Mosselman Turbo Install
Model : Mercedes-Benz, 190 - Series Category : Force Induction
... You will have to reconnect the original feed and take lines on the oil cooler on the correct threads. Now turn the oil cooler horizontal. This is how it will sit. I used the original plastic retainer for the oil cooler to make a "custom" bracket for the oil cooler. Here is a pic of it. This part takes some engineering skills but it really isnt that difficult. In order to get the ... (more)
Posted : 18 June 2005  
 
TIMING CHAIN / TENSIONER REPLACEMENT
Model : Mercedes-Benz, 190 - Series Category : Engine
... on the old chain coming out of the engine and put pressure on the new chain running over the cam sprockets. The pressure is needed to keep the chain from jumping a tooth and getting out of time. Once the new chain has been fed in all the way, and the end is on the exhaust cam sprocket, disconnect the old chain by prying the link apart. DON'T DROP IT INTO THE ENGINE!! Now, connect the ends ... (more)
Posted : 18 June 2005  
 
INSTALLING CROSS-DRILLED BRAKE ROTORS
Model : Mercedes-Benz, 190 - Series Category : Brakes
... the rotor. On the back of the caliper will be two mounting bolts. Remove these bolts. Slide the caliper off. Dont let the damn thing dangle with only the brake line holding it. Place it on a block or string it up somehow. Get a small flathead screwdriver and pry off the Mercedes three star hub cap dealy. It is on the end of the hub and is about 1.5 diameter. If you look on your rotor, there ... (more)
Posted : 18 June 2005  
 
PAINTING GRILLE
Model : Mercedes-Benz, 190 - Series Category : Exterior
... straightforward from here. Just undo the center emblem (not the hood ornament), remove the clips, and the rest of the bolts. Then just slide that chrome trimming off. Now you should have the plastic part of the grill all by itself. Have your lazy buddy wipe off the chrome grill and the small pieces WITHOUT BENDING THEM! Now just get the grill and place it on an old Wallstreet Journal and ... (more)
Posted : 18 June 2005  
 
VALVE CLEARANCE CHECK
Model : Mercedes-Benz, 190 - Series Category : Engine
... the cover off and then place the cover in a safe clean place. Now that your valve cover is removed, you must be careful not to get any debris into the engine. Debris = BAD FOR ENGINE. This is also the time to check the valve cover gasket also. If it feels charred or if it has any cracks or tears, it needs to be replaced. Measure the clearances and make sure they are all within spec. If the lobe ... (more)
Posted : 18 June 2005  
 
EURO HEADLIGHT CONVERSION
Model : Mercedes-Benz, 190 - Series Category : Lights - Headlights
... and the third is on the bottom of the assembly. The easiest was to gain access to this is if you reach behind the spoiler/bumper from the wheelwell area. After removing the assembly some switching is necessary. The stock US-spec 4-pole plug needs to be switched with the included Euro-spec 6-pole plug. This is very straight-foward. Simply pry the cover off of the rear and the pins pull out. ... (more)
Posted : 18 June 2005  
 
REAR COIL SPRINGS REMOVAL AND INSTALL
Model : Mercedes-Benz, 190 - Series Category : Suspension
... Remove this bolt from the cover and then remove the plastic cover. I took the picture while it was off the car for clarity. Ok pay attention. This is easy. On the side of the spring support arm are 3 bolt and nut set up. One for the anti roll bar, one for the rear strut, and the last is for the hub carrier. Here I'm pointing to two of the three and the third bolt the creseant wrench is on. ... (more)
Posted : 18 June 2005  
 
FRONT COIL SPRINGS AND STRUTS REMOVAL AND INSTALL
Model : Mercedes-Benz, 190 - Series Category : Suspension
... thread locking compound and are very difficult to loosen. However, it can be done but I highly recommend a 1/2'' drive socket wrench, it makes a world of difference from the 3/8'' drive. OK, so far so good. This here is the upper mount of the strut. Its difficult to see in the picture but you must use a 7mm allen wrench and loosen the retaining nut with an open end or creseant wrench. After ... (more)
Posted : 18 June 2005  
 
AFTERMARKET IGNITION INSTALL
Model : Mercedes-Benz, 190 - Series Category : Electrical - Ignition
... computer to avoid mounting metal on metal. Also that area of the car is curved and the bottom of the ignition computer is flat. So the styrofoam made for a cheap molding to level the two sides out. Styrofoam is the best material here because it is not biodegradable and will not rot on you. With the kit came a small regulator. You can see it in the pic above. It is on the bottom off center to ... (more)
Posted : 18 June 2005  
 
BRAKE CALIPER PAINTING
Model : Mercedes-Benz, 190 - Series Category : Brakes
... ''geese i've got three more calipers to do, and only 2 beers left.'' Have your buddy go to the nearest liquor store to handle that problem. Meanwhile, take the scrub brush again and clean it off well. Scrub again to clean it extra. Wipe it off w/ the rag really well and make sure it's all dry. Mask that baby w/ tape and newspaper. Don't forget to mask the brake rotor for crying out loud ;=). ... (more)
Posted : 18 June 2005  
 
Dual Gauge POD with Gauges
Model : Mazda, RX, RX - 7 Base Category : Misc
... and are angled the way you want it. The remove the light and fittings off the back of the gauges. Next install the sensors to the selected areas for proper use of your metering gauge. In my case my boost gauge comes right off of the intake manifold right through a rubber water seal in the firewall to the interior by the clutch peddle. Run all your lines through the hole you just made in your ... (more)
Posted : 25 May 2005  
 
White Gauge Cluster
Model : Mazda, RX, RX - 7 Base Category : Misc
... I got them. The first step is to remove the old gauges. There are a few screws underneath the ignition plastic cover that need to be removed, along with the 4 screws under the windshield wiper switch and the headlight switch. Then remove the 3 screws from the underneath of the lip that overhangs the gauge cluster. Now remove the cluster cover. It should look like the below picture at this ... (more)
Posted : 25 May 2005  
 
Front Grill Mod
Model : Mazda, RX, RX - 7 Base Category : Exterior
... connections. After you cut off the stock grill, there will be a little bit of plastic left on the bumper. Use a sanding drum on the dremel to sand it smooth with the rest of the inside lip. This is what it looks like just after cutting out the stock grill. When you finish your touch up sanding and everything is smooth to your liking, you will notice that the plastic is white, and the inside ... (more)
Posted : 25 May 2005  
 
Custom Shift and E-Brake Boots
Model : Mazda, RX, RX - 7 Base Category : Misc
... the boot over itself so that it covers the ugly plastic that is there stock. Then you just tuck in the bottom of the boot into the carpet and you are done! Here are the pictures showing the steps. It is quite easy to do. Now comes another easy part, the shifter boot. You start by removing the plastic/rubber surround of the shifter boot with a flat head screw driver. Then you remove the shifter ... (more)
Posted : 25 May 2005  
 
Indiglo Gauges 89-91 FC3S
Model : Mazda, RX, RX - 7 Base Category : Electrical
... it will start to come out. It is usually easier to start on the left side and work your way to the right. After the first plug is removed, you can reach the speedometer cable. There is an arm on it that needs to be pushed down, then you just pull it out. Repeat the first plug procedure on the second plug. Now you should be able to remove the gauge cluster from your dash. Now you need to remove ... (more)
Posted : 25 May 2005  
 
KYB and Eibach/Suspension Techniques Install
Model : Mazda, RX, RX - 7 Base Category : Suspension
... be installed. In my case it is the only red one I have. The rest are black in color. The reason for that is that I bought the HKS (KYB AGX) kit as an open box buy for $150 since it was missing one front strut. I bought the 4th for the set at www.shox.com The HKS ones are black and the KYB's are red. The adjustments on the fronts are on the top of the strut and are accessible from under the hood ... (more)
Posted : 25 May 2005  
 
Racing Beat Engine Brace
Model : Mazda, RX, RX - 7 Base Category : Suspension
... bolt later, make sure that the ground is touching the engine, and not on the outside of the brace. Next stick the long brace rod through the hole using the short set of threads. Now you need to remove the 6 small screws that hold up the inside plastic wheel well liner. Move the liner out of the way. You should now be able to look up under the fender and see where your rod is coming out ... (more)
Posted : 25 May 2005  
 
Autopower Roll bar Install
Model : Mazda, RX, RX - 7 Base Category : Misc
... why you have so many extra nuts left over? That is because you need to use them later on as lock nuts. With all of the bolts and nuts in place, you can go ahead and start to tighten then all down. I used a torque wrench and tightened them to 250ftlbs per nut. This is your life we are talking about! If you don't have a torque wrench, I would just make sure that they are good and tight. After ... (more)
Posted : 25 May 2005  
 
Kirk Racing Rollbar Install
Model : Mazda, RX, RX - 7 Base Category : Misc
... else that you might drill through!!! Look twice and drill once =) Once you have the holes drilled, take the 8 bolts, 4 each side, and place them through the holes. Then you want to twist on the nuts until they are finger tight. Have a buddy put a wrench on the top of the bolt so you can ratchet the nut on from the bottom of the car.bolt them in using a cross pattern like rotating your tires ... (more)
Posted : 25 May 2005  
 
Moroso Hood Pins
Model : Mazda, RX, RX - 7 Base Category : Exterior - Hood
... the pin. Thread one of the 2 nuts onto the pin so that it will be above the brace. Then put the pin into the hole. Thread the 2nd nut onto the pin from the bottom of the brace. Just tighten the nuts snugly, as you will need to adjust the height later on. After you have mounted both of the front pins, they should look sonething like this. Set the height as high as you can for now so that it ... (more)
Posted : 25 May 2005  
 
D.O.T Stainless Steel Brake Lines from Mazdatrix
Model : Mazda, RX, RX - 7 Base Category : Brakes
... other end and make sure that there is no pressure in the lines. It is a good idea to have the drip pan close by since there will be brake fluid coming from the lines as soon as they break loose. After you break loose both ends, finish removing the old brake line from the wheel well. This is a comparison between the old line and the new one. You can see that the old one has shaped itself into ... (more)
Posted : 25 May 2005  
 
Air Box Mod
Model : Mazda, RX, RX - 7 Base Category : Engine
... you replace the stock air box, you are now sucking hot engine air into your filter. This can be remedied by use of a cold air box. The problem with this is that you must make it yourself, since there aren't any aftermarket products of this kind available to us. (if there are then I haven't seen them yet!) For start, I removed the Bonez Filter and got a few 12-pack boxes for my template. I ... (more)
Posted : 25 May 2005  
 
Radiator Air Deflector MOD
Model : Mazda, RX, RX - 7 Base Category : Engine
... you will need to do is to make a template to work with. I used a piece of leftover al-tin from my cold air box install as my template, seen below. This actually is what alot of people use as a permanent fix. I did this as well for awhile, but decided that it just looked to tacky for me. So I removed that old one, and traced it onto the AL (aluminum) sheeting, as seen below. I think this ... (more)
Posted : 25 May 2005  
 
NOS - Dry System
Model : Mazda, RX, RX - 7 Base Category : Engine
... nozzle aimed towards the front of the car. From what I understand, unless your car is pulling 450+HP then I don't think you are going to push the NOS inside the bottle back so it can't be pulled up by the nozzle. Slightly turn the bottle sideways in it's mounts so that the label is slightly towards the front of the car. After you find where you want the bottle, hold the bottle brackets where ... (more)
Posted : 25 May 2005  
 
NOS - Wet System
Model : Mazda, RX, RX - 7 Base Category : Engine
... solenoid. Take the bracket that comes with the kit and mount both the fuel and nitrous solenoids to it. Find a spot in the engine bay on the passenger side to mount it. I used an old bolt hole from something that I removed earlier. Mount the bracket securely to the inside wheel well or the firewall. Then connect your fuel feed hose to the IN side of the fuel solenoid. Now connect the lines ... (more)
Posted : 25 May 2005  
 
Series V 13BT Rotary Engine Rebuild
Model : Mazda, RX, RX - 7 Base Category : Engine
... 1 (teardown), all you really need is some basic sockets, dead blow hammers, some Ziploc baggies for parts labeling and and keeping all of the little assemblies together. The rebuilding phase is something totally different and will require more attention and procedure. That is of course after you have had all of the parts inspected and measured out for proper tolerances. Anyway, this is to mainly ... (more)
Posted : 25 May 2005  
 
Series IV 13BT Rotary Engine Rebuild
Model : Mazda, RX, RX - 7 Base Category : Engine
... the next step was to remove the oil pan and oil pickup strainer so we would have a flat surface for the motor to rest on our table for the rest of the tear down. While you are under there, it is a good idea to remove the oil pressure control valve. Here is a shot of the motor on the table and another of the oil pan once removed. OK, now that you have the motor on a flat place to work, let's ... (more)
Posted : 25 May 2005  
 
Water Pump Replacement
Model : Mazda, RX, RX - 7 Base Category : Engine - Cooling System
... are $10 a piece from Mazda. Also now that the water pump housing is away from the block, you can unplug the water temp sensor behind it. Make sure not to loose the wire clip that is on the connector. Now is the time to remove the old water pump from the pump housing. Go ahead and set it aside as you will not need it any longer. Now comes the hardest part: removing the old gasket from the housing ... (more)
Posted : 25 May 2005  
 
Fluidyne Radiator Install
Model : Mazda, RX, RX - 7 Base Category : Engine
... or falling apart. I only recommend OEM Mazda thermostats since they last a long time and they are consistent at working all the time. The aftermarket ones like Stant etc, and just not as good as the OEM one is. Once that is removed, clean out the gasket seat and install the new thermostat with the gasket. Replace the housing and tighten back down the 3 bolts and you are done with it. ... (more)
Posted : 25 May 2005  
 
HKS PFC F-CON
Model : Mazda, RX, RX - 7 Base Category : Electrical
... it. OK, first thing is to remove your carpet covering your passenger side floor to expose the stock ECU. Use the 10mm wrench to remove the 2 bolts and 2 nuts that hold the cover in place. Next you can unplug the 3 large wiring harness plugs that go into the stock ECU. Set them to the side for now. Go to the area that the stock boost sendor is (passenger side strut tower) and find a place to ... (more)
Posted : 25 May 2005  
 
Crane Cams HI-6
Model : Mazda, RX, RX - 7 Base Category : Electrical
... the coil should pull freely from the fender wall. Remove the plastic coil connector cover by pushing in on the 2 side snaps. This is what you should see at this point. Now is where we start wiring it up to the coil. The process is fairly simple. Basically the ignition runs like a piggy back fuel computer or the equivalent. The stock coil signal is usually sent from the base igniter to the ... (more)
Posted : 25 May 2005  
 
Fully Electronic 6-Port Actuation "FE6PA
Model : Mazda, RX, RX - 7 Base Category : Electrical
... time at which the Ports open, or when we turn on the Air-pump. Adjustable from 2000rpm to 8000rpm in 200rpm increments. #3-30 Amp Auto Relay #275-226 Source: Radio Shack Price: $6.00 Function: This is used to isolate the high current of the battery from the RPM switch, to increase the switches life, and allow the pump more current to operate effectively. #4-Various radio shack electrical ... (more)
Posted : 25 May 2005  
 
Super Air Flow Converter (S-AFC)
Model : Mazda, RX, RX - 7 Base Category : Electrical
... To turn down the flow so that I am not running too much fuel, causing an over rich condition, I chose to install the A'PEXi S-AFC. Here is how it went... Here is where I originally mounted it. It worked well, but the idea of it being in the open like that bothered me, so I installed in into a custom plastic mount under the aftermarket cd head unit. This is where it is mounted now. It gives it a ... (more)
Posted : 25 May 2005  
 
Actuator Valve Controller Type-R (AVC-R)
Model : Mazda, RX, RX - 7 Base Category : Electrical
... pretty straight forward wiring. RED - Power PURPLE - RPM or injector signal GREEN - Ground (closest to ECU) BLACK - Ground GREY - Throttle WHITE - Speed signal output ORANGE - Scramble Switch Output (wired with scramble switch use only) Here is a close-up of some of the included connectors that come with the kit. You just strip back the wires and crimp these down on top of the exposed wires. ... (more)
Posted : 25 May 2005  
 
6000K Type II HID Conversion Kit
Model : Mazda, RX, RX - 7 Base Category : Lights
... the headlight housing by removing the silver retainer piece that is held in by 4 screws. Put the headlight aside for now. Now you are going to need to mount the starter and the ballast for the driver side headlight. I mounted the ballast just to the outside of the battery box, just in front of the coil. Here it is: Next is to mount the starter. Make sure when you are doing these steps that you ... (more)
Posted : 25 May 2005  
 
Build Your Own Low Cost FCD
Model : Mazda, RX, RX - 7 Base Category : Electrical
... any perf board or box may be used. Construction This circuit is not very sensitive to construction techniques. You can wire wrap it, use point to point wiring on a perf board, dead bug, PCB, or whatever works for you. If you use the perf board specified above, you will probably find that wire-wrap or point-to-point wiring makes the most sense. Connection between adjacent pads can easily be made ... (more)
Posted : 25 May 2005  
 
Oil Change
Model : Mazda, RX, RX - 7 Base Category : Misc
... the old oil. NOTE: Make sure that the motor is completely cooled down. There is nothing worse than feeling hot oil go down your arm! Step 1: Drain the old oil from the bottom of the oil pan. If you look under the motor, you should see a plug that is sort of offset from the main, large pan on the bottom. Make sure that the oil pan is under the area, as the oil will come out fast when you pull ... (more)
Posted : 25 May 2005  
 
Wheel Bearing Inspection/Adjustment
Model : Mazda, RX, RX - 7 Base Category : Wheels and Tires
... Bent the cotter pins legs back so you can remove it from the hub. Once that is finished, put it aside in a clean area. Once the set cover and cotter pin are off, you should just have the nut left. Try to twist it with your fingers. If you can do that, it is really loose. Either way...Get a torque wrench! or the next step, you will need a 23MM socket. *If you want to clean out the bearing grease ... (more)
Posted : 25 May 2005  
 
Maintenance Schedule
Model : Mazda, RX, RX - 7 Base Category : Misc
... : I do mine at every other oil change Spark Plug wires -- Inspect every 15,000 miles: Replace if needed Cooling System -- Inspect every 15,000 miles for leaks Engine Coolant -- Replace/Flush every year Fuel Filter -- Replace every 30,000 miles or once a year Fuel Lines -- Inspect every 15,000 miles Oil Level Warning System -- Inspect every year Coolant Level Warning System -- Inspect every ... (more)
Posted : 25 May 2005  
 
Making the Shift to RX-7 Clutch Work
Model : Mazda, RX, RX - 7 Base Category : Driveterrain
... its nut. This nut is easily reached from the top while you’re pulling the slave cylinder. Next, put the car on a lift and remove the lower shielding from the catalytic converters. Depending on the year, there may be two or three converters. The ‘79s and ‘80s don’t have converters but a ridiculously complex front exhaust pipe and heat exchanger for emissions purposes. If your ... (more)
Posted : 25 May 2005  
 
De-Mystifying Mazda RX-7 Ignition Operation
Model : Mazda, RX, RX - 7 Base Category : Engine
... The 24-tooth trailing coil firing reluctor provides the Ne signal, which is rpm information and trailing-coil firing synch. Like a conventional distributor, the crank angle sensor turns at half crank speed. One crank angle sensor degree is equal to two crankshaft degrees, since the crank turns twice as fast. Known good G and Ne signals are shown in Figure 6. Channel 1 is Ne. Ne ... (more)
Posted : 25 May 2005  
 
Emissions Troubleshooting on the Mazda Rotary Engine
Model : Mazda, RX, RX - 7 Base Category : Engine
... here. The rear cat is a pellet type and frequently wears out. The casings generally will start to leak with wear. For the '82 models, a recall was issued to replace the pellets. Part of the recall included installing an orifice in the hose (air cleaner to air pump) that was about 12mm wide. If the '82 you're servicing has this orifice, the recall has been accomplished. However, not all ... (more)
Posted : 25 May 2005  
 
Easy Intake Mod for cracked turbo inlet duct
Model : Mazda, RX, RX - 7 Base Category : Engine
... end could fit through in the 45 degree bend, stuck the male end through, then tightened the barb onto it. Exact same principle for the PCV breather, just smaller fittings. I got a 1/8th inch barb and used standard 1/8th inch (3mm) vacuum tube - it will work, but it's a VERY tight fit. 1/4 inch fits a lot better. Coming off the metal pipe that the breather is connected to, I attached some ... (more)
Posted : 25 May 2005  
 
Diagnosing and Correcting Rx7 Windshield Wiper Problems
Model : Mazda, RX, RX - 7 Base Category : Misc
... sandpaper to polish up the conductive surface of the gear. Again, no need to bother trying to remove the grease. 4. Replace the cover and test the wipers. If there are still problems, move on to testing the wiper switch. Testing The Wiper Switch The windshield wiper switch (located in the cluster switch unit surrounding the instrument cluster) can be tested fairly thoroughly at the female ... (more)
Posted : 25 May 2005  
 
Diagnosing and Correcting TurboII Idle Problems
Model : Mazda, RX, RX - 7 Base Category : Force Induction
... conductor connector, located in about the same position. In these models, a jumper is connected between the connector and ground. 2. Check the Throttle Position Sensor setting. A variety of instructions for doing this are contained in the FAQ. My personal favorite is the two light bulbs. After setting it, rev the engine a couple of times to let everything settle back into place, and re-check it. ... (more)
Posted : 25 May 2005  
 
O2 Sensors
Model : Mazda, RX, RX - 7 Base Category : Exhaust - Oxygen Sensor
... and/or noise, I used a 5' non shielded wire to the scope on the passenger seat and used ground from the ignition key). With throtle released, the voltage was close to zero (+-100mv), and when accelerated, it jumped to about 750mv. I could not make stabilize it on any value in between. More acceleration raised the voltage up to 850mv (this time the change was more or less continuous). It ... (more)
Posted : 25 May 2005  
 
Build Your Own Low Cost FCD
Model : Mazda, RX, RX - 7 Base Category : Fuel System
... board specified above, you will probably find that wire-wrap or point-to-point wiring makes the most sense. Connection between adjacent pads can easily be made using small pieces of wire (or even solder bridges), resulting in a pretty dense layout. For those who aren't familiar with the dead bug approach, it involves epoxying the IC on its back on a piece of metal or plastic (metal is better ... (more)
Posted : 25 May 2005  
 
Reading Mazda RX7 86-88 Error Codes
Model : Mazda, RX, RX - 7 Base Category : Misc
... two flexible leads about 5" long. The yellow one is the cathode (i.e. negative) and the red is the anode (positive). They are rated for 12VDC but their current (at 12V) is not specified (it is probably in the range of 10-20ma). They seem to be protected from reversed 12VDC but again, we don't have the specification of maximal safe reverse voltage. To build the tester you will need the ... (more)
Posted : 25 May 2005  
 
DIY Open-Air Vented Blow-Off Valve
Model : Mazda, RX, RX - 7 Base Category : Engine
... BOV upside down then turn the hose all the way around so it'd be level. 2. Use the 1/2'' plug and plug the back end of the turbo inlet duct that now has a gaping hole in it. First things first. Use one of the new screw clamps on the plug and make sure it's good and tight. Be sure not to put the plug too far into the inlet duct. Screw clamp it to the threadded portion of the plug. 3. Threadd ... (more)
Posted : 25 May 2005  
 
MX 6 SPEAKERS
Model : Mazda, MX6 Category : Electrical - Radio
... - Our super doorlock interfaced plugged right in! (see the 3 wires, red, green, blue) Picture of our super doorlock interface (great for doorlock actuators) Needed to drill a hole. This is the picture of that This shows how to interface the factory alarm wire so that it will disarm when you unlock the doors Yes, security light. Picture of our Pioneer 6x8 speaker mounted in the door. SO NICE! ... (more)
Posted : 25 May 2005  
 
Stripped Lug Nut Threads on the Mercedes S Class
Model : Mercedes-Benz, S - Class Category : Misc
... either causing an immediate failure or worse - it'll wait until you're on a long trip somewhere and squirt your brake fluid out on the road and strand you. Or worse. Not to mention the brake lines themselves are awfully expensive. Here's the hub with the rotor still on. This is just a picture I had in stock, so pay no attention to the missing bearing cap. I think I was fooling with the ... (more)
Posted : 25 May 2005  
 
Replacing Sway Bar Bushings and Sway Bar Links on the Mercedes S Class
Model : Mercedes-Benz, S - Class Category : Suspension
... Maybe someone's got a better idea but there's only a few inches of clearance without the lift. Here's the old one, showing some age. Can see it well, but the boot is cracked all the way around, and exposed the entire ball joint which had corroded and rusted. Old, dilapidated and squished Sway Bar Bushing before it was removed. Notice the play and clearance around the bar. I could see daylight ... (more)
Posted : 25 May 2005  
 
Replacing Door Checks on the Mercedes S Class
Model : Mercedes-Benz, S - Class Category : Interior - Doors
... about a 1/2" into the back of this wood panel. Don't even think of cracking this wood, it's like a $4,000,000.00 part. But this is the reason I wanted to get some pics on this - I couldn't for the life of me picture how this unhooked until I actually did it. Anyway, slide the blade up in the slot to catch both tabs, and flip them up. The back comes out first. Work this out GENTLY. Take ... (more)
Posted : 25 May 2005  
 
Replacing Front Shock Absorbers on the Mercedes S Class
Model : Mercedes-Benz, S - Class Category : Suspension
... been contemplating the same task. Good luck! Top of the shocks stick up through the frame by the motor. Pop off all the plastic covers and there is is. Holding the center of the shock pin w/a 5mm hex, loosen the bolt holding the top of the shock. My top bolts were a little stiff, but nothing like the bottoms. Do the top when there's weight on the tires so the springs and shocks are still ... (more)
Posted : 25 May 2005  
 
Replacing Cam Oil Line Fittings (Oil Guides) on the amazing Mercedes 119 (5.0L) V8
Model : Mercedes-Benz, S - Class, S500 Base Category : Misc
... in the 1990's! A good look at a few of the cam lobes, right above the lifter that was not getting oil. All 3 of these little oil guides were popped on this side. Notice the cam journals, they come right off with just the two 11mm bolts. I looked around for the little plastic ends, but couldn't find them. I would have really liked to have gotten them out of there so I'm assuming they made ... (more)
Posted : 25 May 2005  
 
EA (Engine Accelerator) and ETA (Electronic Throttle Actuator)
Model : Mercedes-Benz, S - Class, S500 Base Category : Electrical
... throttle valve is integrated in the MESF1 control module. The following information is processed: - engine speed - coolant temperature - throttle valve position - vehicle speed Electronic Accelerator Emergency Running Function Task Ensuring that the car can continue to be driven safely if a fault occurs at the electronic accelerator. Pedal value sensor emergency running If one potentiometer ... (more)
Posted : 25 May 2005  
 
Coupe Headlights
Model : Mercedes-Benz, S - Class, S500 coupe Category : Lights
... all kinds of light, I noticed that the low beam from the driver's side headlight is pointed down and angled toward the center. You say what's wrong with that?? It's supposed to be that way but mine was so extreme that the beam hit the ground about 20 ft in front of the car! And it almost intersected the beam from the passenger side. Not very good! If you think about it, the 'mis-aiming' was ... (more)
Posted : 25 May 2005  
 
Seat Belt Extender
Model : Mercedes-Benz, S - Class, S500 coupe Category : Interior
... the two gears are under tension when assembled. SBE Removal The following disassembly instructions refer to the drivers side. In order to repair the SBE, the rear seat side panel must be removed to gain access to it as the SBE assy is mounted to the car's sidewall for stability. To start, remove the rear driver's side seat bottom. This gains access to the seat back which is held by one bolt ... (more)
Posted : 25 May 2005  
 
Yet another ASR problem
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... get the ETA out from in between the intake manifold ports. The most difficult part was the small spring that serves as a tensioner to the linkage. It attaches (someplace) on the intake manifold and provides tension on the linkage: the #!(#%^% spring fell off and it literally took about an hour to get it back. Before removing the ETA, the codes were read: picked up one new code in the EA/CC/ISC; ... (more)
Posted : 25 May 2005  
 
Engine Detailing with a Common Product
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... with a shop cloth and buff it out. I did all parts shown in the pictures including the air plenum, F23 module box, fuse box and facade covers. Even did the Aux fans and grill work as shown. The rubber parts shine brightly as do the plastic parts such as the air intake tubes. The air cleaner comes out as a satin finish but all parts have a 'deep' luster. No Touch is the only patented product ... (more)
Posted : 25 May 2005  
 
Testing of Sachs Viscous Fan Clutch 2100 013 032
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... every day. The confusion seems that the ''air-flow'' is equated with ''air-temperature''. For example, here's an excerpt from a post on the VFC and bms. '' . . if the bms can not detect changes in the ambient temperatures properly, because of inadequate air flow around it, . . . it does not mean that there is something wrong with its design. The solution would be to increase the air flow ... (more)
Posted : 25 May 2005  
 
Modification of the Viscous Fan Clutch for M119.xxx Engine
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... protective metal cowling in front that holds the Aux fans so that the fan shroud could be removed. This photo shows how to remove the fan shroud bracket for my S500 cpe. This procedure is valid for any W140 chassis car. All screws are 10mm including the recessed one. The bracket is released by pulling it up and over the hard rubber hood bumpers. After removing the bracket, remove the fan ... (more)
Posted : 25 May 2005  
 
Ticking Noise in the Hydraulic Lifters in a 119.xxx Engine
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... and inspecting the oil tubes, two (2) were found to have open ends!! After replacing all tubes, the oil pressure and ticking noise went away! Talk about poor design for an oil tube! Why aren't they made as a solid piece without an end cap? It's not needed at all. The fact that it is there makes the part very susceptible to failure. And they obviously do! DIY Fix! To change a pair of oil tubes ... (more)
Posted : 25 May 2005  
 
Auxiliary Fans Turn-on Point Modification
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... 206 lbs). This modification concentrates on the 'temperature' side so that the fans may be activated when a certain temperature has occurred and does NOT require that the A/C be in use. The fans use the Coolant Temperature Sensor [CTS] (NOT the ECT sensor (B11/2)) and turn on when the resistance of the CTS [PN 008 542 45 17] is as shown above. Note that to TEST the fans cut-in, 310 and 250 ohms ... (more)
Posted : 25 May 2005  
 
Lower Engine Operating Temperature w/ Water Wetter
Model : Mercedes-Benz, S - Class, S500 coupe Category : Engine
... of the past. Aluminum is such an electroactive metal that it requires an impenetrable corrosion inhibitor film to prevent rapid corrosion. Acid neutralization capability is very important. Coolant which has been left in a cooling system for several years has probably become acidic from the oxidation of the glycol to acids. Also, keeping the glycol concentration in the cooling system ... (more)
Posted : 25 May 2005  
 
Fixing a leaking A/C Evaporator in a W140
Model : Mercedes-Benz, S - Class, S500 coupe Category : Interior - Heating and Air Conditioning
... N22 module must function in order for the A/C to meet specs especially on a hot day. The condenser temperature will rise (gets very hot!) and will cause the radiator temperature to also rise. So the Aux fans must operate to lower the condenser temperature and thus, pressure. Assuming that the A/C compressor is operating, to test proper Aux fan operation, connect a pressure gauge on the Hi ... (more)
Posted : 25 May 2005  
 
Automatic Air Conditioner Diagnostics
Model : Mercedes-Benz, S - Class, S500 coupe Category : Interior - Heating and Air Conditioning
... short circuit **) E0 42 A/C system coolant temperature sensor (B10/8), open or short circuit *) E0 43 A/C system coolant temperature sensor (B10/8), open or short circuit **) E0 44 Refrigerant pressure sensor (B12), short circuit *) E0 45 Refrigerant pressure sensor (B12), short circuit **) E0 46 Refrigerant pressure sensor (B12), open or short circuit *) E0 47 Refrigerant pressure sensor ... (more)
Posted : 25 May 2005  
 
Becker Radio
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical - Radio
... 'FMAMR' displays. - Press the 'TUNE' button until '200:10' appears. This means American standards: 200Khz FM and 10Khz AM spacing. Alternately, 100:9 means 100Khz FM and 9Khz AM spacing. - Press and hold the 'SC' button until 'FMAMR' reappears - Turn the radio off. It has now been programmed to American radio standards. Thanks to information from Horst Becker via Willy Mena Description and ... (more)
Posted : 25 May 2005  
 
Convenience Features Module Diagnostics
Model : Mercedes-Benz, S - Class, S500 coupe Category : Misc
... closing time exceeded 15 Left rear power window circuit (S21/3) and left rear power window switch, front console (S21/5): opening time exceeded 16 Right rear power window circuit (S21/4) and left rear power window switch, front console (S21/6): closing time exceeded 17 Right rear power window circuit (S21/4) and left rear power window switch, front console (S21/6): opening time exceeded 18 ... (more)
Posted : 25 May 2005  
 
Anti-Theft Alarm (ATA) System
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical - Alarm
... front ESA control module w/ memory, N32/2 - RHR control module, N32/12 - Speed Sensitive Power Steering (SPS) control module, N49/1 - Remote Control (RCL) module, N54 - Convenience Features (CF) control module, N57 - Fuel Pump (FP) relay, K27 Fault Table, DTC Readout, SRS Control module (N2/2) Socket 1: Black (ground) Socket 3: Red (12V) Socket 23: Yellow (ATA output) DTC Possible Cause 1 No ... (more)
Posted : 25 May 2005  
 
Supplemental Restraint System (SRS)
Model : Mercedes-Benz, S - Class, S500 coupe Category : Interior - Steering Wheel - Air Bag
... system warning lamp will light. Once the voltage is greater than 10 volts, the lamp will go off. The SRS control module (N2/2) is located on the transmission tunnel. This module process vehicle deceleration from an frontal impact. An arming switch is installed to interrupt the deployment circuit during normal driving mode. This allows for system deployment only when the limits have been ... (more)
Posted : 25 May 2005  
 
Anti-Lock Brake System w/ Acceleration Slip Regulation (ABS/ASR)
Model : Mercedes-Benz, S - Class, S500 coupe Category : Brakes
... 3: Red (12V) Socket 6: Yellow (ABS/ASR output) DTC Possible Cause 1 No faults in system 2 Left front axle vehicle speed sensor (L6/1) 3 Right front axle vehicle speed sensor (L6/2) 4 Left rear axle vehicle speed sensor (L6/3) 5 Right rear axle vehicle speed sensor (L6/4) 6 Left front axle solenoid valve (A7/3y1) 7 Right front axle solenoid valve (A7/3y2) 8 Left rear axle solenoid valve ... (more)
Posted : 25 May 2005  
 
Electronic Accelerator/Cruise Control/Idle Speed Control N4/1
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... position recognition (S16/3) - Cruise control switch (S40) - A/C compressor engagement signal - Data exchange via controller area network (CAN) - Wheel speed sensors (L6/1 - L6/4) - Diode matrix (V2) Output signals: - Electronic accelerator actuator (M16/1 with throttle valve) - ABS/ASR control module (N30/1) - LH-SFI control module (N3/1) - EZL/AKR ignition control module (N1/3) - Impulse ... (more)
Posted : 25 May 2005  
 
Base Module N16/1
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... indicator lamp (MIL), A1e26 - LH-SFI control module (N3/1) - Diagnostic module (N59) on California engines - Fuel pump relay module (K27) - Ignition control module (N1/3) knock sensor - Fuel injectors (Y62) F3 Fused voltage supply for: - SPS (N49/1) control module - ADS (N51) control module - TCM (5-speed automatic (N15/1) control module F4 Fused voltage supply for: - Secondary air ... (more)
Posted : 25 May 2005  
 
Hot Wire, Sequential Fuel Injection System: LH-SFI Module N3/1
Model : Mercedes-Benz, S - Class, S500 coupe Category : Fuel System
... the fuel injection frequency (opening duration) so the engine can't exceed 1100 RPM and the vehicle can be slowly driven to the repair shop. Diagnostic Function If the LH-SFI control module detects a specific fault more than four (4) sequential times (ignition switched ON and OFF), a fault code is stored in the module's memory. Only malfunctions which prevent/severely influence starting or ... (more)
Posted : 25 May 2005  
 
On/Off Ratio Testing (Lambda)
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... available at the X11/4 connector as noted above. A readout of 50% AND an oscillating needle (engine running) indicates that all input signals and the Lambda control system are ok. Readouts of 0% to 100% refer to particular fault source (see Fault Tables below). On-Off Ratio Test Conditions for: Ignition ON - Coolant temperature appox 80 deg C - A/C Off - Selector level in park 'P' position - ... (more)
Posted : 25 May 2005  
 
MB Scanners: Trisco "Palm" Scanner
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... Y Y SRS 1988-1995 Y Y CLIMATE CONTROL AC 1988-1995 Y Y New OBD-II Testable System (Data Stream Test) System Read Codes Erase Codes ENG (ME1.0/2.x) Y Y ETC Y Y ESP Y Y SRS Y Y ICM Y Y AAC Y Y PSE Y Y OCP Y Y LCP Y Y PTS Y Y EIS Y Y The operation of the unit is fairly straight forward. Depending on the car to be tested, the user selects the appropriate interface; 38pin, 8pin or 16pin. If ... (more)
Posted : 25 May 2005  
 
Diagnostic Connectors, Controller Area Network and Scan Tools
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... the fault is now moved to permanent (Stored) memory and the CEL lights. Some ECUs that have internal fault registers, the CEL may stay on after the Stored or Permanent fault has been erased if another occurrence of the fault has happened since the 'permanent' fault was stored. To extinguish the CEL, you should always erase both Stored and Registered faults after fixing the faults indicated. ... (more)
Posted : 25 May 2005  
 
Engine Management Systems
Model : Mercedes-Benz, S - Class, S500 coupe Category : Electrical
... to the MB Engine Management Systems Chart below. Of course, the use of a scanner is required to be able to read all codes from each ECU. Climate Systems Many vehicles have climate control systems that can be accessed through the display panel in the passenger compartment. By simply setting the TEMP control wheels and pushing the AUTO function, the complete status of the AC can be determined. ABS ... (more)
Posted : 25 May 2005  
 
Valve Adjustment
Model : Mazda, Millenia, Millenia S Category : Engine
... the valve shims and cams. The valve clearance is the distance between the cam lobe and the valve shim when the tip of the valve lobe is pointing away from the shim. The clearance is measured using feeler gauges, which are thin strips of metal marked with their thickness in thousandths of an inch. The feeler gauges are tried one at a time until one is found that matches the gap between the ... (more)
Posted : 18 May 2005  
 
Eclipse HID Retrofit
Model : Mitsubishi, Eclipse Category : Lights - Headlights
... into the stock reflectors. . . . . Hella 90mm projector vs. Stock Pictures of Hella 90mm projector beam pattern . . . . . . . . . .___ __ . Low beam Low + High beam . . Left only Right only Both sides . . . Left only Right only Both sides Stock Reflector Housings with HID . . Low beam Low + fogs Low + Hi beam . . In car view Notes Stock reflector uses a 9006 Bulb. The HID kit is a 6000K ... (more)
Posted : 18 May 2005  
 
1995 Eclipse A4 Projector Retrofit
Model : Mitsubishi, Eclipse Category : Lights - Headlights
... low-beam cover 13. Stock rear cover for low-beams installed. The (low-voltage) wires you see on top go from the external ballast to the ignitor installed inside. Bottom connector turns on the HID through a new high-capacity relay and custom wiring harness so the factory wiring isn't overloaded. 13) Stock amber turn-signal lense inside the headlight housing. 14. Stock amber turn-signal lense ... (more)
Posted : 18 May 2005  
 
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