Electrical equipment at engine (15, 30)
Ignition (distributor, cables, plugs, coil, choke (15, 30)
The M 180 II engine with distributor and ignition cables in place
The distributor and ignition coil has been gone through a couple of times due to my failing memory. I've done all screws and gotten the vacuum control cleaned up and plated where after everything was tested OK by Bernats Bil. Afterwards I've realized that at least one other shop has gone through and tested the complete ignition system earlier. So it should be in working order. The helical gear, which is part of the mechanism that drives the distributor you will find more stories about under Engine and oil pump.
Click the picture to download in PDF-format, "Swedish exploded-view drawing of Bosch distributor VJU R 6 BR with parts list" (file is 3MB)
Follow the workshop manual for assuring that the cam shaft, distributor are in line together with the timing marker on the counter weight, in my case 5° +/- 1° v. OT/BTDC (vor dem Oberen Totpunkt/Before Top Dead Centre).
Correct position of the rotor on a Bosch VJUR 6 BR 24 distributor when camshaft and counter weight are in their correct positions
The ignition cables for the Ponton I ordered new from Mercedes-Benz, by the the meter. They also provided me with the terminals. The ignition cable plugs should be possible to buy from Bosch Classic. I could however not buy directly from them but had to go via a Swedish distributor which firstly prolonged the process and secondly gave me the wrong plugs in the end. Instead I got the correct ones from Werner Karasch. Cables were cut based on my old cables, the terminals soldered and the plugs screwed in. Done.
Follow the workshop manual for adjusting the mechanism for ignition control. The first picture shows the adjustment of the timing lever and its Bowden cable. The second and third pictures show the cleaned-up rotary control. The cable actually belongs to Pedals article but I decided to put it here, close to the distributor...
Click the picture to download in PDF-format, "Swedish Bosch distributor parts list for Mercedes-Benz Ponton vehicles; 190, 190SL, 219, 220 and 220S" (file is 1MB)
I had the generator completely rebuilt. In this picture you can also see the part of the cable harness (new) that goes to and from the Voltage regulator.
Left for me was to clean up, plate and paint its support, spacer sleeve and generator adjustment mechanism.
Click the picture to download in PDF-format, "BOSCH Service-Liste für Mercedes-Benz Personenkraftwagen 219, Baujahr 1956 - 1959, © Robert Bosch GmbH (file is 1MB)
I also had the starter completely rebuilt, including the pinion since that part, as well as the starter ring gear on the flywheel, was severely worn.
Beside of that, it was just a matter of cleaning the intermediary flange and its screws including have the latter black plated. We'll see if I remember to publish "after" pictures of those...
Click the picture to download in PDF-format, "BOSCH Distributor Spare Parts List, © Robert Bosch GmbH"
Voltage regulator (15)
The voltage regulator has been tested and cleaned up. When painting the cover (semi-gloss black) I decided to keep the old label even though I have a new one. More genuine look :)?!
Before installing the engine, with its auxiliary systems mounted, I wanted to check that everything worked as it should, do necessary adjustments, re-tighten all screws and see to that I had no leaks, see Running the engine on test bed.
Click the picture to download in PDF-format, "Swedish exploded-view drawing of Bosch distributor VJU R 6 AR with parts list" (file is 2MB)
If you have made reparations of the battery floor and the partition-/firewall, maybe my sketch of the layout of all the holes in the latter may be handy when it comes to routing the cables from the coupe into the engine compartment. You can find it in Instrument panel, floor, parcel shelf, window frame (67, 68, 69).