Hi folks -- I am finally back stateside and can dig into my knocking '92 300D (see my thread from late November). I went out and had a good look in the coolant expansion tank -- no oil. Oil level looked good on the dipstick, too. I glanced at the head, and the casting number is 602 016 08 01. Does that mean I have a #8 head? I guess the faulty #14 heads were only on 603's? Just trying to wrap my mind around what may have gone wrong. if the weather stays reasonably warm, I am going to try to pull injectors in the next few days for a better look. Thanks, all!

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

My Original engine head number reads 602 016 06 01,so it's even older than yours.

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'84 300SD sold
124.128

There is no correlation between 602 and 603 head casting numbers. 602 heads aren't susceptible to cracks. They're more tolerant of overheating than 603 #14 heads. There isn't much/any documentation on the succession of 602 head casting numbers.

What's the problem?

Sixto
87 300D

Thanks...

I have a knocking/smoking problem (Officially bummed: knocking 92 300D 2.5T), and just got home from a lengthy trip. I wanted to look at the coolant and oil levels, and while I was poking around under there I noticed the head casting numbers, and I was just curious about the series numbers.

I am going to try to pull injectors today or tomorrow and see what I can find. Maybe I'll get lucky and discover a broken prechamber or something simple like that, though I am preparing myself for worse.

Thanks again!

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

Do you still need the injector socket? I'm around all day today if you do, I can drop it off.

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Dan
2005 E320 CDI - 246k
1987 300SDL TD05-16g, Herlevi pump, Elbe manifold, 2.47 LSD - 213k
Past: 1987 300D - 264k

Actually, I was just going to run to Sears or AutoZone and try to pick one up today and pull injectors today or tomorrow. I am a good ways south of you, though; unless you were planning to head my way for something anyway, it would be quite a hassle to drive all the way down just for that. Thank you for offering, though; it's very kind of you!

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

Always willing to help a little bit!
Good luck in your findings, hope it isn't anything major!

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Dan
2005 E320 CDI - 246k
1987 300SDL TD05-16g, Herlevi pump, Elbe manifold, 2.47 LSD - 213k
Past: 1987 300D - 264k

Ditto.

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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!

Early 602 and 602 turbo heads are susceptible to cracking the same as the early 603. The good news is, that it only affects the '87 190D 2.5 turbo, was updated before the '90 300D went into production.

The head number progression is shown in the same chart in the FSM where the 603 number progression is shown.

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Gone to the dark side

- Jeff

Thanks for the clarification, Jeff, though I've yet to hear of a 190D developing head cracks in this forum or the couple others I monitor. My statistics say the primary cause of 90-93 602 goofiness is timing chain wear.

My point on the sequence is not the sequence itself but what changed from one revision to the next. Folks like gsxr know 603 head telltales well enough to identify a casting number without looking at the casting number. I haven't seen anything shared on what changed from one 602 head casting to the next.

On the 602, I'd be sure to note which castings are designated for turbo engines and which aren't since normally aspirated 602s were offered in the US.

Sixto
87 300D

The 603 is pretty well established as a #17-up casting is the reinforced version. The updated castings all have the angled-injection pre-chambers.

On the 602, a #8-up casting is the reinforced version, production break-point being 07/1989.

I believe that both have the splined retaining ring on the pre-chamber.

The chart is located at 01.10-400/7 of the FSM.

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Gone to the dark side

- Jeff