The document discusses recent changes in Mercedes-Benz electrical systems, specifically the introduction of dual-battery systems using AGM batteries that require different testing and charging methods compared to traditional lead-acid batteries. It provides guidance on identifying the two battery types and understanding how electrical power flows between the main and auxiliary batteries in newer Mercedes models. The article emphasizes the importance of using an appropriate battery tester designed for AGMs to accurately check these batteries.

1. STARTUNED®
Information for the Independent Mercedes-Benz Service Professional
May/June 20 I I U.S. $6.00 € 9.00 Volume I I Number 3
IN THIS ISSUE:
3 MIXTURE FORMATION
Find the cause of a fuel system glitch
6 POWER DISTRIBUTION
Changing Technology revolutionizes power
10 KNOWING OUR ABC's
Keeping the system in Tip Top shape
1
4THE NET
Tech info for you

2. In 1888, the New York piano maker Steinway & Sons obtained the rights to all Daimler
patents in the U.S., and produced the "American Mercedes" from 1905 through 1907.
45 HORSE.POWER AMERICAN MERCEDES

3. Mixture
Formati0n
With emissions and mpg both
looming so large right now, you can't
have your customers driving around with
the MIL on, but it's not always so easy to
find the cause of a fuel system glitch .pressure before you
into high-tech diagnosis.
- Some of the most common driveability / emissions it. That may sound simple enough, but we know
repairs we are asked to perform involve the engine's from experience that if the DTC (Diagnostic Trouble
fuel control system. This is not just because of gas Code) that's present is related to the fuel system,
mileage concerns and illuminated MILs (Malfunction there are often many twists and turns in the trail
Indicator Lamps), but also because more and that leads to the source of the trouble. What tools
more states have adopted some sort of emissions do we have to identify the problem?
inspection program. Typically, if the MIL is on, the
ve hicle will not pass. Also, your customers don't like
seeing that warning light any more than they want First Things First
to be burning extra gasoline. They know there's a - Since the fuel system is one of OBD II's three
problem with the system, so they want it fixed, and continuous monitors, if a problem exists it is
who could blame them? So it becomes your job to probably going to set a DTC. Of course, attend to
identify the source of the malfunction and correct the basics first, such as measuring fuel pressure
.
-. - ------ ~-.-----------
YIN VVD8RFG4 J~ J FO J 91 Jl Ball c·tpr.lld'J" 1. " '" IIIrll:
Vehicle 1203. 064 Control unit F12.8
[- 1.000 ... 1.000] ms
596
L 1-
[-1 .000 ... 1.000] I 0.365 ms
[0 .680 ... 1.320] -1- 'f .000
[0 .680 .. . 1.320) 1.000
-- -. - - +-----+--1
[0 .680 ... 1.320) 1.000
On this '02 C320, you can see that the idle fuel adaptation is displayed in milliseconds and the port-load readings are split
into two different rpm ranges, lower port load and upper part load. In this case, the injectors are pulsed .3 more due to a
leon condition at idle.
Mercedes-Benz May/June 201 1 3

4. MIXTURE FORMATION
and doing a visual check of electrical connections, you should perform testing while the engine is at
wire integrity, hoses, etc. Then there are the many idle. If the problem is above idle and under vehicle
sensors and solenoids that determine how much load, you should look at the "upper part fuel trim,"
fuel is actually injected. If you have an SDS, you or "Multiplicative" number. This represents fuel
will have access to the most comprehensive data trims throughout the rpm range.
available. For example, look at coolant temperature
as the engine warms up to verify that the thermostat
is keeping the coolant within the proper range. A Rose By Any Other Name
Typically, if the thermostat is opening too soon the " These numbers can be represented on several
....
PCM will flag a Code P0128. Engine speed and load different scales. The SDS typically displays them
signals determine the base pulse width, so have the as either a millisecond adaptation (ms), or in
largest affect on mixture formation. This is providing Lambda. If you'll recall, Lambda is a scale based
the Mercedes-Benz self-diagnostics have not found on stoichiometry, the ideal ratio of 14.7 parts air
a problem with other input sensors. to 1 part fuel by weight. This is represented by the
number 1.00. If the adaptation number is below
this, the computer has seen a rich condition from
Feedback, Feedback, Feedback ... the oxygen sensor, so is reducing fuel. If the number
"""'Believe it or not, the oxygen sensor arrived on the is above 1.00, the mixture was lean and the PCM
automotive scene over three decades ago. The PCM is adding fuel. The ms scale is simple. This is how
looks at the signal voltage it generates to tell if the much time in milliseconds the injector is being held
mixture is rich or lean. If the signal indicates lean, open or closed. A negative ms number means fuel
the PCM will add fuel by increasing pulse width, and is reduced. If it's a positive number, then fuel is
vicesa versa. You can see the fuel trim indication in being added. You should compare Bank 1 and Bank
the data stream. Mercedes-Benz breaks down these 2 readings where applicable, but you can also tell if
fuel trim numbers into two readings. The first is the engine has a problem at idle or at part throttle.
"Additive" fuel trim. This reading tells you what the Use this information to isolate the problem.
PCM is doing to the mixture at idle and just off idle.
In the SDS, it is also referred to as the "Idle" trim
reading, and, on older systems, "lower part load." If One Bank, Or Two
you see this number deviating from the center point, '''''''When dealing with an engine with two banks,
compare the fuel trims from one
Control unit 2.7
to the other. If you have a problem
with only one bank, focus on that
side's 02 sensor. Once you have
isolated the problem bank, use
the Additive and Multiplicative fuel
trims to determine if it occurs at
idle or part throttle. If the problem
is at idle, you need to perform
additional testing. If you have a
mV
lean condition and a P0171 /4,
mV
check for vacuum leaks. This
239 mV
can easily be done with a smoke
machine, but keep in mind that
This 12 cylinder breaks fuel trims down to two six-cylinder engines, then down the oil is being burned, which can
further into two banks of three cylinders each. This is an overall Lambda reading. contaminate the MAF element, so
As you can see, each group of three cylinders is close to 1.00. remove the MAF first. If you have
4 StarTuned

5. a rich cond ition, you may have a leaking injector. If dea ling with a lean cond ition at higher rpm, the
If the problem is with both banks, you shou ld look MAF shou ld be at the top on your li st of suspects .
at sensors that affect both. A lean cond ition can Also, you may have a fuel delivery problem. Check
stil l be a vac uum leak, but it can also be low MAF fuel vo lum e as we ll as fuel pressure, particularly
output. At this time you may want to start looking at with return-less systems . All of these fuel trim
the MAF. numbers are based on 02 senso rs that are work in g
we ll and prompt ly. Th ey shou ld be ab le to switch
rich-lean-rich at least once a second. Th en, race
Problems Over The Road the engin e and you sho ul d see a sudden rich
- Sma ll problems li ke a vacuum leak usually do not condition, a result of acce leration enrichment (as
affect the fuel trim much above idle. An inj ector wou ld 've been provid ed by the acce lerator pump
with a weak return sprin g can sti ll cause a rich in a carb uretor - remember those?). If yes, you
cond iti on, but it probab ly won't if it is on ly leaking. have a good 02 sensor. If you have multiple codes,
try clearing them , then clear out fuel adaptations.
Vehi cle 1
220.178 Control unit IME-SFI 2.7
Let the engine id le for five minutes and look at
ILambda control
Vo~a!l! (mV] 5
the idle (Additive) fuel numbers. Foll ow this with
':1
B
ool
-- --- --- - - .- -- 6
8
a short road test and look at the part throttle
Ii f' f fI ti' 1;£ (Multiplicative) numbers to see if it looks li ke codes
100 (l I ~..Jl: "1 'j £i
will set aga in .
~
600j t,
500
::1 ~
2~: }
II/ Ii 1' 1 ,J ) - Of course, there are many causes of fuel trim
: ~I
· 200 .
codes, but using your SDS and fuel trim numbers
0 2 4 6 8 1!l 1214 151 9 20222426 29303234 36 384042 444848 50 52 54 56 58 aD
Tlme[s]
shou ld help reduce your diagnostic time. It also leads
Note: to accurate diagnosis and satisfied customers. I
Actual value curve 1 in color 'Ught green': 0 2 sensor voltage , right. upstream of m G. cylinders 1 ~3
The accuracy of the feedback system is based on good 02
sensor readings. Here, you are looking at cylinders seven
through 12, and two pre-TWC and two post-TWC 02
sensors. The red and green traces are the two front 02
sensors, which are switching normally.
With a quality DMM (Digital Multi-Meter) you con measure
This is the MAF signal reading on an E320 at idle.You should signal voltage using the MAXIMIN feature . While recording,
see between 1.3 and 1.4 volts. If your reading is higher or accelerate to WOT and see what your maximum voltage is.
lower than this, you probably have fuel trim codes. If this is A good MAF should read over 4.0V If not, you probably have
severe enough, you may also be facing a drivability problem. a fuel trim code with high Multiplicative readings.
Mercedes-Benz May/June 2011 5

6. - While the 12-volt automotive battery is still the can properly recharge and test each different type.
electrical storage device of choice for all non-hybrid Having two batteries to deal with also poses some
vehic les, the similarities in late-model electrical questions. For example, does one battery do one
systems to those of the past stop there. Mercedes- thing while the other does something else? The se
Benz sti ll used conventional lead-acid batteries in newer ve hicles draw significant current with the key
the last few years, so you can continue to follow on and the engine off, and even while the engine
t radi ti onal testing methods. But Mercedes-Benz is running electrical loads from computer control
ha s also introduced a dual-battery system that uses units, blower motors, auxiliary coolant pumps,
t he AG M/VRLA battery (Absorbent Glass Mat! wipers, defrosters, heated seats and steering
Va lve Regulated Lead Acid). You need to be able to wheels, etc. can exceed what the alternator can
identify t he differences between the two so that you provide at idle. Adding a second battery provides
the extra electrical storage capacity needed.
Know What You're Working On
- Starting with modern chassis like the 211, there's
a main battery mounted on the passenger side of
the spare tire. It is of the AGM type, whi ch means
yo u need to use different methods to recharge
and test it. In recent years, you've been told to
rapidly charge lead-acid batteries. While AGMs
can be charged with conventional equipment,
they require a low charge rate. Fast charging will
damage the internal parts of the battery. We also
If you see a large auxiliary battery on on earlier dual-
battery system, it's for starting. The battery in the rear cannot use typical testing methods such as app lying
powers the main system. A white case tells you it's not an electrical load with a carbon pile, or checking
on AGM battery, but_ _ _ _ _ _ _ _lead-acid _ _ _ _ _ _ _ _ _ _ _ _ _ _ _specific_gravity._Mercedes-Benz_ _ _ _ _-==~~= the
__
the regular _ _ _ _ _ _ type. _____ _____ _ ______c _ _ _ _ _
•• _
recommends
6 StarTuned

7. use of the Midtronics MCR 717 battery tester or to use them . Look for and read the red protective
equivalent. It applies a specific AC voltage to the battery positive terminal cap and it will warm you if
battery and monitors the responding current flow. it is an AGM.
Many new battery charger/testers are available
and have selections for AGM batteries, so it's okay
Power Flow
- The rear-mounted battery is the main power
supply of the vehicle - it powers the rear pre-fuse
box. There are large high-current fuses of 150 and
200 amps that bolt down, and blade-type fuses in
the box, which power up the front and rear SAMs.
This is necessary since the SAM modules provide
"wake up" Signals for other systems. It also
supplies battery voltage to the interior fuse box.
There is a second pre-fuse box mounted in the
passenger side foot-well under the carpet. It has a
high-capacity capacitor installed in it, so be careful
with tools in the area. Since electrical loads can
exceed the main battery in the trunk, there is an
This rear-mounted battery is the main electrical power auxiliary battery mounted under the hood, typically
supply in some newer systems. A black case tells you it is on the passenger side of the firewall. This battery
an AGM battery. Read the waming on the red cover and is always grounded, but is not always connected
look (or the letters "VRLA" to confirm. You'll need a special to the vehicle on the power feed side. It is cut in
battery tester to check this one. through an auxiliary relay.
Who Pulls Whose Chain
- On the 211 chassis, the relay is mounted under
plastic covers at the base of the windshield.
This auxiliary battery has seen better days. It should supply
I2.6 to I 2.8 volts when properly charged. This one can no
longer hold a charge. The black case tells you to check if it The battery control module, pictured here, monitors the rear
is an AGM type. In this case, it is. Using an OEM battery battery voltage, the front battery voltage, and alternator
is the safest way to repair the problem and prevent false output through the body CAN B. You con talk to it with your
alarms in the future. 50S unit and program it if it needs to be replaced.
Mercedes-Benz May/June 2011 7

8. POW ER DISTRIBUTIO N
power to the auxiliary cigar
li ghter/power supply sockets
to help reduce electri cal loads .
The contro l unit can also request
that consumers be shut dow n
according to its preprogrammed
priorities . There are two stages
of power reduction . If both
stages do not bring up system
vo ltage, t hen the au xiliary battery
relay is energized (connecting
t he auxiliary battery to the
front pre-fuse box) and the red
warning message is displayed on
th e das h. In this case, you will
need to check the condition of
both batteries with yo ur te ste r,
and alternator output to see
what is causing the prob lem .
Remember, before condemning
any component, ma ke sure the
system is not being shut off d ue
This is the auxiliary battery relay. It turns on to allow the auxiliary battery to to excessive electrical load . Pull
charge and, if system voltage is low, to odd current under heavier loads. It is and clear codes after a Ouic k Test
not on all the time, so do not expect the auxiliary battery to always indicate and see if it starts working again.
charging voltage.
With a paid subscription to auxil iary battery when system A Known Quantity
www.startekinfo.com . you can vo ltage is low. The contro l - Th e alternator can be te sted
loo k up component locations mod ul e looks at t he vo ltage of as any other alternator, but yo u
with Starfinder for your particular both ba tteries and the alternato r need to make sure the batte ri es
model. When extra electrica l output t hroug h a CAN . You can are in at least adequate shape
current is needed, the re lay is access t hi s control unit wit h yo ur for testing. If the batteries need
turned on. The au xiliary ba ttery SDS and retrieve DTCs. rep lacement, make sure you get
suppl y voltage is app lied through t he AGM type that meets the
a 150-amp fuse to the front pre- spec ifications of the original s. If
fuse box. This battery is also an Warnings not, you may get false warning
AGM, so the sa me rule s app ly - If th e battery contro l modu le messages in the clu ster and
for chargin g and testing as for detects a fau lt, you' ll see a improper charging and acti vati on
th e main battery. The re lay is message in the instrument cluster of the auxi liary battery. Using
operated by a Battery Control warn ing t he driver. The prob lem OEM batteries is the best way to
Module, which is mounted by the can be no charging, low vo ltage, avo id th is. The specifications are
main battery in the trunk. The or overc harging. If th e vo ltage is printed on both the front and re ar
module activa tes the auxiliary just low, the warn ing message batteries . Also, Battery Control
battery relay in two cases: First, te ll s you to cut off accessories. Modu les are reprogrammabl e
to rech arge the au xiliary battery, The modu le is also in contro l of and your SDS wil l prompt you if
and, sec ond, to connect the a cut-off relay that interrupts updated software is ava ilable . I
8 StarTuned

10. The suspension system is often considered the two. With electronics, they can change ride
the pe rsonality of a vehicle . A soft suspension heights, suspension stiffness, body roll, etc. The two
gives a compliant, comfortable ride, but doesn't main systems the company offers are Active Body
provide enough road feedback for sporty driving. Control (ABC) and Semi-Active Suspension (SAS).
A taut suspension is well suited for motoring fun, ABC is hydrau lic, whereas SAS is pneumatic, us ing
but may not be very comfortable on ro ugh roads. air springs, but also incorporates ADS II, which
Mercedes-Benz engineers believe in the use of controls the vehicle's dampening hyd rau lica lly. Of
creative technology to provide a combination of course, it's very important for proper diagnosis and
repair to be able to know for sure what the vehicle
you're working on is equipped with.
Certain models, such as the early 230 chassis SL-
Class, use the ABC hydraul ic system, which controls
ride height. With its built-in intel ligence, if the driver
has selected a high setting, it will be overridden
whenever the vehicle exceeds 68mph - the bod y
will descend to its lowest position for optimum
center-of-gravity and handling.
SAS can be found on later chassis, such as t he
211 E-Class. It is an evolution of the older Airmatic
system found in the 220 chassis S-Class. It still
uses pneumatics, but now it has two-chamber
struts. Dampening is controlled by decreasing or
increasing the air volume through opening either
The hydraulic pressure of the ABC system is provided by one or two chambers in the ai r spring. The ADS II
a belt-driven pump, the some one that feeds the power hydraulic system provide four levels of dampen ing
steering system. It will be damaged if allowed to run dry for control that the driver can select with a switch
over four seconds, so make sure the fluid is up to the proper mounted in the LCP (Lower Control Panel).
level and that the reservoir (tIters are not clogged.
10 StarTun ed

11. - The ABC hydraulics operate at over 2,900 psi, so
it is important to reduce this pressure to safe levels
before attempting repairs. With any Airmatic or SAS
system, you should also relieve the pressure before
starting any suspension work to prevent damage to
the components . It wi ll also make reassembly much
easier because a collapsed strut can be positioned
more easi ly than an inflated one. The SDS is used
to safe ly reduce this pressure. With ABC, pressure
is generated by a belt-driven hydraulic pump (the
same one that provides psi to the power steering).
A return-flow solenoid contro ls fluid being drawn
in from the reservoir. There are two levels on the
dipstick, one for high suspension levels, and the
other for low. The return lin es for both the power
steering and ABC reservoirs have filters in them,
which should be replaced any time the system is
You'll find a screen in the banjo bolt of the pressure feed opened and refilled with new fluid.
line. It protects the system by blocking debris. It should be
removed and cleaned whenever service work is done to - As an example, in the 230 chassis ABC fluid
prevent pressure drop in the system. pressure is rou ted to a pressure supply va lve unit
The return-flow filter is mounted in the reservoir. While you're visiting your Mercedes-Benz ports dealer, you should pick up these
filters and at least four liters of hydraulic fluid. This will protect your work and give components the longest possible service life.
Merced es-Benz May/June 2011 11

12. LEARN IN G O UR ABCs
Vehicle 1230.471 Control unit
IActuations
Control and locking valve of front left suspension strut I
Control and locking valve of front right suspension strut
Control and locking valve of rear left suspension strut
Control and locking valve of rear right suspension strut
Move toward calibrated level (automatic) .
Using your SDS, you can control each corner. Move to the calibrated position and perform a "Dynamic Test" (Rodeo mode).
Selecting "Release System Pressure" will also allow you to start disconnecting lines for repair.
mounted behind the driver's side front tire in the each corner of the vehicle as we ll as engage the
fen der. It controls the pressure applied to the front "Rodeo" mode where all four corners are raised
and rear axle va lve units. The front valve unit is and lowered. This allows you to completely test the
mounted in the fron t driver's side fender. It controls system and check for any potentia l t rouble codes
both front corners in dividua lly. The rear unit is and leaks . If you've opened any co nnections, yo u'l l
mounted in the driver's side rear fender in front of need to refill the system and purge it of any air.
the wheel, and contro ls the rear corners individually. Once again, Startekinfo provides th is step-by-step
A reservoir mounted in each valve stores pressure procedure . This wi ll prevent the reservo ir fro m
until the pump replenishes t he supply. When running dry and damaging t he pu mp. The system
opening t he system, you should know that there should always be allowed to sit for 10 minutes to
are four bleed screws, one in each corner, which allow fluid to return to the reservo ir fo r an accurate
you can open to let the fluid drain before removing fluid level reading. After purging air and testing with
li nes. Crack the screws open slowly to prevent your SDS, you can confidently retu rn the ve hicle to
spillage . Your SDS un it can also be used to relieve the customer knowing the system will pe rform as
fluid pressure. Support the vehicle so the pressure it's supposed to . I
loss does not al low the chassis to drop.
Union and banjo fittings are used to
connect meta l lines. Push-lock fittings
PageloTI
are used on ru bber lin es. Push the
plastic lock rings in evenly whi le you
pul l the line out to prevent damage to
the connection .
- You can read al l of t he safety
precautions in WIS with a pa id
subscription to www.startekinfo.com .
The ABC control un it monitors fluid
temperature and press ure, and controls
solenoid operation. With your SDS,
you can look at this data, and under With your paid subscription to Startekinfo you can review all of the safety
"Actuations" you can ma nually control
procedures before attempting a repair. You can also look up locations of the
bleed screws to depressurize the system so you can start work.
12 StarTuned

13. • ••
. . . on all eight with www.startekinfo.com.
Mercedes-Benz USA Dealer Workshop Services is the source for all the technical
information needed to support, service, and maintain Mercedes-Benz vehicles.
Mercedes-Benz workshops rely on DWS products and services for getting jobs
done quickly and more efficiently. Our products include:
• STAR TekInfo with WIS-net (Workshop • Maintenance Manuals and Sheets
Information System) • STAR Service Manual Library CDs
• Electrical Troubleshooting Manuals • WIS and DAS software updates
• Installation Instructions • Star Diagnosis System (SDS)
• Technical Bulletins • Operator's Manuals and COMAND Manuals
• Campaigns • Mercedes-Benz Equipment
• Mercedes-Benz Special Tools • Inventory of technical publications
STAR TekInfo
Dealer Workshop Services
Engineering Services,
Mercedes-Benz USA, LLC.
@ Mercedes-Benz

14. I
I
· What's New : Accessories tab added for
direct access to the items that enhance your
Mercedes-Benz vehicle.
Sourcing Mercedes-Benz
Repair and Parts Information · Page with helpful parts information .
~ "
~ · Links to other informative sites like the
Mercedes-Benz Service and Parts
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to look up parts.
"'l' .~".',,~ •• " .:".,~, •..),.L~~..- t 11 ~""~"y ,"""" " ~ " <>1, /",~
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