1996 Mercedes-Benz E320 Service & Repair Manual Software

3.2L 6-CYL VINS [S,T] Article Text 1996 Mercedes-Benz E320 For 1 Copyright © 1998 Mitchell Repair Information Company, LLC Wednesday, December 01, 2010 01:59AM ARTICLE BEGINNING 1995-96 ENGINES Mercedes-Benz - 3.2L 6-Cylinder E320 * PLEASE READ THIS FIRST * NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL INFORMATION section. ENGINE IDENTIFICATION The engine family designation is shown on the emission control information plate (attached to radiator crossmember). The first character identifies the model year ("S" for 1995, "T" for 1996) while the fourth and fifth characters identify the engine displacement. ENGINE IDENTIFICATION CODES TABLE Application & (1) Engine Engine Engine Size ID Code 1995 ................... 104.992 .......... SMB3.6VJGFFA 1996 ................... 104.995 .......... TMB3.6VJGFFA (1) - The engine identification number must be used when ordering replacement parts. ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve lifters are used, and valve clearance adjustment is not necessary. REMOVAL & INSTALLATION FUEL PRESSURE RELEASE Disconnect fuel pump connector. Start engine. Allow engine to run until it stalls. Turn ignition off. Reconnect fuel pump connector. NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal.

3.2L 6-CYL VINS [S,T] Article Text (p. 2) 1996 Mercedes-Benz E320For 1 Copyright © 1998 Mitchell Repair Informatio ENGINE Removal & Installation 1) Release fuel pressure. See FUEL PRESSURE RELEASE. Raise hood to vertical position and secure. Obtain radio anti-theft code. Remove small access panel located below right rear seat. Disconnect negative battery cable located behind access panel. 2) Remove engine undercover. Remove air cleaner assembly. Remove viscous fan assembly. Drain cooling system. Remove radiator. Attach a guard plate to A/C condenser. 3) Disconnect control module connectors located in right rear corner of engine compartment. Disconnect 3 electrical connectors located under Hot Film Engine Management Sequential Fuel Injection (HFM-SFI) engine control module connector. Disconnect cable and bracket located in engine compartment located outside driver's footwell area. 4) Remove windshield washer reservoir. Disconnect electrical connector located in left rear corner of engine compartment attached to fenderwell. 5) Disconnect power steering pump interference suppression ground connection located on left fenderwell near power steering pump. Disconnect A/C compressor electrical connector. 6) Disconnect generator wiring. Disconnect ground connection located at left rear bottom corner of engine (next to transmission). 7) Disconnect mass air sensor connector. Disconnect vacuum line at brake servo unit. Disconnect all other vacuum line connections as necessary. Disconnect fuel supply and return lines at fuel distributor. Disconnect accelerator cable assembly. 8) Remove power steering pump reservoir fluid. Disconnect power steering pump hydraulic lines at power steering pump. Placing wrench on tensioning pulley nut, swivel tensioning pulley clockwise. 9) Remove serpentine accessory drive belt. Slowly release tension at tensioning pulley. Disconnect coolant hose located at left rear corner of engine compartment. 10) Unbolt A/C compressor and set aside with A/C hoses attached to compressor. Disconnect exhaust system at exhaust manifold flange. Attach a hose to coolant drain located on right side of engine block, behind engine mount. Open coolant drain, and drain coolant from engine block. 11) Disconnect drive shaft from transmission. Remove 2 bolts attaching rear engine carrier to rear of transmission. Using a jack, support rear engine/transmission assembly. 12) Remove 4 bolts attaching rear engine support to vehicle chassis. Disconnect transmission shift rod. Disconnect front engine mounts from vehicle body. Remove cover located at top front of engine. Remove automatic transmission dipstick. 13) Attach hoist to lifting lugs of engine. Ensure all necessary electrical connections, hoses, linkages and vacuum lines are disconnected from engine and transmission. Remove engine and transmission as an assembly. To install, reverse removal procedure. Adjust all fluid levels.

3.2L 6-CYL VINS [S,T] Article Text (p. 3) 1996 Mercedes-Benz E320For 1 Copyright © 1998 Mitchell Repair Informatio Fig. 1: Identifying Hydraulic Line Bracket Bolts & Holders Courtesy of Mercedes-Benz of North America. Fig. 2: Identifying Starter Lockout Switch Connector Locking Element Courtesy of Mercedes-Benz of North America. INTAKE MANIFOLD NOTE: All models are equipped with a 2-piece variable resonance intake manifold.

3.2L 6-CYL VINS [S,T] Article Text (p. 4) 1996 Mercedes-Benz E320For 1 Copyright © 1998 Mitchell Repair Informatio Removal & Installation 1) Release fuel pressure. See FUEL PRESSURE RELEASE. With hood open, press locking lever on left hood hinge. Raise hood slightly until locking lever does not engage. Press locking lever on right hood hinge. Raise hood to vertical position. Ensure hood is secure in vertical position. 2) Disconnect negative battery terminal. Disconnect crankcase breather hoses. Disconnect vacuum line located on top rear of upper intake manifold. Disconnect resonance flap switchover valve electrical connector. See Fig. 3. 3) Remove bolts for upper intake manifold. Remove dipstick tube bracket. Loosen top hose clamps connecting lower intake manifold to upper intake manifold. Remove upper intake manifold. See Fig. 3. If necessary to remove lower intake manifold, go to next step. 4) Remove guide piece from fulcrum lever for throttle cable. Compress plastic clip in throttle cable bracket. Remove throttle cable. Disconnect transmission control cable. Disconnect EGR line. 5) Ensure all necessary electrical and vacuum line connections are disconnected from lower intake manifold assembly. Remove lower intake manifold attaching bolts. Remove lower intake manifold from engine. See Fig. 3. To install, reverse removal procedure. Fig. 3: Identifying Upper & Lower Intake Manifold Assemblies Courtesy of Mercedes-Benz of North America. EXHAUST MANIFOLD

3.2L 6-CYL VINS [S,T] Article Text (p. 5) 1996 Mercedes-Benz E320For 1 Copyright © 1998 Mitchell Repair Informatio Removal & Installation Disconnect negative battery cable. Remove exhaust pipe-to- manifold nuts. Disconnect exhaust support at transmission. Remove nuts attaching exhaust manifold to engine. Remove exhaust manifold. To install, reverse removal procedure. IGNITION COILS Removal & Installation Unclip cable duct at rear of engine. Remove center cover from valve cover. Remove guide rail. Remove ignition coil assemblies and spark plug wiring. See Fig. 4. To install, reverse removal procedure. Fig. 4: Removing & Installing Ignition Coils Courtesy of Mercedes-Benz of North America. CYLINDER HEAD Removal 1) Release fuel pressure. See FUEL PRESSURE RELEASE. With hood open, press locking lever on left hood hinge. Raise hood slightly until locking lever does not engage. Press locking lever on right hood hinge. Raise hood to vertical position. Ensure hood is secure in vertical position. 2) Disconnect negative battery terminal. Remove shield under vehicle covering engine. Drain coolant. Disconnect coolant and heater hoses at cylinder head. Position crankshaft so No. 1 cylinder is at TDC. Remove ignition coils. See IGNITION COILS. Remove valve cover.

3.2L 6-CYL VINS [S,T] Article Text (p. Remove top front cover. See TOP FRONT COVER. 3) Using paint, mark position of timing chain in relation to camshaft sprockets. Using a slide hammer, extract guide pin for slide rail on intake side of engine. Disconnect electrical wiring as necessary. Disconnect cruise control linkage. 4) Disconnect vacuum hoses as necessary. Disconnect exhaust manifolds at flange. Disconnect air injection line at cylinder head. Unbolt bracket for air injection line on side of cylinder block. 5) Unbolt dipstick guide tube bracket and intake manifold support. Disconnect crankcase breather hose. Disconnect fuel supply and return lines. 6) Unbolt automatic transmission dipstick guide tube at rear of cylinder head. Disconnect throttle linkage. Remove heater hose return line. With engine cold, remove cylinder head bolts in order shown in Fig. 5 or 6. Remove cylinder head. Fig. 5: Removing Cylinder Head Bolts Courtesy of Mercedes-Benz of North America. Fig. 6: Removing Cylinder Head Bolts Courtesy of Mercedes-Benz of North America. CAUTION: Check cylinder head bolts for excessive stretching. Failure to replace stretched bolts may result in bolts breaking.

3.2L 6-CYL VINS [S,T] Article Text (p. 7) 1996 Merce Installation 1) To install, reverse removal procedure. Install new cylinder head gasket. Ensure head gasket is positioned on locating pins. Check length of cylinder head bolts. Cylinder head bolts stretch permanently when installed. 2) Measure from bottom of bolt head to bottom of bolt. Check cylinder head bolt length. New cylinder head bolt length is 6.30" (160 mm). Maximum cylinder head bolt length is 6.44" (163.5 mm). If length exceeds 6.44" (163.5 mm), replace all cylinder head bolts. 3) Oil threads and bolt head contact surface of cylinder head bolts. With engine cold, tighten cylinder head bolts in proper sequence. See Fig. 7 or 8. See TORQUE SPECIFICATIONS. Ensure paint marks on timing chain and camshaft sprockets are aligned. To complete installation, reverse removal procedure. Fig. 7: Installing Cylinder Head Bolts Courtesy of Mercedes-Benz of North America. Fig. 8: Installing Cylinder Head Bolts Courtesy of Mercedes-Benz of North America. TOP FRONT COVER Removal 1) Release split pin of fan shroud ring, turn and remove.

3.2L 6-CYL VINS [S,T] Article Text (p. 8) 1996 Mer Remove belt from air pump. Loosen air pump and swivel aside. Loosen screw in center of chain tensioner about one turn. Unscrew chain tensioner from cover. CAUTION: If top curved slide rail is removed from its bearing, pressure pin in chain tensioner moves in tensioning direction by one detent. Chain tensioner must be removed to prevent overtensioning timing chain. See Fig. 9. 2) Unbolt heater water return line from front cover. Unbolt electrical wiring bracket from front cover. Disconnect adjustable camshaft timing solenoid. Unbolt tensioning device (shock absorber) from front cover. Press down and turn tensioning device to move aside. Remove top front cover bolts. On engines with coolant return through top front cover, remove 2 bolts for coolant return. Remove top front cover.See Fig. 9. Fig. 9: Removing & Installing Top Front Cover Courtesy of Mercedes-Benz of North America. Installation 1) Clean all mating surfaces. Apply sealant to ends of seal where seal meets cylinder head. See Fig. 10. Install seal (without sealant) into oil-free groove. Coat top of seal with engine oil. Coat contact surfaces of front cover to cylinder head with sealant. 2) If adjustable camshaft timing solenoid was removed, coat threads of screws with sealant. Install top front cover. Tighten

3.2L 6-CYL VINS [S,T] Article Text (p. 9) 1996 Mer bottom bolts first. See Fig. 10. To complete installation, reverse removal procedure. Fig. 10: Installing Top Front Cover Courtesy of Mercedes-Benz of North America. FRONT TIMING COVER Removal 1) With hood open, press locking lever on left hood hinge. Raise hood slightly until locking lever does not engage. Press locking lever on right hood hinge. Raise hood to vertical position. Ensure hood is secure in vertical position. 2) Disconnect negative battery terminal. Remove engine undercover. Remove air cleaner assembly. Remove pulley bolts from fan clutch, coolant pump and power steering pump. Remove pulleys. Remove vibration damper. Remove top front cover. See TOP FRONT COVER. 3) Remove center bracket center bolt. Remove 3 remaining center bracket bolts. Remove center bracket. Remove 3 bolts for lower bracket. Remove lower bracket. See Fig. 11. Remove any remaining brackets as necessary. Remove front cover bolts. Remove front cover. Installation Clean all mating surfaces. Replace crankshaft seal. Replace small seal near top of front timing cover. Apply sealant to front cover sealing surface. To complete installation, reverse removal procedure.

3.2L 6-CYL VINS [S,T] Article Text (p. 10) 1996 Mercedes-Benz E320For 1 Copyright © 1998 Mitchell Repair Informat Fig. 11: Removing Brackets From Front Timing Cover Courtesy of Mercedes-Benz of North America. TIMING CHAIN Removal & Installation 1) A split-link timing chain is available for repairs without dismantling engine. Set No. 1 piston at TDC of compression stroke. DO NOT use camshaft sprocket bolts to rotate engine. Remove spark plugs and camshaft covers. Remove air cleaner adapter. Cover chain guard and grind open both link pins in timing chain. 2) Remove old link and install new split link with new chain attached. Turn crankshaft slowly in normal direction, while feeding in new chain and removing old chain. Ensure chain does not slip on sprockets. Install master link from rear of chain. 3) Position jaws in Rivet Maker (Tool No. 000 589 43 00) so that numeral "2" is facing out. Place outer plate of Riveted Link into Rivet Maker and fit tool onto rollers under Riveted Link. See Fig. 12. Screw in bolt of Rivet Maker until resistance is felt. NOTE: When clamping link together, ensure that pins of link are guided into holes of plate. 4) Remove Rivet Maker tool. Turn jaws of Rivet Maker tool to riveting profile. Position Rivet Maker tool over pins of link and tighten to 22 ft. lbs (30 N.m). Repeat on other pin. Rotate crankshaft one complete revolution and check for proper alignment of timing marks. To complete installation, reverse removal procedure. Check cam timing. Set distributor rotor alignment.

1996 Mercedes-Benz E320 Service & Repair Manual Software

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