LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 1994 >> C220 >> Repair and Diagnosis >> External Pages >> Different car >> Section 44 (Complete Engine - 140 Chassis) >> Testing & Repair (Diesel) >> Remove/install precombustion chambers - ra01006010417x(0417)

Remove/install precombustion chambers - ra01006010417x(0417)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Engines 601, 602 (except 602.98), 603 

Preceding work:

Mount for engine control removed.

Nozzle holders removed.

Operation no. of operation texts and work units or standard texts and flat rates

Fig 1: Identifying Precombustion Chambers Removal And Installation Components - Vertical Injection
G05438181Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Precombustion Chambers Removal And Installation Components - Angular Injection
G05438182IMPORTANTCourtesy of MERCEDES-BENZ OF NORTH AMERICA.
Glow plugs (R9) screw out, screw in, 20 + 2 Nm (step 1).
Vertical injection:   
Threaded ring (112) screw out, screw in, 100 Nm, pronged wrench 615 589 00 07 00 (step 2).
IMPORTANT When screwing in or out assure that the pin wrench is seated in the grooves in the threaded ring.
Angular injection:   
Threaded ring (112a) screw out, screw in, 130 Nm, splined wrench 603 589 00 09 00 (step 3).
Precombustion chamber (110) knock out, install, impact puller 602 589 00 33 00 and check (steps 4, 6).
NOTE: Install precombustion chamber so that the lug on the collar of the precombustion chamber is located in the recess in the cylinder head.
Precombustion chamber mounting bore in cylinder head, clean, check and cover (step 5).
NOTE: Refinish precombustion chamber sealing surface if required.
PRECOMBUSTION CHAMBER SURVEY

Engine 601.91(1)
602.91(1)
603.91(1)		 603.96 up to 9/88 601.91 SWITZERLAND ONLY(2)
as of 10/86 up to 8/88		 602.961 up to 09/88 601.91(2)
602.91(2)
603.91(2)		 602.961 as of 09/88 602.962 Standard 602.96 AUSTRIA ONLY as of 1989 603.96 AUSTRIA ONLY as of 09/88 603.962 (2) 603.970 (2)USA ONLY as of 09/88 603.971 (3) as of 09/92 as of 04/94 602.96/603.96(6) 603.97(6)
Code 601/07 or 17 601/09 or 23 601/14 601/15 601/25 or 29(5) 601/26 601/36(4) 601/30 601/36(3)
Version A A B B C C C
Combustion neck OD (mm) 14 15 14 15 14 15 15
(1) Without exhaust gas recirculation

(2) With exhaust gas recirculation starting 02/89

(3) As of 02/92 USA Only , ECE as of 01/93, certain burner bores countersunk 4°, prechamber volume increased to 11.37 cm3

(4) Engine 602.96 as of 05/92 with EGR, certain burner bores countersunk 4°

(5) As of 03/92 with EGR

(6) As of 04/94 all turbocharged engines, (standard prechamber of 11. 37 cm3 ) prechamber volume and certain burner bores countersunk 4°

Differentiation, vertical and angular injection 

Fig 3: Identifying Precombustion Chamber Vertical Injection
G05438178Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

A Precombustion chamber, vertical injection inclined 5°

Code 601/07, 601/17, 601/09, 601/23

Fig 4: Identifying Precombustion Chamber Angular Injection
G05438179Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

B Precombustion chamber angular injection, Code 601/14, 601/15

x Cone

y Recess

C Precombustion chamber, angular injection Inclined 5°, turned 180°

Code 601/25, 601/26, 601/30/36

Fig 5: Identifying Precombustion Chamber Angular Injection Inclined 5°, Turned 180°
G05438180Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Differentiation, combustion neck diameter 

The individual combustion neck diameters (d) differ on naturally aspirated engines and turbo-engines.

Fig 6: Identifying Combustion Neck Diameter
G05438186Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Differentiation, combustion bores 

6 combustion bores with different diameters are located in different planes and at different angles in the bottom section of the precombustion chamber (combustion neck).

The injection angle is 180°, on engine 602.61, 603.971 - 164°.

Fig 7: Identifying Combustion Bores With Different Diameters
G05438187Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMBUSTION BORE DIAMETERS (DIA. IN MM)

Precombustion chamber code 601/07 or 17 601/09 or 23 601/14/25 601/15/26 601/30
H Firing duct 7.0 7.0 7.0 7.0 7.0
J Combustion neck 14.0 15.0 14.0 15.0 15.0
K Combustion bore 1.5 1.5 1.8 1.8 1.8
L Combustion bore 3.2 3.2 3.0 3.0 3.0
M Combustion bore 3.0 3.0 3.0 3.0 3.0
N Combustion bore 2.0 2.0 2.5 2.5 2.5
O Bore for glow plug 10.0 10.0 10.0 10.0 10.0
Tightening torques Nm
Glow plugs 20+2
Threaded ring, vertical injection 100
Threaded ring, angular injection 130

Special tools 

Fig 8: Identifying Special Tools (615 589 00 07 00)
G05438188Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Special Tools (603 589 00 09 00)
G05438189Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Identifying Special Tools (602 589 00 33 00)
G05438190Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 11: Identifying Special Tools (001 589 65 09 00)
G05438191Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 12: Identifying Special Tools (001 589 72 21 00)
G05438192Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 13: Identifying Special Tools (001 589 66 21 00)
G05438193Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal, installation 

  1. Screw out glow plugs (R9).

    Installation note 

    Tightening torque 20 + 2 Nm.

    Fig 14: Identifying Glow Plugs (R9)
    G05438194Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Vertical injection: 

  2. Screw threaded end (03) of pin wrench 615 589 00 07 00 into threaded ring of precombustion chamber.
    Fig 15: Identifying Threaded End Of Pin Wrench 615 589 00 07 00
    G05438195Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    2.1 Slide sleeve (02) of pin wrench over threaded end and insert into grooves in threaded ring.

    IMPORTANT The sleeve must be seated tightly in the grooves of the threaded ring.

    2.2 Counter sleeve (02) with hex. head bolt (01).

    Fig 16: Screwing Out Threaded Ring With Open-End Wrench On Hex. End Of Sleeve
    G05438196Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    2.3 Screw out threaded ring with open-end wrench on hex. end of sleeve (02).

    Installation note 

    Oil threaded ring.

    Tightening torque 100 Nm.

    Angular injection: 

  3. Screw out threaded ring with splined wrench 603 589 00 09 00.

    Installation note 

    Oil threaded ring.

    Tightening torque 130 Nm.

    Fig 17: Screwing Out Threaded Ring With Splined Wrench 603 589 00 09 00
    G05438197Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. Screw impact puller 602 589 00 33 00 into precombustion chamber and knock out precombustion chamber.
    Fig 18: Screwing Impact Puller 602 589 00 33 00 Into Precombustion Chamber And Knock Out Precombustion Chamber
    G05438198Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Installation note 

    Insert precombustion chamber into mounting bore so that lug on collar of precombustion chamber fits in recess in cylinder head (arrows).

  5. Clean mounting bore for precombustion chamber in cylinder head, check and cover.
    Fig 19: Locating Lug On Collar Of Precombustion Chamber Fits In Recess In Cylinder Head
    G05438199Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: Refinish precombustion chamber sealing surface if required.
  6. Check precombustion chambers.
    NOTE: The spherical pin must not be burned or scaly.

    If the combustion tips are burned or cracked in the bottom section of the precombustion chamber, check the following:

    1. Oil level at oil temperature of approx. 80°C. If the quantity of oil in the oil pan is too high, correct oil level.
    2. Check piston vacuum pump for damage or replace vacuum box on injection pump.

      Which of the two components is unfit for use can be seen on the vacuum lines (blackened with oil).

  7. Install in opposite order.
scientia non olet · About LEMON Manuals