07.3-165 Checking fuel pump relay with electronic rpm control (breakaway speed) Job No, of fa ates or standard texts ond la rates date 07-5792, ‘Versions and regulating (breakaway) speeds Engine | MB part No Breakaway speed | Kickdown Remarks timin tin Standard version 116.960 | 001 545 08 08 : 116.961 001 545 16 05 pend coe 117.960 | 001 545 05 05 : 117.961 001 545 1705 I pied 7 20) 116.962 118963 i with kickdown 116963 | oor s45a40s | 5950 250 575050 a 117.963 are with kickdown NV KAT 001 545 53 05 5500 + 50 5300+ 50 Lola hutot (cose foe] @® 81 116.960 | 001 54505 05 i 116,961 001 545 1705 eee oe it @®® 1002-1005 @ 1983-1985 116.962 i | with Kickdown 116967 | gor sas 4005 | s9s0 +50 | s7050 a Cem 116.960 | 001 545 06 05 116.961 001 545 1505 eae te ae ae D@ we 116.962 : ‘ with kickdown 6862 | oor 545.2608 | 530050 510050 a D@® 1983-1985 se - [ i cc 1s | oo sessa05 | se00-+50 500280 | whedon ona7i-rest 3Conventional testers Voltmeter, revolution counter Note ‘The fuel pump relay is controlled via ignition impulses. The impulse number is computed as follows: Rom x number of cylinders 2 Example: Breakaway of pump relay 001 545.07 05 for engine 110.98 (6850 + 50/min) starts at approx. 19 950 impulses per minute; breakaway of relay 001 545 04 05 {6600 + 50/min) for engine 116.96 will not start be: fore 26 400 impulses, If these relays are mixed up, the engine 110 may rev up and breakaway for engine 116.96 would start too soon, even though the relay shows almost similar breakaway speeds, Layout of fuel pump relay ‘Model 107 Lefthand steering At the right inside vehicle behind glove box. For re pair jobs, remove glove box and lining Righthand steering ‘At the right inside vehicle above pedals. For repairs, remove lining o7a7 1682 F2Model 126 Letthand steering At the left in fuse box. Righthand steering ‘At the right in fuse box Testing Test condition Battery charged at least 60 %. Note: For wiring diagram and test sequence for mix ture control unit with safety switch refer to repair instructions engine 116 (3.5) and 117 (45), A. Prior to September 1981 Wiring diagram prioe to September 1981 1, Eu! pump relay 2 Fuel pump 3 Warrmup compensator 4 Ter Guitehing ot 07.37 11-165/3 F2 ee ® 8 - CopeChecking activation of fuel pump relay Remove fuel pump relay. Connect negative cable of voltmeter to vehicle ‘ground. Measure voltage with positive cable of voltmeter on jack 2 of coupling approx. 12 volts Ovolt eager Check line (terminal 30, red) to cable connector of engine harness for inter ruption. Repair interruption. Seer eee Switch on ignition fae? oe 9 999 a oe r [666 a ps eee eee eee cece rene Test line (terminal 18, black/red) to igni- tion starter switeh for interruption. Repair interruption. w w o7a7 1650 F2Connect positive cable of voltmeter to jack 2 ‘and negative cable of voltmeter to jack 5 of ‘coupling and measure voltage. approx. 12 volts volt Se Test line (terminal 31, brown) to groun ding point for interruption Repair interruption, ———— Connect revolution counter to jack 3 and jack 4 of coupling. ‘Actuate starter. ‘approx. 200/min. O/min a Test line (terminal TD, green/yellow) to TCI switching unit for interruption, in order, renew switching wv 0737 165/52Checking function of fuel pump relay Connect negative cable of voltmeter to vehicle ground, Plug fuel pump relay on coupling in such a manner that the voltage can be measured with positive cable of voltmeter. Actuate starter for this purpose. approx, 12 volts Ovolt SS Run engine at idle. Renew fuel pump relay. Fe Engine running, Engine not running w~ ora 7-656 F2 i Renew fuel pump relay.If the engine is not regulated (breakaway speed) after attaining engine max. speed, renew fuel pump relay. The respective breakaway speed is punched into, fuel pump relay. End of test B. Starting September 1981 Wiring diagram starting September 1981 Fuel ume Coupling 8.pole Kckoown site Warmup renter CCovping, ai lamp wiring harness Snatch selector lever position “B! {og terminat 30 Cable connecior terminal TO Gontiotunitof electronic idle speed control {Cable connector engine terminal 80 Fase capsule terminal 15 Access fuse 14 ‘Magnets valve automatic transmission 9 Model 107" Coupling, tail lamp wiring harness (7) Tarpote,jack 2 Mode! 128. uel pump relay (19) Feronnat 87, jack 7 Line colors ge = yellow org7 N65) FSTesting activation of fuel pump relay Remove fuel pump relay. Connect negative cable (black) of voltmeter to vehicle ground, Measure voltage with positive cable (red) of voltmeter on jack 8 (terminal 30) of coupling. approx. 12 volts Ovort ~ With jack 7 and 8 Repair interruption bridged, the fuel pump} according to wiring should run, diagram. Ht not End of test Pec Switeh on ignition. Measure voltage with positive cable (red) of volt- meter on jack 9 (terminal 15) of coupling approx. 12 volts volt w o7a7 1658 F2Repair interruption according to wiring diagram. End of test ~~ Connect positive cable (red) of voltmeter to jack 8 (terminal 30) and negative cable (black) of voltmeter to jack 11 (terminal 31) of coupling and measure voltage. approx. 12 volts Ovott Repair interruption according to wiring diagram End of test SE. Connect engine tester. Connect dwell angle ‘measuring cable to jack 10 (terminal TD). Operate starter. Dwell angle 7-34, Yes No 65/9 2‘Test line (terminal TD, greeniyellow) to TCI switching unit for interruption. Test ignition system, if required. End of test —= Connect postive cable ed of voltmeter 0 joc 12 erin 30) and eptve cable lok) = of voltmeter to jack 11 (terminal 31) of coupling + oO pure D Qo Repair interruption according to wiring diagram, End of test Check kickdown shutoff. With engine running the B-pole coupling (arrow) terminal 7 is energized. Voltage should drop at 200/min prior to breakaway speed. Ww or a7 -nsio F2Renew relay. End of test If all tests are in order and the fuel pump acti vation is stil at fault, renew relay. If there is no breakaway after the engine max. speed has been attained, renew fuel pump relay. ‘The respective breakaway speed is punched into fuel pump relay. End of test o7a7 i srt F2