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Testing and adjustment of the engine - ra07016021100x(1100)

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Engines 602.96, 603.96/97 TURBO 

Preceding work:

Operation no. of operation texts and work units or standard texts and flat rates: 07-1100

Fig 1: Testing And Adjusting Engine
G05436857Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Coolant level check, correct.
Engine oil level check; pay attention to condition of oil (visual inspection).
Air filter element remove, install (visual inspection).
Testers (001, 013, 017) connect.
Pulse generator (021) connect.
Accelerator control linkage check ease of movement, condition.
Lubricate bearing points, relay levers, ball sockets.
Full throttle stop check from accelerator pedal, adjust Bowden cable if necessary.
Idle stop check; adjust at Bowden cable if necessary.
Voltage at battery test. Specification min. 11.5 volts.
Engine warm up to operating temperature (coolant temperature approx. 80 °C).
Air conditioner or automatic climate control switch off.
Idle speed check, adjust if necessary. Unplug connector from actuator, plug in.
Start of delivery test with digital tester.
Max. speed at no load test.
Injection timer test.
Electronic diesel system (EDS) test with pulse counter (013), see (07.1-1120).
Anti-jerk control (ARA) test with pulse counter (013), see (07.1-1841).
TEST AND SETTING DATA

Engine Idling speed in rpm with control Idling speed in rpm without control connector at servomagnet unplugged Start of delivery with digital tester RI specification Max. speed without load or end of governed speed in rpm Timing device w/o load or end of governed speed RIV meth. in°
602.96 (1) 740 ± 20 690 ± 40 15 ± 1° after TDC.
USA ONLY as of 09/89, Base version Code 62/0 as of 06/91, AUSTRIA ONLYFINLAND ONLYSWITZERLAND ONLYDENMARK ONLY as of model year 1991: 14 ± 0.5° after TDC.		 5150 ± 150 +3° to+5°
602.96 (2) 680 ± 20 620 ± 40
603.96 630 ± 20 570 ± 40 15 ± 1° after TDC.
680 ± 20(3) 620 ± 40(3) Base version Code 62/0 as of 06/91, AUSTRIA ONLYFINLAND ONLY as of model year 1991: 14 ± 0.5° after TDC.
603.970 630 ± 20 570 ± 40 15 ± 1° after TDC. USA ONLY as of 09/89: 14 ± 0.5° after TDC. 4650 ± 150
603.971 610 ± 20 560 ± 40 14 ± 0.5° 4750 ± 150
(1) Manual transmission.
(2) Automatic transmission
(3) 4MATIC with manual transmission.

Special tools 

Fig 2: Identifying Special Tools 07 (603 589 00 21 00)
G05436858Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Special Tools 07 (617 589 09 21 00)
G05436859Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Special Tools 07 (617 589 10 21 00)
G05436860Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Special Tools 00 42 80 (201 589 13 21 00)
G05436861Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TESTERS

Designation e. g. make, order no.
Used without adapter 
Digital testers Bosch, ETD 019.02 or MOT 350/500/501
Sun, DIT 9100
AVL, Diesel-Tester 873
Used with adapter 
Digital testers Bosch, MOT 001.03
Lambda tester Bosch, KDJE-P 600
(only for EDS) Hermann, L 115

Connection diagram for testers with adapter

Fig 6: Connection Diagram For Testers With Adapter
G05436862Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Testing, adjusting engine 

  1. Check coolant level, correct if necessary.
  2. Check engine oil level, paying attention to condition of oil (visual inspection).
  3. Remove air filter element (visual inspection), and install.
  4. Connect testers (013, 001, 017) according to connection diagram.
  5. Connect pulse generator (021).
  6. Check accelerator control for ease of movement and condition. Lubricate bearing points, relay levers and ball sockets.
  7. Check full throttle stop from accelerator pedal; adjust at adjusting screw (229) if necessary.

    Engine 602.96

    Fig 7: Identifying Accelerator Pedal And Adjusting Screw (Engine 602.96)
    G05436863Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Engine 603.96

    Fig 8: Identifying Accelerator Pedal And Adjusting Screw (Engine 603.96)
    G05436864Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Check idle stop.

    The spring plate (226) of the Bowden cable (230) must be resting against the compression spring (227) free of tension.

    Engine 602.96

    Fig 9: Locating Compression Spring (Engine 602.96)
    G05436865Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Engine 603.96

    Fig 10: Locating Compression Spring (Engine 603.96)
    G05436866Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Adjust Bowden cable (230) with adjusting nut (232) from the car interior, if necessary.

    Fig 11: Identifying Bowden Cable With Adjusting Nut
    G05436867Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Test voltage at battery.

    Specification: at least 11.5 V.

  10. Raise engine to operating temperature (coolant temperature approx. 80 °C).
  11. Switch off air conditioner or automatic climate control.

    Test idling speed.

    Unplug 2-pin coupling at actuator, plug in. Set idling speed by slackening locking nut (arrow).

    Engine Idle speed in rpm with control Idle speed rpm connector at actuator unplugged without control
    602.96 manual transm. 740 ± 20 690 ± 40
    602.96 automatic transm. 680 ± 20 620 ± 40
    603.96 630 ± 20 570 ± 40
    680 ± 20 (1) 620 ± 40 (1)
    603.970 630 ± 20 570 ± 40
    603.971 610 ± 20 560 ± 40
    (1) 4MATIC with manual transmission.
    Fig 12: Locating Locking Nut
    G05436868Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Test start of delivery dynamically, read off on digital tester (07-8244).

  12. Test "max. speed" without engine load.
  13. Test injection timing device without load.
  14. Test electronic diesel system, see (07.1-1120).
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