Checking and correcting adjustment of TDC sensor - ra03006010345x(0345)

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

Preliminary jobs:

Radiator removed (20-420).

Precombustion chamber on cylinder 1 removed (01-417).

Operation No. of operation texts and operation values or standard texts and flat rates 03-1101

Fig 1: Checking TDC Sensor

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying TDC Sensor And Bolt

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Holder for TDC sensor, engines 601.911/921 and engine 601.912 2nd version

Fig 3: Identifying Crankshaft Pulley TDC Sensor And Bolt

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Holder for TDC sensor, engine 601.912 1st version starting 10/85 and engines 602 and 603 from start of production

Cylinder 1	turn to approx. 10° BTDC, ignition stroke (item 1).
Gauge (01)	screw into preignition chamber bore and set dial gauge (07) on gauge to 5 mm pretension (item 2).
	NOTE: If cylinder head is removed, position gauge pin of dial gauge directly on piston crown (177). Use dial gauge holder 363 589 02 21 00.
Engine	turn in running direction until dial gauge pointer stands still (TDC position), set dial gauge scale to zero (item 3).
Engine	turn until dial gauge moves back 3.22 mm on engines 601.911/912, 602, 603 or until dial gauge moves back 3.65 mm on engines 601.921, 603.97 (item 4).
	NOTE: Corresponds to crankshaft position of 20° ATDC.
Holder for TDC sensor (42) or (44)	install locating device 603 589 01 21 00 (item 5).
	NOTE: The pin on the crankshaft pulley or on the vibration damper must catch in the groove on the locating device, if not, correct position of holder.
Holder for TDC sensor (42) or (44)	correct by loosening bolt (41), move holder for TDC sensor until pin on crankshaft pulley or vibration damper catches in locating device 603 589 01 21 00 and tighten bolt (41) (items 6 - 8).

Special tools

Fig 4: Identifying Special Tool (601 589 07 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Special Tool (363 589 02 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Special Tool (603 589 01 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS AND TESTERS

Designation	e. g. make	Order no.
Dial gauge A 1 DIN 878	Mahr, 73457 Esslingen	810

NOTE: The holder for the TDC sensor is fastened to the timing case cover.

Fig 7: Identifying TDC Sensor And Timing Case Cover

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Check adjustment of holder and correct, if required:

a) When holder is replaced.
b) When crankshaft and hub, vibration damper and crankshaft pulley are replaced.
c) When timing case cover is removed, installed or replaced.

Testing

Position piston in cylinder 1 to approx. 10° BTDC, ignition stroke.

Fig 8: Identifying Ignition Timing 10°
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Ignition Timing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Screw gauge 601 589 07 21 00 into precombustion chamber bore and attach dial gauge to gauge with 5 mm pretension (small pointer on dial gauge).

Fig 10: Measuring Precombustion Chamber Bore Dimension With Dial Gauge
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

If the cylinder head is removed, the measuring pin on the dial gauge can be positioned directly on the piston crown. Set dial gauge holder 363 589 02 21 00 on crankcase parting surface.

Fig 11: Checking Cylinder Head Surface With Dial Gauge
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn crankshaft slowly in normal direction of rotation until large pointer on dial gauge (07) stops (TDC position). Turn dial gauge scale until large pointer points to zero.

Fig 12: Identifying Dial Gauge And Piston Crown
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn crankshaft in normal direction of rotation slowly until the gauge moves back 3.22 mm on engines 601.911/912, 602 and 603 or 3.65 mm on engines 601.921 and 603.97.
NOTE: After the dial gauge has moved back (crankshaft position 20° ATDC) the pin in the crankshaft pulley or in the vibration damper should be located exactly below the TDC sensor (arrow).

Fig 13: Locating TDC Sensor Position
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position locating device 603 589 01 21 00 in holder for TDC sensor.
The pin on the crankshaft pulley or on the vibration damper must catch in the groove in the locating device.

If the pin on the crankshaft pulley or on the vibration damper does not catch, correct position of holder for TDC sensor.

Fig 14: Identifying Pin On Crankshaft Pulley
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Correcting
Loosen holder (42 or 44) with screw (41) and move until pin on crankshaft pulley or on vibration damper catches in the groove in the locating device 603 589 01 21 00.
42 Holder for TDC sensor, engines 601.911/921 and engine 601.912 1st version

Fig 15: Identifying Holder With Screw
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Screw holder for TDC sensor down tight.
Remove dial gauge and gauge 601 589 07 21 00 and locating device 603 589 01 21 00.

44 Holder for TDC sensor, engine 601.912 2nd version starting 10/85 and engines 602, 603 from start of production

Fig 16: Identifying Holder And TDC Sensor

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.