaks 1010HA
Model 220 except 220.074 /174
Model 171.473 AR20.00-P-
1010P
Model 203.076/ 276
Model 220.074/174 AR20.00-P-
1010RVK
Model 230.475

Number Designation Engine 112.942/ 970,
113.942/ 965/981

Number Designation Engine 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992 993/995
BA20.10-P-1003- Bolt for coolant M6 Nm 10
01C thermostat housing

Number Designation Engine 112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975
BA20.10-P-1003- Bolt for coolant M6 Nm 14
01M thermostat housing

Number Designation Engine Engine 113.989
113.987/988/
990/991
BA20.10-P- Bolt for coolant M6 Nm 14 14
1003-01L thermostat
housing
Remove/install coolant thermostat - AR20.10-P-2460H
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 77: Identifying Coolant Thermostat Remove/Install Components - Engine 275 In Model 215.216,220
Remove/install
Risk of injury to skin and eyes caused by
scalding from contact with hot coolant spray. AS20.00-Z-
coolant.
AR20.00-P-
1142H
AH20.00-N-
Notes on coolant
2080-01A
AR14.30-P-
2 Remove air shutoff valve
7200H
3
Remove coolant line (1) from housing top Installation: Install new sealing
section (6) and place to one side ring (2).
*BA20.10-
P-1005-01C
*BA20.10-
P-1006-01C
Screw out bolt (4), remove temperature
probe for coolant (B11/4) with holder from Installation: Replace sealing
4
upper part of housing (6) and lay it to one ring (3).
side
*BA20.10-
P-1003-01C
Unscrew bolts (5) and remove upper part of
5 Installation: Replace seal (7).
housing (6)
*BA20.10-
P-1003-01C
Remove coolant thermostat (8) from housing
6
top section (6)
Checking
AR20.00-P-
8 Inspect cooling system for leaks Model 215, 220, 230, 240
1010HA
AR20.00-P-
Model 216, 221
1010SX
AS00.00-Z-
0005-01A
near the engine as it is running Do not touch hot or rotating parts.
Conduct engine test run and check engine for
9
leaks

Number Designation Engine 137, Engine
275 285
BA20.10-P-1003-
Bolt, coolant thermostat housing M6 Nm 15 15
01C
BA20.10-P-1005- Bolt, coolant line on housing of coolant
M6 Nm 8 8
01C thermostat
BA20.10-P-1006-
Bolt connecting coolant line to cylinder head M6 Nm 8 8
01C
Remove/install coolant thermostat - AR20.10-P-2460L

Fig. 78: Identifying Coolant Thermostat Remove/Install Components - Engine 137 In Model 215,220
Remove/install
temperature is below 90°C. Open cap slowly
and release the pressure. Do not pour coolant AS20.00-Z-
into beverage containers. 0001-01A
swallowing coolant.
safety glasses.
AR20.00-P-
1142HA
2 Remove coolant connection (4)
Detach coolant hose to
Inspect condition of coolant hose and hose
3 expansion reservoir on
clamp, replace if necessary.
connector (5)
Remove thermostat housing (1)
4 Installation : Replace compression ring (3).
with thermostat (2)
*BA20.10-P-
1003-01C
Remove thermostat (2) from
5
thermostat housing (1)
AR20.00-P-
1010HA

BA20.10-P-1003-01C Bolt, coolant thermostat housing M6 Nm 15
Remove/install coolant thermostat - AR20.10-P-2460RVK
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074
Shown on engine 113.992
Fig. 79: Identifying Coolant Thermostat Remove/Install Components - Engine 113.990 In Model 211.076
Remove/install
and release pressure. Do not pour coolant into AS20.00-Z-
Wear protective gloves, protective clothing
swallowing coolant.
and safety glasses.
AR20.00-P-
1142RVK
AH20.00-N-
Notes on coolant All engines
2080-01A
2 Remove upper engine cover (2)
Detach top engine cover (2) at both air
filter boxes and at bracket toward top.
Check condition of coolant hose (3) and
3 Detach coolant hose (3) hose clamp (6). Install new parts if necessary
in order to avoid a loss of coolant.
*WH58.30-Z-
1001-06A
*WH58.30-Z-
1002-06A
Remove poly-V-belt for AR13.21-P-
4
compressor (8) 1202RVK
AR13.22-P-
5 Remove poly-V-belt (9) Models 215.374, 220.074, 230.472 /474
1202R
AR13.22-P-
Models 211.076 / 276
1202RV
Unscrew bolts for coolant *BA20.10-P-
6 Engines 113.990/ 991
thermostat housing (5) 1003-01L
*BA20.10-P-
Engines 113.992/ 995 1003-01C
Take off coolant thermostat
Installation: Replace sealing ring (4), in
7 housing (1) together with
order to avoid loss of coolant.
coolant thermostat
Checking
Models 211.076 /276, 215.374, 220.074, AR20.10-P-
8 Test coolant thermostat
230.474 2455AV
AR20.10-P-
Model 230.472
2455RVK
AR20.00-P-
1010RVK

Number Designation Engines 113.987/988/ 990/991
BA20.10-P-1003-01L Bolt for coolant thermostat housing M6 Nm 14

Number Designation Engines 113.940/941/ 942/943/944/ 945/946/948/
960/961/962/ 963/965/966/ 967/968/969/ 980/981/982/
984/986/992 993/995
BA20.10-P- Bolt for coolant
M6 Nm 10
1003-01C thermostat housing

Number Designation
REMOVE, INSTALL COOLANT THERMOSTAT HOUSING - AR20.10-P-2710M
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Shown on model 220
Fig. 80: Identifying Coolant Thermostat Housing Remove/Install Components - Show On Model 220
Remove/install
swallowing coolant.
safety glasses.
AR20.00-P-
1142H
AH20.00-N-
2080-01A
AR01.10-P-
2 Remove front engine cover Engine 275.95
2405LA
AR01.10-P-
Engine 275.98
2405IM
Dismount coolant line (1) and
3 Installation: replace O-ring (2).
place to the side
*BA20.10-P-
1005-01C
*BA20.10-P-
1006-01C
Disconnect electrical connector
4 at coolant temperature sensor
(B11/4)
Dismount pneumatic line (3)
5 and air hose (4) from aspirator
shutoff valve (5)
Dismount coolant hose of Inspect condition of coolant hose and hose
6 coolant pump at coolant clamp.
thermostat housing (6) Installation: Replace if required.
Remove bolts (7, 8) and coolant Installation: Clean sealing surfaces,
7
thermostat housing (6) upwards replace O-ring (9) and gasket (10).
*BA20.10-P-
1007-01C
AR20.00-P-
9 Inspect cooling system for leaks Model 215, 220, 230
1010HA
AR20.00-P-
Model 216, 221
1010SX

BA20.10-P-1005-01C Bolt, coolant line to coolant thermostat housing M6 Nm 8
BA20.10-P-1006-01C Bolt connecting coolant line to cylinder head M6 Nm 8
BA20.10-P-1007-01C Bolt, coolant thermostat housing to cylinder head M6 Nm 8
REMOVE/INSTALL RADIATOR - AR20.20-P-3865
Remove/install radiator - AR20.20-P-3865AB
ENGINE 112.944 in MODELS 220.065 /165
ENGINE 113.941 in MODELS 220.070 /170
ENGINE 113.960 in MODELS 215.375, 220.075 /175 /875

ENGINE 113.991 in MODELS 215.374, 220.074 /174
ENGINE 112.972 in MODELS 220.067 /167
ENGINE 112.975 in MODELS 220.087 /187
ENGINE 113.948 in MODELS 220.083 /183
ENGINE 113.966 in MODELS 220.084 /184
Fig. 81: Identifying Radiator Remove/Install Components
Remove/install
Remove lower engine compartment AR61.20-P-
1
paneling 1105M
Risk of injury to skin and eyes due to coolant temperature is below 90°C.
scalding caused by contact with hot Open cap slowly and release the
AS20.00-Z-
coolant spray. pressure. Do not pour coolant into
0001-01A
Risk of poisoning from swallowing beverage containers. Wear protective
coolant. gloves, protective clothing and safety
glasses.
AH20.00-N-
Notes on coolant
2080-01A
2 Drain coolant at radiator (1) Open radiator drain plug (3).
AR20.00-P-
All engines except engine 113.991
1142HA
AR20.00-P-
Engine 113.991
1142RVK
*BF20.00-P-
1001-02K
Disconnect automatic oil lines at
3 Seal off oil lines.
connection (5, 6) at radiator (1)
Fig. 82
*BA20.20-P-
1003-01A
*BA20.20-P-
1001-01A
Disconnect coolant line (radiator-
4
thermostat housing) (2) at radiator (1)
Disconnect connection of coolant line
(radiator-coolant pump) (7), connection
5
of coolant line (radiator-expansion
reservoir) (10) at radiator (1)
AR20.40-P-
6800AB
Dismount condenser at nuts (8) at Dismount AC line at radiator
7
radiator (arrow).
8 Dismount bracket of radiator (4).
Installation: The studs on the
9 Take out radiator (1) radiator must be located at the bottom in
the rubber mounts on the crossmember.
AR20.00-P-
11 Pour in coolant All engines except engine 113.991
1142HA
AR20.00-P-
Engine 113.991
1142RVK
*BF20.00-P-
1001-02K
Risk of accident due to vehicle starting Secure vehicle to prevent it from
off when engine is running. moving by itself.
AS00.00-Z-
Risk of injury caused by contusions Wear closed and snug-fitting work
0005-01A
and burns during starting procedure or clothes.
when working near the running engine Do not grasp hot or rotating parts.
Check oil level in automatic AR27.00-P-
12
transmission, correct if necessary 0100AC
AR20.00-P-
13 Inspect cooling system for leaks All engines except engine 113.991
1010HA
AR20.00-P-
Engine 113.991
1010RVK

Number Designation Engine 112 except 112.942/970, engines Engine
113.940/941/ 943/944/945/ 946/948/960/ 113.987/
961/962/963/ 966/967/968/ 969/980/982/ 988/990/ 991
984/986/992/ 993/995
Union nut, automatic
BA20.20-P-
transmission oil line to Nm 20 18
1001-01A
radiator
BA20.20-P-
Banjo bolt M12X1.5 Nm 30 30
1003-01A
COOLING SYSTEM
112.922/944/972 in 112.975 in 113.941/960 in
model 220 model 220 model 220
Total filling capacity Liters approx. 10.5 approx.10.4 approx.11.5
Capacity of
anticorrosion/antifreeze Liters approx. 5.0 approx. 5.2 approx. 5.75
BF20.00- Filling capacity of
Cooling
P-1001- anticorrosion/antifreeze Liters approx. 5.5 approx. 5,7 approx. 6.25
system
02K down to -45°C
BB00.40-P-0310- BB00.40-P- BB00.40-P-
Sheet
Specifications for 01A 0310-01A 0310-01A
Operating Fluids BB00.40-P-0325- BB00.40-P- BB00.40-P-
Sheet
00A 0310-01A 0325-00A
COOLING SYSTEM
113.948/966 in 113.960/986 in
model 220 model 215
Total filling capacity Liters approx. 11.6 approx.11.5
Capacity of
anticorrosion/antifreeze agent Liters approx. 5.8 approx.5.75
down to -37°C
BF20.00-P- Cooling Filling capacity of
1001-02K system anticorrosion/antifreeze down to - Liters approx.6.4 approx.6.25
45°C
BB00.40-P-0310- BB00.40-P-0310-
Specifications for Operating Sheet
01A 01A
Fluids
BB00.40-P-0325- BB00.40-P-0325-
Sheet 00A 00A
COOLING SYSTEM
Number Designation Engine 113.991 Engine 113.986/991
Total filling capacity Liters approx. 14.5 approx.13.5
Capacity of anticorrosion/
Liters approx.7.3 approx.6.8
antifreeze agent down to -37°C
Filling capacity of
BF20.00-P- Cooling anticorrosion/ antifreeze down Liters approx.8 approx.7.4
1001-02K system to -45°C
BB00.40-P-0310- BB00.40-P-0310-
Sheet
Specifications for Operating 01A 01A
Fluids BB00.40-P-0325- BB00.40-P-0325-
Sheet
00A 00A
Removing and installing radiator - AR20.20-P-3865IM
ENGINE 275.980 in MODEL 215.379, 220.179
Shown on model 220

Fig. 83: Identifying Radiator Remove/Install Components - Shown On Model 220
Fig. 84: Identifying Radiator And Air Ducting
Remove/Install
Align vehicle between the columns of
the hydraulic hoist and position the
Risk of death cased by vehicle slipping or AS00.00-Z-
four support plates below the hoist
toppling off of the lifting platform. 0010-01A
support points specified by the vehicle
manufacturer.
Risk of injury to skin and eyes suffering
scalding from contact with hot coolant AS20.00-Z-
spray. Risk of poisoning from swallowing 0001-01A
beverage bottles.
coolant.
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.
AR20.20-P-
1 Remove radiator unit
3871IM
2 Remove air ducting on left and right (5)
Unscrew screws (3) at low temperature
3 water circuit radiator (1) and at Steering oil
cooler (2)
4 Remove radiator (4)
AR20.00-P-
6 Pour in coolant
1142H
AR20.00-P-
7 Bleed cooling system
1142-06GA
AR20.00-P-
1010HA
Remove/install radiator - AR20.20-P-3865MC
ENGINE 137.970 in MODEL 215.378, 220.178 /878
Fig. 85: Identifying Radiator Remove/Install Components - Shown On Model 220.176

Fig. 86: Identifying Removal/Installation Plastic Cover, Bracket And Bolt - Shown On Model 220.176
Fig. 87: Identifying Removal/Installation Coolant Line, Radiator And Bolt - Shown On Model 220.176
Remove/install
Risk of death caused by vehicle lifting platform and position the four
AS00.00-Z-
slipping or toppling off the lifting support plates at the lifting platform support
0010-01A
platform. points specified by the vehicle
manufacturer.
Risk of injury to skin and eyes due temperature is below 90°C. AS20.00-Z-
to scalding caused by contact with Open cap slowly and release the pressure. 0001-01A
hot coolant spray Do not pour coolant into beverage
Risk of poisoning caused by containers. Wear protective gloves,
swallowing coolant. protective clothing and safety glasses.
caused by swallowing battery acid. Wear acid-resistant gloves, clothing and AS54.10-Z-
Risk of injury caused by burns to glasses. Only pour battery acid into suitable 0001-01A
skin and eyes from battery acid or and appropriately marked containers.
when handling damaged lead-acid
batteries
Risk of accident due to vehicle
starting off when engine is running Secure vehicle to prevent it from moving by
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 the Do not touch hot or rotating parts.
Turn key in electronic ignition With Keyless Go, code 889: Press Start-
1 Stop button once more until ignition is off,
switch EIS to position "0".
remove Keyless Go cards from vehicle and
place out of the transmitter range.
AR54.10-P-
2 Disconnect ground line from battery
0003I
AH54.10-P-
Notes on battery
0001-01A
AR20.40-P-
3 Remove fan shroud
6800AC
AR20.00-P-
4 Drain coolant at radiator Engine 137
1142HA
AR20.00-P-
Engine 275
1142H
AH20.00-N-
Notes on coolant
2080-01A
Remove front parts of the fender AR88.10-P-
5
liner in the front fender 1300M
AR82.10-P-
6 Remove both lamp units Model 215
4730N
AR82.10-P-
Model 220 without Xenon headlamp unit
4730M
Model 220 with Code 612b Xenon AR82.10-P-
headlamp unit 4730MA
Detach left and right front engine
AR88.40-P-
7 hood catch (1) from radiator Model 215
3200N
crossmember (2)
AR88.40-P-
Model 220
3200M
Remove both clamps (3) from
8
radiator crossmember (2)
9 Remove bolts (4)
Detach right bracket (5) of radiator
10
crossmember (2)
11 Remove radiator crossmember (2)
Unscrew bolts (6) at both headlight
12
mounts
Remove bracket (7) for ABC Vehicles with Active Body Control (Code
13.1
distributor 487) only.
Dismount transmission oil line (8)
14 Seal the connections.
at radiator (9)
*BA20.20-P-
1001-01A
Unscrew bolts (10) for low
15.1 temperature water circuit circulation Engine 275
pump bracket at radiator (9)
16 Remove bracket (11)
Remove left and right plastic cover
17
(12)
Unscrew bolts (13) for low
18.1 temperature water circuit cooler at Engine 275
radiator (9)
Unscrew bolt (14) for A/C line
19
bracket at radiator (9)
Installation: fit new O-rings to the
Disconnect coolant lines (15, 16, connection fittings.
20
17) at the radiator (9) Inspect coolant lines (15, 16, 17) for
damage, replace if necessary.
21 Unscrew bolts (18) at radiator (9)
AR20.00-P-
23 Pour in coolant Engine 137
1142HA
AR20.00-P-
Engine 275
1142H
AR20.00-P-
1142-06GA
AR20.00-P-
25 Inspecting cooling system for leaks
1010HA
Check oil level in automatic AR27.00-P-
26
transmission, correct if necessary 0100AC
Check / adjust the sensor setting of AR30.30-P-
27.1 Vehicles with Distronic (DTR) Code 219a
Distronic (DTR) 1000R
BA20.20-P-1001-01A Union nut, automatic transmission oil line to radiator Nm 25
REMOVING/INSTALLING ADDITIONAL RADIATOR - AR20.20-P-3866IM
Engine 275.980
in model 215.379 up to 29.2.04, 220.179
Shown on model 220
Fig. 89: Identifying Additional Radiator Remove/Install Components - Shown On Model 220
Shown on model 220

Fig. 90: Identifying Removal/Installation Additional Radiator, Air Ducting And Lock - Shown On Model
220
Removing/installing
Risk of death caused by vehicle
hydraulic hoist and position the four support AS00.00-Z-
plates below the hoist support points specified 0010-01A
lifting platform.
by the vehicle manufacturer.
1 Remove air inlet grille (6)
Installation: Only install lower engine
Remove lower engine AR61.20-P-
2 compartment paneling after inspecting for
compartment paneling 1105M
leaks.
AR20.00-P-
1142H
AH20.00-N-
2080-01A
Remove coolant hose (1) on the
4 left and right on the additional
radiator (5)
Unscrew nuts (3a) and take out
5
right bracket (4)
Pull additional radiator (5) with
6 air ducting (7) out of the left
bracket (4)
Unfold air ducting (7) and take When replacing the additional radiator (5).
7.1
out additional radiator (5) Do this by lifting the lock (7a).
Checking
Check for wear and correct seating, if
Check rubber mount (2) in the
8 required: ?
left and right bracket (4)
Replace rubber mount (2.
*BR00.45-Z-
Lubricant
1002-06A
AR20.00-P-
10 Pour in coolant
1142H
AR20.00-P-
1142-06GA
AR20.00-P-
1010HA
REPAIR MATERIALS
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
REMOVE/INSTALL RADIATOR UNIT - AR20.20-P-3871IM
ENGINE 275.980 in MODEL 215.379, 220.179
Fig. 91: Identifying Radiator Unit Remove/Install Components - Engine 275.980 In Model 215.379
Fig. 92: Identifying Removal/Installation Transmission Oil Line, Radiator And Coolant Line
MODIFICATION NOTES
1.12.05 Cooling system Engine 275.980 in model 215 *BF20.00-P-1001-02Q
Cooling system Engine 275.980 in model 220 *BF20.00-P-1001-02Q
Remove/install
lifting platform and position four
support plates at lifting platform
or toppling off the lifting platform. 0010-01A
manufacturer.
Risk of injury to skin and eyes caused by coolant temperature is below 90°C.
scalding from contact with hot coolant Open cap slowly and release the
AS20.00-Z-
spray. pressure. Do not pour coolant into
0001-01A
Risk of poisoning caused by swallowing beverage containers.
coolant. Wear protective gloves, protective
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. AS54.10-Z-
clothing and glasses. Only pour
Risk of injury caused by burns to skin and 0001-01A
eyes from battery acid or when handling
Secure vehicle to prevent it from
moving by itself.
clothes.
procedure or when working near the
Turn key in electronic ignition
switch EIS into position "0". Key
cannot be withdrawn.
Vehicles with Keyless Go, code
889: Switch off engine, remove
Keyless Go cards from the vehicle and
store outside of transmitter range. AR54.10-P-
1 Disconnect battery ground line Installation: After connecting, 0003I
read out diagnostic trouble code
memory, set time at instrument
cluster, encode radio, normalize
power windows and activate steering
angle sensor.
Vehicles with stationary heater: adjust
time display on stationary heater.
AH54.10-P-
Notes on battery All models
0001-01A
AR20.40-P-
2 Remove fan shroud
6800IM
AR20.00-P-
1142H
AH20.00-N-
2080-01A
AR20.00-P-
4 Drain coolant from low-temperature circuit
1142HM
Remove fender liner front section in front AR88.10-P-
5
fender 1300M
AR82.10-P-
6 Remove both lamp units
4730MA
Remove hood lock (1) from radiator AR88.40-P-
7
crossmember (2) 3200M
Remove both clips from radiator
8
crossmember (2)
9 Remove bolts (4)
10 Remove radiator crossmember (2)
11 Unscrew bolts (6) at both headlight mounts
Detach transmission oil line (8) at radiator
12 Seal the connections.
(9)
*BA20.20-
P-1001-01A
Remove screws (10) on bracket for
13 circulation pump for low-temperature
water circuit at the radiator (9)
Disconnect coolant lines from radiator for
14
low-temperature water circuit
Unscrew bolt (14) for the AC line bracket
15
at the radiator (9)
Installation: Fit new O-rings to
the connection fittings.
Disconnect coolant lines (15, 16, 17) from
16 Check coolant lines (15, 16, 17)
the radiator (9)
for wear and damage, replace as
necessary.
Disconnect power steering fluid lines from
17
steering radiator
Unscrew condenser nuts from low-
18
19 Remove radiator unit by extracting upward
AR20.00-P-
21 Pour in coolant
1142H
AR20.00-P-
1142-06GA
23 Bleed low temperature circuit
AR20.00-P-
1145H
AR20.00-P-
24 Inspecting cooling system for leaks
1010HA
Check oil level in automatic transmission, AR27.00-P-
25
correct if necessary 0100AC
Check / adjust sensor setting of Distronic Vehicles with Distronic (DTR), code AR30.30-P-
26.1
(DTR) 219a. 1000R

COOLING SYSTEM
Main circuit Liters approx. 12.5 approx. 12
Total filling capacity Low
temperature Liters approx. 2.1 approx. 2.1
circuit
Filling capacity of Main circuit Liters approx. 6.25 approx. 6
BF20.00-P- Cooling anticorrosion and Low
1001-02Q system Antifreeze down to - temperature Liters approx.1 approx.1
37°C circuit
BB00.40-P- BB00.40-P-
Sheet
0310-01A 0310-01A
BB00.40-P- BB00.40-P-
Sheet
0325-00A 0325-00A
TEST COOLING SYSTEM CAP - AR20.30-P-4300FV
ENGINES 112,113
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250

ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
ENGINE 113.993 in MODELS 463.270 /271
Fig. 94: Identifying Cooling System Cap Test Components
Remove
skin and eyes temperature is below 90°C. Open cap slowly 01A
caused by and release the pressure. Do not pour coolant
scalding from into beverage bottles. Wear protective gloves,
contact with hot protective clothing and eye protection.
coolant spray.
Risk of poisoning
from swallowing
coolant.
1.1 Fit cap with detent For model 463.206/209/232/233/ 240/241
(5) with cap with notch (5).
Carefully rotate cap up to the first detent,
release overpressure, then unscrew cap (5). If
corrosion present at cap with detent (5), the cap
must be replaced.
1.2 Remove 1 or 2- A 1-stage cap (5a) is installed in model 163.
stage cap (5a) In models 140, 170, 199, 202, 203, 208, 209,
210, 211, 215, 220, 230, 463.243/244/245/
246/247/248/249/250/254/270/271 there are 2-
stage caps (5a) installed.
Turn 1 or 2-stage cap (5a) half a turn in an
anti-clockwise direction, release pressure and
then unscrew cap.
Check cap with
detent
2.1.1 Attach test cap (3) Only on model 463.206/209/232/233/240/ 241
and adapter (4) to with cap with notch (5).
tester (2)
Tester Fig. 19
Test cap Fig. 20
Adapter Fig. 95
2.1.2 Screw cap (5)
with detent onto
the adapter (4)
2.1.3 Inspect pressure Only on model 463.206/209/232/233/240/ 241
relief valve (6) with cap with notch (5).
The pressure relief valve (6) must be resting
against the rubber seal (arrow), it must be
possible to lift it easily and it must spring back
after being released.
Determine the opening pressure of the cap with
notch (5) by pump and replace cap with notch
(5) if necessary.
Cap code number *BE20.30-P-
1001-01A
Pressure relief valve opens *BE20.30-P-
1002-01A
Pressure relief valve opens (Reference value) *BE20.30-P-
1003-01A
Test pressure *BE20.30-P-
1005-01A
Test the 1 or 2-
stage cap
2.2.1 Attach adapter Only on models 163, 140, 170, 199, 202, 203,
(3a) to tester (2) 208, 209, 210, 211, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271.
Tester Fig. 19
Adapter for models 140, 170, 199, 202, 203,
208, 209, 210, 211, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271:
Adapter Fig. 99
Test cap for Model 163: ?
Test cap Fig. 98
2.2.2 Screw 1 and 2- Only on models 163, 140, 170, 199, 202, 203,
stage cap (5a) 208, 209, 210, 211, 215, 220, 230,
onto adapter (3a) 463.243/244/245/246/247/248/249/250/
254/270/271.
2.2.3 Inspect pressure Only on models 163, 140, 170, 199, 202, 203,
relief valve 208, 209, 210, 211, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271.
Determine opening pressure of the cap (5a)
by pumping and replace cap (5) if necessary.
Cap code number *BE20.30-P-
1001-01A
1002-01A
Vacuum valve opens (reference value) *BE20.30-P-
1003-01A
1004-01A
Test pressure *BE20.30-P-
1005-01A
Installing
3.1 Fit cap with detent For model 463.206/209/232/233/240/241
(5) with cap with notch (5).
3.2 Install Remove 1 For models 140, 163, 170, 199, 202, 203,
or 2-stage cap (5a) 208, 209, 210, 211, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271 with 1 or 2-stage cap (5a).
CAP OF RADIATOR OR EXPANSION RESERVOIR

Number Designation Cap 2-stage cap 1-stage cap
model 163
BE20.30-P- Cap code number 140 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar gage 1.4 (+0.1) - 1.4 (+0.1)
1002-01A valve opens Used bar gage 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 1st stage bar gage - 1.4 ( ± 1) -
1004-01A valve opens Coolant temp. - > or = -
130/134
2nd stage bar gage - 2.0 (± 1) -
Coolant temp. - > or = -
137/143
BE20.30-P- Test pressure for pressure- bar gage 1.4 1.4 -
1005-01A testing cooling system

Number Designation 2-stage cap 2-stage closing
engine 113.968 cover on model
in model 209 211
BE20.30-P- Cap code number 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar gage - 1.5 (-0.2)
1002-01A valve opens Used bar gage - 1.5 (-0.2)
BE20.30-P- Vacuum valve opens (reference bar vacuum 0.1 0.1
1003-01A value)
BE20.30-P- Pressure relief 1 st stage bar gage 1.4 (± 1) 1.5 (-0.2)
1004-01A valve opens Coolant temp. > or = 130/134 135 (+5)
2nd stage bar gage 2.0 (± 1) 1.5 (-0.2)
Coolant temp. > or = 137/143 145 (+5)
BE20.30-P- Test pressure for pressure-testing bar gage 1.4 1.4
1005-01A cooling system

REMOVE/INSTALL FAN SHROUD - AR20.40-P-6800
Remove/install fan shroud - AR20.40-P-6800AB
ENGINES 112, 113 in MODEL 220

Shown on model 220 with M112
Fig. 100: Identifying Fan Shroud Remove/Install Components - Shown On Model 220 With M112
MODIFICATION NOTES
22.11.02 Detach coolant line on Step 5
expansion reservoir -
added
Remove/install
Risk of injury to skin Do not open cooling system AS20.00-Z-0001-01A
and eyes caused by unless coolant temperature
scalding from contact is below 90°C. Open cap
with hot coolant spray. slowly and release pressure.
Risk of poisoning from Do not pour coolant into
swallowing coolant. beverage containers.
safety glasses.
1 Drain coolant from Engines 112, 113 except AR20.00-P-1142HA
radiator engines 113.963 /992/995
Engines 113.963/ 992/ 995 AR20.00-P-1142RVK
2 Remove left air intake
pipe to air filter
3 Unscrew bolts from
retaining tabs (3) on fan
shroud (1)
4 Disconnect electric plug
connections for suction
fan
5 Detach expansion
reservoir coolant line on
coolant line thermostat
housing to engine radiator
6 Detach coolant line (2) at
bottom right on engine
radiator
7.1 Remove plate attaching Models 215, 220
ATF line At bottom of fan shroud
(arrow).
7.2 Lever off clips at top of Model 230
fan shroud
8 Remove fan shroud (1) Pull fan shroud with
retaining tabs (4) out of
retaining lugs on radiator.
10 Check coolant level and Engines 112, 113 except AR20.00-P-1010HA
cooling system for leaks engines
113.963 /991 /992 /995
Engines AR20.00-P-1010RVK
113.963 /991 /992 /995
Remove/install fan shroud - AR20.40-P-6800AC
ENGINE 275.950 in MODEL 215.376, 220.176
Shown on model 220
Fig. 101: Identifying Fan Shroud Remove/Install Components - Shown On Model 220
MODIFICATION NOTES
12.8.02 Fastening of ATF line modified in coolant line. Step 5
Remove/install
Remove front part of AR01.10-P-
1.1 Model 215.376, 220.176, 230.476 /477
engine cover 2405LA
AR01.10-P-
Model 215.379, 220.179, 230.479
2405IM
Remove left and right
2
suction fan duct
Unscrew bolts from
3 retaining tabs (3) on fan
shroud (1)
Disconnect electric plug
4
sockets at suction fan
Before opening the automatic transmission or its
components, the ambiance of the separation point has to
be cleaned thoroughly. Even the smallest particles of
Remove automatic oil dirt, introduced into the hydraulic components, can
5
line result in malfunctions and a total failure of the automatic
transmission.
Only remove at top right of radiator. Seal ATF lines
so that no ATF flows out.
*BA20.20-
P-1001-01A
Remove fastening
shackles (3) for coolant
6.1 Model 215, 220
line below at fan shroud
(1)
Pull fan shroud (1) with retaining lugs (4) out of
retaining tabs at radiator.
8
order
Check oil level in
AR27.00-P-
9 automatic transmission,
0100AC

137.970 275
BA20.20-P-1001- Union nut, automatic transmission oil line to
Nm 20 25
01A radiator
Remove/install fan shroud - AR20.40-P-6800IM
ENGINE 275.980 in MODEL 215.379, 220.179

Shown on model 220
Fig. 102: Identifying Fan Shroud Remove/Install Components - Shown On Model 220
Shown on model 220
Fig. 103: Identifying Removal/Installation Coolant Line And Bolts - Shown On Model 220
Fig. 104: Identifying ATF Line And Radiator Remove/Install Components
Remove/install
AR01.10-P-
1 Remove engine trim panel
2405IM
Remove left and right
2
suction fan duct
AR20.00-P-
3 Drain coolant at radiator (9)
1142H
AH20.00-N-
2080-01A
Unscrew bolts (6), coolant
line (2) and coolant line (7)
4
from coolant temperature
control switch to radiator
Unscrew bolt from retaining
5
tabs (3) on fan shroud (1)
Separate electric plug
6
sockets at suction fan
Before opening the automatic transmission or its
components, the ambiance of the separation point
has to be cleaned thoroughly. Even the smallest
Unscrew automatic oil line particles of dirt, introduced into the hydraulic
7
(8) components, can result in malfunctions and a total
failure of the automatic transmission.
Only remove at top right of radiator. Seal ATF
lines so that no ATF flows out.
*BA20.20-
P-1001-01A
Remove fastening shackles
8 for engine oil line below at
fan shroud (1)
Remove mounting clamps
9 for fan shroud (1) at radiator
(9)
Pull fan shroud (1) with retaining lugs (4) out of
retaining tabs at radiator (9).
Adjust coolant to correct AR20.00-P-
12
level 1142H
AR20.00-P-
1142-06GA
Inspecting cooling system AR20.00-P-
14
for leaks 1010HA
Check oil level in automatic
AR27.00-P-
15 transmission, correct if
0100AC
necessary

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, 602.91 /96, BE20.10-P-1000-02B
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-1000-02A
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
Number Designation Engine 119 Engine 155 Engine 271
BE20.10-P-1001- Start of opening °C 82...86 85...89 88...92
02A
BE20.10-P-1002- Minimum stroke °C - 102 105
02A mm - 8 8
BE20.10-P-1003- Thermostat bypass valve mm 29 - -
02A dia.
TEST VALUES FOR COOLING SYSTEM CAP - BE20.30-P-1000-01A
All engines

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- 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 -
CAP FOR RADIATOR OR EXPANSION RESERVOIR

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
CAP FOR RADIATOR OR EXPANSION RESERVOIR

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
ENGINE COOLING SYSTEM - CHECK FLUID LEVEL, ADJUST TO CORRECT LEVEL. INSPECT
ANTICORROSION/ANTIFREEZE PROTECTION, ADJUST TO CORRECT CONCENTRATION -
AP20.00-P-2010
Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to
correct concentration - AP20.00-P-2010H
ENGINE 275.950 in MODELS 215.376, 220.176
ENGINE 285.950 in MODEL 240.078 /178
ENGINE 275.980 in MODEL 215.379, 220.179

ENGINE 285.980 in MODEL 240.079 /179
Shown on engine 285.950 in model 240.078
Fig. 105: Identifying Expansion Reservoir, Engine Cover And Cap - Shown On Engine 285.950
Check
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
swallowing coolant. Wear protective gloves, protective clothing
and safety glasses.
Main circuit
Open the cap (1) of the expansion Slowly screw open end cover (1) and
1
reservoir (2) release pressure, then unscrew end cover (1).
AH20.00-N-
Notes on coolant
2080-01A
If mixing ratio is incorrect, adjust
Check coolant for adequate corrosion
2 correctly coolant composition: ?
and antifreeze agent content
Drain, pour in coolant:
Engine 275 in 215, 220, 230
engine 285 in model 240.078/178
AR20.00-P-
Engine 285 in model 240.079/179
1142H
Use only approved anticorrosion and
antifreeze agents.
*WH58.30-Z-
Antifreeze tester 1001-25A
Check coolant level, if required adjust
3
correctly.
AH20.00-P-
1142-01V
In the event of fluid loss which is not due
to consumption, check cooling system for
leaks: ?
Inspect cooling system for leaks:
Engine 275 in 215, 220, 230
AR20.00-P-
engine 285 in model 240.078/178
1010HA
Engine 285 in model 240.079/179
Close end cover (1) of expansion
4
reservoir (2).
Low temperature circuit
5.1 Remove engine trim panel (3)
Model 240.078/178 with engine 285.950 AR01.10-P-
Remove/install engine cover
Model 240.079/179 with engine 285.980 2405LA
Open cap (4) only at a coolant
Open end cover (4) of low temperature temperature below 40°C, otherwise coolant
6 can flow out.
circuit
If coolant has flown out, the low temperature
circuit must be bled: ?
AR20.00-P-
Bleed low temperature circuit.
1145H
Check coolant for adequate corrosion If mixing ratio is incorrect, adjust
7 correctly coolant composition: ?
and antifreeze agent content
Drain, pour in coolant:
Engine 275 in model 215, 220, 230 low AR20.00-P-
temperature circuit 1142HM
Engine 285 in model 240 low temperature
circuit AR20.00-P-
Use only approved anticorrosion and 1142HN
antifreeze agents.
*WH58.30-Z-
Antifreeze tester 1001-25A
Check coolant level, if required adjust
8
correctly.
AH20.00-P-
1142-01V
In the event of fluid loss which is not due
to consumption, check cooling system for
leaks: ?
AR20.00-P-
Inspect cooling system for leaks
1010HN
Close end cover (4) of low temperature
9
circuit
10.1 Install engine cover (3).
Model 240.078/178 with engine 285.950 AR01.10-P-
Remove/install engine cover
Model 240.079/179 with engine 285.980 2405LA

Number Designation
WH58.30-Z-1001-25A Antifreeze tester
Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to
correct concentration - AP20.00-P-2010Z
MODEL
203.004 /006 /016 /018 /020 /035 /040 /042 /043 /045 /046 /061 /064 /065 /076 /081 /084 /204 /206/216 /218 /22
MODEL
211.004 /006 /007 /008 /016 /020 /022 /023 /026 /028 /029 /041 /042 /052 /054 /056 /061 /065 /070 /072 /076 /07
MODEL 414
MODEL
209.308 /316 /320 /341 /342 /343 /354 /356 /361 /365 /375 /376 /420 /441 /442 /454 /456 /461 /465 /475 /476
MODEL 215 (except 215.376 /379)
MODEL 220 (except 220.176 /179)
MODEL 230 with ENGINES 112, 113
MODEL 124, 129, 140, 168, 170, 202, 208, 210
Check
Risk of injury to skin Do not open cooling system unless AS20.00-Z-0001-01A
and eyes caused by coolant temperature is below 90°C.
scalding from contact Open cap slowly and release the
with hot coolant pressure. Do not pour coolant into
spray. beverage containers.
Risk of poisoning Wear protective gloves, protective
caused by swallowing clothing and safety glasses.
coolant.
1 Remove screw cap of
coolant expansion
reservoir
2 Check coolant level Coolant cold: Engine coolant level
up to marking "Cold water level".
Coolant warm: Engine coolant level
approx. 1 cm above marking "Cold
water level".
3 Inspect cooling If loss of fluid is not due to normal
system for leaks consumption (against separate order)
Engine 103 ra20001020017x
Engine 119 ra20001190170x
Inspect cooling Engine 111 in model 203 AR20.00-P-1010HA
system for leaks Engine 112 except
112.912/916/946/947/953/955/960/961,
Engine 113 except
113.963/968/987/988/990/991/992/995
Engine 120, 137, 601, 602, 603, 604,
605, 606, 613, 628, 646 except 646.8,
647, 648,
Engine 611 except in model 203
Engine 612 except in model 203,
Engine 156 in model 209, 211 AR20.00-P-1010TMG
Engine 272, 273 in model 211 AR20.00-P-1010TS
Engine 642 in model 211 AR20.00-P-1010TI
Engine 629 in model 211 AR20.00-P-1010TJ
Engine 113.963/990/991/992/995 AR20.00-P-1010RVK
Engine 112.961 in model 203.065/265
Engine 111, 112, 113, 271, 611, 612, AR20.00-P-1010P
646 in model 203
Engines 271, 646.8 in model 211
Engine 112 in Model 170
Engine 112, 113, 271, 612 in MODEL
209
Engine 642 in model 209 AR20.00-P-1010PI
Engine 272 in model 209 AR20.00-P-1010QB
Engine 166, 668 in model 168 AR20.00-P-1010GF
Engine 166, 668 in model 414 AR20.00-L-1010VA
4 Inspect anticorrosion Use only approved anticorrosion
and antifreeze agent in and antifreeze agents.
coolant and coolant If the coolant composition is
composition incorrect: Correct the coolant
composition (subject to separate repair
order).
5 Mount screw cap for
coolant expansion
reservoir
REPLACE COOLANT - AP20.00-P-2080
Replace coolant - AP20.00-P-2080DA
ENGINE 112.913 in MODEL 211.061 /261
ENGINE 112.949 in MODEL 211.065 /265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.990 in MODEL 211.076 /276
ENGINE 113.960 in MODEL 215.375, 220.875
ENGINE 112.922 in MODEL 220.063 /163
ENGINE 112.944 in MODEL 220.065 /165
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.986 in MODEL 220.073 /173
ENGINE 113.991 in MODEL 220.074 /174
ENGINE 113.960 in MODEL 220.075 /175
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084 /184
ENGINE 112.975 in MODEL 220.087 /187

ENGINE 271.941 in MODEL 211.042 /242
ENGINE 137.970 in MODEL 215.378, 220.178 /878
ENGINE 112.917 in MODEL 211.080 /280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083 /283
ENGINE 272.964 in MODEL 211.056 /256
ENGINE 272.972 in MODEL 211.087 /287
ENGINE 272.943 in MODEL 211.054 /254
ENGINE 272.944 in MODEL 211.092 /292
ENGINE 271.956 in MODEL 211.041 /241
ENGINE 273.960 in MODEL 211.072 /272
ENGINE 273.962 in MODEL 211.090 /290
MODIFICATION NOTES
6.3.06 Cooling system Engine 272, 273 *BF20.00-P-1001-02U
Replace
Risk of injury to skin and
eyes caused by scalding Do not open cooling system unless coolant temperature is
from contact with hot below 90°C. Open cap slowly and release the pressure. Do AS20.00-Z-
coolant spray. not pour coolant into beverage containers. Wear protective 0001-01A
Risk of poisoning caused gloves, protective clothing and safety glasses.
by swallowing coolant.
AH20.00-N-
Notes on coolant
2080-01A
1 Drain coolant
Engine 112, 137
Engine 113 except 113.990/991/992/995 and except in model AR20.00-P-
211.270 1142HA
Engine 113 in model 211.270
AR20.00-P-
Engine 113.990/991/992/995
1142RVK
AR20.00-P-
Engine 271
1142T
Engine 272, 273 in model 211
In the event of fluid loss which is not due to normal AR20.00-P-
consumption at first As a separate repair order: ? 1142TS
Inspect cooling system for leaks:
AR20.00-P-
Engine 112, 137, Engine 113 except 113.990/991/992/995
1010HA
AR20.00-P-
Engine 271 in model 211
1010P
AR20.00-P-
1010TS
AR20.00-P-
Engine 113.990/991/992/995
1010RVK
AH20.00-N-
Notes on coolant
2080-01A
2 Pour in coolant Use only approved anticorrosion and antifreeze agents.
Engine 112, 137
Engine 113 except 113.990/991/992/995 and except in model AR20.00-P-
211.270 1142HA
Engine 113 in model 211.270
AR20.00-P-
Engine 113.990/991/992/995
1142RVK
AR20.00-P-
Engine 271
1142T
AR20.00-P-
1142TS
AH20.00-P-
1142-01V
*BF20.00-P-
Engine 112, 113 1001-02K
*BF20.00-P-
Engine 137 1001-02M
*BF20.00-P-
Engine 271 1001-02P
*BF20.00-P-
Engines 272, 273 1001-02U
COOLING SYSTEM
112.913/917/ 112.922/944/972 112.973 in
949/954 in in model 220 model
Model 211 230.467
Total filling capacity Liters approx. 9.5 approx.1 0.5 approx. 10,8
Capacity of
anticorrosion/antifreeze Liters approx. 4,75 approx. 5.0 approx.5.4
Cooling
P-1001- anticorrosion/antifreeze Liters approx. 5,25 approx. 5.5 approx. 6
system
02K down to -45°C
BB00.40-P- BB00.40-P-0310- BB00.40-P-
Sheet
Specifications for 0310-01A 01A 0310-01A
Operating Fluids BB00.40-P- BB00.40-P-0325- BB00.40-P-
Sheet
0325-00A 00A 0310-01A
COOLING SYSTEM
112.975 in 113.948/966 in 113.963 in
model 220 model 220 model 230.475
Total filling capacity Liters approx.10,4 approx.11,6 approx.11,5
Capacity of
anticorrosion/antifreeze Liters approx. 5.2 approx. 5.8 approx. 5.8
Cooling
P-1001- anticorrosion/antifreeze Liters approx. 5.7 approx. 6,4 approx. 6.5
system
02K down to -45°C
BB00.40-P- BB00.40-P- BB00.40-P-
Sheet
Specifications for Operating 0310-01A 0310-01A 0310-01A
Fluids BB00.40-P- BB00.40-P- BB00.40-P-
Sheet
0310-01A 0325-00A 0325-00A
COOLING SYSTEM
Number Designation Engine Engine Engine 113.968
113.967/969 in 113.960/986 in in Model 209,
model 211 model 215 211 Engine
113.969 in Model
211
Total filling capacity Liters approx. 10,75 approx. 11.5 approx. 11,5
Capacity of
anticorrosion/antifreeze Liters approx.5,25 approx.5,75 approx.5.75
BF20.00- Cooling Filling capacity of
P-1001- system anticorrosion/antifreeze
Liters approx.6.0 approx.6,25 approx.6.25
02K down to -45°C
BB00.40-P- BB00.40-P- BB00.40-P-0310-
Sheet
Specifications for 0310-01A 0310-01A 01A
Operating Fluids BB00.40-P- BB00.40-P- BB00.40-P-0325-
Sheet
0325-00A 0325-00A 00A
COOLING SYSTEM
113.941/960 in 113.986/991 in 113.990
model 220 model 220
Total filling capacity Liters approx. 11,5 approx.13,5 approx.13.2
Capacity of
anticorrosion/antifreeze agent Liters approx. 5.75 approx. 6,8 approx. 6.6
down to -37°C
Cooling
P-1001- anticorrosion/ antifreeze Liters approx. 6.25 approx. 7,4 approx. 7.3
system
02K down to -45°C
BB00.40-P- BB00.40-P- BB00.40-P-
Sheet
Specifications for Operating 0310-01A 0310-01A 0310-01A
Fluids BB00.40-P- BB00.40-P- BB00.40-P-
Sheet
0325-00A 0325-00A 0325-00A
COOLING SYSTEM
in model 215 113.992/995 in
model 230
Total filling capacity Liters approx. 14,5 approx. 13,0
Capacity of
anticorrosion/antifreeze agent Liters approx. 7.3 approx. 6,5
down to -37°C
Filling capacity of
BF20.00-P- Cooling
anticorrosion/antifreeze down to - Liters approx. 8 approx. 7.3
1001-02K system
45°C
BB00.40-P- BB00.40-P-0310-
Sheet
0310-01A 01A
BB00.40-P- BB00.40-P-0325-
Sheet
0325-00A 00A
COOLING SYSTEM
Total filling capacity (initial filling capacity) Liters approx.8
Total filling capacity (workshop change
Liters approx. 5.6
capacity)
Liters approx. 2.8
down to -37°C
Liters approx. 3.3
BF20.00-P-1001- Cooling down to -45°C
02P system BB00.40-P-0310-
Sheet
01A
BB00.40-P-0325-
Sheet
00A
COOLING SYSTEM
Number Designation Engine 272 in model Engine 272 in model
164, 211, 251, Engine 230 Engine 272.960/970
272.964 in model 219 in model 203
approx.
Total filling capacity 6.5 7.5
Liters
Up to -
50/50 50/50
BF20.00-P- Cooling Antifreeze/water 37°C
1001-02U system Up to -
55/45 55/45
45°C
Specifications for Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A
Operating Fluids Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM
Total filling capacity Liters approx. 12
Liters approx.6
down to -37°C
BF20.00-P-1001- Cooling Liters approx. 6,6
down to -45°C
02M system
BB00.40-P-0310-
Sheet
01A
BB00.40-P-0325-
Sheet
00A
COOLING SYSTEM
Number Designation Engine 273 in model 211,
219
approx.
Total filling capacity 7
Liters
BF20.00-P-1001- Cooling Up to -37°C 50/50
Antifreeze/water
02U system Up to -45°C 55/45
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A
Replace coolant - AP20.00-P-2080H
ENGINE 275.950 in MODELS 215.376, 220.176
ENGINE 275.980 in MODEL 215.379, 220.179
ENGINE 285.950 in MODEL 240.078 /178
ENGINE 285.980 in MODEL 240.079 /179
MODIFICATION NOTES
Cooling system Engine 275.950 in model 215/220 *BF20.00-P-1001-02Q
Cooling system Engine 275.951/954 in model 230 *BF20.00-P-1001-02Q
1.12.05
Cooling system Engine 285.950/980 in model 240 *BF20.00-P-1001-02Q
Risk of injury to skin and

eyes caused by scalding Do not open cooling system unless coolant temperature is
from contact with hot below 90°C. Open cap slowly and release the pressure. Do AS20.00-Z-
coolant spray. not pour coolant into beverage containers. Wear protective 0001-01A
Risk of poisoning from gloves, protective clothing and safety glasses.
swallowing coolant.
AH20.00-N-
Notes on coolant
2080-01A
Inspect cooling system for
1
leaks
Inspect cooling system for
Main circuit
leaks
Engines 275, 285.950 AR20.00-P-
Engine 285.980 1010HA
AR20.00-P-
Low temperature circuit
1010HN
2 Drain coolant
Drain/fill in coolant Main circuit
Engines 275, 285.950 AR20.00-P-
Engine 285.980 1142H
Engine 275 in model 215, 220, 230 low temperature circuit AR20.00-P-
1142HM
AR20.00-P-
Engine 285 in model 240 low temperature circuit
1142HN
3 Pour in coolant Use only approved anticorrosion and antifreeze agents.
Drain/fill in coolant Main circuit
Engines 275, 285.950 AR20.00-P-
Engine 285.980 1142H
AR20.00-P-
Engine 275 in model 215, 220, 230 low temperature circuit
1142HM
AR20.00-P-
Engine 285 in model 240 low temperature circuit
1142HN
AH20.00-P-
1142-01V
*BF20.00-P-
1001-02Q
COOLING SYSTEM
in model 215/220 275.951/954 in
model 230
Main circuit Liters approx.12,2 approx. 9,4
Total filling Low
capacity temperature Liters approx.1,55 approx. 1,5
circuit
Filling capacity of Main circuit Liters approx. 6,1 approx. 4,7
1001-02Q system antifreeze down to - temperature Liters approx. 0,75 approx. 0,75
37°C circuit
BB00.40-P-0310- BB00.40-P-0310-
Sheet
01A 01A
BB00.40-P-0325- BB00.40-P-0325-
Sheet
00A 00A
COOLING SYSTEM
Main circuit Liters approx. 12,5 approx. 12
Total filling capacity Low
temperature Liters approx. 2,1 approx. 2,1
BF20.00-P- Cooling circuit
1001-02Q system Filling capacity of Main circuit Liters approx. 6,25 approx. 6
anticorrosion and Low
antifreeze down to - temperature Liters approx.1 approx.1
37°C circuit
BB00.40-P- BB00.40-P-
Sheet
0310-01A 0310-01A
BB00.40-P- BB00.40-P-
Sheet
0325-00A 0325-00A
COOLING SYSTEM
in model 230 285.950/980 in
model 240
Main circuit Liters approx. 12 approx. 10,3
Total filling Low
capacity temperature Liters approx.2,1 approx.1.6
circuit
Filling capacity of Main circuit Liters approx.6 approx.5,15
1001-02Q system antifreeze down to - temperature Liters approx. 1 approx. 0,8
37°C circuit
BB00.40-P- BB00.40-P-0310-
Sheet
0310-01A 01A
BB00.40-P- BB00.40-P-0325-
Sheet
0325-00A 00A

RETROFIT COOLANT PREHEATER - AN20.30-P-0001
Retrofit coolant preheater - AN20.30-P-0001MMM
Installation sequence
Fig. 106: Identifying Retrofit Coolant Preheater - Engine 113.9 In Model 215
Line routing
Fig. 107: Identifying Tie Strap, Rubberized Hose Clamp And Connector
Removing
swallowing coolant.
safety glasses.
Remove lower engine
1
AR61.20-P-
1105M
2 Drain coolant at radiator and crankcase
AR20.00-P-
1142HA
Remove coolant hose between
3 Vehicle coolant hose can be discarded.
coolant pump and radiator
Install
AH20.00-P-
Notes on coolant preheater
1001-01A
Screw coolant preheater (20) into Clamp housing in vise and adjust distance *BA20.00-P-
4
housing (10) with sleeves or nuts. 1001-01A
Use new O-ring.
Fig. 108
Attach housing (10) with coolant
5 hose (11) to coolant pump and
secure each with clamp (12)
Attach housing (10) to timing
Take great care when screwing in the self-
6 case cover with two self-tapping
tapping screws.
screws (13)
Insert new bottom coolant hose
(14) between housing (10) and
7
radiator and attach each with a
clamp
Attach electric cable of coolant
preheater (20) with rubberized *BA01.45-P-
8 Screw to oil pan
clamp (15) to existing screw of oil 1001-01B
pan
Continue routing along left
Attach cable to existing wiring with cable
9 longitudinal member to
strap (2).
crossmember above left headlamp
Attach retaining spring (a) with
Make holes for sheet metal screws with
10 two sheet metal screws (c) to
chisel.
upper frame crossmember
Fit cap (b) onto plug (8) and insert The plug is locked in the retaining spring
11
into retaining spring (a) (a) by turning the cap (b) clockwise.
AR20.00-P-
1010HA
Fig. 19
Fig. 22
OIL PAN
Number Designation Engines 113.940/941/ 942/943/944/ 945/946/960/ Engine
961/962/963/ 965/967/968/ 969/980/981/ 113.987/
982/984/986/ 992/995 988/991
BA01.45-P- Bolt, oil pan to M6 Nm 9 9
1001-01B crankcase M8 Nm 20 20
COOLANT PREHEATER
BA20.00-P-1001-01A Coolant preheater in engine block Nm 35
Fig. 109: Identifying Tester (124 589 24 21 00)

140 995 00 44 Clip 1
KG20G (see EPC) Preheater parts kit 1
KG20G (see EPC) Housing 1
210 501 53 82 Coolant hose between housing and coolant pump 1
220 501 10 82 Lower coolant hose 1
KG20G (see EPC) Screw M6, self-tapping 2
Retrofitting coolant preheater - AN20.30-P-0001Q
ENGINE 112.9, 113.9 in MODEL 220
Installation sequence with engines 112, 113
Fig. 111: Identifying Retrofitting Coolant Preheater - Engine 112.9, 113.9 In Model 220
Installation sequence with Engine 112
Fig. 112: Identifying Tie Strap, Cable Clamps And Connector - Engine 112
Installation sequence with Engine 113

Fig. 113: Identifying Tie Strap, Cable Clamps And Connector - Engine 113
Removing
temperature is below 90°C. Open cap slowly and
release the pressure. Do not pour coolant into AS20.00-Z-
swallowing coolant.
safety glasses.
1 Drain coolant at radiator and crankcase
AR20.00-P-
1142HA
Remove lower engine
2
AR61.20-P-
1105M
Installing
AH20.00-P-
Notes on coolant preheater
1001-01A
Screw coolant preheater (20) Clamp housing in vise and adjust distance *BA20.00-P-
3
into housing (10) with sleeves or nuts. 1001-01A
Use new O-ring.
Fig. 108
Connect housing (10) to coolant
4
pump with hose (11)
Screw housing (10) onto timing
Take special care when screwing in the self-
5 case cover with self-tapping
tapping screws.
screws (13)
Fasten hose (11) with clamps
6
(12)
Install and tighten new lower
7 water hose (14) between
housing (10) and radiator
Fasten electric cable of coolant
8
preheater (20) to oil pan using *BA01.45-P-
rubberized clamps (15), 1001-01B
Continue routing along left
longitudinal member to
9 Fasten cable to existing wiring with tie strap (2).
crossmember above left
headlamp
Fasten retaining spring (a) with
10 cap (b) and self-tapping screws
(c) to crossmember (9)
Hang cable plug (8) in retaining
11
spring and attach cap (b)
AR20.00-P-
1010HA
Fig. 19
Fig. 22
OIL PAN
Number Designation Engines 113.940/941/ Engine Engine
942/943/944/ 945/946/960/ 112.916/953/975, 113.987/
961/962/963/ 965/967/968/ 113.948/966 988/991
969/980/981/ 982/984/986/
992/995
BA01.45-P- Bolt, oil pan M6 Nm 9 9 9
1001-01B to crankcase M8 Nm 20 20 20
OIL PAN
Number Designation Engines 112.910/911/ 912/913/914/ 915/917/920/ 921/922/923/
940/941/942/ 943/944/945/ 946/947/949/ 951/954/955/
960/961/970/ 972/973/976
BA01.45-P- Bolt, oil pan to M6 Nm 9
1001-01B crankcase M8 Nm 20
COOLANT PREHEATER
BA20.00-P-1001-01A Coolant preheater in engine block Nm 35
Fig. 115: Identifying Tester (124 589 24 21 00)

KG20G (see EPC) Clip 1
KG20G (see EPC) Preheater parts kit 1
KG20G (see EPC) Housing 1
210 501 53 82 Coolant hose 1
220 501 09 82 Coolant hose on Engine 112 1
220 501 10 82 Coolant hose on Engine 113 1
KG20G (see EPC) Self-tapping screw M6 (mounted to housing) 2
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-1000-02D
Engine 275, 285

Number Designation Engine 275.950/951/ Engine 275.953/954/ 982,
952/980/981, 285.950 285.980
Nm 14 14
1001-02D crankcase
Nm 12 -
1002-02D alternator
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

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

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-1000-01L
ENGINE 113, 155

113.987/988/990/991
BA20.10-P- Bolt of coolant pump to M6 Nm 14 14
1001-01L timing case M8 Nm 20 20
1002-01L
BA20.10-P- Bolt of coolant thermostat M6 Nm 14 14
1003-01L housing
BA20.10-P- Bolt of major assembly carrier to Nm - -
1004-01L crankcase

BA20.10-P-1001- Bolt of coolant pump to timing case M6 Nm 9
01L M8 Nm -
BA20.10-P-1002- Belt pulley to coolant pump Nm 9
01L
BA20.10-P-1003- Bolt of coolant thermostat housing M6 Nm -
01L
BA20.10-P-1004- Bolt of major assembly carrier to crankcase Nm 20
01L
Coolant pump, coolant thermostat - BA20.10-P-1000-01M
Engine 112
MODIFICATION NOTES
1.9.04 Value changed from 10 Value in model series 1003 modified on engine
Nm to 14 Nm 112.910/911/912/913/914/915/916/917/
920/921/922/923/940/941/942/943/944/
945/946/947/949/953/954/955/960/961/
970/972/973/975
Value changed from 10 Value in model series 1004 modified on engine
Nm to 14 Nm 112.910/911/912/913/914/915/916/917/
920/921/922/923/940/941/942/943/944/
945/946/947/949/953/954/955/960/961/
970/972/973/975
Value changed from 10 Figure in line 1004 engine 112.951 modified
Nm to 14 Nm

112.910/911/912/913/914/915/ 112.951/976
916/917/920/ 921/922/923/
940/941/942/ 943/944/945/
946/947/949/ 953/954/955/
960/961/970/ 972/973/975
BA20.10-P- Self-tapping bolt of Thread not M6 Nm 14 -
1001-01M coolant pump to pre-tapped
timing case Thread not M8 Nm 35 -
pre-tapped
Thread pre- M6 Nm 10 -
tapped
Thread pre- M8 Nm 25 -
tapped
1002-01M
BA20.10-P- Bolt of coolant thermostat M6 Nm 14 14
1003-01M housing
BA20.10-P- Coolant pump at the timing case M7 Nm 14 14
1004-01M
BA20.10-P- Bolt of coolant pump to timing M8 Nm - 20
1005-01M case cover and crankcase
BA20.10-P- Bolt of thermostat to timing case Nm - 14
1006-01M cover
RADIATOR, COOLANT HOSES - BA20.20-P-1000-01A
Engines 103, 111, 112, 113, 119, 137, 155, 272, 273, 275

Number Designation Engine Engine Engine Engine 112 except
103 111 111.977 112.942/970, engine
except 113.940/941/
111.977 943/944/945/
946/948/960/
961/962/963/
966/967/968/
969/980/982/
984/986/992/ 993/995
BA20.20-P- Union nut, automatic Nm 20 20 20 20
1001-01A transmission oil line to
radiator
BA20.20-P- Nut for transmission oil Nm 20 25 25 -
1002-01A cooler in refrigerant
cooler
BA20.20-P- Banjo bolt M12 x Nm - - - 30
1003-01A 1.5
BA20.20-P- Hose clamp Nm - - 3 -
1004-01A

Number Designation Engine Engine Engine Engine 119
112.942/970, 113.987/ 113.989
113.942/ 988/990/ 991
965/981
BA20.20-P- Union nut, automatic Nm 20 18 18 20
radiator
BA20.20-P- Nut for transmission oil Nm - - - -
1002-01A cooler in refrigerant cooler
BA20.20-P- Banjo bolt M12 x Nm 30 30 30 -
1003-01A 1.5
BA20.20-P- Hose clamp Nm 3 - - -
1004-01A

Number Designation Engine Engine 155 Engines 272, Engine 275
137.970 273 in
model 230
BA20.20-P- Union nut, automatic Nm 20 - 20 25
radiator
BA20.20-P- Nut for transmission oil Nm - - - -
1002-01A cooler in refrigerant cooler
BA20.20-P- Banjo bolt M12 x Nm 30 - 30 -
1003-01A 1.5
BA20.20-P- Hose clamp Nm - - - -
1004-01A
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
ENGINE
Electrical System - Engine - 215 & 220 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - AH15.00-Z-9999AZ
MODEL all
General notes on ENGINE 112, 113... AH15.10-P-1002-

contactless high voltage 01WA
distribution
General notes on ENGINE 104, 111... AH15.10-P-1002-
contactless high voltage 01WD
distribution
General notes on ENGINE 119, 120... AH15.10-P-1002-01WE
contactless high voltage
distribution
General notes on testing ENGINE 104, 111, 112, 113, AH15.10-P-1003-01W
contactless high voltage 119, 120...
distribution
Notes on ignition coil ENGINE 104, 111, 112, 113, AH15.10-P-1001-01A
characteristics of ignition 119, 120...
systems
Notes on avoiding ENGINE AH15.10-P-0002-01AK
damage to ignition 266.920 /940 /960 /980 in
system MODEL 169.0/3,245.2
Notes on avoiding ENGINE 111 with Gasoline- AH15.10-P-0002-01B
damage to the ignition inject-and Ignition system
system PMS
Notes on avoiding ENGINE 104, 111 with AH15.10-P-0002-01C
damage to the ignition Gasoline-inject-and Ignition
system system HFM
Notes on avoiding ENGINE 103, 104, 119 with AH15.10-P-0002-01E
damage to the ignition Gasoline fuel injection
system system KE
Notes on avoiding ENGINE 104, 119, 120 with AH15.10-P-0002-01F
damage to the ignition Gasoline fuel injection
system system LH
Notes on avoiding ENGINE 166 with Gasoline- AH15.10-P-0002-01G
damage to the ignition inject-and Ignition system
system MSM
Information on avoiding ENGINE 137, 275, 285 AH15.10-P-0002-01L
damage to ignition
system
Notes on avoiding ENGINE 272, 273 AH15.10-P-0002-01V
damage to ignition
system
Notes on avoiding ENGINE 104, 111, 112, 113, AH15.10-P-0002-01D
damage to ignition 119, 120, 156, 271, 112 with
system Gasoline-inject-and Ignition
system ME
Notes for ceramic glow ENGINE 646.8, 642 AH15.20-P-0001-01A
plugs
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002
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.
Information on avoiding damage to ignition system - AH15.10-P-0002-01L
Engine 137, 275, 285

Engine 137, 275, 285 with ignition system ECI
It is not possible to test the ignition sparks for example during a roadside assistance on this ignition system.
It is only possible to determine faults in the ignition system through read out of diagnostic trouble code memory
by means of STAR DIAGNOSIS.
The separation of electrical connectors at components of ignition system can only take place after switching off
the ignition.
To avoid damage, the ignition must not be switched on without ground supply at power supply unit ECI (N91).
A sufficient ground supply can only be assured, if the power supply unit ECI (N91) is bolted to the intake
manifold (1).
Shown on Engine 137
Fig. 1: Identifying Intake Manifold And ECI Power Supply Unit
NOTES ON IGNITION COIL CHARACTERISTICS OF IGNITION SYSTEMS - AH15.10-P-1001-01A
Engine 104, 111, 112, 113, 119, 120
In the case of the twin-spark ignition coil with kV pickup in ignition systems ME-SFI 2.1 and HFM-SFI, no
measurement facility exists at the ignition coil using the kV pickup although a kV pickup is fitted. It is only
possible to test the primary ignition circuit with adapter cable A.
IGNITION COIL CHARACTERISTICS OF IGNITION SYSTEMS

Engine Model HFM-SFI ME-SFI PEC Twin-spark Twin-spark Single-
ignition coil ignition coil spark
without kV with kV ignition coil
pickup pickup with kV
pickup
104 129 up to X X
05/96
104 129 as of 2.1 X
06/96
104 140 up to X X
05/96
104 140 as of 2.1 X
06/96
104 202 up to X X
07/96
104 202 as of 2.1 X
08/96
104 210 X X
104 210 up X X
to 05/96
104 210 as 2.1 X
of 06/96
111 163 X X
111 170.435 X X
111 170.445 2.1 X
111 170.447 2.1 X
111 202.018/020 X X
up to 07/96
111 202.018/020 X X
as of 08/96
111 202.025 up to X X
07/96
111 202.025 as of 2.1 X
08/96
111 202.022 up to X X
07/96
111 202.023 as of X X
08/96
111 202.023 as of 2.1 X
08/96
111 202.024 up to X X
07/96
111 202.024 as of 2.1 X
08/96
111 210 up to X X
05/96
111 210 as of X X
06/96
112 163 2.0 X
112 202 2.0 X
112 208 2.0 X
112 210 2.0 X
112 220 2.0 X
113 163 2.0 X
113 202 2.0 X
113 208 2.0 X
113 210 2.0 X
113 220 2.0 X
119.982 129 1.0 X
119.980 140 1.0 X
119.981 140 1.0 X
119 210 1.0 X
120.983 129 1.0 X
120.982 140 1.0 X
GENERAL NOTES ON CONTACTLESS HIGH VOLTAGE DISTRIBUTION - AH15.10-P-1002-01WA
Engine 112, 113 with ME-SFI fuel injection and ignition system
The ignition system can be tested at the primary side and secondary side. It is only possible to test ignition
circuit a and ignition circuit b one after the other.
The ignition coils are fitted as standard with cast mounts for the secondary adapters (kV pickup C). The primary
ignition voltage curve can be plotted with a primary adapter cable (D).
Fig. 2: Identifying Connection Cables Of Double Ignition Coil
Diagnosis with engine tester:

Connect green connector (terminal 1) of engine tester alternatively to the yellow socket or green socket for
assessing an ignition circuit with the primary adapter cable.
Connect yellow connector (terminal 15) of engine tester to positive (tml. 30 /tml. 15).
GENERAL NOTES ON TESTING CONTACTLESS HIGH VOLTAGE DISTRIBUTION - AH15.10-P-

1003-01W
If a complaint exists in the start or warming-up phase, do not condition engine to operating temperature but
proceed on a complaint-related basis.
Connections: set diagnostic tester to cylinder number 1 primary or secondary (if possible) and test through the
ignition circuits one after the other.
Diagnosis test oscilloscope / good image contactless high voltage distribution Secondary side (single
image) Engine idling
(shown on engine M119.981, cylinder 1 with Bosch ignition coil)
Measuring range: 40 kV
Time range: 5 ms
Fig. 3: Diagnosis Test Oscilloscope / Good Image Contactless High Voltage Distribution Secondary Side
(Single Image) Engine Idling
Diagnosis test oscilloscope / good image contactless high voltage distribution Primary side (single image)
Engine idling
Fig. 4: Diagnosis Test Oscilloscope / Good Image Contactless High Voltage Distribution Primary Side
(Single Image) Engine Idling
BASIC KNOWLEDGE
SPARK PLUGS, DESCRIPTION OF COMPONENTS - GF15.10-P-2000SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 5: Identifying Spark Plugs - Engine 113.988

Location
Two spark plugs per cylinder are fitted in the cylinder head
Task
The spark plugs ignite the suctioned and compressed fuel-air mixture due to arcing between the electrodes.
Body
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).
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.
COMPONENT DESCRIPTION OF IGNITION COIL - GF15.10-P-2100SM
ENGINE 113.986
ENGINE 113.987
ENGINE 113.988
ENGINE 113.989
Fig. 6: Identifying Ignition Coils - Engine 113.988
For each cylinder, a double ignition coil is fitted to the cylinder head cover.
Task
The ignition coils provide sufficient ignition power under all operating conditions for the respective ignition
circuit (cylinder).
Design
The engine has two spark plugs (R4) per cylinder, which are actuated via a double ignition coil.
The double ignition coils have two separate ignition circuits, two sets of ignition wiring and a 3-pole plug
connection.
Fig. 7: Identifying Cylinder 1 To 8 Ignition Coils - Engine 113.988
Function
Fig. 8: Ignition Coil Circuit Diagram - Engine 113.988
The ME control unit simultaneously actuates both primary windings of the double ignition coils at circuits 1a
and 1b with 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 ignition voltages reach the spark plugs via the high-voltage connections "circuit 4a" and "circuit 4b".
Voltage is supplied to the double spark plugs via "circuit 15 fused".
Diodes are built-in to the secondary ignition 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.
SPARK PLUGS, LOCATION/TASK/DESIGN/FUNCTION - GF15.10-P-3101
Spark plugs, location/task/design/function - GF15.10-P-3101AM
ENGINES 113.990 /991 /992 /993 /995
Fig. 9: Identifying Spark Plug
Spark plugs, location Two spark plugs per

cylinder are fitted in the
cylinder head
Spark plugs, task The spark plugs ignite the
suctioned and compressed
fuel-air mixture due to
arcing between the
electrodes.
Spark plugs, design All of the spark plug
features are assigned in the
manufacturer's specific type
symbol (e. g. heat rating,
shape of seating, thread,
width across flats, electrode
material, spark position).
Spark plugs, function The ignition voltages flow
from the ignition lines of the
ignition coils to the spark
plugs and cause arcing in
the air gap between the
central electrode and ground
electrode.
Spark plugs, location/task/design/function - GF15.10-P-3101F
ENGINE 104, 111, 112, 113/, 119, 120, 137, 166 (except, 112.96, 113.98/99)
Spark plugs, location One or two spark plugs are

located in the cylinder head
per cylinder.
Spark plugs, task The spark plugs ignite the
suctioned and compressed
fuel-air mixture due to
arcing between the
electrodes.
Spark plugs, design In the manufacturer's
specific type symbols, all
the spark plug features are
assigned (e. g. heat rating,
Spark plugs, function The ignition voltage travels
to the spark plugs from
directly connected ignition
coils or over the ignition
lines from the ignition coils
causing arcing in the air gap
between the center and
ground electrodes.
Spark plugs, location/task/design/function - GF15.10-P-3101M
Spark plugs, location Two spark plugs per

cylinder are fitted in the
cylinder head
Spark plugs, task Ignite the compressed fuel-
air mixture through sparks
between the electrodes
according to actuation of the
ECI ignition system. Detects
the ion current.
Spark plugs, design In the manufacturer's
specific type symbols, all
spark plug features are
assigned (e. g. heat rating,
Spark plugs, function The ignition voltage flows
from the directly-inserted
ignition coils in the ECI
ignition modules (N92/1,
N92/2) to the spark plugs
and causes arcing in the gap
between the central
electrode and ground
electrode.
IGNITION COILS, LOCATION/TASK/DESIGN/FUNCTION - GF15.10-P-3102
Ignition coils, location/task/design/function - GF15.10-P-3102A
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
Fig. 12: Identifying Ignition Coil Components - Shown On Engine 112
Ignition coils, location GF15.10-P-3102-01A

Ignition coils, task Supplying adequate
ignition energy in all
operating conditions for
the particular ignition
circuit.
Ignition coils, design One double ignition coil
for each cylinder.
Attached to cylinder head
cover.
Ignition coils, function GF15.10-P-3102-02A
Ignition coils, location - GF15.10-P-3102-01A
Fig. 13: Identifying Cylinder 1 To 6 Ignition Coil - Location On Engine 112
Fig. 14: Identifying Cylinder 1 To 8 Ignition Coil - Location Engine 113
Ignition coils, function - GF15.10-P-3102-02A
Each spark plug is actuated separately via its own ignition coil by the ME control unit. Both ignition coils of a
cylinder are combined to form a dual ignition coil.
The ME control unit actuates the primary wirings (L1) of the double ignition coils at circuits 1 a or 1 b with
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 (L2). The ignition
voltage flows through the high voltage connection (4a and 4b) and through the spark plug connector to the
respective spark plug (R4).
The voltage supply of the double ignition coils is protected at circuit 15 (a).
Diodes are built-in 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.
Fig. 15: Identifying Ignition Coils, Function
Ignition coils, location/task/design/function - GF15.10-P-3102AM

Fig. 16: Identifying Cylinder 1 To 8 Ignition Coils
Ignition coils, location GF15.10-P-3102-01AM

Ignition coils, task The ignition coils provide
sufficient ignition energy
under all operating
conditions for the
respective ignition circuit.
Ignition coils, design The ignition coils are
designed as double
ignition coils (with two
ignition wirings) and are
fitted with a 3-pin plug
connector.
Ignition coils, function GF15.10-P-3102-02AM
Ignition coils, location - GF15.10-P-3102-01AM
Fig. 17: Identifying Ignition Coils Location
For each cylinder, a double ignition coil is located at the cylinder head cover.
Ignition coils, function - GF15.10-P-3102-02AM

Fig. 18: Identifying Ignition Coils, Function
Engine 113 has two spark plugs per cylinder.
Each spark plug is actuated separately via its own ignition coil by the ME control unit. Both ignition coils of a
cylinder are combined to form a dual ignition coil.
The ME-SFI [ME] control unit actuates the primary wirings of the double ignition coil simultaneously at
terminals 1a and 1b with ground. The primary current flows are interrupted at the moment in time of ignition
timing. Sudden collapse of the magnetic fields causes the ignition voltages to be induced in the secondary
windings. The ignition voltages pass to the respective spark plugs via the high-voltage terminals, the ignition
cable and the spark plug connector.
The voltage supply for the double ignition coils is provided via "circuit 15 fused".
Diodes are built-in to suppress additional ignition sparks when the primary current is switched on.
Because of these diodes, it is not possible to measure the resistances of the secondary windings.
IGNITION SYSTEM - GENERAL - GF15.10-P-9611-03AA

Fig. 19: Identifying Ignition System - Firing Order, Engine 137
ME-SFI IGNITION SYSTEM FUNCTION - GF15.12-P-0001
ME-SFI ignition system function - GF15.12-P-0001F
ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
ENGINE 104.995
with CODE (498) as of Model Year 97 Japanese version
ENGINE 111.921 /942 as of 1.9.98,
111.943,
111.944 as of 1.8.96,
111.946 as of 1.6.98,
111.947/973,
111.975 as of 1.8.96
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
202.020/080 as of 1.9.98
ENGINE 111.974
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE 137.970
Fig. 20: Identifying ME-SFI Ignition System Components
Signal assignment
Fig. 21: Identifying Signal Assignment - Shown On Engine 119
Function
When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor by the teeth
of the driven plate. In this case, each tooth generates an alternating voltage signal. No voltage is generated
through the gap of 2 missing teeth. The ME-SFI control unit detects the TDC position of the crankshaft with the
2nd negative slope after the gap.
Engine Recognition of TDC position of Ignition TDC

cylinder
111 1 and 4 Cylinder 1
104, 112, 113, 119 1 and 6 Cylinder 1
120, 137 Right hand cylinder bank: 1 and 6 Cylinder 1
Left cylinder bank: 7 and 12 Cylinder 7
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 the fuel injectors. The high
voltage is distributed rotorlessly. Advantages of the rotorless high voltage distribution are:
 significantly reduced electromagnetic interference level (no naked sparks)

 no rotating parts
 reduction in noise
 reduced high voltage connections.
1. Determine ignition angle according to input signals, actuate ignition coils and release ignition
spark.
The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
 Engine load
 Crankshaft position sensor
 Camshaft Hall sensor
 Coolant temperature sensor
 Intake air temperature sensor/charge air.
Coil ignition: The ME control unit interrupts at the point of ignition timing at the ground end the ignition
coil primary circuit of the ignition coil.
ECI ignition system (engine 137): The ME control unit actuates the output stages in the ECI ignition
modules.
The ignition angle can only be checked with the HHT/STAR DIAGNOSIS.
2. Ignition angle adaptation
2.1 Catalytic converter heating-up (warming-up)
The ignition angle is continuously retarded for about 20 seconds in order to more rapidly warm up the catalytic
converter to its operating temperature if:
 coolant temperature at start > 15 °C and < 40 °C

 Selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2.2 Idle speed
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.
Altering the ignition angle provides a more rapid control than altering the position of the throttle valve (idle
speed control).
2.3 Deceleration fuel shutoff
The ignition angle is briefly retarded when combustion is resumed (fuel injectors actuated) in order to prevent a
sudden increase in torque.
2.4 Intake air temperature/coolant temperature
The ignition angle is retarded under load, as a function of the intake air temperature and coolant temperature, in
order to prevent any knocking tendency at high intake air and coolant temperatures. The ignition angle is
"Retarded" if:
 Intake air temperature > 35 °C

 Coolant temperature > 105 °C
In supercharged engines the charge air temperature is used as information for the ignition timing adjustment in
place of the intake air temperature.
The values of the retardation of the ignition angle of intake air temperature and coolant temperature are added
together.
2.5 Transmission overload protection
In order to protect the shift elements of the automatic transmission during power shifts (1-2-1, 2-3-2) from
excessive thermal stresses, the ignition angle is briefly retarded during the gearshift and the engine torque
reduced as a result. The ME-SFI control units are supplied with a signal for this purpose from the ETC control
unit (N15/3) over the CAN databus.
2.6 ESP/ASR 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) prior to the control mode being activated. The
information from the ESP/ASR control unit is supplied over the CAN databus to the ME-SFI control unit.
2.7 Anti-knock control (AKC)
If uncontrolled combustion (knocking) occurs at one or several cylinders, the ignition angle at the relevant
cylinder or cylinders is "Retarded".
2.8 Smooth engine running analysis
To restrain the three way catalytic converter from thermal overload through combustion misfiring and in order
to keep the exhaust emission values, the smooth operation of the engine is continuously monitored.
If combustion misfiring is identified at one or several cylinders, the corresponding fuel injection valves are no
longer actuated after a certain number of misfires.
Engine 104, 111, 112, 113, 119, 120: Smooth operation evaluation is performed through the signals of the
crankshaft position sensor.
Engine 137: Identification of combustion misfiring by means of ionic current signal, see ECI ignition system
function.
2.9 Double ignition engine 112,113,137
Two spark plugs for each cylinder are beneficial because of the arrangement of the valves for achieving optimal
emission levels and smooth engine running.
Each spark plug is actuated separately by the ME-SFI control unit through its own ignition coil. On engine 112,
113 both ignition coils of a cylinder are combined to form a dual ignition coil.
In the lower part load range up to approx. 2000 rpm both ignition sparks of a cylinder are triggered
simultaneously. At moderate and high engine loads, the ignition sparks are triggered offset by as much as 10°
crank angle. In this case, the sequence of actuation is constantly varied in order to achieve a uniform wear of
both spark plugs and to avoid deposits on only one side of the combustion chamber.
For troubleshooting in the dual ignition system, it is possible to switch off one ignition circuit each with HHT or
STAR DIAGNOSIS.
ME-SFI ignition system Engine 104 GF15.12-P-0001-01D

function diagram Engine 111 GF15.12-P-0001-01G
Engine 112 GF15.12-P-0001-01A
Engine 113 GF15.12-P-0001-01B
Engine 119 GF15.12-P-0001-01E
Engine 120 GF15.12-P-0001-01F
ME-SFI control unit GF07.61-P-5000F
ECI ignition system function Engine 137 GF15.15-P-3000L
Ignition coils, Engine 119, 120 GF15.10-P-3102F
location/task/design/function Engine 104, 111 GF15.10-P-3102G
Engine 112, 113 GF15.10-P-3102A
Crankshaft position sensor, GF07.04-P-4116F
Camshaft Hall sensor, GF07.04-P-4117F
Spark plugs, GF15.10-P-3101F
Intake air temperature sensor, GF07.04-P-2100F
Hot film mass air flow sensor, Engine 119, 120 (round GF07.07-P-4118E
location/task/ design/function connector)
Engine 104, 111, 112, GF07.07-P-4118G
113, 137
Coolant temperature sensor, Engine 104, 111 GF07.04-P-5026G
location/task/ design/function Engine 112, 113, 137 GF07.04-P-5026A
Engine 119, 120 GF07.04-P-5026F
Electronic accelerator, Engine 104, 111, 112, GF30.20-P-3010E
location/design/function 113, 119, 137
Engine 120 GF30.20-P-3010F
Anti-knock control function GF15.12-P-4024F
Transmission overload with automatic GF07.61-P-4026F
protection function transmission
Overheating/pinging protection GF07.61-P-4027F
function
Intake air temperature GF07.61-P-4028F
correction function
ME-SFI synchronizing fuel GF07.61-P-4009F
injection and firing order
function
ME-SFI ignition system signal Engine 104 GF15.12-P-0001-02D
assignment Engine 111 GF15.12-P-0001-02G
Engine 112 GF15.12-P-0001-02A
Engine 113 GF15.12-P-0001-02B
Engine 119 GF15.12-P-0001-02E
Engine 120 GF15.12-P-0001-02F
Engine 137 GF15.12-P-0001-02L
ME engine speed signal GF07.61-P-3017F
function
ASR V control unit with code 471a GF42.40-P-4500A
location/task/design/function Model 129, 140, 202 as
of 6/94, 170, 208, 210
ESP control unit location / task / with code 472a GF42.45-P-4500A
function Model 129 with engines
104, 119, 120
Model 140
Model 210 with engine
119
with code 472a GF42.45-P-4500B
112, 113
Model 163 up to 8/02,
168, 215
Model 220 (except
220.08/18)
Model 202, 208 with
engine 112, 113
111, 112, 113
with code 472a GF42.45-P-4500C
Model 170 with engines
111, 112
Model 202, 208 with
Engine 111
Model 203
Model 211, 230 GF42.45-P-4500SL
ETC control unit, location/task Transmission 722.6 GF27.19-P-4012G
ME-SFI ignition system function diagram - GF15.12-P-0001-01A
Fig. 22: Identifying ME-SFI Ignition System Components - Engine 112
ME-SFI ignition system function diagram - GF15.12-P-0001-01B

Fig. 23: Identifying ME-SFI Ignition System Components - Engine 113
ME-SFI ignition system signal assignment - GF15.12-P-0001-02A
Fig. 24: Identifying ME-SFI Ignition System Signal Assignment - Signal Assignment Engine 112
ME-SFI ignition system single assignment - GF15.12-P-0001-02B

Fig. 25: Identifying ME-SFI Ignition System Signal Assignment - Signal Assignment Engine 113
TNA rpm signal on ME2.8 with 3 pulses for each engine revolution
ME-SFI ignition system signal assignment - GF15.12-P-0001-02L
Engine 137.970
Signal assignment engine 137

Fig. 26: ME-SFI Ignition System Signal Assignment - Engine 137
ME-SFI ignition system, function - GF15.12-P-0001M

Fig. 27: ME-SFI Ignition System, Function
When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor by the teeth
of the drive 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 [ME] control unit detects the TDC
position of cylinders 1 and 7 via the 2nd negative signal edge after the gap:
If the signal from the camshaft Hall sensor of the respective cylinder bank is at 0 V ("Low") at this moment, the
ME-SFI [ME] control unit processes this to detect ignition TDC for cylinder 1 and, with the MESFI 2.7.1,
additionally for cylinder 7. This is used to actuate the ignition modules and the fuel injection valves.
The high voltage distribution is performed statically and directly from the ECI ignition modules to the spark
plugs.
1. Determining the ignition angle in line with the input signals and actuating the ECI ignition modules
For determining the ignition angle, the ME-SFI control unit essentially analyzes the signals of the
following sensors:
 Pressure sensor downstream of throttle valve actuator (engine load)

 Crankshaft position sensor
 Camshaft Hall sensor
 Coolant temperature sensor
 Charge air temperature sensor
The ME-SFI [ME] control unit actuates the output stages in the ECI ignition modules. The output stages
generate the high voltage from an ac voltage for each spark plug.
The ignition angles can be checked using the DAS.
2. Ignition angle adaptations

2.1 Catalytic converter heating up (warming-up phase)
The ignition angle is continuously retarded for about 20 seconds in order to warm up the catalytic
converter more rapidly to its operating temperature, if:
 coolant temperature at start > 15°C and < 40°C

 Selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2.2 No-load speed
To assist idle speed control, the ignition angle can be retarded briefly by as much as 36° crank
angle or advanced by as much as 20° crank angle.
The control by altering the ignition angle reacts more rapidly than altering the position of the
throttle valve (idle speed control).
2.3 Deceleration fuel shutoff
When combustion is restored (actuation of the fuel injectors), the ignition angle is briefly retarded
in order to prevent a sudden increase in torque.
2.4 Overheating and pinging protection
The ignition angle is retarded under load, as a function of the charge air temperature and coolant
temperature, in order to prevent any knocking tendency at high charge air and coolant temperatures.
2.5 Transmission overload protection
In order to protect the shift elements of the automatic transmission from excessive thermal stresses
during powershifts (1-2-1, 2-3-2), the ignition angle is briefly retarded during the gearshift and the
engine torque is thus reduced. The ME-SFI [ME] control unit is supplied with a signal from the
ETC [EGS] control unit for this purpose via the CAN.
2.6 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 data bus to the ME-SFI control unit.
2.7 Anti-knock control (AKC)
If uncontrolled combustion (knocking) occurs at one or several cylinders, the ignition angle at the
relevant cylinder or cylinders is "retarded".
2.8 Smooth engine running analysis
To restrain the three way catalytic converter from thermal overload through combustion misfiring
and in order to keep the exhaust emission values, the smooth operation of the engine is
continuously monitored.
If combustion misfiring is identified at one or several cylinders, the corresponding fuel injection
valves are no longer actuated after a certain number of combustion misfires.
Detection of combustion misfires is performed through a smooth running analysis and at high rpms,
in addition through the evaluation of the ion current. The size of the ion current is detected by the
ECI ignition module and is transmitted to the ME-SFI control unit.
2.9 Double ignition
Two spark plugs for each cylinder are beneficial on the basis of the valve arrangement for
achieving optimal exhaust emission levels and smooth engine running.
Each spark plug is actuated via its own ignition coil in the ECI ignition modules separately by the
ME-SFI control unit.
In the lower part load range up to approx. 2000 rpm both ignition sparks of a cylinder are triggered
simultaneously. At medium and high loads, ignition is offset by up to 10° crank angle.
The order of actuation is constantly varied in this case in order to ensure uniform wear of both spark plugs and
to avoid deposits on one side of the combustion chamber. The signals for ignition circuit change and ignition
offset are transmitted by the ME-SFI control unit to the respective ECI ignition module.
ME-SFI ignition system signal GF15.12-P-0001-02M

assignment
ME-SFI [ME] control unit, GF07.61-P-5000M
Crankshaft position sensor, GF07.04-P-4116M
Camshaft Hall sensor, GF07.04-P-4117M
Spark plugs, GF15.10-P-3101M
Coolant temperature sensor, GF07.04-P-5026M
ME-SFI ignition system signal assignment - GF15.12-P-0001-02M
Fig. 28: ME-SFI Ignition System Signal Assignment
ANTI-KNOCK CONTROL FUNCTION - GF15.12-P-4024
Anti-knock control function - GF15.12-P-4024AM

Fig. 29: Anti-Knock Control Function - Engine 113.990 In Models 211, 219
The task of the anti-knock control (AKC) is to ensure knock-free operation of the engine with different fuels
and under 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 is integrated in the ME control unit.
Input signals:
 Knock identification --> knock sensors

 Engine speed --> Crankshaft position sensor
 Ignition circuit detection --> Crankshaft position sensor and camshaft Hall sensor
 Engine temperature --> Coolant temperature sensor
 Air mass --> pressure sensor and charge air temperature sensor
 Engine load --> Accelerator pedal sensor
 Presetting (programming) --> 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 knock sensor fault is detected
The anti-knock control is active from engine start. If knocking was detected at a cylinder, the ignition angle of
this cylinder is retarded from the next ignition. If knocking continues to occur, the ignition angle (depending on
engine speed) continues to be retarded in stages until maximum retardation is achieved.
If knocking-free combustion exists, the retardation is reduced in stages after a few ignitions (depending on
engine speed) until the normal 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 then the engine control
system reduces the engine power output to protect the engine.
Fault if knocking is 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 deactivated 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).
When determining the individual ignition angles, the stored adaptation values are taken into account, so that the
optimal ignition angle can be calculated immediately for each cylinder.
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 preprogrammed using the STAR DIAGNOSIS.
The ignition angle corrections of the overheating/pinging protection and anti-knock control are added based on
the performance map.
Crankshaft position sensor, GF07.04-P-4116AM

Camshaft Hall sensor, GF07.04-P-4117HA
Coolant temperature sensor, GF07.04-P-5026AM
Ignition coils, GF15.10-P-3102AM
Knock sensors, GF15.12-P-4101AM
Accelerator pedal sensor, GF30.20-P-4010HA
Anti-knock control function - GF15.12-P-4024F
ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
ENGINE 104.995
with CODE (498) as of Model Year 97 Japanese version
ENGINE 111.921 /942 as of 1.9.98,
111.943,
111.944 as of 1.8.96,
111.946 as of 1.6.98,
111.947/973,
111.975 as of 1.8.96
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
202.020/080 as of 1.9.98
ENGINE 111.974
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE 137.970
Fig. 30: Identifying Anti-Knock Control Components - Shown On Engine 119
Task
Ensuring knock-free operation of the engine with different fuels in all operating conditions from idling speed up
to maximum speed of engine, from an engine load of more than approx. 40%. For this purpose, if uncontrolled
combustion (knocking) occurs, the ignition angle at the relevant cylinder or cylinders is retarded.
Design/function
The anti-knock control (AKC) function is integrated in the ME-SFI control unit. The range of functions has
been enlarged compared to previous versions.
Input signals:
 Engine speed (crankshaft position sensor)

 Camshaft position (camshaft Hall sensor)
 Knock identification:
Engine 104, 111, 112, 113, 119, 120 by means of knock sensors Engine 137 by ionic current
measurement
 Engine temperature (coolant temperature sensor)

 Engine load (hot film air flow sensor or pressure sensor on supercharged engines)
 Accelerator pedal position (accelerator pedal sensor)
 Precontrol by means of automatic RON switch (internal)
Output signals:
 Cylinder specific ignition angle correction on the calculated map value of the ME control unit.
 Ignition angle emergency mode if fault identified.
Basic function
The anti-knock control is active from a coolant temperature of 70 °C. If knocking is detected at a cylinder above
an engine load of approx. 40%, its ignition angle is retarded from the next ignition by about 2.3° crank angle
(e.g. M119) or by about 3.0° crank angle (e.g. M120). If knocking continues to be detected, the ignition angle is
continuously retarded in steps of 2.3° crank angle (e.g. M119) until the maximum retardation is reached
(approx. 10 to 15° crank angle, depending on engine speed). In addition, the automatic RON switch 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 engine speed) until the map value (a) is achieved, or knocking once again occurs.
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 angle 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 in the case of knocking detection
If no signals are received from the knock sensors or from the ionic current measurement, the ignition angle of
all the cylinders is retarded, for safety reasons, by as much as approx. 11° crank angle 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 the HHT, the anti-knock 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 the HHT/STAR DIAGNOSIS is at
first active.
Crankshaft position sensor, GF07.04-P-4116F

Camshaft Hall sensor, GF07.04-P-4117F
Knock sensors, GF15.12-P-4101F
Coolant temperature sensor, Engine 119, 120 GF07.04-P-5026F
location/task/ design/function Engine 104, 111 GF07.04-P-5026G
Engine 112, 113, 137 GF07.04-P-5026A
Hot film mass air flow sensor, Engine 119, 120 (round GF07.07-P-4118E
location/task/ design/function connector)
Engine 104, 111, 112, GF07.07-P-4118G
113, 137
Engine 111 EVO GF07.07-P-4118GS
Pedal value sensor, GF30.20-P-4011L
ME-SFI control unit GF07.61-P-5000F
position/task/design/ function Engine 111 EVO GF07.61-P-5000GS
ME-SFI synchronizing fuel GF07.61-P-4009F
injection and firing order
Engine 111 EVO GF07.61-P-4009GS
function
Anti-knock control function - GF15.12-P-4024M

Fig. 31: Anti-Knock Control Function - Engine 275.950 In Model 215, 220
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 relevant cylinder or
cylinders is retarded. The anti-knock control (AKC) function is integrated in the ME-SFI [ME] control unit
(N3/10).
Input signals:
 Engine speed (crankshaft position sensor)

 Camshaft position (camshaft Hall sensor)
 Recognition of knocking over 4 knocking sensors
 Engine temperature (coolant temperature sensor)
 Engine load (pressure sensor downstream of throttle valve actuator)
 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 alternator control unit
 Ignition angle emergency mode if fault identified.
Anti-knock control is active from a coolant temperature of 70°C. If cylinder knocking is recognized above an
engine load of about 40%, its ignition angle is retarded by approx. 3.0° crank angle after the next ignition. If
knocking continues to be detected, the ignition angle is continuously retarded in 3° crank angle increments 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 retardation of ignition timing - the higher the selected
RON stage, the less the maximum retardation of ignition timing.
If knocking-free combustion exists, retardation is reduced in approx. 0.75° crank angle increments after a few
ignitions (depending on the engine speed) until the performance map value is achieved, or knocking occurs
again.
Adaptation of anti-knock control is active from a coolant temperature of approx. 75°C. Any corrections required
to the ignition angle due to 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 to avoid any incorrect adaptation values.
Automatic RON switch
In addition to the RON correction using STAR DIAGNOSIS, the anti-knock 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 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 performed via STAR DIAGNOSIS is active at first.
Faults in knocking detection
If no signals are received from the knock sensors or from ionic current measurement, the ignition angle of all
cylinders is retarded for safety reasons by as much as approx. 11° crank angle depending on engine speed and
temperature. The anti-knock control and the adaptation are deactivated and a fault is stored.
The engines are designed to run with RON 98 fuel. If only fuel with RON 91 is available, the RON correction
must be carried out immediately using STAR DIAGNOSIS, otherwise engine damage is possible.
Crankshaft position sensor, GF07.04-P-4116M

Camshaft Hall sensor, GF07.04-P-4117M
Knock sensors, GF15.12-P-4101M
Coolant temperature sensor, GF07.04-P-5026M
Accelerator pedal sensor, GF30.20-P-4010M
ME-SFI synchronization of fuel GF07.61-P-4009M
injection and firing order,
function
KNOCK SENSORS, LOCATION/TASK/DESIGN/FUNCTION - GF15.12-P-4101
Knock sensors, location/task/design/function - GF15.12-P-4101AM

Fig. 32: Identifying Knock Sensors Location Right And Left Side
Knock sensors, location GF15.12-P-4101-01AM

Knock sensors, task The knock sensors detect
the vibrations at the
crankcase of the respective
cylinder bank.
Knock sensors, design The knock sensors are all
in one a closed system.
Inside the sensor are piezo
crystals. The screened 2-
pin connection lines are
directly put onto the knock
sensors.
Knock sensors, function GF15.12-P-4101-02AM
Knock sensors, location - GF15.12-P-4101-01AM
The knock sensors are located at the crankcase in the engine V-angle.
Fig. 33: Identifying Knock Sensors 1 And Knock Sensors 2
Knock sensors, function - GF15.12-P-4101-02AM
Knock sensor signal

Fig. 34: Identifying Knock Sensor Signal Pattern
The knock sensors detect the vibrations at the crankcase of the respective cylinder bank.
The vibrations are converted by the interior piezo-crystals of the knock sensors into electrical voltage signals
and passed on to the ME control unit (N3/10) for evaluation.
Piezoelectric effect: If a mechanical force acts on a crystal and electrical voltage is produced.
Knock sensor signals can also indicate engine damage (e.g. increased engine noise due to widened piston
grooves).
Knock sensors, location/task/design/function - GF15.12-P-4101F
ENGINE 104.941 /942 /943 /944 /945 /991 /992 /994 /995
ENGINE 111.921 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977
ENGINE 111.942 as of 1.6.96
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 166.940 /960 /990 /995
Fig. 35: Identifying Knock Sensors
Knock sensors, location Engine 104 GF15.12-P-4101-01D

Engine 111 GF15.12-P-4101-01G
Engine 112 GF15.12-P-4101-01A
Engine 113 GF15.12-P-4101-01B
Engine 119 GF15.12-P-4101-01E
Engine 120 GF15.12-P-4101-01F
Engine 166 GF15.12-P-4101-01GC
Knock sensors, task The knock sensor detects
vibrations at the
crankcase.
Knock sensors, design The knock sensor is a self-
contained system. Inside
the sensor are piezo
crystals. The screened
cable is fitted directly onto
the knock sensor.
Knock sensors, function GF15.12-P-4101-02KE
Knock sensors, location - GF15.12-P-4101-01A
Fig. 36: Identifying Knock Sensors - Engine 112

Knock sensors, location - GF15.12-P-4101-01B
Fig. 37: Identifying Knock Sensors - Engine 113
Knock sensors, function - GF15.12-P-4101-02KE
Fig. 38: Identifying Knock Sensors Oscilloscope Signals
Any vibrations which occur are converted with the aid of the piezo ceramic into electrical signals.
Piezo-electric effect: If a mechanical force acts on a crystal, electrical voltages are produced.
Knock sensor signals may also indicate engine damage, e.g. increased engine noise resulting from a widened
piston groove.
Knock sensors, location/task/design/function - GF15.12-P-4101M

Fig. 39: Identifying Knock Sensors, Location - A29/1, A29/2
Knock sensors, location GF15.12-P-4101-01M

Knock sensors, task The knock sensor detects
vibrations at the
crankcase.
Knock sensors, design The knock sensor is a self-
contained system. Inside
the sensor are piezo
crystals. The screened
cable is fitted directly onto
the knock sensor.
Knock sensors, function GF15.12-P-4101-02M
Knock sensors, location - GF15.12-P-4101-01M

Fig. 40: Identifying Knock Sensors, Location
Knock sensors, function - GF15.12-P-4101-02M
Fig. 41: Identifying Knock Sensor Function
Any vibrations which occur are converted with the aid of the piezo ceramic into electrical signals.
Piezo-electric effect: If a mechanical force acts on a crystal, electrical voltages are produced.
Knock sensor signals may also indicate engine damage, e.g. increased engine noise resulting from a widened
piston groove.
ECI IGNITION SYSTEM FUNCTION - GF15.15-P-3000
ECI ignition system function - GF15.15-P-3000L
ENGINE 137.970
Fig. 42: Identifying ECI Ignition System Function - Engine 137.970
Left ignition module ME-SFI control unit Right ignition module

(N92/2) (N3/10), coupling 3 (N92/1)
ion current Pin 6 --> Pin 32 Pin 33 <-- Pin 6 ion current
signal signal
cylinders 7 to cylinders 1 to
9 3
ion current Pin 7 --> Pin 45 Pin 46 <-- Pin 7 Ion current
signal signal
cylinders 10 cylinders 4 to
to 12 6
Ground, ion Pin 5 - Pin 44 Pin 47 - Pin 5 Ground, ion
current current
signals signals
Ignition Pin 1 <-- Pin 37 Pin 49 --> Pin 1 Ignition
trigger signal, trigger signal,
cylinder 7 cylinder 1
Ignition offset Pin 10 <-- Pin 29 Pin 15 --> Pin 10 Ignition offset
cylinders 7 to cylinders 1 to
12 6
change change
(ignition (ignition
circuit a/b) circuit a/b)
Power pack (N91)
Battery Pin 15 <-- Pin 13 Pin 12 --> Pin 15 Battery
voltage, voltage,
terminal terminal
Ground Pin 8 - Pin 14 Pin 11 - Pin 8 Ground
Auxiliary Pin 14 <-- Pin 8 Pin 7 --> Pin 14 Auxiliary
voltage voltage
approx. 23 approx. 23 V
Voltage Pin 16 <-- Pin 16 Pin 9 --> Pin 16 Voltage
approx. 180 V approx. 180 V
Voltage supply
Voltage supply --> Pin 4
Circuit 87 --> Pin 5
The short name for the AC ignition system ECI means:
E = Energy (energy)
C = Controlled (controlled)
I = Ignition (ignition system)

Task
The ignition system ECI must initiate combustion by creating a spark at the spark plugs. This requires an
adequately high voltage for generating a spark at the end of the spark plug and the sparks must also have
sufficient energy to ensure guaranteed combustion of the fuel / air mixture.
The ignition system must be insensible to carbon fouled spark plugs and guarantee a high spark plug working
life.
Design
The ignition system ECI consists of:
 The ignition module ECI for the right cylinder bank

 The ignition module ECI for the left cylinder bank
 ECI ignition system mains unit
 Evaluation circuit for the ion current in the ME control unit
 Actuation of the ignition system ECI by the ME control unit
 Ignition map in the ME control unit.
No spark tests can be undertaken with the ignition system ECI.
Function
The ignition system ECI has the following sub-functions:
1. Generation of the ignition voltage (ac voltage).
There is an output stage for each spark plug in the ignition modules. The ignition coils are arranged in the
spark plug connectors. The output stages with oscillating circuit generate the ignition voltage from an
input of about 180 V.
The ME control unit produces the following actuation impulses:
Triggering of the ignition spark according to the ignition angle

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ACCESSORIES/SAFETY EQUIPMENT

Mercedes-Benz - Air Bag Restraint Systems

DESCRIPTION & OPERATION

SYSTEM OPERATION CHECK

AIR BAG SAFETY PRECAUTIONS

DISABLING & ACTIVATING AIR BAG SYSTEM

 Scrapping a vehicle containing deployed air bag modules and ETRs.

DEPLOYED AIR BAG OR ETR

UNDEPLOYED AIR BAG OR ETR

REMOVAL & INSTALLATION

Removal and installation information is not available.

Mercedes-Benz - Air Bag Restraint Systems

DESCRIPTION & OPERATION

SYSTEM OPERATION CHECK

AIR BAG SAFETY PRECAUTIONS

DISABLING & ACTIVATING AIR BAG SYSTEM

CAUTION: On CL500, open doors before disconnecting battery. Opening doors

WARNING: An undeployed air bag module or ETR should never be disposed of

 Scrapping a vehicle containing a deployed air bag module and-or ETR.

DEPLOYED AIR BAG OR ETR

UNDEPLOYED AIR BAG-ETR

REMOVAL & INSTALLATION

Removal & Installation

Removal & Installation (C Class)

Removal & Installation (E Class)

Removal & Installation (S Class)

Removal & Installation (SL Class)

Removal & Installation (CLK & SLK)

DRIVER-SIDE AIR BAG MODULE

Removal & Installation

SIDE AIR BAG UNIT (DRIVER-SIDE & PASSENGER-SIDE)

Removal & Installation

Fig. 2: Removing Side Air Bag Unit (2000 Models)

SIDE AIR BAG SENSOR (DRIVER-SIDE & PASSENGER-SIDE)

Removal & Installation

OCCUPIED SEAT RECOGNITION SENSOR

Removal & Installation

PASSENGER-SIDE AIR BAG MODULE

Removal & Installation (C Class)

Removal & Installation (E Class)

Removal & Installation (S Class)

Removal & Installation (SL Class)

Removal & Installation (CLK 320)

Removal & Installation (SLK 320)

NOTE: After component replacement, perform a system operation check to ensure

RETRIEVING FAULT CODES

Fig. 6: Diagnostic Trouble Code (DTC) Memory (2000 Models-1 Of 4)

Fig. 7: Diagnostic Trouble Code (DTC) Memory (2000 Models-2 Of 4)

Fig. 9: Diagnostic Trouble Code (DTC) Memory (2000 Models-4 Of 4)

CLEARING FAULT CODES

UNDERSTANDING DIAGNOSTIC CHART INFORMATION

SRS & ETR Diagnosis Chart Column Identification

Using SRS & ETR Diagnosis Chart

CONTROL MODULE PROGRAMMING

Vehicles Without Side Air Bag

Vehicles With Side Air Bag

Fig. 27: SRS & ETR Diagnosis (2000 E Class-1 Of 23)

Fig. 29: SRS & ETR Diagnosis (2000 E Class-3 Of 23)