0110 - Checking and tuning the engine (note deviations for off-road vehicles) Engines 601, 602.91, 603.91 · ra07016010110x · Mercedes-Benz WIS

07.1-110 Checking, tuning engine

Job no. of Job Texts and Work Units or Standard Texts

and Flat Rates 07-1100

0110 - Checking and tuning the engine
(note deviations for off-road vehicles)
Engines 601, 602.91, 603.91

Test sheet	complete.
Coolant level	check, correct.
Engine oil level	check, observe oil condition (visual inspection).
Oil level in automatic transmission	check, correct.
Air cleaner	remove, reinstall.
Testers (001, 017)	connect
Pulse generator (021)	connect.

Control linkage	check for easy operation and condition. Lubricate pivots of reverse-transfer levers, ball sockets.
Full throttle stop on Bowden cable	check, adjust if required.
Idle stop on Bowden cable	check, adjust if required
Battery voltage	check. Set value: minimum 11.5 V.
Engine	run to 60-80 °C coolant temperature.
Air conditioner or automatic climate control	switch off.
Idle speed	check, adjust if required. Pull plug off electromagnetic actuator.
Start of delivery	check.
Maximum speed	check.
Injection timing device	check. Set value: approx. +3° to +5° after RIV at approx. 5100/min.
Smooth engine running	check. Depress service brake. Move selector lever into Drive position. Switch on AC compressor. Turn power steering to full lock. Engine must continue to run smoothly.

Test and adjusting values


Engine		601	602.911 602.912	603.912 603.9131)	603.9132)
Idle speed 1/min	Pneumatic idle speed increase	75050	70050	-	-
	Electronic idle speed control	72020	68020	63020	68020
Maximum no-load speed		5150150	5150150	5150150	5150150
Start of delivery with digital tester	RI set value	-15°1° 3) nach OT	-15°1° 3) nach OT	-15°1° 3) nach OT	-15°1° 3) nach OT

1) Automatic transmission
2) Manual transmission

3) Vehicles with oxidation catalytic convertor -14°+0,5°.

Special tools

Commercially available testers


Use without adapter
Digital testers	e. g. AVL, Diesel-Tester 873
	e. g. Bosch, ETD 019.002 or MOT 350/500/501
	e. g. Sun, DIT 9100
Use with adapter
Digital testers	e. g. Bosch, MOT 001.03

Connection diagram for testers without adapter

021	TDC impulse sensor
59	TDC sensor pin
2	Governor
2i	Governor impulse sensor pin

001	Digital testers
015	Test cable with plug
016	Diagnostic socket
017	Governor impulse sensor

Connection diagram for existing testers with adapter

017	Governor impulse sensor
021	TDC impulse sensor
59	TDC sensor pin
2	Governor
2i	Governor impulse sensor pin

001	Digital tester
010	Adapter
011	Crocodile clamp
015	Test cable with plug
016	Diagnostic socket

Checking, tuning

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1 Complete test sheet, enter measured values.

2 Check, correct coolant level.

3 Check engine oil, inspect oil condition.

4 Check oil level in automatic transmission.

5 Connect testers (001, 017) according to connection diagram.

6 Connect pulse generator (021).

7 Remove, reinstall air cleaner element; check for contamination.

8 Check control for easy operation and condition and lubricate.

9 Check full load stop.

With engine switched off, fully depress accelerator pedal. The control lever must contact the full load stop (arrow).

10 Check idle stop.

In idle speed position the spring retainer (226) of the Bowden cable (230) must contact the compression spring (227) without preload.

Adjust Bowden cable (230) with the adjusting nut (232) from the vehicle inside if required.

11 Check battery voltage.
Set value: at least 11.5 V.

12 Run engine to a coolant temperature of
60-80 °C.

13 Switch off air conditioner and automatic climate control.

14 Check idle speed; read off start of delivery.
RI set value 151° ATDC.

a) Engines 601, 602 with pneumatic idle speed increase

By turning the vacuum unit (4) adjust idle speed; to do so, loosen lock nut (4a).


Engine	Idle speed 1/min
601	75050
602	70050

b) Engines 601, 602, 603 with electronic idle speed increase

Pull double coupling off electromagnetic actuator. Loosen lock nut (arrow) and adjust idle speed.

15 Check maximum no-load speed.

16 Check injection timing device without load.
Set value: 3° to 5° BTDC according to RIV at approx. 5100/min.

17 Check smooth engine running.

Depress service brake.

Move selector lever into Drive position.

Switch on AC compressor.

Turn power steering to full lock.

Engine must continue to run smoothly.

0110 - Checking and tuning the engine (note deviations for off-road vehicles) Engines 601, 602.91, 603.91

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