1997 Mercedes-Benz CLK-Class (C208/A208) Service & Repair Manual

MERCEDES‐BENZ W208 CLK 320 WIS CONTENTS 1) REMOVING AND INSTALLING PUSHBUTTON CONTROL MODULE 2) REMOVING AND INSTALLING AIRBAG ON STEERING WHEEL 3) REMOVING AND INSTALLING PASSENGER AIRBAG UNIT 4) INSTALL LEFT FRONT OR RIGHT RPM SENSOR 5) FUNCTION OF WHEEL SPEED SENSOR 6) REMOVING AND INSTALLING ACTIVATED CHARCOAL CANISTER 7) INSTALL LEFT OR RIGHT REAR AXLE SPEED SENSOR 8) ESP HYDRAULIC UNIT 9) INSTALL TRANSMISSION WITH TORQUE CONVERTER 10) REMOVING AND INSTALLING BAS DIAPHRAGM TRAVEL SENSOR 11) BLEED BRAKE SYSTEM 12) REMOVING, CHECKING AND INSTALLING REAR AXLE BRAKE PADS 13) INSTALL FRONT AXLE BRAKE PADS 14) INSTALL BRAKE DISC 15) ADJUST PARKING BRAKE 16) INSTALL CAMSHAFTS 17) INSTALL CRANKSHAFT 18) INSTALL RADIATOR 19) REMOVE, INSTALL POLY V‐BELT 20) INSTALL CYLINDER HEAD COVER 21) VIBRATION DAMPER 22) DRIVE PLATE 23) INSTALL INJECTION VALVES (ME‐SFI) 24) INSTALL INTAKE MANIFOLD 25) INSTALL GENERATOR POLY‐V BELT PULLEY 26) INSTALL EXHAUST MANIFOLD 27) INSTALL EXHAUST GAS RECIRCULATION VALVE 28) REMOVE, INSTALL AIR PUMP 29) REPLACE SPARK PLUGS 30) INSTALL KNOCK SENSORS 31) INSTALL CRANKSHAFT POSITION SENSOR 32) INSTALL IGNITION COILS 33) REMOVE STARTER, INSTALL 34) INSTALL ENGINE MOUNT 35) INSTALL ALTERNATOR 36) ENGINE OIL AND FILTER CHANGE 37) INSTALL COOLANT PUMP 38) INSTALL COOLANT THERMOSTAT 39) INSTALL ACCELERATOR PEDAL 40) REMOVING AND INSTALLING TORSION BAR ON FRONT AXLE 41) INSTALL REAR SPRING 42) REMOVING AND INSTALLING FRONT SPRING 43) INSTALL REAR SUSPENSION STRUT 44) INSTALL FRONT SHOCK ABSORBER 45) INSTALL REAR SHOCK ABSORBER 46) INSTALL COMPLETE REAR AXLE 47) INSTALL PROPELLER SHAFT 48) REMOVAL AND INSTALLATION OF PROPELLER SHAFT INTERMEDIATE BEARING AND REPLACEMENT OF GROOVED BALL BEARING 1

49) REPLACE BRAKE FLUID 50) CARRYING OUT BLEEDING OPERATION 51) REMOVING AND INSTALLING BRAKE BOOSTER 52) REMOVING AND INSTALLING MECHANICAL STOP LAMP SWITCH 53) SPECIFIED GEAR OILS (CARS, CROSS‐COUNTRY VEHICLES) ‐ SURVEY 54) DISMANTLING AND ASSEMBLING RIGID JACKET TUBE 55) REMOVING AND INSTALLING ELECTRONIC STEERING LOCK 56) STARTER SWITCH (EZS 57) REMOVING AND INSTALLING CONTACT SPIRAL 58) REMOVING AND INSTALLING JACKET TUBE 59) CHECKING OIL PRESSURE OF POWER STEERING PUMP 60) FILL POWER STEERING PUMP AND BLEED 61) INSTALL POWER STEERING PUMP 62) INSTALL STEERING IDLER ARM, REPLACING BEARING BUSH 63) INSTALL TIE ROD BALL JOINT 64) REPLACE FUEL FILTER 65) REMOVING AND INSTALLING EXPANSION RESERVOIR 66) DRAINING AND FILLING FUEL TANK 67) REMOVE, INSTALL FUEL GAGE SENSOR 68) INSTALL FUEL TANK 69) REMOVING, INSTALLING FUEL PUMP 70) REMOVING, INSTALLING SHUTOFF VALVE 71) REMOVING AND INSTALLING EXHAUST SYSTEM COMPLETE 72) INSTALL THE OXYGEN SENSOR 73) REMOVING AND INSTALLING CATALYTIC CONVERTER OR FRONT EXHAUST SYSTEM 74) REMOVING AND INSTALLING BATTERY 75) STAMPING IN VEHICLE IDENTIFICATION NUMBER 76) VEHICLE IDENTIFICATION NUMBER 77) INSTALL FRONT AXLE HALF 78) INSTALL DRAG LINK 79) REMOVING AND INSTALLING FRONT SEATS 80) INSTALL FRONT DOOR 81) REMOVING AND INSTALLING INSTRUMENT PANEL 82) REMOVING AND INSTALLING ENGINE HOOD 83) INSTALL FRONT FENDERS 84) INSTALL WINDSHIELD 85) REMOVING AND INSTALLING FRONT BUMPER 86) REMOVING AND INSTALLING COVER BELOW INSTRUMENT PANEL (LEFT) 87) REMOVING AND INSTALLING CENTER CONSOLE 88) ADJUST FRONT DOOR 89) STARTER SWITCH CONTROL MODULE 90) INSTALL BULBS OF HEADLAMP UNIT 91) REMOVING AND INSTALLING TELESCOPING NOZZLE FOR HEADLAMP CLEANING SYSTEM 92) REMOVING AND INSTALLING HEADLAMP CLEANING SYSTEM WASHING WATER RESERVOIR 93) REMOVING AND INSTALLING OVERHEAD CONTROL PANEL CONTROL MODULE 94) INSTALL RAIN SENSOR 95) REMOVING, DISASSEMBLING AND INSTALLING REAR SHELF 96) VENTILATION 97) REMOVING AND INSTALLING BLOWER MOTOR 2

AR83.40-P-6350C Removing and installing pushbutton control module 23.9.96 MODEL 129 as of 1.6.96, 140, 202 as of 1.9.95, 208, 210 with CODE (581a) Air conditioning (automatic) P83.40-0386-09 Shown on model 129 2 Connector 3 Connector 1 Removal tools N22 Pushbutton control module ed Removal, installation 1 Pull out A/C pushbutton control module iFor this purpose insert removal (N22) tools (1) Press back retaining springs (arrow) on removed pushbutton control module and pull out removal tools (1) 2 Disconnect connectors (2, 3) on A/C iUnhook connectors by pivoting retaining pushbutton control module (N22) strap 3 Reinstall in opposite order i Installation When replacing automatic A/C pushbutton control module on models 140, 202, 208, 210, version coding must be carried out. Page 1 of 1 © Daimler AG, 8/1/15, G/04/14, ar83.40-p-6350c, Removing and installing pushbutton control module MODEL 129 as of 1.6.96, 140, 202 as of 1.9.95, 208, 210 with CODE (581a) Air conditioning (automatic) 3

AR91.60-P-0660G Removing and installing airbag on steering wheel 4.2.10 MODEL 170, 208 Illustrated on model 170 P91.60-0407-06 ed Removal, installation a Injury hazard when testing or repairing Store airbags with opening surface pointing AS91.00-Z-0001-01A Danger! airbags or emergency tensioning retractors up, do not expose to temperatures above 100 °C. Interrupt electric circuit when working on these units p Important instructions for performing repair, Model 129 as of 1.7.93, 163, 168, 170, 202 as AH91.00-P-0002-01B body work and welding on vehicles with of 1.7.93, 208, 210, 463, 638, 901, 902, 903, airbags and emergency tensioning retractors 904 p Evaluation of airbags and emergency Model 129 as of 1.7.93, 163, 168, 170, 202 as AH91.00-P-0006-01B tensioning retractors on accident vehicles of 1.7.93, 208, 210, 463, 638, 901, 902, 903, 904 i Legal regulations on handling and storing Models 124, 129, 140, 163, 168, 170, 202, 208, AH91.00-P-0004-01A airbags and emergency tensioning retractors 210,314, 316, 318, 463, 638, 901, 902, 903, 904, 950, 952, 953, 954 o Instructions on disposal of airbags and All models OS91.00-P-0001-01A emergency tensioning retractors 1 Disconnect ground lead from battery 2 Unscrew two screws (arrow) n *BA91.60-P-1001-01A iHold airbag while unscrewing l *126589001000 3 Remove airbag from steering wheel and disconnect connector from squib on gas generator 4 Disconnect horn contacts Rendering airbags unusable AR91.60-P-0611A 5 Install in opposite order iAfter the driver's airbag has triggered it is always necessary to replace the steering wheel 6 Check combination switch automatic return 7 Perform diagnosis AD91.60-P-6000A nAirbag Number Designation Model 170 Model 208 Screw for airbag on steering wheel Nm 8 8 BA91.60-P-1001-01A Page 1 of 2 © Daimler AG, 8/1/15, G/04/14, ar91.60-p-0660g, Removing and installing airbag on steering wheel MODEL 170, 208 4

126 589 00 10 00 Screwdriver attachment Page 2 of 2 © Daimler AG, 8/1/15, G/04/14, ar91.60-p-0660g, Removing and installing airbag on steering wheel MODEL 170, 208 5

AR91.60-P-0680K Removing and installing passenger airbag unit 5.12.96 MODEL 208 1 Bolt R12/8 Initiator for front passenger airbag (AB) P91.60-0513-04 ed Remove/install a Risk of injury Danger! when carrying out test or Store airbag unit with expulsion area on top, AS91.00-Z-0001-01A repair work on airbag or emergency do not subject to temperatures above 100 tensioning retractor units °C. Interrupt power supply when working on such units. p Important instructions for performing repair, Models 129 as of 1.7.93, 163, 168, 170, 202 AH91.00-P-0002-01B body work and welding on vehicles with as of 1.7.93, 208, 210, 463, 638, 901, 902, airbags and emergency tensioning retractor 903, 904 units i Legal regulations concerning the handling Models 124, 129, 140, 163, 168, 170, 202, 208, AH91.00-P-0004-01A and storage of airbag and emergency 210, 314, 316, 318, 463, 638, 901, 902, 903, tensioning retractors 904, 950, 952, 953, 954 o Notes on disposal of airbag and emergency All models OS91.00-P-0001-01A tensioning retractors 1 Disconnect ground cable of battery AR54.10-P-0003A 2 Remove instrument panel AR68.10-P-1000K 3 Disconnect connector from the initiator i Installation: Connector must audibly (R12/8) at the inflator latch into position 4 Unscrew nut (2) for front passenger airbag unit 5 Remove front passenger airbag unit 6 Make airbag units unusable AR91.60-P-0611A 7 Install in the reverse order 8 Carry out diagnosis. a AD91.60-P-6000A Page 1 of 1 © Daimler AG, 8/1/15, G/04/14, ar91.60-p-0680k, Removing and installing passenger airbag unit MODEL 208 6

AR42.30-P-0712A Remove/install left front or right rpm sensor 8.12.11 MODEL 129, 140, 170, 202, 203, 208, 210 P42.30-0238-06 Modification notes 29.11.11 Long-life grease repair materials replaced by hot-grease paste Fig. item etc. Work instructions L6/1a, L6/2a Self-locking hexagon socket head bolts for np *BA42.30-P-1001-01A Replace bolts. rpm sensor L6/1, L6/2 Front rpm sensor i Installation: Check rotor on wheel hub for signs of damage. Pay attention to cleanliness of magnetic tip. models 202, 210: p Rpm sensors from Bosch and Teves cannot be installed together. k Front axle rpm sensor mounting changed Model 202 as of 09.95 BT42.30-P-0001-01A L6/1b, L6/2b Centering sleeve p Replace centering sleeve. Model 202 iAs of 9.95 Apply light coating of grease to steering knuckle. Hot lubricating paste *BR00.45-Z-1005-06A n Front axle rpm sensor Number Designation Model 129 Model 140 Model 170 Model 202 Model 203 BA42.30-P-1001-01A Self-locking bolt, front axle rpm sensor to Nm 22 22 22 22 25 steering knuckle n Front axle rpm sensor Number Designation Model 208 Model 210 Page 1 of 2 © Daimler AG, 8/1/15, G/04/14, ar42.30-p-0712a, Remove/install left front or right rpm sensor MODEL 129, 140, 170, 202, 203, 208, 210 7

BA42.30-P-1001-01A Self-locking bolt, front axle rpm sensor to Nm 22 22 steering knuckle Repair materials Number Designation Order number BR00.45-Z-1005-06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 Page 2 of 2 © Daimler AG, 8/1/15, G/04/14, ar42.30-p-0712a, Remove/install left front or right rpm sensor MODEL 129, 140, 170, 202, 203, 208, 210 8

GF42.45-P-4550A Location / task / design / function of wheel speed sensor 13.5.96 MODEL 129, 140, 202 as of 1.6.94, 163, 168, 170, 208, 210 with CODE (470a) Anti-lock brake system (ABS) with CODE (212a) Electronic traction system (ETS) with CODE (471a) Acceleration slip regulation (ASR) MODEL 129, 140 as of 1.6.94, 163 up to 31.8.02, 168, 170, 210 with CODE (472a) Electronic Stability Program (ESP) MODEL 202 with ENGINES 112, 113, 604 with CODE (472a) Electronic Stability Program (ESP) MODEL 208 with ENGINES 112, 113 with CODE (472a) Electronic Stability Program (ESP) L6/1 Left front wheel speed sensor L6/2 Right front wheel speed sensor ABS only L6 Rear axle speed sensor ETS, ASR, ESP only L6/3 Left rear wheel speed sensor L6/4 Right rear wheel speed sensor P42.30-0221-06 Wheel speed sensor, location The front wheelspeed sensors (L6/1 and L6/2) are mounted on the front steering knuckle assemblies. ABS: The rear wheelspeed sensor (L6) is located on the differential assembly. ETS, ASR, ESP: The rear wheelspeed sensors (L6/3 and L6/4) are mounted on the rear wheel carriers. Wheel speed sensor, task To supply the current wheel speed to the ABS, ETS, ASR or ESP control module (N47-7, N47-2, N47-1 or N47-5). Wheel speed sensor, design Inductive sensor: Coil with magnetic core installed at a defined distance from reluctor on the front wheel hub, the rear halfshafts or the drive pinion at the rear axle. Wheel speed sensor, function The magnetic field of the wheel speed sensor is intersected by the teeth of a rotor. This changes the magnetic field and the coil induces an AC voltage. The frequency of this alternating current, governed by the number of teeth on the reluctor, fluctuates to reflect variations in wheelspeed, is proportional to wheelspeed. Page 1 of 1 © Daimler AG, 8/1/15, G/04/14, gf42.45-p-4550a, Location / task / design / function of wheel speed sensor MODEL 129, 140, 202 as of 1.6.94, 163, 168, 170, 208, 210 with CODE (470a) Anti-lock brake system (ABS) with CODE (212a) Electronic traction system (ETS) with CODE (471a) Acceleration ... 9

AR47.30-P-8212DA Removing and installing activated charcoal canister 18.12.97 MODEL 202, 208 with CODE (491) as of Model Year 99 USA version 77 Activated charcoal canister Y58/4 Activated charcoal canister shutoff valve 82/4 Hose clips A Activated charcoal canister line to purge control valve B Activated charcoal canister line to reservoir C Activated charcoal canister line to shutoff valve P47.30-2010-06 ed Removing, installing a Risk of explosion from ignition. Risk of No fire, naked flame or smoking. AS47.00-Z-0001-01A Danger! poisoning from inhaling and swallowing fuel. Pour fuels only into suitable and Risk of injury as a result of fuel coming into appropriately marked containers. contact with skin and eyes. Wear protective clothing when handling fuel. 1 Remove wheel housing liner Rear left 2 Detach lines (arrow) at shutoff valve (58/4) 3 Slacken hose clips (82/4) and detach lines (A) and (B) 4 Remove activated charcoal canister (77) i GF47.10-P-3004A On-board refuelling vapor recovery ORVR function 5 Install in the reverse order Page 1 of 1 © Daimler AG, 8/1/15, G/04/14, ar47.30-p-8212da, Removing and installing activated charcoal canister MODEL 202, 208 with CODE (491) as of Model Year 99 USA version 10

1997 Mercedes-Benz CLK-Class (C208/A208) Service & Repair Manual

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