Ignition system

Description - Ignition System

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.

Warning: Do not operate the ignition system at starting speed unless all of the HT Wires are connected.

Warning: Before working at cranking speed eg to check compression pressure, switch off ignition and disconnect Ignition Control Unit from 12V.

Issues - Spark Plugs

• Old spark plugs can show worn electrodes and a wider than specification gap.
• Broken insulators are common during removal of seized OEM plugs.
• Fouled spark plugs.
• 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.

Parts - Spark Plugs

• 2003 Update W220 S500 Chassis Number: 220.175 and Engine Number: 113.960.
• 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.
• Bosch equivalent spark plug is FR8DPP33+.

• Denso equivalent spark plug PK16PRL11. (Denso OE quality resisted platinum spark plug with pre-set gap of 1.1mm.)

Service - Spark Plugs

• 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.
• The resistance of the spark plug (electrode to HT connector) is about 10K ohms.
• There should be extremely high resistance between the electrode and the plug metal thread.
• Set the spark plug electrode gap to 0.039” or 1mm.
• Tightening torque 15 - 22 ftlbs or 20 - 30Nm.

Parts - HT Wires

A new plug wire resistance is approximately 2.18K ohms.

The spark plug wires come in sets of sixteen.

Issues - HT Wires

• Spark HT wires have a limited life.
• The resistance element in the HT wires often fails or goes high resistance due to fatigue.
• HT lead insulation can break down causing arcing to ground.
• 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.

JTC Spark Plug Wire Removal Tool J-1308

• 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.

Permatex 22058 Dielectric Tune-Up Grease

• A regular 5/8" 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 3/8" drive extension on the tight spots in conjunction with a with swivel head.

Description - Ignition Plug Pack

Edit required.

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.youtube.com/watch?v=eycUkQ9T1V0&feature=related

http://www.benzworld.org/forums/w220-s-class/1598302-05-s500-spark-plug-replacement-video.html

Summary of contributions at references.

• Step 1: Put Bonnet/Hood in Service Position

Push on the locks on the hinges at LH side and then the RH side and raise Bonnet/Hood to the Service Position.

• Step 2: Remove the Air Intake Tubes
• Step 3: Remove the Air Box
  • Remove Front Cover. First pull it up and slide it forward.

• • Pull the Air Box Back Cover forward and up.

• Step 4: Remove Ignition Coil Packs and Spark Plug Wires
  • Identify Ignition Coil Packs on the Valve Covers. Mark appropriately and do not mix them as the leads are different lengths.

• • Unhook electrical connectors on Coil Packs by squeezing in tabs and pull straight up.

• • 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.

• • Remove Coil Pack and keep in correct order as the wire lengths are all different. Do not mix them up. (Mark with masking tape.)

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

• Step 6: Add anti seize to new plug threads
  • Add some hi-temp anti-seize compound to the plug threads before installing. Just a little dab will do.
• Step 7: Start New Plugs by Hand
  • Use socket with extension and start new plugs by hand to avoid cross threading.

    

• Step 8: Remove the Spark Plug Wires from Coil Packs
  • Just twist the Spark Plug Wires and pull straight out to remove from Coil Packs.
• Step 9: Identify New Plug Wires

• • Carefully observe new spark plug wire annotations. Sixteen Spark Plug Wires are labelled ‘A’, ‘B’.... ’O’, ‘P’.

These are the ‘G’ and ‘L’ Wires.

• • 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.

• • 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.

• Step 10: Install Plug Wires on Spark Plugs
  • 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.
  • 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.

    

• Step 11: Re-install Ignition Coil Packs
  • Coil bolt is T-30, torque 71 in.lb. or 8Nm

Repair - Ignition Plug Pack

Article by Benz World Member haoz129 Howard 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

http://mbworld.org/forums/s-class-w220/431985-ongoing-maintenance-repair-2003-s600-2.html