Conversion of USA tourist vehicles with catalytic convertor - ra49lh1040002x(0002)

Engine 104 LH-Injection 

Operation No. of operation texts and operation values or standard texts and flat rates

Tourist vehicles are supplied with a catalytic convertor. The difference to the USA version consists of the ignition system and the information plate for the emissions control system on the radiator cross member.

Tourist vehicles must be converted in the VPCs as follows:

1. Replace spark plugs.
2. Test exhaust system and oxygen sensor for lead residues with Plumbtesmo test paper.
3. Replace information plate for emissions control system on the radiator cross member.
4. Operational test.

1. Replacing spark plugs 

   Install spark plugs as stated in the spark plug table below.

   Tightening torque with flat seat and seal 20-30 Nm.

   Maximum permissible speed 160 km/h (100 mph).

   SPARK PLUG TABLE
   
   

   BERU	14F-9DUO
   BOSCH	F-9DCO
   CHAMPION	C12YCC

2. Testing exhaust system and oxygen sensor for lead residues with Plumbtesmo test paper 

   Fuse which contain lead affect proper operation of the oxygen sensor and the catalytic convertors. For this reason, it is necessary to verify that the vehicle has been operated with unleaded fuel. Adopt the following procedure for this purpose:

   • Engine switched off, exhaust tail pipe and oxygen sensor must be warm (not glowing hot).

     Remove oxygen sensor and install.

   • Moisten Plumbtesmo test paper with 2 drops of distilled water and press with your thumb against the inner wall of the exhaust tail pipe for about 2 minutes or place test paper around the protective cage of the oxygen sensor and likewise press on for about 2 minutes.
   • Take off test paper and assess (see table).

   Color	Assessment
   unchanged	No lead residues, test negative.
   pink	Very slight lead residues, test negative (up to 0.015 g lead/ltr. is permissible in unleaded fuels). Does not affect proper operation.
   red	Lead residues too high, test positive. Test must be repeated.

   NOTE: As the lead test is very sensitive, it is essential to operate with great care to ensure that positive lead results are not obtained incorrectly because of traces of lead being introduced. For this reason, it is recommended after each positive test to wash your hands or to wear disposable gloves. Test papers which have dropped onto the ground must not be re-used as the dust may contain traces of lead.

   If the test paper likewise colors read after repeating the test, the oxygen sensor or the catalytic convertor system, respectively, must be replaced.

3. Replacing information plate for emissions control system on radiator cross panel 

   Pull off the information plate "CATALYST APPROVED FOR IMPORT" on the radiator cross panel. Clean the contact surface. Stick on information plate for emissions control system/ catalyst.

   Fig 1: Identifying Information Plate For Emissions Control System On Radiator Cross Panel

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Operational test 
   NOTE: If the test specifications are not achieved by adjusting, the test sequence must be interrupted. Rectify faults on the basis of the Diagnosis Manual Engine.

   Test procedure: 

   Connect testers for oil temperature, engine speed, ignition angle and lambda control.

   Warm up vehicle on roller dynamometer by driving at part load in D position or 3rd gear (60 km/h, about 25 kW). The engine oil temperature should be about 80°C.

   1. Check the accelerator control to ensure it operates freely and is properly adjusted.
   2. Check air injection:

      Start engine and at the same time pay attention to air pump.

      When the engine is starting, the air pump must also run briefly.

   3. Check exhaust gas recirculation:

      Connect vacuum tester to exhaust gas recirculation valve using Y distributor. Increase engine speed to 3000 rpm.

      Specification: >400 mbar.

   4. Check ignition angle:

      Engine idling.

      Specification with vacuum: 6-10° before TDC.

   5. Check idle speed:

      See Diagnosis Manual Engine, Volume 1.

      + 100

      Specification position P/N: 780 rpm

      - 50

      Specification position D: < 550 to 800 rpm

   6. Check regeneration valve:

      Detach line from activated charcoal filter at regeneration valve and connect vacuum tester to the regeneration valve.

      Specification: >400 mbar.

   7. Check lambda control:

      See Diagnosis Manual Engine, Volume 1.

      Specification: 50% ± 10

   8. Check the "Check Engine" display:

      Switch off engine, disconnect testers.

   Switch on ignition → "Check Engine" lamp on.

   Start engine → "Check Engine" lamp off.

   INFORMATION PLATE
   
   

   Model	Emissions control system information plate, part no.
   	Federal	California
   140.032/033	140 584 65 17	140 584 66 17

   COMMERCIALLY AVAILABLE TESTER
   
   

   Designation
   Plumbtesmo test paper	available commercially

   NOTE: Operation text and flat rates 02-1412/01 basic operation