Removing Flap Valves
Sealing Shaft Holes
After flap removal, tap the shaft to accept a bolt. In this case we tapped m10x1.5 and inserted flange bolts to seal everything off. No welding, no sealant, no fuss..:)
Installing Arm to Servo
Install the Arm into place on the Servo and install the screws and washers.
Installing Arm to servo tip 2
The arm installs a little easier if the servo is rotated 90 degrees like in the picture.
Attaching arm to servo
Make sure the ARM is drawn up against the servo so no space is left. Careful not to over tighten and strip the screws. This is the Gen-1 servo and is used on millions of vehicles.
Attach sensors to Mount
Install both sensors as shown. Sensors are held in place with screws and washers. To prevent any rotation a small wire tie is used to secure each sensor.
Mark area to trim if required
There is a small interaction problem on some servos. The area marked in silver will be trimmed down to provide clearance from the servo arm during operation. failure to maintain clearance will prevent the servo from adjusting itself correctly.
File or dremel away part of servo rib
It is advisable to trim away part of the rib as shown in the picture. This assures that the servo arm will not be able to make contact. The servo auto adjusts during startup/shutdown and will incorrectly calibrate if anything interferes with movement in any way. Be careful not to cut too deep and create a hole in the servo body that moisture can enter and cause premature failure.
New Style Servo
There is a new style servo that functions very well with only a small change to the arm geometry. Your Platinum kit may come with this new style or you may retrofit using this servo. This servo is considered the Gen-2 style. Internals have not been modified.
Install Servo onto Mount
Using the (3) M5 socket cap screws provided, install the Servo onto the Main Mount. Note: One cap screw is longer.
Drill Template
The Drill Template will assist in marking and drilling the mounting holes for the servo assembly. Choose a flat surface, away from heat, moisture, loose wiring, and anything else that could interfere with the servo operation. 1/4″ mounting bolts are recommended. Self tapping screws or nut/bolt work well for mounting, but 1/4-20 rivnuts are the best option for blind hole in sheet metal. Amazon link https://a.co/d/iz9ZQWM, or https://a.co/d/0IzF9qd
Test for function
Install the three wire extensions. Test for function. The servo will always cycle several times after the key is turned off, as well as movements based on throttle position ( after closed loop status )this is normal. Depending on where the servo is mounted, it is very likely you will hear the servo operate from inside the interior, during shutdown. This is also normal as the sound/vibration is now transmitted by the chassis.
Electrical Harness
Using original Mercedes weather pack connectors on the wire extensions, ensures years of trouble free operation. Sometimes the old connectors can be stubborn to separate. This type of connector uses a “grey” locking tab to prevent inadvertent disconnects. Make sure to unlock the grey tab before disconnecting all harnesses. Also avoid pulling on the wire on the harness directly. Grip and apply pressure to the plastic connectors only.
ARM Set Screw adjustment
The ARM component has two (black) steel set screws to activate the proximity sensors. Normally flush with the bottom will be appropriate for normal operation. If there is a need to adjust the “air gap” between the set screw and the sensor, 1/8″ of an inch or 3 mm is normal.
Why do I need Benzservofix??
When you build a tough 3.0l diesel engine that can effectively get 500k or more miles is very good. Then to include fragile plastic parts that always fail, is very bad.. Removing these components will increase the reliability of your engine. eliminating the leading cause of engine related service.