Testing the exhaust gas turbocharger - Engines 602.96, 603.96/97 TURBO Engines - ra09006025911x(5911)

A. With overload protection, B. Without overload protection (Model 463.3 : for deviations see introductory notes) 

Operation no. of operation texts and work units or standard texts and flat rates: 09-5911

1. Engines with engine overload protection 
   Fig 1: Testing Exhaust Gas Turbocharger - Engines With Engine Overload Protection

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Tester (001)	connect, disconnect.
   Pulse generator (021)	connect, disconnect.
   Tester (020) with Y distributor	connect to measuring point "A" and test boost pressure.
   Tester (020) with Y distributor	connect to measuring point "B" and test boost pressure.
   Tester (020) with Y distributor	connect to measuring point "C" and test boost pressure.

   Specification: 0.85-0.95 bar at 4000 rpm full load in drive position "3".

   NOTE: The test can be performed on the dynamometer or on the road. If the specified boost pressure is not achieved, check the following: Connection line from boost pressure control valve to compressor housing.

   Engine overload protection switchover valve (09-250).

   White vacuum line and rubber connections. If all parts are in order, replace the exhaust gas turbocharger.

   TEST DATA
   
   

   Engine	Boost pressure at n=4000 rpm full load in drive position "3", in bar		Reduction in boost pressure as of engine end no.
   	up to 08/91 or Model Year 1991	as of 09/91 or Model Year 1992	manual transmission	automatic transmission
   602.961	0.85-0.95	0.75-0.85	4831	9157
   602.962	0.85-0.95	0.75-0.85	10588	8842
   603.960	0.85-0.95	0.75-0.85	-	035636
   603.963	0.85-0.95	0.75-0.85	-	031125
   603.960	0.85-0.95	0.75-0.85	-	035636

   Special tool 

   Fig 2: Identifying Special Tool (603 589 03 21 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   COMMERCIALLY AVAILABLE TOOLS AND TESTERS
   
   

   Designation	e. g. make, order no.
   Digital tester (or tachometer fitted to vehicle)	Bosch, MOT 002.01 Sun, DIT 9000 Sun, FMT-1019/Master 3, Sun, MCM-2110, All-Test 3610-MB

2. Engines without engine overload protection 

Fig 3: Testing Exhaust Gas Turbocharger - Engines Without Engine Overload Protection

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Specification: 0.75-0.85 bar at 4000 rpm full load in drive position "3".

White vacuum line and rubber connections.

EDS pressure sensor (B5/1).

Restriction (61c).

If all parts are in order, replace the exhaust gas turbocharger.

Special tool 

Fig 4: Identifying Special Tool (603 589 03 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.