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  #1  
Old 08-27-2008, 03:09 PM
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Engine stalls on '96 E300D in mid-drive

Twice this morning the engine just quit on me while driving without warning. It was at low RPM; one was idling at a light, the other just cruising along at 50. It starts just fine right afterwards and has been running fine all day. There is no sign of loss of power, hesitation or anything else while it runs. I'm going to keep an eye on this because it happened once before about two weeks ago.

We've been having some cold nights here in michigan and there's been lots of dew on the cars every morning. I'm thinking maybe there is water in the fuel? If so what's the best way to get that out on a diesel?

Also, is there a way to re-start the engine while coasting without being in 'P'?

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  #2  
Old 08-27-2008, 03:19 PM
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Quote:
Originally Posted by gersti View Post
Twice this morning the engine just quit on me while driving without warning. It was at low RPM; one was idling at a light, the other just cruising along at 50. It starts just fine right afterwards and has been running fine all day. There is no sign of loss of power, hesitation or anything else while it runs. I'm going to keep an eye on this because it happened once before about two weeks ago.

We've been having some cold nights here in michigan and there's been lots of dew on the cars every morning. I'm thinking maybe there is water in the fuel? If so what's the best way to get that out on a diesel?

Also, is there a way to re-start the engine while coasting without being in 'P'?
I'll buy your car! Just kidding. Can't post on this forum without getting a joke or two like that.

Anyways, I'd doubt that water in fuel is your issue. More likely that it's air in fuel. The 606 is known for leaks at the plastic fuel lines or fittings of the lines on the IP. We read about that frequently here. Also seems that the fuel shutoff can get a leak.

There are a few people with your car on this forum. I've got it's older brother with the OM603 6 cylinder and it has a little heavier duty of a fuel plumbing system.

Another thing to check is the K40 relay. I believe it's behind the battery and I think it is red in color.
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  #3  
Old 08-27-2008, 03:26 PM
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If (and this seems to be the case) it dies "w/o warning, as if key were turned off" the problem will usually be the K40 relay. Occassionally will be the shutoff valve.

K40 is in the right side computer apparatus box; front most unit. Its black, but may have a red fuse on top.....part number starts with 540.

The PCB develops minute cracks in the circut board; expansion and contraction causes an interruption in power causing the SOV to close same as occurs when key is turned off.
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  #4  
Old 08-27-2008, 03:29 PM
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It will start in "N" also.
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  #5  
Old 08-27-2008, 03:30 PM
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It is likely the K40. If it is not that, it could be the ignition switch contacts.

The K40 is in the relay module box under the hood, right side rear, just ahead of the ACC air intake. The module itself is at the very front inside the box, with several fuses and several small connectors attached (some with fairly large wires). Mine is black.
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  #6  
Old 09-19-2008, 01:30 PM
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Smile K40 it was!!!

I took out the K40 module last weekend, opened it up and saw right away that there were 4 cold solder joints . I resoldered every connection in the module just to be sure. Car's been running flawless now for a week.

Thanks for all the help on this issue everyone. You guys all rock.
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  #7  
Old 10-09-2008, 08:50 AM
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still having issues

So for the last couple of weeks the car ran fine - no more stalls. Then yesterday I drove it, stopped at a store and when I came back out it wouldn't start. Engine cranked like always but no joy. I called my mechanic, he thought maybe something got messed up on the entry code when I used the fob to unlock the car. He had me close/open the door and trunk manually - still no luck. That's when I noticed that after I unlocked the car with the fob the red & green lights on the mirror flashed back and forth as I try to start. I assume that's some sort of signal that something went wrong with the unlocking/entry procedure. I tried several times - nothing. I waited about 10 min and tried once more and it started instantly.

So now this morning the engine quit on me while driving and same thing. After waiting a while it started again. Red/green lights flashed again. Then I stoped at a store again and it started just fine after that.

I replaced batteries in key fob about a week ago, so it can't be that.

Is there some sort timed lockout when an incorrect entry was received?
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  #8  
Old 10-09-2008, 09:27 AM
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Go back to square 1...most likely the K40 not powering the diesel fuel computer (IFI).

Therefor the DAS system isn't seeing the IFI computer responding.
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  #9  
Old 10-09-2008, 09:49 AM
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M.B.Doc - I looked at the K40 already and suspected it again but it looks very good. Unless one of the actual relays is bad. But what's different now is that the red/green lights are flashing which I don't believe they did before.

Question - what is the 'DAS' ?
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  #10  
Old 10-09-2008, 10:54 AM
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DAS= drivers authorization system. (anti theft)

ON that model DAS looks for correct signals from INFRA-RED signals from key.

WHEN the red/green lights flash on the mirror it means there is a DAS issue.

IF the IFI computer isn't being powered properly then there is DAS issue!

Again the K40 is most likely...IGNITION switch must properly power the K40 as well.

Are all of the dash lights coming on with the key?
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  #11  
Old 10-09-2008, 11:03 AM
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It took me two tries to resolder the K40 module in my '96.

After I soldered the big leads to the board, it worked great for a couple of weeks, then failed again. Resoldering the big leads let the relays "float" a bit on the board and stressed the small (control) leads. These small leads then developed cracks at the solder joints.

I resoldered the whole thing again, first the big ones, let it cool, then the small ones. It has worked since then.

If it quits, the first step for me will be a new K40 module as it is not expensive and very easy to change. The next step is the ignition switch.

If the K40 is not powering the engine computer and DAS is installed on your car, the lamps on the mirror will alternate, and the engine will not start. This also happens if you lock the car from the outside, then try to start the engine.
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  #12  
Old 10-09-2008, 11:07 AM
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I agree that it sounds like a DAS issue and your suggestion that the IFI is not getting powered up sounds very plausible. NOW how do I troubleshoot the K40? I've had it apart a couple of times now and it alloks clean and nice inside. I suppose I could clean the relay contacts with some alcohol or contact cleaner. All the solder joints looked good when I re-checked the K40 module. If I had a wiring diagram I could check for proper voltages on the K40 to see if it's getting powered up from the ignition switch. Any idea where I might get my hands on one? There are 3 relays inside.
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  #13  
Old 10-09-2008, 11:10 AM
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OK, I'll get the K40 out again and resolder EVERY solder joint just to be sure.
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  #14  
Old 10-09-2008, 11:43 AM
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I'm not an avocate of spending $$$ but that relay has a MB list of $107...210-540-03-72

Walking or towing can cost a lot more!
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  #15  
Old 10-09-2008, 11:48 AM
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Agreed. I searched Fastlane but that part no. doesn't come up? do you have another source?

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