Mercedes-Benz 201.024, 201.028 Service Manual

Mercedes-Benz

Mercedes-Benz of North America, Inc. - Montvale, NJ 07645

0 Mercedes-Benz of North America, Inc., 1993

All rights reserved. Reproduction by any means, elec­tronic or mechanical, including photocopying, record­ing, or by any information storage and retrieval system
or translation in whole or part is not permitted without
written authorization from the publisher.

Published by Mercedes-Benz of North America, Inc.
Printed in U.S.A.

Part number S-2347-93A

Introduction

This service manual is the product of existing technical publications. Special care has been taken
to provide accurate information on removal, disassembly, inspection, installation, and adjustment
procedures, together with the necessary technical data for the particular job.

The material in this manual is divided according to the Mercedes-Benz Component Group System
as outlined on the GROUP INDEX page. This page will quickly direct the reader to the Major
Component Group. Each Major Component Group begins with a JOB INDEX listing all jobs within
that group.

Mercedes-Benz of North America, Inc. recommends that repairs to, and maintenance of
Mercedes-Benz automobiles be performed by

trained Mercedes-Benz personnel

at authorized

Mercedes-Benz dealerships.
The information contained in this special publication is ordinarily issued by Mercedes-Benz of

North America, Inc., in conjunction with supplementary service literature and special tools supplied

only to

its authorized dealers.

The repair and maintenance procedures outlined herein are

intended for use by

trained Mercedes-Benz service and dealership personnel. This

manual
can also be useful for Mercedes-Benz owners in diagnosing vehicle systems and performing
repairs. Supplementary service literature will not be provided with this publication, but may be

contained in reprints of this service manual.
Please note that this manual has been compiled from various sources, some of which cover

models other than the subject of this book.

Always refer to the engine and vehicle identification

table for model and component information.
Special tools required in performing certain service jobs are identified in the manual and are

recommended for use. Any part numbers given are only used for identification and easier
differentiation between individual components, and are not intended for ordering purposes.

If your Mercedes-Benz model differs from the specifications contained in the manual you select,
consult your authorized Mercedes-Benz dealer.

All procedures, illustrations and specifications contained in this manual were based on the latest
information available at the time of publication. All rights are reserved to make production, design
and specification changes at any time, without notice and without obligation to give notice. Any
such changes will not be contained in this manual.

Caution!

The proper performance of service and repair procedures is essential for both the safety of the
mechanic and the safe and efficient operation of the vehicle. The use of incorrect service

procedures and tools may greatly increase the risk of personal injury and render the vehicle
unsafe. The procedures in this manual are described in such a manner that the service may be
performed safely and accurately.

However, it is a general assumption that the reader is familiar with basic automotive
procedures and Mercedes-Benz vehicles. You should not attempt to use this manual if this
the case.

repair
is not

Mercedes-Benz of North America, Inc. assumes no liability for any damage to person or property
caused by the utilization of this publication to effect maintenance or repair work on Mercedes-Benz
automobiles.

MERCEDES-BENZ OF NORTH AMERICA, INC.

Service and Parts Literature

Group Index

General, Technical Data

00

Crankcase and cylinder head

01

Crankshaft assembly

03

Engine timing, valvetrain

05

Continuous Fuel Injection System (CFI) 07.3

Air filter

09

Belt drive

Intake and exhaust manifolds, emission control system

14

Electrical system, engine

15

Engine lubrication system

Engine cooling system

20

Engine suspension

22

Accelerator control, cruise control, electronic accelerator

30

Fuel system

Exhaust system

General,

technical

data

00

00

General,

technical

Job No.

Instructions for use of service manual

....................................... 00 - 005

Engine and vehicle identification

............................................

-

010

Vehicle identification number locations

.......................................

-

015

Technical data ........................................................

-

020

00/l

Instructions for use of

servic

00-005

Complete Service Manual coverage for late
model year Mercedes-Benz vehicles requires
four individual manuals:

Service Manual, Engine
Service Manual, Chassis and Body
Service Manual, Automatic Climate Control
Electrical Troubleshooting Manual

Throughout these manuals, the vehicles are
identified by their chassis and engine numbers.
These numbers are made up of the first six digits
of the respective serial number. For the actual
location of chassis and engine numbers, see
page

00-015’1.

In cases where the repair
instructions apply to all versions, only the first
three digits of the respective number are
referenced.

For example, chassis 124 applies to all

124

models. However, chassis

124.051

would apply

only to model 300CE with engine 104.

Location of specific repair instructions

First locate the Group No. in the Group Index.
Individual groups are separated by an easily
visible dividing page, which is followed by the job
index page. The exact job required is found in
the job index. The initial page of a typical job
description appears as follows:

03-324

Replacement of front crankshaft
radial seal

Job Title appears on
same line as Group
No.

Job No.

Page No.

Technical data, tightening torques and tools are
listed at the beginning of each job.

All dimensions are in metric units unless
otherwise indicated. Any part numbers given are
only used for identification and differentiation
between individual components, and are not
intended for ordering purposes.

Special Instructions

AWarning

Appears throughout service instructions indicating the possiblity of personal injury
if procedures are not followed.

Caution!

Indicates possible equipment or vehicle damage if procedures are not followed.

Note

Provides helpful information for the described procedure.

Installation note

Provides detailed information during assembly.

.oo -

005 11

ine

and vehicle identification

This manual applies to the following passenger cars, starting model year 1984.

Gasoline engines

Model Year

1

Model

1

Sales Designation

IE

9

n.

ine

1984

I

201.024

I

190

E 2.3

I

102.961

1985

I

201.024

I

190

E 2.3

I

102.985

1991

I

201.028

I

190

E 2.3

I

102.985

1992

I

201.028

I

190

E 2.3

I

102.985

1993

I

201.028

I

190

E 2.3

I

102.985

00 -

010/l

Identification number locations

00-615

Model

201

When ordering spare parts, please specify
chassis and engine numbers.

7

a

Certrfication

Tag (left door

plllar)
ldentlficatlon Tag (left wlndow post)
Vehicle ldentlficatlon No.
Engine

No.
Body No. and Paintwork No.
lnformatron Tag
California version
Vacuum line routing for

emission

control system

Emlsslon

Control Tag

Emlsslon

Control Tag
Catalyst Information
(from model year 1964 up to 1966)

00 - 015 I1

Technical

data

00

Gasoline engines

201.024

1

201.028

Model

20

1.024

190 E 2.3

(Model year 1984)

102.961

4-stroke spark ignition,
mechanicallyielectronically

controlled continuous fuel
injection system with airflow
sensor (CIS-E)

Normal
4

In-line

15”

inclination

95580.25

2299

8.0 : 1

l-3-4-2

5700 t 50

8415000

11315000

18113500
13313500

S(multi-component,

anti-

friction bearings)
Overhead, 2 per cylinder

1 overhead camshaft

Coolant circulation pump,
thermostat with bypass line,
fan with electromagnetic
clutch, finned tube radiator

Pressure lubrication via gear
type

pump

Full flow filter
Dry air filter with paper

cartridge

190 E 2.3 190 E 2.3

(Model years

1985-86)

I

(Model years

1987-8, 1991-3)

Sales

designation

Engine
Operation

102.985

102.985

4-stroke spark ignition,
mechanically/electronically
controlled continuous fuel
injection system with airflow
sensor (CIS-E)

4-stroke spark ignition,

mechanically~‘electronically

controlled continuous fuel
injection system with airflow
sensor (CIS-E)

Normal

I

Normal

Aspiration
Number of

cylinders
Cylinder

arrangement
Bore, stroke mm

In-line

15”

inclination

I

In-line 15” inclination

95.5180.25

I

95.5/80.25

Total effective
piston
displacement cc

Compression
ratio

l-3-4-2 l-3-4-2

Firing order
Maximum speed

rpm
Engine output

(SAE)kWrpm

net

bhp,

rpm

6200 A 50

6200 2 50

Maximum torque

Nm,

rpm

net

lb-fti’rpm

Crankshaft

bearings
Valve

arrangement
Camshaft

arrangement
Oil cooling
Cooling

184/3500

1361’3500

198/3500

14613500

S(multi-component, anti-

friction bearings)

5 (multi-component, anti-
friction bearings)

Overhead, 2 per cylinder

Overhead, 2 per cylinder

1 overhead camshaft

I

1 overhead camshaft

Coolant circulation pump,
thermostat with bypass line,
fan with electromagnetic
clutch, finned tube radiator

Coolant circulation pump,
thermostat with bypass line,
fan with electromagnetic
clutch, finned tube radiator

Lubrication

Pressure lubrication via gear

I

Pressure lubrication via gear

type

pump

type pump

Full flow filter

Full flow filter

Oil filter
Air filter

Dry air filter with paper

cartridqe

I

Dry air filter with paper

cartridae

00 -

020/l

.i._. . . . . . .

.

QQ

Technical

data

Filling capacities

Model

1

201.024

1

201.024

1

201.028

Sales

designation

190 E 2.3 190 E 2.3 190 E 2.3

(Model Year

1984)

(Model Years

1985-6)

(Model Years

1987-8,

1991-3)

I

I

I

Engine

1

102.961

I

102.985

1

102.985

Fuel tank/reserve approx. I

Electrical system

Starter Bosch

00 - 02012

Crankcase and cylinder head

01

01

Crankcase and cylinder head

Job No.

Engine and model survey

................................................

01 - 001

Overview - Engines

....................................................

01 - 005

Removal and installation of bottom engine compartment cover

.....................

01 - 006

Testing compression pressure

..............................................

-

010

Testing cylinder leaktightness

...............................................

-

015

Illuminating cylinders

.....................................................

-

020

Removal and installation of engine

...........................................

-

030

Crankcase ventilation - function

.............................................

-

040

Measuring, boring and honing cylinders

........................................

-

110

Facing crankcase parting surface

............................................

-

120

Removal and installation of steel balls in main oil gallery

............................

-

130

Replacing core plug in crankcase

...........................................

-

140

Removal and installation of timing case cover

...................................

-

210

Removal and installation of end cover

.........................................

-

222

Removal and installation of oil pan

...........................................

-

310

Repair instructions for crankcase,

.............................................

-

403

Removal and installation of cylinder head cover

..................................

-

406

Reconditioning spark plug thread in cylinder head

................................

-

407

Removal and installation of cylinder head

......................................

-

415

Matching measuring sensors to cylinder head

...................................

-

416

Facing cylinder head mating face

............................................

-

418

Enlarging camshaft bearing bores (repair size)

...................................

-

419

Pressure-testing cylinder head

..............................................

-

420

01.11

01-001

Engine and Model Survey

Engine1 Model1

y;m;l

1

Sales designation) Power in kW at rprn /

z;pression

*

102.961

201.024

1984

190 E

2.3

84:5000

8.O:l

102.985

I

201.024

11985-86

1190E2.3

I

90/5000

I

9.0:1

102.985

1201.028

1;;;;;;;

ll9OE2.3

197:5100 19.0:1

01.1101 l-001/1

01-005

Overview - Engines, Models, Output and Compression Ratio

102.961 @

as of 1984

201.024

Sales

designation

190 E 2.3

190 E 2.3

190 E 2.3

Output in KW
at rpm
net bhpirpm

84/5000

113i5000

90/5000

12015000

97:5100

130/5100

Compression
ratio E : 1

8.0

8.0

9.0

01.0904

-

005il

01-006

Removal and installation of bottom engine compartment cover

Model

201

Self-tapping screws (arrows)

. . . . . . . . . . . . . ,

, .

remove, screw in and remove, install engine
compartment cover.

Note

On Model 201.028 @ install engine
compartment cover so that the edge of the side
parts grips above the bottom part.

01.0904 .

006/l

,_L,x,~~.~...z.Y

.

.

________ii__________...........

..,

01-010

Testing compression pressure

Precedmg

work:

Rernovtng

spark plug

(15-016).

01

Compression pressure

recorder,

special tool

001

58976‘21

00

02

Adapter piece

04

Sealing cone with check valve

Test data with engine at normal operating temperature (80

“C)

in bar

Subject

I

When new

1

Limit value

Compression ratio

E

= 9.0 - 9.4

I

10 - 12

1

approx. 8.5

E=

10.0

113.5 -

15.5

I

aDDrox.

12

E

= 7.5 - 8.3

I

9-10

I

approx. 7.5

E

= 7.2 (102.92)

1

8-9

1

approx. 6.5

Permissible difference between individual cylinders max. 3

01.0904

-

010/l

Special tools

001 589 76 21 001

1124589366300

Notes

Test compression pressure at normal operating
temperature.
If the minimum compression pressure is not
reached, test cylinder leaktightness (01-015).

Unscrew all the spark plugs for testing.

Turn crankshaft with starter and compression
pressure recorder.

Warning!

The engines are equipped with an ignition
system with variable ignition characteristics

(EZL).

Because of high ignition voltage, it is very
dangerous to touch components of the ignition
system (ignition coil, ignition cables, spark plug
connector, plug-on unit)

when

l

the engine is running,

l

the engine is started,

l

the key in the steering lock is in position

2

and the engine is cranked by hand.

’

Geftihrliche Hochspannung!

Vorsicht

bei

Arbeiten an der

Danger! High voltage

Observe caution when working
on the ignition system

PIS-0241-13

01.0904 . 01012

Testing

1

Switch off ignition. Detach connector from
ignition distributor pickup (green cable on control
module) (arrow).

Caution!

On injection engines, detach the fuel pump relay
module (N1614) before turning the crankshaft to
ensure that no fuel is injected.

Model 201

2

Connect compression pressure recorder.
This is done by clamping one of the two alligator
clamps (arrow) of the compression pressure
recorder, Part No. 001 589 76 21 00, to the
positive terminal post of the battery.

3

Detach connector (X27) from plug

connection (terminal 50).

4

Plug in connector of adapter cable (01),

Part

No. 124

589

36

63 00.

Model 201

01.0904 - 01

o/3

5

motor, in idle position, selector

“P”,

and parking brake applied

and soot are ejected.

Crank engine several times with starter

lever in position
so that residues

6

To test each cylinder, press the compression
pressure recorder into the spark plug hole of the
particular cylinder and, with the throttle valve

fully opened, crank engine approx. 8 revolutions.

Test all the cylinders in this way.

7

Blow out spark plug recesses with
compressed air. Remove any residues on the
tapered sealing seat.

01.0904 - 01014

01-015

Testing cylinder leaktightness

Data

Total pressure loss

max. 25%

At valves and cylinder head gasket

max. 10%

At pistons and piston rings

max.

20%

Tightening torque

Nm

Spark plugs

Special tools

Commercial tool

Cylinder leaktightness tester

e. g. Bosch, EFAW 210 A

Sun, CLT 228

Testlng

1

Run engine until at normal operating

temperature.

2

Blow out spark plug recesses with

compressed air.

3 Remove spark plugs.

01.0904 - 01511

4

Top off coolant and leave filler opening at

coolant expansion tank open.

5

Remove oil filler cap.

6

Remove air filter (09-400 or

09-410).

7

Connect cylinder leaktightness tester to a

compressed air system and calibrate tester.

8

Position piston of No. 1 cylinder to ignition
TDC. This is done by turning the crankshaft with
a tool combination consisting of wrench socket
(27 mm,

l/2”

square) and reversible ratchet

handle, at the central bolt (front of crankshaft).

Note

The respective pistons are in the TDC position
when the markings shown in the drawing
opposite on the vibration damper or on the belt
pulley are below the TDC pointer.

9 Open throttle fully.

10 Screw connection hose into the 1 st spark
plug bore and attach to the connecting hose of
the tester.
The crankshaft must not turn when performing
this step.

11 Read off pressure loss at tester.

12 Determine by listening whether the pressure
escapes through intake manifold, exhaust, oil
filler opening, spark plug bore of adjacent
cylinder or coolant filler opening.

-_-.-I

‘r

1342

VE

tA

P05.0110-13

13 Test all the cylinders in the firing order.

01.0904 - 015/2

Notes

It is possible that the piston ring gaps of
individual pistons are directly above each other
which falsifies the test result.
In cases of doubt, allow vehicle to run and test

cylinder leaktightness once again after some
time.
After spraying oil onto the piston crown, it is
possible to determine whether the leak exists at
the piston rings or at the valves or the cylinder

head gasket.

01.0904 - 015/3

01-020

Illuminating cylinders

Preceding work:

Removing spark plugs (15-018).

C

iylinder (01)

. . . . . . . . . . . . . . . . . , . . . . . . . .

illuminate with cylinder inspection lamp (Ol),
distinguish between “optical rub marks and
seizing rub marks”.

“Optical rub marks” may result from the ring
gap. Traces of honing are still visible, engine in
order.

“Seizing rub marks”; honing marks no longer
visible, recondition engine.

Commercial tool

Cylinder inspection lamp

8.

g. Karl Storz

GmbH,

D-7200

Tuttlingen

Motoskop TW (cold light) with
lens probes 103 26 CW
(570 mm) and 103 26 CT (210)

01 0904 - 02011

01-030

Removal and installation of englne

Preceding work:
Removal and

installation

of bottom engine compartment

fairing

(01-006).

Removal and

installation

of air filter (09-400 or 09-410).

R

emoval and installation of radiator (20-420).

Battery positive cable

....................

Fan (75)

.............................

Alternator cable connector

.................

Lines for pressure oil pump

................

Cover for evaporator

.....................

Cover for engine wiring harness

.............

Starter wiring harness

....................

Terminal block terminal 50

.................

Terminal 30

...........................

Engine wiring harness

....................

disconnect, connect.
remove, install, 25 Nm.
detach (step 3).
detach, attach (step 4).
insert (step 5).
remove at component partition wall

(steps 6 and 7).
remove, install (step 8).
disconnect, connect (step 9).
disconnect, connect at terminal block (step 10).
disconnect, connect at the individual

connections (steps

11

to 18).

01.0904 .

030/l

Fuel evaporation system

..................

Ground cable

..........................

Accelerator control

......................

Fuel lines

.............................

Coolant hose, heater supply line

............

Vacuum line, brake booster

................

Air conditioning compressor (425)

...........

Engine hoist

...........................

Guard plate

...........................

Exhaust system (48)

. . . . . . . . . . . . .

Lambda sensor

........................

Engine supporting bracket

(12)

.............

Drive shaft to transmission (2) . . . . . . . . .

.

Clamping nut (2a)

.......................

Speedometer shaft

.....................

Ground cable at transmission

...............

Shift rods at transmission

.................

Cable connector for starter lockout, backup
light switch

............................

Cable for

kickdown

solenoid valve

...........

Front engine mounting (22)

................

detach, attach (step 19).

unbolt, bolt on at intake manifold (step 20).

disconnect, connect

Bowden

cable, adjust

(step 21).

detach, attach (step 22).
detach, attach (step 23).
detach, attach (step 24).

Note

On vehicles with air conditioning, the

AC

compressor can be unbolted with the lines
connected and without draining the system

(steps 25 to 34).

attach to suspension lugs, detach (step 35).

insert between component compartment and

engine, remove (step 37).

unbolt at exhaust manifold and transmission
mount (51) bolt on (steps 38 and

39)

25 Nm.
remove, install (step 40).
unbolt, bolt on (step 42).

Tightening torques:
Bolt (1) 25 Nm,

Nut (2)

70 Nm.

detach, attach, replace self-locking nuts (7a)
(step 44).

loosen, tighten (step

45),

45 Nm.
disconnect, connect to transmission (step 46).
disconnect, connect (step 47).
detach, attach (step 48).

unplug, plug in (step 49).
disconnect, connect (step 50).
unbolt, bolt on at bottom (step

51),

40 Nm.

01

0904 -03012

Engine with transmission . . . . . . . . . . . . . . .

.

lift out, insert (step 52).

Lines, hoses and engine mounts. . . . . . . .

.

examine for signs of wear, replace if necessary.

Examine antifreeze protection, adjust to correct

level if necessary. Test leaktightness.

Viscosity grades for engine oils according to SAE

Adhering to the SAE grades In accordance with ambient temperatures would result in frequent oil
changes. Consequently, the temperature ranges are merely guidelines, which can be exceeded in the

upper or lower limits for brief periods.
In moderate climatic zones SAE 30 may be used from the spring on for all engine models. SAE

low-40

or SAE

low-50

may be used as an all-seasons oil for all gasoline engines.

Refer to the most current “Factory Approved Service Products” for further information regarding

specified viscosity grades and approved engine oils.

Oil capacity in liters

(refer to Factory Approved Service Products for approved engine oils)

Engine (total capacity when refilling)
Engine capacity when changing oil and filter

5.5

5.0

01.0904

-

030 3

Tightening torques

Nm

Fan to engine coolant pump

25

Exhaust pipe to exhaust manifold
Exhaust bracket to transmission
Hexagon bolt of belt pulley to power steering pump

25
25
25

Bracket for

A/C

compressor to oil sump

10

Bracket for AC compressor to AC compressor

25

V bracket servo pump -engine supporting bracket - AC compressor

25

Servo pump to supporting bracket

25

AC

compressor to supporting bracket

30

Propeller shaft to transmission

45

Clamping nut to spline end of propeller shaft

45

Ground cable to transmission

45

Engine mount to axle carrier

40

Special tools

Commercial tool

Engine hoist No. 3188 self-locking e. g. Messrs. Backer

HerderstraOe

D-5630 Remscheid

Shoe-made

tools

Guard plate for radiator/evaporator

Dimensions approx. 480 X 600 X 1

Metal panel for component compartment wall

Dimensions approx. 320 X 380 X 1

01.0904 -

03014

Note

Remove and install engine together with

transmission.

1

Disconnect battery negative terminal,

connect.

2 Remove fan. install.

3

Unplug cable connector (327) at alternator,

plug in.

4

Detach lines for pressure oil pump at

cylinder head, connect (arrows).

5

If equipped with air conditioning: install guard
plate (arrow) to evaporator of air conditioning
system.

01

0904 -

030!5

7

On Model 201, pull off rubber strip (1) above
fire wall.
Take out clips (arrows), fold fixture upwards.

Model201

9

On Model 201, unplug cable connector (50)

at the plug connection, plug in.

Model201

10 Unbolt battery positive terminal. Disconnect
terminal (30) at cable connector and pull cable
through component compartment wall and place
over engine.

Model201termlnal30

01.0904 -

03016