Programed Repairs Engines 601, 602, 603 Mechanical III
03 Pistons
Additional subjects are contained in the microfilms Up-to-date trouble diagnosis or Trouble diagnosis.
Complaint: Ticking noises at idle speed on vehicles with low mileage (<10 000 km). |
Cause/Remedy:
Noises may occur on engines from production period 08/84 - 03/85.
Engine | starting with engine end no. | up to engine end no. |
601.911 | 10.028240 12.003361 | 10.092787 12.008973 |
601.912 | from start of series | 10.008804 12.000033 |
602.911 | from start of series | 10.000151 12.000069 |
602.912 | from start of series | 10.000494 12.000099 |
603.912 | from start of series | 10.001931 12.001480 |
Loud piston reversal noises in cylinder at TDC when pistons change direction.
To exclude valve control noises from the hydraulic valve clearance compensating elements, allow engine to run for approx.
7 min. at 3000 rpm.
If the noise is caused by the pistons, it should still be heard.
These noises were eliminated by changing the shape of the piston.
In the event of a complaint, install modified pistons part no. 601 030 08 17 after consulting ZKD-G.
Complaint: Ticking noises at approx. 1500 rpm with cold and warm engine, also heard while driving Engines 601, 602, 603 |
Cause/Remedy:
These noises may occur on engines from production period middle of 01/86 to 02/86.
Engine | starting with engine end no. | up to engine end no. |
601.911 | 10.138770 12.013450 | 146025 014087 |
601.912 | 10.029984 12.002364 | 034605 002780 |
602.911 | 10.012781 12.002800 | 014877 003686 |
602.912 | 10.017565 12.002830 | 022759 003741 |
603.912 | 10.010330 12.006272 | 012569 007615 |
Loud piston reversal noises in cylinder at TDC when pistons change direction.
To exclude valve control noises from the hydraulic valve clearance compensating elements, allow engine to run for approx. 7 min. at 3000 rpm.
If the noise is caused by the pistons, it should still be heard.
These noises were eliminated by changing the shape of the piston.
In the event of complaints, consult ZKD-G.
03 Connecting rods, pistons
Complaint: Ticking noises from about 1500 rpm when engine cold and warm, also heard while driving Engines 601, 602, 603 |
Cause/Remedy:
The following engines may be affected:
Engine | as of engine end no. | up to engine end no. |
601.911 601.912 | 10.028240/12.003361 as of start of series prod. as of start of series prod. as of start of series prod. as of start of series prod. | 10.196278/12.018007 10.060313/12.005066 10.034400 up to 12/86/12.008286 10.051330/12.008634 10.023961/12.014718 |
Cause
Connecting rod shaft offset too large relative to plane faces of small and large eye. This causes loud piston reversal noises in cylinder when pistons change direction in TDC range.
Remedy
Install connecting rods made of modified material, part no. 601 030 36 20.
In addition, likewise replace pistons which, apart from the code figure 08, do not have any of the stamped letters "L", "M", "N", "O", "S" or "T".
The code letters "A, X, B" are group code letters which refer to the piston or cylinder diameter. They must not be confused with the letters listed under Remedy.
03 Crankshaft radial sealing ring
Complaint: Replacing front crankshaft radial sealing ring. Engines 601, 602, 603 |
Cause/Remedy:
If oil leakages occur at the front of the crankshaft, it is only necessary in the most frequent cases to replace the crankshaft radial sealing ring. Replacing hub at the same time is only necessary in those cases where two wear tracks (grooves) are visible on the hub. For hubs which have only one wear track (groove) a radial seal with a sealing lip offset 2 mm to the rear is available (repair version). If the sealing surface of the hub is only ground bright, only the standard version of radial seal may be fitted.
Note
Press the radial seal dry (without grease) into the timing case cover and coat the sealing lip (Fig., item 1) with engine oil - do not use grease.
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