Programmed Repairs Engine 601, 602.91, 603.91 Combustion
Complaint: Jerking during load changes |
Remedy
Installation of strengthened tension/compression damper 601 070 14 67.
Additional work on engine 601: install spring rod 603 070 12 75 if not already fitted. Check accelerator control at injection pump for full throttle stop. If full throttle stop is not reached, adjust control linkage. Should it not be possible to reach full throttle stop, remove spring rod and install connecting rod again.
Complaint: Engine surges when idling |
Engine 603.91 without AJC |
Remedy
Run engine at idling speed.
Unplug 2-pin connector (arrow) at servomagnet (Y22).
If engine runs properly, check idling speed and set, if necessary, to 58020 rpm.
Install modified control module part no.
006 545 36 32 and plug in 2-pin connector again.
P07-6354-13
Note
Coding bridge of the old control module must not be plugged into the new control module. When inserting the new control module, pierce the non-assigned contact 5 (arrow) in the connector.
P07-6357-13
Complaint: Combustion noise (rumbling) at idling up to about 1300 rpm |
Engines without exhaust gas recirculation |
Remedy
Set start of delivery to 13° after TDC (governer impulse method) (GIM) with digital tester.
Replacing the injection nozzles does not provide any remedy.
No further remedy possible.
Complaint: Warm engine does not start or only hesitantly after standing about 10 min |
Cause
Excessive portion of petrol in diesel fuel. Not more than 20% regular grade petrol is approved at
temperatures below -23 °C, i.e., it is not necessary to add petrol at temperatures higher than -23 °C.
Complaint: After car parked on hill, engine can no longer be started, fuel level 1/4 full |
Cause
Injection pump suction chamber running empty. Internal leak. Air bubbles visible at fuel feed.
Remedy
Check fuel full flow filter for leaks, replace if necessary.
Check connections of top part of filter for leaks and vent drilling for fuel return flow for blockage. Check overflow restrictor at injection pump return flow.
Check injection pump for leaks: fuel tank 1/4 full. Raise car about 40 cm, no air bubbles should be visible in the fuel feed pipe within 10 min when engine switched off, and also not in fuel return flow pipe of injection pump; replace injection pump if necessary.
Complaint: Engine misfires when cornering sharply, with low fuel level 1/4 full |
Models 124.1/3, 201.1 |
Cause
Fuel pump drawing in air.
Remedy
Install fuel tank with splash pot.
Fuel tank
Model | Part no. | Prod. breakpoint |
124.1/3 Sed. | 124 470 63 01 | 01/88 |
124.1/3 | 124 470 57 01 | 09/86 |
201.1 | 201 470 08 01 | 09/87 Bremen Plant 02/88 Sindel-fingen Plant |
Complaint: Engine speed increases and blue exhaust after driving sharply |
Cause
Excessive fluid level in oil sump.
Remedy
Check engine oil level and adjust to correct level, if necessary. Perform oil change if necessary.
Complaint: Engine cannot be easily switched off or not at all |
Cause/Remedy
Vacuum hose at vacuum pump (67) may be split.
Filter (62) blocked or leaking.
Restrictor (61b, orange) may be blocked.
Vacuum of vacuum pump not sufficient. Check vacuum at ancillaries connection. Specification when engine idling, after 30 sec, at least 700 mbar.
P07-6356-55
Complaint: Engine misfiring evident when throttle depressed slowly (up to about 1000 rpm when car stationary) |
Engines 602, 603 with AJC |
Cause
Linked to operation of AJC.
Remedy
Install AJC control module with designation RO2 (was RO1). Part no. unchanged. Standard equipment as of end 04/88. No further remedy possible.
Complaint: Sharp drop in power (> 10 kW) at full throttle |
Note
Engine does not vibrate when idling, no noise evident, compression and pressure loss in order, fuel filter not blocked.
Cause
Exhaust or inlet valve spring broken.
Remedy
Replace valve spring.
Complaint: Jerking during deceleration when throttle released |
Engines 602, 603 with AJC |
Cause
Deceleration damper has insufficient effect.
Remedy
Install damper 601 070 13 67.
In critical cases, the strengthened tension/compression damper 601 070 14 67 may also be installed.
Complaint: Engine cuts out after lengthy motorway trip (200 - 300 km) when clutch disengaged, or does not idle |
Cause
Pump governor group jams briefly (centrifugal element in governor of injection pump).
Damage code for warranty/goodwill cases: 07 013 15
Remedy
Replace injection pump.
Complaint: Injection pipes at cylinders 1-4 leaking because of fatigue fracture |
Remedy
Install injection pipes with double cone.
Ensure the plastic clips are correctly installed.
Parts | Part no. |
Cyl 1 injection pipe Cyl 2 injection pipe Cyl 3 injection pipe Cyl 4 injection pipe | 601 070 23 33 601 070 36 33 601 070 26 33 |
Complaint: Engine misfires between 2000 and 3000 rpm |
Cause
Overshooting of AJC servomagnet causes quantity reduction.
Remedy
Install AJC control module with designation RO2 (was RO1). Part no. unchanged. Standard equipment as of end 04/88. Adjust AJC control with 2.4 kW or 4.7 kW reference resistor (see 07.1-105, pages 13, 14).
Complaint: Engine cannot be switched off when cold (was SI 07.1/37 and 43/6) |
Cause
Damaged piston vacuum pump (models up to May 1986).
Remedy
If this problem exists on models manufactured prior to this date, which do not have a second drilling in the oil spray nozzle for the oil supply of the piston vacuum pump, or when performing work on such models which involves taking off the vacuum pump, remove the centereing sleeve and install a modified seal to improve the oil supply.
Procedure
1 Remove fan shroud, fan and belt (see Repair Instructions Gr. 13, Op. No. 342).
2 Remove piston vacuum pump (see Repair Instructions Gr. 43, Op. No. 618).
3 Remove centering sleeve (3). It must no longer be installed.
Note
The centering sleeve must be installed as an aid when removing the injection pump. This avoids the injection timing device jamming when the engine is cranked.
P43-2001-13
4 Install the modified seal (10) in place of the previous one.
5 If the aforementioned problem exists, install new vacuum piston pump.
6 Do not connect vacuum pipes to the brake unit at the piston vacuum pump at this stage.
7 Install V-belt, fan and fan shroud.
8 Run engine and pour about 50 cm3 engine oil into the piston vacuum pump through the open vacuum connection with an oil spray can.
P43-2002-13
9 Connect the vacuum pipe to the brake unit immediately.
Refer to the microfiche "Operation texts and work units" under Op. no. 43-0610 for the work units.
Part | Part no. |
Piston vacuum pump | 000 230 19 65 |
Seal | 601 238 03 80 |
Production breakpoint for second drilling in oil spray nozzle: May 1986
Model | Engine | Transmission | As of engine end no. |
201.122 | 601.911 | manual | 157499 |
124.120/180 | 601.912 | manual | 041801 003380 |
201.126 | 602.911 | manual | 019187 |
124.125/185 | 602.912 | manual | 029464 004808 |
124.130 | 603.912 | manual | 015367 009219 |
Complaint: EGR valve noisy when opening or closing | Engines 601, 602, 603 up to 30.9.91 with Code 620a, models with catalytic converter |
Remedy
Remove EGR valve, replace, install.
Damage code: 14 315 36
Complaint: Hard combustion noise (clattering) when engine cold and warm |
Cause
Different compression of individual cylinders (from about 3 bar).
Note
Replacing the injection nozzles does not provide any remedy.
Remedy
Check cylinder for leaks (Repair Instructions Gr. 01, Op. No. 015), and rectify any leaks.
Complaint: Combustion noise accompanied by mechanical noise at about 1500 rpm |
Engines 601.911/912, 602, 603 as of 1.12.91 |
Cause
Axial clearance of injection timing device.
Diagnostic note
Noise is easily assigned to the injection pump governor.
Remedy
Remove injection timing device, replace, install (see 07.1-240).
Damage code: 07 111 36
Complaint: EGR pipe splits between exhaust manifold and EGR valve | Engine 603 up to 18.10.91 with Code 620a, models with catalytic converter |
Remedy
Replace EGR pipe.
Note
Install new version of EGR pipe.
Damage code: 14 305 06
Complaint: Engine vibrates when idling |
Cause
Excessive range of idling speed quantity of injection pump.
Note
Replacing engine mounts and injection nozzles does not provide any remedy.
Remedy
Check idling speed, adjust (see 07.1-100), except engines with electronic idle speed control.
Set engine 601 to upper tolerance limit, engine 602 to lower tolerance limit.
If problem persists: adjust synchronized delivery of injection pump <0.5 mm3/stroke) on injection pump test bench.
Damage code: 07 506 60
Complaint: Engine has to be cranked for some time before starting after switched off for lengthy period (overnight), has poor throttle response and cuts out again immediately |
Engine 601.912, also applies to models with retrofitted immobilizer |
Cause
Air bubbles in fuel pipes.
Damage code: 82 815 XX
Remedy
Replace check valve.
Note
On engine 601.912 the fuel pipes upstream and downstream of the check valve must additionally be converted (because of installation position).
Part | Part no. |
Check valve (black anodized) | 000 476 37 32 |
Hose clamp Engine 601.912 | 003 997 90 90 |
Complaint: Engine moves back too slowly to idling speed when accelerator released |
Engine 601 with transmission 716, 717 |
Cause
Damper effect of accelerator control
Damage code: 07 507 53
Remedy
Check that accelerator control operates freely
(see 30-335).
Install restoring torsion at accelerator control lever. Install double springs at injection pump.
Part | Part no. |
Restoring torsion spring | 603 993 02 20/05 |
Spring | 601 993 75 10/05 |
Spring | 601 993 76 10/05 |
Complaint: Poor engine performance, sluggish acceleration, top speed is not reached |
Remedy
1 Check full load stop, adjust (see 07.1-110).
2 Conduct comparison of speedometer on roller dynamometer (see 07.1-115).
Note
Perform comparison of speedometer up to about 160 km/h. If difference is impermissible, calibrate speedometer.
3 Test start of delivery (see 07.1-111, 07.1-112).
4 Adjust start of delivery (see 07.1-116, 07.1-117).
5 Test maximum engine speed without
load(see 07.1-115).
6 Adjust maximum engine speed to top tolerance limit by turning hexagon socket bolt (2m) to the right.
Note
1/2 turn equals about 150 rpm.
P07.11-0001-15
7 Test full load CO (see 07.1-115). If full load quantity is < 0.1% , full load quantity should be increased.
Note
On models with exhaust gas recirculation (Code 620), no full load CO can be measured at the tailpipe. An adjustment should be performed only once. If this does not result in any increase in output, proceed with step 9.
8 Increase full load quantity.
a) Engines without anti-jerk control (AJC):
- Turn slotted screw (2f) about 1/4 turn to the left.
P07.11-0001-15
b) Engines 601.912/913 with anti-jerk control (AJC):
- Turn soft iron core (166) about 1/4 turn to the left, counter-hold sliding pin at face end with a 3 mm Allan key for this step.
Tightening torque: 5 Nm
Note
Do not turn sliding pin (2w) otherwise full load quantity will be altered.
P07.11-0201-15
c) Engines 602, 603 with anti-jerk control (AJC)
- Remove AJC servomagnet (Y22/3) and flange.
Note
Use T30 Torx; bolts are microencapsulated.
- Slacken lock nut of sliding pin (2y).
- Turn sliding pin (2y) about 1/4 turn to the left.
- Tighten lock nut of sliding pin (2y).
- Bolt on flange and insert servomagnet (Y22/3) without O-ring (162).
Note
When inserting servomagnet, no resistance should be felt; shorten lift rod (163) of servomagnet (Y22/3) up to max. 0.3 mm if necessary.
- Install servomagnet (Y22/3) with O-ring (162).
- Check injection pump for leaks.
9 Models with exhaust gas recirculation
(Code 620):
- Remove injection pump, install (see 07.1-200).
- Adjust injection pump on injection pump test bench.
P07.11-0002-15
Complaint: Engine surges after cold start |
Engine 603.91 up to 19.10.94 |
Cause
ISC control module
Remedy
1 Read fault memory.
2 Test ISC (see 07.1-103), test idling speed, adjust (see 07.1-100).
3 Install ISC control module with 10/94 softward and green dot identification or as of production date 41/94.
Designation | Part no. |
ISC control module with 10/94 software and green dot identification or as of prod. date 41/94 - autom. transmission | 007 545 96 32 |
ISC control module with 10/94 software and green dot identification or as of prod. date 41/94 - manual transmission | 006 545 36 32 |
Complaint: Misfiring or sluggish performance when accelerating | Engine 601.912 as of 1.2.93, 601.913 as of 1.6.93 with transmission 716, 717 |
Cause
AJC excessive travel.
Note
Injection pumps as of production code 365 are in order.
Damage code: 07 039 XX
State problem in message box.
Remedy
1 Read off production date on model plate. If production code is < 365, perform the following steps.
2 Remove air cleaner cross pipe, install (see 09-405).
3 Remove intake manifold, install (see 14-180).
4 Remove oil filter housing, install (Repair Instructions Gr. 18 Op. No. 110).
5 Remove AJC servomagnet (Y22/3), install.
6 Alter AJC travel by machining the brass disk:
P07.11-0200-17
- Remove soft iron core (166), install; counter-hold sliding pin at face end with 3 mm Allan
key for this step.
Tightening torque: 5 Nm
Note
Do not turn sliding pin (2w) otherwise full load quantity will be altered.
- Take off restoring spring (2x) and brass disk (40); pay attention to installation position of restoring spring (2x).
- Grind off 0.6 mm at brass disk (40) (e.g., by dressing with fine emery cloth or file).
- Install restoring spring (2x) and brass disk (40).
4 Test full load quantity on injection pump test bench and adjust, if necessary.
P07.11-0201-15
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