Ignition system: Difference between revisions

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==Ignition System==
[[File:W220_EPC_ignition_system.png|thumb|none|Parts in [[EPC]] related to ignition system.]]


==Description - Ignition System==
This page covers W220 petrol engines M112 (V6 engine used in [[S350]]) and M113 (V8 engine used in [[S430]] and [[S500]]).
The W220 S Class series uses a twin-spark ignition coil with kV pickup (a test connector on each coil pack) and dual spark plugs per cylinder.


'''Warning:''' No tests such as holding an ignition HT Wire at a distance from ground and observing a spark must be performed.
The W220 uses a twin-spark ignition system for each cylinder and thus the V8 has eight ignition coils (or ignition plug packs).
There is one coil pack per cylinder, which produces spark for two spark plugs per cylinder.


'''Warning:''' Do not operate the ignition system at starting speed unless all of the HT Wires are connected.
Misfiring frequently occurs because of burnt ignition coils, faulty ignition cables and spark plugs. These elements have to be replaced regularly.


'''Warning:''' Before working at cranking speed eg to check compression pressure, switch off ignition and disconnect Ignition Control Unit from 12V.
In case of failure, the following codes can be thrown:
* P2050 Misfiring, Damages TWC (P0300) STORED
* P2056 Misfiring of cylinder 4, damages TWC (P0304) STORED
* P205B Misfiring of cylinder 8, damages TWC (P0308) STORED


==Issues - Spark Plugs==
== Notes on avoiding damage to ignition system ==
* Old spark plugs can show worn electrodes and a wider than specification gap.
<!-- AH15.10-P-0002-01D
* Broken insulators are common during removal of seized OEM plugs.
Notes on avoiding damage to ignition system
* Fouled spark plugs.
ENGINE 104, 111, 112, 113, 119, 120, 156, 271, 272
* Corroded spark plug threads make it difficult to remove an old plug. Solution is to use high temperature anti-seize grease available from autoparts stores when re-installing new plugs.
With gasoline injection and ignition system ME-SFI
-->


==Parts - Spark Plugs==
''The main points:''
* 2003 Update W220 S500 Chassis Number: 220.175 and Engine Number: 113.960.
* '''No tests such as holding an ignition HT Wire at a distance from ground and observing a spark must be performed.'''
* M-B part number is 003-159-66-03-26 which is the same plug as the Bosch F 8 DPP 332 which is no longer available.
* '''Do not operate the ignition system at starting speed unless all of the HT Wires are connected.'''
* Bosch equivalent spark plug is FR8DPP33+.
* '''Before working at cranking speed e.g. to check compression pressure, switch off ignition and disconnect Ignition Control Unit from 12V.'''


[[File:Spark_Plug_Bosch_FR8DPP33+.JPG|300px|center]]
Notes on avoiding damage to ignition system:
* To avoid damage to control unit, only connect and disconnect the two connectors on control unit when ignition is switched off.
* Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as antitheft protection.
* Only install original ignition system components.
* Do not operate ignition system at starting speed unless all of the ignition cables are connected.
* No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is running.
* Every high voltage circuit must be loaded with at least 2 kΩ (spark-plug connector).
* If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with a spark plug at a cylinder ignition cable. Ensure that spark plug has good contact to ground.
* Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect connector "2" from control unit.


* Denso equivalent spark plug PK16PRL11. (Denso OE quality resisted platinum spark plug with pre-set gap of 1.1mm.)
'''Use of testers and testing units:'''
* Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical engine and ignition are switched off.
* If the short-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not possible to conduct the test with this test instrument.
* Do not connect test lamp to ignition coil terminals 1 and 15.


==Service - Spark Plugs==
== Remove/install ignition coils ==
* M-B specifies replacement of plugs at every 100,000Km or 4 Years. Spark plug HT wires don't last much longer than that either.
<!-- AR15.12-P-2003A
* The resistance of the spark plug (electrode to HT connector) is about 4.5K to 6K ohms.
Remove/install ignition coils
* There should be extremely high  resistance between the electrode and the plug metal thread.
6.11.09
* Set the spark plug electrode gap to 0.039” or 1mm.  
ENGINES 112.910 in MODEL 202.026 /086
* Tightening torque 15 - 22 ftlbs or 20 - 30Nm.
ENGINES 112.920 in MODEL 202.029 /089
ENGINES 112.921 in MODEL 210.063 /081 /263 /281
ENGINES 112.922 in MODEL 220.063 /163
ENGINES 112.923 in MODEL 129.059
ENGINES 112.940 in MODEL 208.365 /465
ENGINES 112.941 in MODEL 210.065 /082 /265 /282
ENGINES 112.942 in MODEL 163.154
ENGINES 112.943 in MODEL 129.064
ENGINES 112.944 in MODEL 220.065 /165
ENGINES 112.945 in MODEL 463
ENGINES 113.940 in MODEL 210.070 /270
ENGINES 113.941 in MODEL 220.070 /170
ENGINES 113.960 in MODEL 215.375, 220.075 /175 /875
ENGINES 113.961 in MODEL 129.068
ENGINES 113.962 /982 in MODEL 463
ENGINES 113.980 in MODEL 210.074 /274
ENGINES 113.944 in MODEL 202.033 /093
ENGINES 113.942 in MODEL 163.172
ENGINES 113.943 in MODEL 208.370 /470
ENGINES 113.984 in MODEL 208.374 /474
ENGINES 113.981 in MODEL 163.174
ENGINES 112.912 in MODEL 203.061 /261, 209.361 /461
ENGINES 112.946 in MODEL 203.064 /264
ENGINES 112.947 in MODEL 170.465
ENGINES 112.960 in MODEL 170.466
ENGINES 113.986 in MODEL 215.373, 220.073 /173
ENGINES 112.961 in MODEL 203.065 /265
ENGINES 113.965 in MODEL 163.175
ENGINES 113.963 in MODEL 230.475
ENGINES 113.968 in MODEL 209.375 /475
ENGINES 112.913 in MODEL 211.061 /261
ENGINES 112.949 in MODEL 211.065 /265
ENGINES 113.967 in MODEL 211.070 /270
ENGINES 113.992 in MODEL 230.474
ENGINES 113.987 in MODEL 209.376 /476
ENGINES 112.955 in MODEL 209.365 /465
ENGINES 113.990 in MODEL 211.076 /276
ENGINES 113.991 in MODEL 215.374, 220.074 /174
ENGINES 112.916 in MODEL 203.081 /281
ENGINES 112.953 in MODEL 203.084 /284
ENGINES 112.972 in MODEL 220.067 /167
ENGINES 112.973 in MODEL 230.467
ENGINES 112.970 in MODEL 163.157
ENGINES 112.975 in MODEL 220.087 /187
ENGINES 113.948 in MODEL 220.083 /183
ENGINES 113.966 in MODEL 220.084 /184
ENGINES 112.917 in MODELS 211.080 /280
ENGINES 112.954 in MODEL 211.082 /282
ENGINES 113.969 in MODEL 211.083 /283
ENGINES 113.988 in MODEL 203.076 /276
ENGINES 113.993 in MODEL 463.270 /271
ENGINES 113.989 in MODEL 171.473
ENGINES 113.995 in MODEL 230.472
-->


==Parts - HT Wires==
{|
A new plug wire resistance is approximately 2.18K ohms.
|Shown on engine 112


[[File:W220_Spark_Plug_HT_Wire.JPG|300px|center]]
* 5/1 - Spark plug connector
* 5/3 - Screw
* T1/1 - Cylinder 1 ignition coil
* T1/2 - Cylinder 2 ignition coil
* T1/3 - Cylinder 3 ignition coil
* T1/4 - Cylinder 4 ignition coil
* T1/5 - Cylinder 5 ignition coil
* T1/6 - Cylinder 6 ignition coil
* T1/7 - Cylinder 7 ignition coil
* T1/8 - Cylinder 8 ignition coil


The spark plug wires come in sets of sixteen.
Arrow: Identification of the connector
|[[File:W220_remove_install_ignition_coils.png]]
|}


[[File:Bosch_Spark_Plug_Wire_Set.JPG|300px|center]]
# Unclip cover on front side of engine
# Remove engine cover with integrated air filter. The air filter is integrated in the engine cover. Remove the engine cover or the air filter housing by pulling it from the cylinder head covers vertically in the upward direction.
# Remove air filter housing.
# Remove screw (5/3). ''Remove Torx 30 bolts that hold down the coil packs on the valve cover. One T30 bolt per ignition coil.''
# Detach spark plug connector (5/1) from the spark plugs. Pry off spark plug connector (5/1) using open-end wrench, double over the cylinder head cover of the spark plugs. Installation: Observe the identification of the connector (arrow) on the cylinder head cover and the ignition coil of cylinders 1 to 6 or 1 to 8 for the corresponding spark plug connector (5/1). ''Installing: put pressure on the ignition cable connector to push it all the way on the plug. Listen for a click as it goes on properly.''
# Separate electrical connector of ignition coil of cylinder 1 to 6 (T1/1 to T1/6) or 1 to 8 (T1/1 to T1/8). Installation: Install new cable ties.
# Remove ignition coil of cylinder 1 to 6 (T1/1 to T1/6) or 1 to 8 (T1/1 to T1/8)
# Install in the reverse order


For a W220 with Engine Number: 113.960 xxxx the lengths of the spark plug wires are as follows:
Torque specification:
* Cylinder - 1, Ignition Coil Port - a; HT wire size - L.
* Bolt, ignition coil to cylinder head cover (Engine 112, 113): 8 Nm
* Cylinder - 1, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 2, Ignition Coil Port - a; HT wire size - H.
* Cylinder - 2, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 3, Ignition Coil Port - a; HT wire size - K.
* Cylinder - 3, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 4, Ignition Coil Port - a; HT wire size - K.
* Cylinder - 4, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 5, Ignition Coil Port - a; HT wire size - H.
* Cylinder - 5, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 6, Ignition Coil Port - a; HT wire size - K.
* Cylinder - 6, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 7, Ignition Coil Port - a; HT wire size - G.
* Cylinder - 7, Ignition Coil Port - b; HT wire size - G.
* Cylinder - 8, Ignition Coil Port - a; HT wire size - G.
* Cylinder - 8, Ignition Coil Port - b; HT wire size - K.


Where HT Wire Sizes (Tip to Tip) are (NB not in length sequence.):
''A special spark plug cable removal tool is available (110 589 01 01 00). It is a 17mm, open ended tool with a 25mm off-set and is made by JTC with part number J-1308. It can be found in eBay for $20.''
* G: 245mm
{|
* H: 290mm
|[[File:Open_ended_wrench_double_110589010100.png|thumb|none|Open-end wrench, double (110 589 01 01 00)]]
* K: 265mm
|[[File:JTC_Spark_Plug_Wire_Removal_Tool_J-1308.JPG|thumb|none|JTC Spark Plug Wire Removal Tool J-1308.]]
* L: 315mm
|}


==Issues - HT Wires==
== Replace spark plugs ==
* Spark HT wires have a limited life.
<!-- AP15.10-P-1580AB
* The resistance element in the HT wires often fails or goes high resistance due to fatigue.
Replace spark plugs 16.6.15
* HT lead insulation can break down causing arcing to ground.
112.913 in model 211.061/261
* A special spark plug wire removal tool is available. It is a 17mm, open ended tool with a 25mm off-set and is made by JTC with part number J-1308. It can be found in eBay for $20.
112.917 in model 211.080/280
112.922 in model 220.063/163
112.944 in model 220.065/165
112.949 in model 211.065/265
112.954 in model 211.082/282
112.972 in model 220.067/167
112.973 in model 230.467
112.975 in model 220.087/187
113.941 in model 220.070/170
113.948 in model 220.083/183
113.960 in model 215.375, 220.875
113.960 in model 220.075/175
113.963 in model 230.475
113.966 in model 220.084/184
113.967 in model 211.070/270
113.969 in model 211.083/283
113.986 in model 215.373
113.986 in model 220.073/173
113.990 in model 211.076/276
113.991 in model 215.374
113.991 in model 220.074/174
113.992 in model 230.474
113.995 in model 230.472
-->


'''JTC Spark Plug Wire Removal Tool J-1308'''
{|
|Shown on engine 112 in model 210
* 01 - Spark plug wrench
* 1 - Spark plug
|[[File:W220_replace_spark_plugs.png]]
|}


[[File:JTC_Spark_Plug_Wire_Removal_Tool_J-1308.JPG|400px|center]]
{|
|Shown on ignition coil of engine 157.980
* 2 - Spark plug connector
* 3 - Rubber lip
|[[File:W220_replace_spark_plugs_ignition_coil.png]]
|}


* The rubber boot on the HT Wire is difficult to remove from a spark plug even when using the special removal tool. Solution is to apply a small quantity of dielectric grease when re-installing new plugs. This helps keep moisture away and stops corrosion. Makes it infinitely easier to remove HT Wire boot.
# ''Put hood in service position. Push on the locks on the hinges at left side and then the right side and raise hood to the service position (90 degrees fully open).''
# Remove ignition coils. ''Keep in correct order as the wire lengths are all different. Do not mix them up (mark with masking tape).''
# Blow out any dirt residue in the spark-plug recesses using compressed air
# Remove spark plugs (1) using spark plug wrench (01) from cylinder heads. ''Use an air ratchet with a swivel extension and a 3/8" drive 5/8" spark plug socket.''
# Screw new spark plugs (1) using spark plug wrench (01) into cylinder heads. ''Start screwing new spark plugs by hand to avoid cross threading.''
# Check spark plug connector (2), ignition coils and ignition lines for damage, deformation and crack formation.
# Grease rubber lips (3) of spark plug connectors (2) with spark plug connector grease (A0029898051) before installing
# Install ignition coils


'''Permatex 22058 Dielectric Tune-Up Grease'''
''Always remove spark plugs on a stone cold engine or else risking stripping the threads.''


[[File:Permatex_22058_Dielectric_Tune-Up_Grease.JPG|200px|center]]


* A regular 5/8" (15.8mm) spark plug socket with a rubber insert works well for removing spark plugs. However the secret is to use a variety of extensions eg a short 74mm 3/8" drive extension on the tight spots in conjunction with a with swivel head.
Torque specifications:
* Spark plugs (engine 112 and 113): 28 Nm


[[File:W220_Swivel_Extension_and_Spark_Plug_Socket.JPG|300px|center]]
{|
|[[File:W220_‘G’_and_‘L’_Spark_Plug_Wires.JPG|thumb|none|Cable length symbol on ignition cable connectors.]]
|[[File:W220_Valve_cover_annotations_cylinder_5_H_goes_to_a_and_G_goes_to_b.JPG|thumb|none|The valve cover has ignition coil and ignition cable annotations for each cylinder (cylinder 5 H-cable goes to ''a'' and G-cable goes to ''b'').]]
|[[File:W220_ignition_coil_wire_spark_plug_job.jpg|thumb|none|Parts for ignition coil, ignition wire and spark plug replacement job]]
|}


==Description - Ignition Plug Pack==
{|
The W220 uses a twin-spark ignition system for each cylinder and thus the V8 has eight Ignition Plug Packs or Ignition Coils.
|[[File:W220_Swivel_Extension_and_Spark_Plug_Socket.JPG|thumb|none|Swivel extension and spark plug socket. A regular 5/8" (15.8mm) spark plug socket with a rubber insert works well for removing spark plugs. However the secret is to use a variety of extensions e.g., a short 74mm 3/8" drive extension on the tight spots in conjunction with a with swivel head.]]
 
|[[File:W220_pliers_spark_plug_socket.jpg|thumb|none|In practice, spark plug jobs on M112 and M113 can be done by using pliers with bent nose for ignition plug removal and swivel wrench with short extension and spark plug socket]]
[[File:W220_WIS_Diagram_Showing_Spark_Plug_Pack_Annotations.JPG|600px|center]]
|[[File:W220_spark_plug_socket_in_action.jpg|thumb|none|Swivel wrench with extension and spark plug socket in action (on M113)]]
 
|}
It is possible to perform basic tests on an Ignition Plug Pack using a Digital Multi Meter (DMM).
 
Each Coil Secondary Resistance measured from the High Tension (HT) connector to any of the three pins in the input electrical connector is approximately 4.8 M Ω (Mega Ohms).
 
The HT circuit is isolated from ground thus the resistance between the HT Pin and Ground is infinity Ohms or Open Circuit.
 
==Issues - Ignition Plug Pack==
* Burnt coil.
* Cracked Pack.
 
==DIY Procedures - Ignition System==
===Replace Spark Plugs and HT Wires - DIY===
With acknowledgement of the excellent video produced by Benz Werks and article by BenzWorld Member Justin Alvarez. Refer to:


<!-- http://www.benzworld.org/forums/w220-s-class/1598302-05-s500-spark-plug-replacement-video.html -->
<!-- http://www.benzworld.org/forums/w220-s-class/1598302-05-s500-spark-plug-replacement-video.html -->
{|
{|
|{{#ev:youtube|https://www.youtube.com/watch?v=eycUkQ9T1V0|320|left|SPARK PLUGS AND WIRES REPLACEMENT|frame}}
|{{#ev:youtube|https://www.youtube.com/watch?v=dSTbh8fDHtc|320|left|Spark plugs and wires replacement (by Masood)|frame}}
|{{#ev:youtube|https://www.youtube.com/watch?v=eycUkQ9T1V0|320|left|Spark plugs and wires replacement|frame}}
|{{#ev:youtube|https://www.youtube.com/watch?v=qzCdqlpRN3g|320|left|How to replace spark plugs and wires|frame}}
|{{#ev:youtube|https://www.youtube.com/watch?v=qzCdqlpRN3g|320|left|How to replace spark plugs and wires|frame}}
|}
|}
<br clear=all>


'''Summary of contributions at references.'''
== Spark plug connector grease ==


* Step 1: Put Bonnet/Hood in Service Position
The rubber boot on the ignition cable is difficult to remove from a spark plug even when using the special removal tool.
Solution is to apply a small quantity of dielectric grease to the top conductor and the ceramic insulator (or to the spark plug connector) when re-installing new plugs.
This helps keep moisture away and stops corrosion.
Makes it infinitely easier to remove the spark plug connector.


Push on the locks on the hinges at LH side and then the RH side and raise Bonnet/Hood to the Service Position.
* OE - A0029898051 (12 EUR)
* BERU ZKF01 - 0890300029 (8 EUR)
* Permatex 22058


* Step 2: Remove the Air Intake Tubes
{|
* Step 3: Remove the Air Box
|[[File:A0029898051_grease_for_spark_plug_adaptors.jpg|thumb|none|Grease for spark plug adaptors (0029898051)]]
** Remove Front Cover. First pull it up and slide it forward.
|[[File:BERU_ZKF01_a.jpg|thumb|none|BERU ZKF01 grease for spark plug adaptors]]
|[[File:BERU_ZKF01_b.jpg|thumb|none|BERU ZKF01 grease for spark plug adaptors]]
|[[File:Permatex_22058_Dielectric_Tune-Up_Grease.JPG|thumb|none|Permatex 22058 Dielectric Tune-Up Grease]]
|}


[[File:W220_Remove_Air_Box_Front_Cover.JPG|300px|center]]
== Parts ==
** Pull the Air Box Back Cover forward and up.


[[File:W220_Remove_Air_Box_Back_Cover.JPG|300px|center]]
=== Spark plugs ===


* Step 4: Remove Ignition Coil Packs and Spark Plug Wires
* Mercedes-Benz specifies replacement of plugs at every 100 000km or 4 years. Spark plug ignition cables don't last much longer than that either.
** Identify Ignition Coil Packs on the Valve Covers. Mark appropriately and do not mix them as the leads are different lengths.
* The resistance of the spark plug (electrode to ignition cable connector) is about 4.5K to 6K ohms.
* There should be extremely high resistance between the electrode and the plug metal thread.
* The spark plug electrode gap is 0.039” or 1mm.
* Tightening torque for spark plugs is 20-30 Nm (28 Nm according to WIS).
* Old spark plugs can show worn electrodes and a wider than specification gap.
* Broken insulators are common during removal of seized OEM plugs.
* Corroded spark plug threads make it difficult to remove an old plug. Solution is to use high temperature anti-seize grease (see below) when re-installing new plugs.


[[File:W220_WIS_Diagram_Showing_Spark_Plug_Pack_Annotations.JPG|600px|center]]
Part numbers:
* OE - A0041591903
* OE - A0031599403
* OE - A0041595003 (15 EUR)
* Bosch 0242230500 (5 EUR)
* Denso PK16PRL11 (6 EUR)
* Denso IK16TT (8 EUR) - recommended for [[LPG]], up to 100 0000 km
* NGK 4292 (EUR 8)
* BRISK DR17YS-9 (EUR 3) - suited for [[LPG]], interval max 30 000 km


[[File:W220_Ignition_Coil_Packs_and_HT_Wires.JPG|300px|center]]
[[File:Spark_Plug_Bosch_FR8DPP33+.JPG|thumb|none|BOSCH 0242230500]]


** Unhook electrical connectors on Coil Packs by squeezing in tabs and pull straight up.
=== Ignition coils ===


[[File:W220_Removing_Connectors_on_Ignition_Coil_Packs.JPG|300px|center]]
* It is possible to perform basic tests on an ignition coil using a digital multi meter (DMM). Each coil secondary resistance measured from the plug cable to any of the three pins in the input electrical connector is approximately 4.8 M Ω (Mega Ohms). The cable circuit is isolated from ground thus the resistance between the cable pin and ground is infinity Ohms or open circuit.
* For BOSCH ignition coils the production date is visible on the coil (21T008 means production year 2021).


** Give the spark plug covers a slight tweak to rotate and loosen them a little first before attempting to lever them off. Use special tool to remove plug leads. When using a 17mm open ended spanner to pry off the spark plug covers, make sure you counter balance the leverage you're applying to ensure the cover comes off in line with the plug. Otherwise there's a tendency to push down on the cover which actually makes it very hard to remove.
<!--
** Remove T30 Bolts that hold down the coil packs on the valve cover. One T30 Bolt per coil pack.
[http://mbworld.org/forums/s-class-w220/431985-ongoing-maintenance-repair-2003-s600-2.html Article]
on fixing a burnt coil pack, right bank, on cylinder 4 which threw the following codes:
* P2050 Misfiring , Damages TWC (P0300) STORED
* P2056 Misfiring of cylinder 4, damages TWC (P0304) STORED
* P205B Misfiring of cylinder 8, damages TWC (P0308) STORED
-->


[[File:W220_One_T30_Bolt_Per_Coil_Pack.JPG|300px|center]]
Parts:
* OE A0001587303 (replaced by A0001587803).
* BOSCH 0221503035 (40 EUR)


** Remove Coil Pack and keep in correct order as the wire lengths are all different. Do not mix them up. (Mark with masking tape.)
{|
|[[File:A0001587803_ignition_coil.jpg|thumb|none|Ignition coil (A0001587803)]]
|[[File:A0019907212_coil_pack_screw_T30.jpg|thumb|none|T30 screw for attaching ignition coil to engine (A0019907212).]]
|}


* Step 5: Remove Spark Plugs
=== Ignition cables ===
** Use an air ratchet with a swivel extension and a 3/8" drive 5/8" spark plug socket.


[[File:W220_Swivel_Extension_and_Spark_Plug_Socket.JPG|300px|center]]
* Spark plug ignition cables have a limited life. The resistance element in the cables often fails or goes high resistance due to fatigue.
* Step 6: Add anti seize to new plug threads
Cable lead insulation can break down causing arcing to ground. The resistance for new plug wire is approximately 2.18K ohms.
** Add some hi-temp anti-seize compound to the plug threads before installing. Just a little dab will do.
* It is possible to perform basic tests on an ignition coil using a digital multi meter (DMM). Each coil secondary resistance measured from the plug cable to any of the three pins in the input electrical connector is approximately 4.8 M Ω (Mega Ohms). The cable circuit is isolated from ground thus the resistance between the cable pin and ground is infinity Ohms or open circuit.
* Step 7: Start New Plugs by Hand
<!--
** Use socket with extension and start new plugs by hand to avoid cross threading. [[File:W220_Start_New_Spark_Plugs_by_Hand.JPG|300px|center]]
[http://mbworld.org/forums/s-class-w220/431985-ongoing-maintenance-repair-2003-s600-2.html Article]
on fixing a burnt coil pack, right bank, on cylinder 4 which threw the following codes:
* P2050 Misfiring , Damages TWC (P0300) STORED
* P2056 Misfiring of cylinder 4, damages TWC (P0304) STORED
* P205B Misfiring of cylinder 8, damages TWC (P0308) STORED
-->


* Step 8: Remove the Spark Plug Wires from Coil Packs
Ignition cables are in different lengths:
** Just twist the Spark Plug Wires and pull straight out to remove from Coil Packs.
* G-cable: 245mm - A1121500118 (45 EUR), BOSCH 0356912948 (14 EUR) - M112 x8, M113 x9 (If G-cable is not available, a slightly longer K-cable can be used instead.)
* Step 9: Identify New Plug Wires
* K-cable: 265mm - A1121500218 (45 EUR), BOSCH 0356912950 (14 EUR) - M112 x4, M113 x4
* H-cable: 290mm - A1121500318 (56 EUR), BOSCH 0356912952 (30 EUR) - M112 x0, M113 x2 (If H-cable is not available, a slightly longer L-cable can be used instead.)
* L-cable: 315mm - A1121500418 (56 EUR), BOSCH 0356912954 (32 EUR) - M112 x0, M113 x1


[[File:W220_Bosch_Ignition_Wire_Set.JPG|300px|center]]
{|
 
|[[File:W220_Spark_Plug_HT_Wire.JPG|thumb|none|Ignition cable.]]
** Carefully observe new spark plug wire annotations. Sixteen Spark Plug Wires are labelled ‘A’, ‘B’.... ’O’, ‘P’.
|[[File:Bosch_Spark_Plug_Wire_Set.JPG|thumb|none|BOSCH spark plug wire set for M113.]]
These are the ‘G’ and ‘L’ Wires. [[File:W220_‘G’_and_‘L’_Spark_Plug_Wires.JPG |300px|center]]
|}
 
** Carefully observe new ignition coil pack annotations which are labelled on the top.
Eg this coil pack has ‘a’ and ‘b’ marked on the top. [[File:W220_Coil_Pack_marked_a_and_b.JPG|300px|center]]
 
** Carefully observe valve cover annotations. The Valve Cover also has Coil Pack and Plug Wire Annotations for each cylinder.
W220 Valve cover annotations cylinder 5 H goes to a and G goes to b. [[File:W220_Valve_cover_annotations_cylinder_5_H_goes_to_a_and_G_goes_to_b.JPG|300px|center]]


* Step 10: Install Plug Wires on Spark Plugs
Ignition cable lengths for M112 (V6 [[S350]]):
** Put Plug Wires on before re-installing Coil Packs. Add dielectric grease or Silicon Spray to the plug end of the wires. This will make future plug changes easier and prevent any water problems.
* Cylinder 1, port a; K-cable
** Use the Special Tool to put pressure on the plug wire to push it all the way on the plug.  Listen for a click as it goes on properly. [[File:W220_Reinstall_plugs_apply_pressure_and_listen_for_click.JPG|300px|center]]
* Cylinder 1, port b; G-cable
* Cylinder 2, port a; G-cable
* Cylinder 2, port b; G-cable
* Cylinder 3, port a; G-cable
* Cylinder 3, port b; K-cable
* Cylinder 4, port a; K-cable
* Cylinder 4, port b; G-cable
* Cylinder 5, port a; G-cable
* Cylinder 5, port b; G-cable
* Cylinder 6, port a; G-cable
* Cylinder 6, port b; K-cable


* Step 11: Re-install Ignition Coil Packs
Ignition cable lengths for M113 (V8 [[S430]] and [[S500]]):
** Coil bolt is T-30, torque 71 in.lb. or 8Nm
* Cylinder 1, port a; L-cable
 
* Cylinder 1, port b; G-cable
===Repair - Ignition Plug Pack===
* Cylinder 2, port a; H-cable
Article by Benz World Member haoz129 Howard on fixing a burnt coil pack, right bank, on cylinder 4 which threw the following codes:
* Cylinder 2, port b; G-cable
* P2050 Misfiring , Damages TWC (P0300) STORED
* Cylinder 3, port a; K-cable
* P2056 Misfiring of cylinder 4, damages TWC (P0304) STORED
* Cylinder 3, port b; G-cable
* P205B Misfiring of cylinder 8, damages TWC (P0308) STORED
* Cylinder 4, port a; K-cable
* Cylinder 4, port b; G-cable
* Cylinder 5, port a; H-cable
* Cylinder 5, port b; G-cable
* Cylinder 6, port a; K-cable
* Cylinder 6, port b; G-cable
* Cylinder 7, port a; G-cable
* Cylinder 7, port b; G-cable
* Cylinder 8, port a; G-cable
* Cylinder 8, port b; K-cable


http://mbworld.org/forums/s-class-w220/431985-ongoing-maintenance-repair-2003-s600-2.html
Cable kits:
* Valeo 346141 (130 EUR)- M112
* NGK 7800 (221 EUR) - M113
* MAGNETI MARELLI 941318111285 (80 EUR) - M113

Latest revision as of 22:05, 14 September 2023

Ignition System

Parts in EPC related to ignition system.

This page covers W220 petrol engines M112 (V6 engine used in S350) and M113 (V8 engine used in S430 and S500).

The W220 uses a twin-spark ignition system for each cylinder and thus the V8 has eight ignition coils (or ignition plug packs). There is one coil pack per cylinder, which produces spark for two spark plugs per cylinder.

Misfiring frequently occurs because of burnt ignition coils, faulty ignition cables and spark plugs. These elements have to be replaced regularly.

In case of failure, the following codes can be thrown:

  • P2050 Misfiring, Damages TWC (P0300) STORED
  • P2056 Misfiring of cylinder 4, damages TWC (P0304) STORED
  • P205B Misfiring of cylinder 8, damages TWC (P0308) STORED

Notes on avoiding damage to ignition system

The main points:

  • No tests such as holding an ignition HT Wire at a distance from ground and observing a spark must be performed.
  • Do not operate the ignition system at starting speed unless all of the HT Wires are connected.
  • Before working at cranking speed e.g. to check compression pressure, switch off ignition and disconnect Ignition Control Unit from 12V.

Notes on avoiding damage to ignition system:

  • To avoid damage to control unit, only connect and disconnect the two connectors on control unit when ignition is switched off.
  • Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as antitheft protection.
  • Only install original ignition system components.
  • Do not operate ignition system at starting speed unless all of the ignition cables are connected.
  • No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is running.
  • Every high voltage circuit must be loaded with at least 2 kΩ (spark-plug connector).
  • If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with a spark plug at a cylinder ignition cable. Ensure that spark plug has good contact to ground.
  • Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect connector "2" from control unit.

Use of testers and testing units:

  • Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical engine and ignition are switched off.
  • If the short-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not possible to conduct the test with this test instrument.
  • Do not connect test lamp to ignition coil terminals 1 and 15.

Remove/install ignition coils

Shown on engine 112
  • 5/1 - Spark plug connector
  • 5/3 - Screw
  • T1/1 - Cylinder 1 ignition coil
  • T1/2 - Cylinder 2 ignition coil
  • T1/3 - Cylinder 3 ignition coil
  • T1/4 - Cylinder 4 ignition coil
  • T1/5 - Cylinder 5 ignition coil
  • T1/6 - Cylinder 6 ignition coil
  • T1/7 - Cylinder 7 ignition coil
  • T1/8 - Cylinder 8 ignition coil

Arrow: Identification of the connector

  1. Unclip cover on front side of engine
  2. Remove engine cover with integrated air filter. The air filter is integrated in the engine cover. Remove the engine cover or the air filter housing by pulling it from the cylinder head covers vertically in the upward direction.
  3. Remove air filter housing.
  4. Remove screw (5/3). Remove Torx 30 bolts that hold down the coil packs on the valve cover. One T30 bolt per ignition coil.
  5. Detach spark plug connector (5/1) from the spark plugs. Pry off spark plug connector (5/1) using open-end wrench, double over the cylinder head cover of the spark plugs. Installation: Observe the identification of the connector (arrow) on the cylinder head cover and the ignition coil of cylinders 1 to 6 or 1 to 8 for the corresponding spark plug connector (5/1). Installing: put pressure on the ignition cable connector to push it all the way on the plug. Listen for a click as it goes on properly.
  6. Separate electrical connector of ignition coil of cylinder 1 to 6 (T1/1 to T1/6) or 1 to 8 (T1/1 to T1/8). Installation: Install new cable ties.
  7. Remove ignition coil of cylinder 1 to 6 (T1/1 to T1/6) or 1 to 8 (T1/1 to T1/8)
  8. Install in the reverse order

Torque specification:

  • Bolt, ignition coil to cylinder head cover (Engine 112, 113): 8 Nm

A special spark plug cable removal tool is available (110 589 01 01 00). It is a 17mm, open ended tool with a 25mm off-set and is made by JTC with part number J-1308. It can be found in eBay for $20.

Open-end wrench, double (110 589 01 01 00)
JTC Spark Plug Wire Removal Tool J-1308.

Replace spark plugs

Shown on engine 112 in model 210
  • 01 - Spark plug wrench
  • 1 - Spark plug
Shown on ignition coil of engine 157.980
  • 2 - Spark plug connector
  • 3 - Rubber lip
  1. Put hood in service position. Push on the locks on the hinges at left side and then the right side and raise hood to the service position (90 degrees fully open).
  2. Remove ignition coils. Keep in correct order as the wire lengths are all different. Do not mix them up (mark with masking tape).
  3. Blow out any dirt residue in the spark-plug recesses using compressed air
  4. Remove spark plugs (1) using spark plug wrench (01) from cylinder heads. Use an air ratchet with a swivel extension and a 3/8" drive 5/8" spark plug socket.
  5. Screw new spark plugs (1) using spark plug wrench (01) into cylinder heads. Start screwing new spark plugs by hand to avoid cross threading.
  6. Check spark plug connector (2), ignition coils and ignition lines for damage, deformation and crack formation.
  7. Grease rubber lips (3) of spark plug connectors (2) with spark plug connector grease (A0029898051) before installing
  8. Install ignition coils

Always remove spark plugs on a stone cold engine or else risking stripping the threads.


Torque specifications:

  • Spark plugs (engine 112 and 113): 28 Nm
Cable length symbol on ignition cable connectors.
The valve cover has ignition coil and ignition cable annotations for each cylinder (cylinder 5 H-cable goes to a and G-cable goes to b).
Parts for ignition coil, ignition wire and spark plug replacement job
Swivel extension and spark plug socket. A regular 5/8" (15.8mm) spark plug socket with a rubber insert works well for removing spark plugs. However the secret is to use a variety of extensions e.g., a short 74mm 3/8" drive extension on the tight spots in conjunction with a with swivel head.
In practice, spark plug jobs on M112 and M113 can be done by using pliers with bent nose for ignition plug removal and swivel wrench with short extension and spark plug socket
Swivel wrench with extension and spark plug socket in action (on M113)
Load video
YouTube
Spark plugs and wires replacement (by Masood)
Load video
YouTube
Spark plugs and wires replacement
Load video
YouTube
How to replace spark plugs and wires

Spark plug connector grease

The rubber boot on the ignition cable is difficult to remove from a spark plug even when using the special removal tool. Solution is to apply a small quantity of dielectric grease to the top conductor and the ceramic insulator (or to the spark plug connector) when re-installing new plugs. This helps keep moisture away and stops corrosion. Makes it infinitely easier to remove the spark plug connector.

  • OE - A0029898051 (12 EUR)
  • BERU ZKF01 - 0890300029 (8 EUR)
  • Permatex 22058
Grease for spark plug adaptors (0029898051)
BERU ZKF01 grease for spark plug adaptors
BERU ZKF01 grease for spark plug adaptors
Permatex 22058 Dielectric Tune-Up Grease

Parts

Spark plugs

  • Mercedes-Benz specifies replacement of plugs at every 100 000km or 4 years. Spark plug ignition cables don't last much longer than that either.
  • The resistance of the spark plug (electrode to ignition cable connector) is about 4.5K to 6K ohms.
  • There should be extremely high resistance between the electrode and the plug metal thread.
  • The spark plug electrode gap is 0.039” or 1mm.
  • Tightening torque for spark plugs is 20-30 Nm (28 Nm according to WIS).
  • Old spark plugs can show worn electrodes and a wider than specification gap.
  • Broken insulators are common during removal of seized OEM plugs.
  • Corroded spark plug threads make it difficult to remove an old plug. Solution is to use high temperature anti-seize grease (see below) when re-installing new plugs.

Part numbers:

  • OE - A0041591903
  • OE - A0031599403
  • OE - A0041595003 (15 EUR)
  • Bosch 0242230500 (5 EUR)
  • Denso PK16PRL11 (6 EUR)
  • Denso IK16TT (8 EUR) - recommended for LPG, up to 100 0000 km
  • NGK 4292 (EUR 8)
  • BRISK DR17YS-9 (EUR 3) - suited for LPG, interval max 30 000 km
BOSCH 0242230500

Ignition coils

  • It is possible to perform basic tests on an ignition coil using a digital multi meter (DMM). Each coil secondary resistance measured from the plug cable to any of the three pins in the input electrical connector is approximately 4.8 M Ω (Mega Ohms). The cable circuit is isolated from ground thus the resistance between the cable pin and ground is infinity Ohms or open circuit.
  • For BOSCH ignition coils the production date is visible on the coil (21T008 means production year 2021).


Parts:

  • OE A0001587303 (replaced by A0001587803).
  • BOSCH 0221503035 (40 EUR)
Ignition coil (A0001587803)
T30 screw for attaching ignition coil to engine (A0019907212).

Ignition cables

  • Spark plug ignition cables have a limited life. The resistance element in the cables often fails or goes high resistance due to fatigue.

Cable lead insulation can break down causing arcing to ground. The resistance for new plug wire is approximately 2.18K ohms.

  • It is possible to perform basic tests on an ignition coil using a digital multi meter (DMM). Each coil secondary resistance measured from the plug cable to any of the three pins in the input electrical connector is approximately 4.8 M Ω (Mega Ohms). The cable circuit is isolated from ground thus the resistance between the cable pin and ground is infinity Ohms or open circuit.

Ignition cables are in different lengths:

  • G-cable: 245mm - A1121500118 (45 EUR), BOSCH 0356912948 (14 EUR) - M112 x8, M113 x9 (If G-cable is not available, a slightly longer K-cable can be used instead.)
  • K-cable: 265mm - A1121500218 (45 EUR), BOSCH 0356912950 (14 EUR) - M112 x4, M113 x4
  • H-cable: 290mm - A1121500318 (56 EUR), BOSCH 0356912952 (30 EUR) - M112 x0, M113 x2 (If H-cable is not available, a slightly longer L-cable can be used instead.)
  • L-cable: 315mm - A1121500418 (56 EUR), BOSCH 0356912954 (32 EUR) - M112 x0, M113 x1
Ignition cable.
BOSCH spark plug wire set for M113.

Ignition cable lengths for M112 (V6 S350):

  • Cylinder 1, port a; K-cable
  • Cylinder 1, port b; G-cable
  • Cylinder 2, port a; G-cable
  • Cylinder 2, port b; G-cable
  • Cylinder 3, port a; G-cable
  • Cylinder 3, port b; K-cable
  • Cylinder 4, port a; K-cable
  • Cylinder 4, port b; G-cable
  • Cylinder 5, port a; G-cable
  • Cylinder 5, port b; G-cable
  • Cylinder 6, port a; G-cable
  • Cylinder 6, port b; K-cable

Ignition cable lengths for M113 (V8 S430 and S500):

  • Cylinder 1, port a; L-cable
  • Cylinder 1, port b; G-cable
  • Cylinder 2, port a; H-cable
  • Cylinder 2, port b; G-cable
  • Cylinder 3, port a; K-cable
  • Cylinder 3, port b; G-cable
  • Cylinder 4, port a; K-cable
  • Cylinder 4, port b; G-cable
  • Cylinder 5, port a; H-cable
  • Cylinder 5, port b; G-cable
  • Cylinder 6, port a; K-cable
  • Cylinder 6, port b; G-cable
  • Cylinder 7, port a; G-cable
  • Cylinder 7, port b; G-cable
  • Cylinder 8, port a; G-cable
  • Cylinder 8, port b; K-cable

Cable kits:

  • Valeo 346141 (130 EUR)- M112
  • NGK 7800 (221 EUR) - M113
  • MAGNETI MARELLI 941318111285 (80 EUR) - M113
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