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Rewiring the Right Side Electronic Throttle Actuator (ETA)

The V12 engine in this car has two Electronic Throttle Actuators (ETA). They are electrically operated. They control the amount of air that is drawn into the engine. The right side ETA controls the left side bank of cylinders, and the left side ETA controls the right side bank of cylinders. The right side ETA is commanded by the left side ETA. Although the left side ETA has cables from the gas pedal attached to it, the primary means of actuation is not mechanical. There is a potentiometer linked to the gas pedal that functions as a position sensor. The position of the gas pedal is transmitted electrically via wires to the onboard computers. From this info, the computers calculate how to actuate the ETA's. It is a drive-by-wire system. This is how the car's traction control can decrease engine speed if necessary, regardless of how hard you press on the gas pedal. I will not go into the workings of these devices here. Many more details on ETA function can be found on several Mercedes Benz Forums.

Mercedes Benz used a wire insulation material that was unsuitable for the high-temperature environment of an engine compartment. Rumor has it that it was developed to be biodegradable in an effort to be environmentally conscious. While the intentions were good, unfortunately the insulation degrades in the car. This seems to be the case with many different types of MB models around 1992 to 1995. The problem was corrected in year 1996 and on. The insulation begins to break down and crack. If the problem is not addressed, the insulation will eventually fall off the wires and cause short circuits. At the least, this could cause all sorts of caution lights to light up on your dashboard. It is also the cause of many Traction Control and “Limp Home” problems or engine stalling. At the worst, it could damage very expensive electronic components or possibly cause an engine fire. In my car, I got an intermittent Check Engine (CE) caution light. Pulling fault codes from the onboard computers did not really point to anything specific, but one recurring fault code was Faulty Electronic Throttle Actuator.

One way to determine the condition of insulation quality is to do an Insulation Breakdown test. To do this requires specialized equipment though, something that most people don’t have in their garage. In addition, there are some very sensitive electronic components within the ETA that could be damaged by performing such a test. The best way to examine the condition of the wires in the ETA's is to remove the ETA’s from the intake manifold and inspect the wire visually.

This page describes the Right Side ETA repair project in detail. These basic guidelines can be used to repair the Left Side ETA as well, but keep in mind that the wiring will be different than that shown for the Right Side ETA. In addition, the Left Side ETA has the throttle cable connections. These instructions do not cover the disassembly. It is fairly straightforward. If you do the Left Side ETA, I strongly recommend taking digital pictures as you go. That way you have a record of where that "extra" screw is supposed to go. The Left Side ETA cables have springs attached to the linkages...DON'T lose them!

One thing you should be aware of is that there are potentiometers in these units that can also fail. This project does not address failed potentiometers. Check out Jim F's web page for further details on that.

It is assumed that you know how to solder well.
If not, find a friend who can to help you.

Parts / Materials Needed:

  • Military grade wiring per M22759/11. It is rated for a conductor temperature of 200° C, and the insulation is able to withstand a constant temperature of 260° C. There are three different gages of wires that needed to be replaced. The original gages are metric in size, and are .35, .75, and 1.5 mm in size.

For .35 mm, I used 26 gage
For .75 mm, I used 20 gage
For 1.5 mm, I used 14 gage

This means that you will need;

For Right Side ETA (US Passenger Side)

For Left Side ETA (US Driver Side)

Two 48" lengths of M22795/11-14
Two 48" lengths of M22795/11-20
Four 48" lengths of M22795/11-26
Two 48" lengths of M22795/11-14
Two 48" lengths of M22795/11-20
Seven 48" lengths of M22795/11-26

The color designator is also a number, and is placed at the end of the wire and gage number. So for example, M22759/11-26-6 is a 26 gage wire with blue insulation.

Possible Wire Suppliers:

Whitmor / Wirenetics
27737 Hopkins Ave
Valencia, CA 91355
800-822-9473
Sea Wire and Cable, Inc.
P.O. Box 647
451 Lanier Road
Madison, AL 35758
800-633-7210
Galaxy Wire and Cable
420 Babylon Road, Suite D
Horsham, PA 19044
888-425-4454
RDS Wire & Cable
225 E. Gardena Blvd
Carson, CA 90248
310-323-7131
Dearborn Wire
250 W. Carpenter
Wheeling, IL 60090
847-459-1000
 
  • Sheathing

Supplier:

Varflex
512 W. Court Street
Rome, New York 13440
Sheathing Data
I used Varflo (size 3), which according to their literature is good to 130° C.  I personally tested it to 190° C, and it withstood the temperature without any problem.

  • Raychem Heat Shrink tubing, 1/2 inch DR-25.
  • Adhesive / Sealant

Dow Corning 3145 RTV Gray (Room Temp Vulcanizing)
MIL-A-46146
Available from:
Ellsworth Adhesive Systems
Germantown, WI
800-888-0698
Approximately $18.00 for a 3 ounce tube.

Tools needed:

  • T20 Torx bit
  • 5 mm hex key
  • Pliers
  • 10 mm socket, ratchet wrench, and various length extensions
  • Flat blade screwdriver
  • Philips blade screwdriver
  • Wire cutters / strippers
  • Soldering Iron, along with flux and solder.

Disconnect the air temp sensor from the intake runner. Gently bend the plastic retaining tabs up out of their locking slot, and rotate the sensor 90 degrees to pull it straight up and out.

Pull the small plastic rivet holding the auxiliary fan grill out of it's receptacle. Gently pull the grill away from the car. Disengage the two clips on the intake funnel from the air filter box, and pull the funnel as far forward as possible.
Remove two 10 mm nuts securing the air filter box to it's brackets. Nut #2 requires using a universal joint to access it. This nut can easily fall into a cranny. Don't let it fall.
Undo the two spring clips from either side of the air filter box where it connects to the Mass Air Flow (MAF) Sensor.
Disconnect the MAF connector by rotating it counter clockwise when viewed from the wire side. Move the connector and wire bundle out of the way.
Lift the air filter box up to clear the studs that hold it in place. You may have to gently twist it to dislodge it from the MAF. Again, make sure the intake funnel is forward enough to provide clearance.

Loosen the band clamp on the rubber intake runner where it mates with the MAF using a Phillips screwdriver. Gently twist the MAF to break the seal between it and the rubber intake runner.  CAREFULLY pull the MAF out of the rubber intake runner. Do not damage the screens on either end of the MAF, they are delicate. Bag and seal the MAF in a zip-loc bag to prevent contamination.

Air Filter box and MAF removed.

Loosen the band clamp on the rubber intake runner where it mates with the ETA using a Phillips screwdriver. Gently twist the intake runner to break the seal between it and the ETA.  Pull the rubber intake runner out.
Rubber intake runner removed.
Remove the EGR vacuum module from the side of the intake manifold using a 10 mm socket. Disconnect the red vacuum hose from the diaphragm below the ETA. Position this module out of the way.
Remove the clip securing the ETA wire bundle to the frame, as well as the vacuum line with the bend in it from the ETA.

Remove the hose clamp holding the rubber hose going to the bottom of the ETA using pliers.

I cut one short length off of the hex key for loosening and tightening the cap screws by hand. Much easier and faster to use once the cap screws are loosened.

 

Using the 5 mm hex key, remove the 4 socket head cap screws holding the ETA to the intake manifold. You may have to gently "persuade" the heat shield away from the body to get enough clearance for the hex key as shown.

Make sure you are holding the ETA securely when pulling out the last bolt. Don't let it fall.

Remove the ETA from the intake manifold.
The passenger ETA connector is located on the passenger side wheel well underneath the plastic removable cover. Flip the ETA connector retainer clip up, and swing it out of the way. Pull the ETA connector out of the mating connector. It's in there pretty tight.

Carefully route and pull the ETA wire bundle out of the surrounding area. The ETA is now able to be pulled out of the car.
Remove the larger cover from the ETA body using the T20 Torx bit. You may have to gently pry the cover away from the ETA body. There is a pin that probably functions as a tamper indicator that makes it difficult to remove the cover (red arrow). It will break when you remove the cover, but that is not a problem.

Look closely at the wires. If the insulation is cracked like the ones shown here, you will have to rewire the ETA. If the insulation looks good, you're probably in luck!

I would hazard to guess that if the wire insulation inside the Actuator is OK, the insulation within the sheathing is probably OK too.

Slap it all back together. Make sure the black seal on the face of the casting is in place before you torque down the cover. You will need a new gasket for between the ETA and intake manifold. It is MB P/N 104 141 07 80. Cost is around US $1.50.

Close-up of cracked insulation on wires.

There are some smaller gage wires that have a different type of insulation on them. The colors of these wires are pastel. You can see them under the other wires. These wires come from the potentiometer on the other side of the ETA. These wires were OK on my vehicle, and did not need to be replaced. These instructions do not include this step.

Here is a picture of the Pastel wires after the other wires are cut away. The insulation on these wires was still good, so they were left alone.

 

!! You should take very good records/notes/pictures of your particular unit BEFORE you start cutting wires !!

 

The wire sheathing on the ETA is attached to the ETA body. I'm told you can pry the retaining ring out of the ETA, which will allow you to pull out the entire wire bundle. I decided not to attempt to remove the entire length of sheathing from the ETA, but to leave about 6 inches of the sheathing intact. I cut through the wire bundle and sheathing about 10 inches from the exit point on the ETA. Note that the Left Side ETA is shown for illustrative purposes as I do not have a photo of the Right Side ETA. The concept is the same regardless of the side being worked on.
Strip back about 4 inches of the sheathing to expose the inner wiring.
You will see some solid black wires in the bundle. These are not wires, but simple strands of plastic. My guess is that they are there to create a good tight pack for the wires inside the sheathing.
Note the cracks in the insulation.
Cut the wires needing replacement close to the circuit board. DO NOT cut the Pastel wires.
Pull one wire at a time from the sheathing. Pull the wire either from the circuit board side, or the cut sheath side, whichever end is easier. The first wire will be the most difficult. The wires are packed tightly within the bundle. As you pull more wires out, they become easier to remove. Continue until all wires within the sheathing are pulled out. Note that the Pastel wires are all within the ETA, they do not continue out of the ETA through the sheathing.
Carefully remove the o-ring from the connector.
Now comes a tricky part. You need to disassemble this connector. It is a multi-piece connector, but it is heat or solvent welded together. It can be taken apart with care and patience.

First cut through the wire bundle as close as you can to the back of the connector.

Examine the connector to find the mold line between the two halves. Using a sharp new utility razor blade or X-Acto knife, repeatedly score the mold line on both sides of the connector until the cut is about 1/16th of an inch deep. You MUST follow the mold line as closely as possible in order to split the connector safely.

Go slowly and carefully, do not try to make too deep a cut at one time. It is better to make many gentle cuts.

Place the connector into a socket that will support the connector securely.

Place a utility razor blade onto the mold line, and slowly / carefully tap it with a hammer until it starts to split the halves apart.

Do not push the blade further than the largest diameter of the connector. Once you split the connector this far, remove the blade and continue to carefully pry the halves apart with a flat blade screwdriver.

Again, go slowly, and move the blade to different areas to get the halves to split.

The connector halves apart.
Carefully pry out the inner barrel.

Remove remnants of sheathing from connector halves.

Move the 2 locking tabs out and away from the inner piece as shown, and pull the gray pin holder up and out.
At this point you can pull the connector pins out of the pin holder.
Pull the pins out in the direction of the arrows.

De-solder the old wire from the pins. Keep the pins as we will reuse them. Remove all the old solder from the pins using a solder pump or solder wick.

Notice the brown residue around the solder joints. This is flux that was not cleaned off properly after soldering. In some cases, this can cause corrosion of the solder joint.

De-solder the remainder of the cut wires from the circuit board. Do not keep the solder iron tip on the board any longer than you have to or you can damage the traces on the board. Again, remove all the old solder from the board.

Remember to use a flux suitable for the solder you are using, and to clean the solder joint thoroughly using Isopropyl Alcohol and a stiff soft bristle brush.

An examination of the inner surface of the cover shows residue, probably insulation that fell off and into the gear-train, and was ground up.

There was also some residue in the gear teeth.

Clean all this residue from the various parts.

Now we can begin rewiring the ETA with new wire.

I used Military grade wiring for this as it is can withstand high temperature. The wire number series is M22759/11. It is rated for a conductor temperature of 200° C, and the insulation is able to withstand a constant temperature of 260° C. There are three different gages of wires that needed to be replaced. The original gages are metric in size, and are .35, .75, and 1.5 mm in size.

For .35 mm, I used 26 gage
For .75 mm, I used 20 gage
For 1.5 mm, I used 14 gage

This means that you will need;

Two 48" lengths of M22795/11-14
Two 48" lengths of M22795/11-20
Four 48" lengths of M22795/11-26

The color designator is also a number, and is placed at the end of the wire and gage number. So for example, M22759/11-26-6 is a 26 gage wire with blue insulation.

I chose to use different colors to help keep the wires identified. I did have to use the same color code for both wires for the motor as I was not able to find 2 different color codes in this size. Note that you do not have to use different color wires. All wires can be the same color as long as you identify them correctly when soldering them in place. I do recommend that different colors be used as it helps keep them easily identified.

Note that the color code listed below is from MB wiring diagrams. 
I noticed that the wire colors in my Left Side ETA did not match this.
You should take very good records/notes of your particular unit BEFORE you start cutting wires.

Cut the wires to a length of 32 inches (~81cm). Strip the insulation from the ends of the wire approximately 1/4 inch (6 mm). Do not cut or knick the wire strands while stripping the insulation off. Tin the stripped ends of the wires with solder.

Left Side ETA (US Passenger Side)

Right Side ETA (US Driver Side)

Board Location Connector Pin Color Code Wire Gage Board Location Connector Pin Color Code Wire Gage
Motor (+) terminal 4 BL/YE 14 Motor (+) terminal 4 BK 14
Motor (-) terminal 11 BK/YE 14 Motor (-) terminal 11 BL 14
b 3 VT/YE 26 k 12 WH/BK 20
c 14 VT 26 j 13 WH/GR 20
k 12 GY/BL 20 c 14 GY/BK 26
e 9 VT/WH 26 g 2 RD/YE 26
g 7 VT/GY 26 b 3 GY/RD 26
i 5 GY/YE 20 f 10 GY/GR 26
        h 6 BL/YE 26
        i 8 BR/WH 26
        e 1 RD/WH 26
* A big Thank You goes to our MB friend Philippe for getting me details on the Right Side ETA wiring connections.  Thanks!
Cut a length of wire sheathing ~20.5 inches long, and slip it over the new wires. Butt the end of the sheathing up against the original sheathing.  Place a 3 inch length of 1/2 inch DR-25 Raychem Heat Shrink tubing over the sheathing. Do not shrink it in place yet. Note that this photo shows the tubing shrunk.
Solder one end of each wire into a connector pin. Make sure you have a good solder joint.
Once all the wires are soldered into the pins, start inserting the pins into the pin holder portion of the connector as shown per the table above.

Push the pins into each respective slot, again making sure you have the right location for each wire. Make sure they are fully inserted, or you will not be able to reassemble the connector.

After all pins are inserted, insert the pin holder back into the barrel portion of the connector. It must be properly aligned to re-insert it. Make sure the pin holder seats fully into the barrel. You may have to play around with the pins to align them into the holes of the barrel. This can be difficult. Make sure all pins are snapped fully into their slots, or you will not be able to reassemble it.

Position the new sheathing approximately 1 inch from the back of the connector barrel, and heat shrink the Raychem heat shrink tubing in place using a heat gun. This will seal the new and old sheathing together, and lock the new sheathing in place.

Coat the insides of both connector halves using sealant / adhesive where indicated by the blue areas.

Note that the picture shows the old wiring. I do not have a photo of the new wiring at this stage. The new wiring would obviously extend past the connector, and the new sheathing would be placed over the new wire to within one inch of the back surface of the pin holder.

Place the connector barrel into one of the connector halves, making sure the mating grooves are properly seated to each other.

Also make sure that the sheathing is placed inside the connector halves, and is completely surrounded by sealant. We don't want water getting into the wire bundle.

Assemble the other half of the connector barrel, also making sure it is lined up properly. Clamp the halves together, and wipe off the excess sealant that squeezes out. Let the connector dry/cure fully before handling. I would allow 5 full days at room temp for this sealant to cure due to the amount we used. It cures using humidity in the air. Elevating temperature, or blowing with a fan will not accelerate cure.
You're now ready to re-install the ETA onto the car. Make sure you route the ETA wire bundle as it was, keeping it away from the exhaust manifold. Also ensure that there is a sufficient loop in the cable for the rubber intake runner to pass through it.
Once the ETA is installed and re-connected to it's mating connector, you will need to allow the ETA to "relearn" idle and full throttle positions.

NEW "Relearn" Procedure!


-Start and bring engine to normal temp, 80 deg C
-Stop engine and move ignition key CW to #2 position w/o starting engine
-Wait for basic training sequence/ protocol.  ETA will hum, and you will hear actuator clicking.  Wait for all sounds/noises to end completely!
-Now, without turning key off, continue moving key C/W and start engine.
-Operate the vehicle for 30-40 minutes without turning off the engine, bring speed up to or over 65 mph if possible. Operate in a variety of conditions.
-Once time period is over, return to secure parking spot and park, DO NOT turn engine off... allow to idle for 15-20 minutes minimum!
-When time period is over, turn engine off.
-Congratulations, your ETA has been correctly put through the Mercedes Benz Engineering (Slang: Relearn)" Operational  Sequence for 119 and 120 power plants.

These instructions are courtesy of Robert Ohlings EE, ME, AES and Hibbo (Dutch) Ohlings .ME, PE, AES.  Both of these gentlemen are retired Mercedes Benz Engineer and Diagnostic Technicians.

Thank you Robert and Hibbo!
If all has gone well, your engine should be running well.  Sleep well knowing that there are no electrical short-circuits in your ETA's future. Congratulations on a job well done!

 

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