Testing the engine output and exhaust on the roller dynamometer - ra07016021203x(1203)

Engines 602.96, 603.96/97 TURBO 

Preceding work:

Testing, adjusting engine (07-1100)

Operation no. of operation texts and work units or standard texts and flat rates: 07-1203 or 07-1206

Fig 1: Testing Engine Output And Exhaust On Roller Dynamometer

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Fluid level, automatic transmission fluid	check, correct.
Testers (001, 005, 006, 013, 020)	connect.
Pulse generator (021)	connect.
Trunk contents	check.
	Remove any heavy or heat-sensitive objects.
Front wheels	secure. Chocks placed approx. 100 mm ahead of front wheels.
Tyre inflation pressure of rear wheels	check, adjust to specified pressure.
Extractor facility (014)	position behind exhaust pipe.
Coolant temperature	raise to approx. 80 °C at part load, keeping a check on speedometer.
Blower	cool engine, do not exceed engine oil temperature of 120 °C.
Air conditioning or automatic climate control	switch off.
Lever of service valve on 4MATIC cars	move from "A" to "B".
Full-load output	check (refer to Table). Pay attention to notes regarding testing output and exhaust.
	Run at full-load output only for as long as necessary to read instruments.
Emissions level under load	test.
	Specification: max. 0.1 % CO
Charge pressure under load	test. Specification: 0.85-0.95 bar, at 4000 rpm in drive position "3".
Exhaust back pressure California	test. Specification: < 2.0 bar.
Model Year 1986/87

Engine		602.96	603.960/961	603.963	603.971
Version		Std.	Std.	Std.
Idle speed	rpm	680 ± 20 (4)	630 ± 20	630 ± 20	610 ± 20
Start of delivery with digital tester	RI specification(1)	15 ± 1° ATDC.	15 ± 1° ATDC.	15 ± 1° ATDC.	15 ± 1° ATDC.
		As of Model	As of Model	As of Model	As of Model
		Year 1992: 14 ±	Year 1992: 14 ±	Year 1992: 14 ±	Year 1992: 14 ±
		0.5° ATDC	0.5° ATDC	0.5° ATDC	0.5° ATDC
Full-load output (2) in kW	kW	64	77	73	80
Drive position "3"		at 4500/min	at 4500/min	at 4500/min	at 3900/min
Opacity (3) (absorption coefficient)	1/m	<1.8	<1.8	<1.8	<1.8
(1) RI value - indirect start of delivery. (2) Test data are minimum output figures. (3) Pay attention to drive position and load value. (4) With manual transmission 740 ± 20.

Special Tools 

Fig 2: Identifying Special Tools 07 (603 589 00 21 00)

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Fig 3: Identifying Special Tools 07 (126 589 11 63 00)

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Fig 4: Identifying Special Tools 07 (617 589 09 21 00)

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Fig 5: Identifying Special Tools 07 (617 589 10 21 00)

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Fig 6: Identifying Special Tools 00 42 80 (201 589 13 21 00)

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Fig 7: Identifying Special Tools 00 09 (603 589 03 21)

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Fig 8: Connection Diagram For Existing Testers With Adapter

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Connection diagram for existing testers with adapter

Testing 

1. Check fluid level in automatic transmission.
2. Connect testers (001, 005, 006, 020) according to connection diagram.
3. Connect pulse generator (021).
4. Check contents of trunk. Remove any heavy and heat-sensitive objects.
5. Secure front wheels by placing chocks approx. 100 mm ahead of front wheels.
6. Check inflation pressure of the rear wheels; adjust to specified pressure if necessary.
7. Position exhaust extraction device behind exhaust pipe.
8. On 4MATIC vehicles move lever of service valve from "A" to "B".
9. Switch off air conditioner or automatic climate control.
10. Warm up coolant at part load to 60-80 °C coolant temperature; at the same time check speedometer.
11. Cool engine with blower. Do not exceed a coolant temperature of 120 °C.
12. Test full load output.
    Fig 9: Identifying Service Valve Lever Position

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    Pay attention to instructions regarding testing engine output and exhaust on dynamometer, as well as correction of output, driving instructions and work instructions.

13. Test exhaust level under load. If the specified exhaust levels under load are not achieved, set injection pump to the upper tolerance limit on the pump test stand.
14. Test charge pressure under load at the electrical switchover valve (Y30). Specification: 0.85-0.95 bar gauge at 4000 rpm in drive position "3".
    Fig 10: Identifying Electrical Switchover Valve

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15. Test exhaust backpressure at exhaust manifold, only California.

    Move selector lever to position "P" and read off test value at 4000 rpm.

    Specification: <2.0 bar

    If not, perform regeneration of trap oxidizer as follows: With selector lever in position "2", run car on roller dynamometer or on road for 2 minutes at full load.

    Repeat regeneration (max. 1 time). If the specification is not achieved, replace trap oxidizer and perform EDS short test (07-1121, "B").

    Fig 11: Identifying Roller Dynamometer

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Instructions regarding testing engine output and exhaust on dynamometer as well as correction of output, driving instructions and work instructions. Testing engine output 

This test should only be conducted if a complaint is received regarding engine output. The valid output reference values are minimum outputs and apply to cars with power steering. Allow for barometer level and intake air temperature (refer to use of correction table).

Exhaust tests 

The exhaust test at full load is intended to assess fuel consumption and engine output. It is not possible to determine absolute consumption. Instruments operating on the infrared absorption method should be used for the exhaust test.

Correcting engine output on dynamometer 

A standard Directive as specified in 80/1269 EEC has been laid down for the European Community for determining engine output. It differs from the hitherto valid DIN 70020 Part 6 method, for example in respect of atmospheric reference conditions (air temperature now 25 °C, previously 20 °C, air pressure 990 hPa (mbar) instead of 1013 hPa (mbar).

Driving instructions, work instructions 

It is important to adhere strictly to the following instructions in order to keep tire wear within permissible limits:

1. The car must not be driven on the dynamometer with winter tires The car
2. Check inflation pressure of the driven wheels, but do not increase beyond the pressure specified for on-road running.
3. High axle load of the driven wheels is not permitted.
4. Restrict duration of running to the time absolutely necessary for reading the instruments (about 5 seconds for exhaust test).
5. Road speed max. 130 km/h (120 km/h if SR tires fitted) on dynamometers with roller diameter of at least 318 mm with original tires.

   If roller diameter 220-318 mm, shop test tires must be fitted to cars with SR tires for speeds in excess of 100 km/h. Function and engine output tests up to max. 100 km/h may also be conducted with original tires.

6. Observe the test specifications and the following sequence:

   Warming-up - engine output test - exhaust test at full load. The full load tests (output, exhaust) should be conducted immediately after the warming-up run so long as tire temperature is still low, as the temperature rises most rapidly during these measurements. Two repeat measurements after adjusting work are permitted. It is essential to wait (45 minutes) before conducting further measurements to allow the tires to cool down.

7. Cool car with blower (minimum capacity 15,000 m³ /h). Direct air flow onto radiator and underside of car (oil sump, exhaust, tires). Maintain a distance of about 1 meter between blower and car.
8. Warm-up under part load (drive position 3 or 3rd gear, approx. 60 km/h, approx. 25 kW) up to a coolant temperature of 60-80 °C.
9. Insert exhaust probe (special tool 126 589 11 63 00) at least 300 mm into the exhaust pipe.
10. When performing output test, run engine in specified gear at the specified engine speed with engine running at full load. Read off instruments. Release pressure on accelerator pedal. Compare indicated output with reference value. Allow for car equipment, barometer level and intake temperature (refer to use of correction table and specifications for correcting output).
11. When performing exhaust test, run engine at full load in the specified gear at the stated engine speed and dynamometer setting. Do not run for longer than is necessary to read off instruments. The air filter must be fitted. If necessary, the engine must be allowed to cool down after a full load test.

Use of correction table 

All engine output data relate to normal operating conditions:

1. Reference pressure:
2. Reference inlet air temperature:

   990 hPa = 990 mbar +25 °C

The engine output measured on the dynamometer must be corrected if different test conditions exist to enable it to be compared with the performance data in the technical documentation.

Air pressure measuring system of meteorological station 

The barometer of the meteorological station indicates air pressure related to sea level. The barometer must be set to the air pressure indicated by the local meteorological office before being used.

In addition to the barometer reading, allowance must also be made for altitude and inlet air temperature.

Fig 12: Identifying Output Correction Formula

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The output correction factors can be obtained from the correction table.

Correction of engine output on dynamometer for diesel engines conforming to 80/1269 EEC 

Air press. p hPA (mbar)

Correction factor

Inlet air temperature t+°C

Altitude correction 

If the air pressure reading is related to sea level (meteorological station), deduct the following air pressure as stated in the correction table.

Repair order arrangement 

Note for the use of operation numbers in the various workshop areas.

Order processing 

The repair order is to be issued by the service receptionist in line with the complaint of the customer, taking into account the mileage of the vehicle and any due or recently carried out service. To inform the workshop personnel, the customer complaint must be written precisely and clearly on the order.

Two examples for specifying operation numbers:

Example 1 

Vehicles with engine complaint without a service due.

In this case perform Operation No. 07-1100 "check, adjust engine", incorporating additional related work depending on the complaint.

Example 2 

Vehicles with a service due and engine complaint.

In order to avoid overlaps, do not state Operation No. 07-1100 as "Testing, adjusting engine" is already contained in Part II of the service.

In this case, it is advantageous to have Part II performed in the test group in order to carry out any additionally required work as combined work.

Notes on standard texts and flat rates microfilm 

The identification "*" in front of the operation text in the work unit documentation means that a detailed included text is listed in connection with the respective operation group.

The flat rates stated are matched to the scopes of work in the corresponding microfilm "Engine Combustion".

Notes for workshop supervisor 

The engine test program is structured in such a way that the repair order can be extended as necessary.

Extensions as a result of additionally necessary combined work must be justified by the results of the tests and measurements.

Diesel engines 

07-1203 and 1206

Testing engine output and exhaust on test bench. This operation number provides for the work being conducted on the dynamometer.

If no dynamometer is available, individual items (related to the complaint) should be specified.