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#1
11-01-2010, 08:25 PM
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Serious '87 300D Problem
Need your help, guys.
'87 300D, a sweet car and good rugged cab. Has developed a serious problem, and I am at a loss. Over a few months, it became very doggy and underpowered, to the point where drivers wouldn't drive it. Originally we thought maybe the turbo had failed, so we ripped it apart and made sure it was working properly, including going through the entire vacuum system. (Luckily we have a sister car to compare with.) Problem continued to deteriorate, with car blowing very heavy black smoke. My sense from driving the car was that the valves were improperly timed - a lot of top end noise, running warm, no power, frequent stall, hard starting. So we went back and checked valve timing, injection pump timing, timing chain stretch. Everything was balls-on. We have checked the timing with three different pairs of eyes more than a dozen times over this saga. Next we disconnected the exhaust to ensure that there was no clog/back pressure in the exhaust, but there was no change in symptoms. Since the turbo checked and the exhaust wasn't to blame, it was down to the cylinder head, which I am told the OM603 heads had known issues. Lo and behold! we found half a dozen small cracks around the valves. So we swapped heads. I was convinced that we had found the problem and buttoned the car up with glee, mirth and giddy anticipation. Only not. The car is somewhat better, way less smoke, and stalls less, but in most other respects the symptoms persist. My gut still tells me this is a timing problem, but the timing marks line up. Every time. I am stumped. We are obviously overlooking something... At one point before the troubles, my shop assistant replaced a front main seal on this car. Is it possible the he incorrectly re-installed the harmonic balancer? I've not ever done the job myself, but I thought the dowels make this pretty much impossible. Is the harmonic balancer on the OM602 the same as on the OM603? Maybe he put the wrong part on? We have tons of parts engines laying around. Can the harmonic balancer "drift" on the crankshaft? I have searched "harmonic balancer" on the diesel forums, but have not found much to help. Appreciate the help in advance. Josh Ace Taxi Bangor, ME
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Josh Ace Taxi Bangor, ME Cab 2: '87 300D Cab 3: '92 300D Cab 4: '90 300E 4Matic Wagon Cab 6: '96 E300D Cab 7: '87 300TD Cab 8: '91 300E 4Matic Wagon Cab 9: '98 E320 4Matic Wagon Cab 10: '98 E300D Cab 11: '98 E320 4Matic Wagon '96 Suburban 6.5 Turbodiesel 
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#2
11-01-2010, 08:45 PM
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You say the problem developed over a period of months. I don't see how the timing can change over a period of time like that unless the chain is stretching or jumped a tooth or something like that. Black smoke is unburned fuel. Are you sure the turbo is working? Have you put a boost gauge to it? Have you changed the air filter?
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1977 300d 70k--sold 08 1985 300TD 185k+ 1984 307d 126k--sold 8/03 1985 409d 65k--sold 06 1984 300SD 315k--daughter's car 1979 300SD 122k--sold 2/11 1999 Fuso FG Expedition Camper 1993 GMC Sierra 6.5 TD 4x4 1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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#3
11-02-2010, 04:21 AM
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I haven't put a boost gauge on the turbo, but it spins freely and if you rev the engine with the crossover tube off you can feel the turbo spool up. New filters (air, fuel) all the way around.
I also don't understand the gradual onset of problems. Diagnostically, I approach these problems by asking myself "what's changed?" Problem is, cab drivers are reluctant to report damage on their watch - overheatings, underbody damage and worse, so it's hard to pinpoint. Today I am going to re-examine the harmonic balancer. Is there a way to verify that cylinder #1 is at TDC?
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Josh Ace Taxi Bangor, ME Cab 2: '87 300D Cab 3: '92 300D Cab 4: '90 300E 4Matic Wagon Cab 6: '96 E300D Cab 7: '87 300TD Cab 8: '91 300E 4Matic Wagon Cab 9: '98 E320 4Matic Wagon Cab 10: '98 E300D Cab 11: '98 E320 4Matic Wagon '96 Suburban 6.5 Turbodiesel
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#4
11-02-2010, 04:27 AM
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Injector & heat shield out. Place a stick in the hole so that it is resting on the piston. As you turn the motor the stick will come out the hole. At TDC it will stop & then go back down.
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Grumpy Old Diesel Owners Club group I no longer question authority, I annoy authority. More effect, less effort....  1967 230-6 auto parts car. rust bucket. 1980 300D now parts car 800k miles 1984 300D 500k miles  1987 250td 160k miles English import  2001 jeep turbo diesel 130k miles  1998 jeep tdi ~ followed me home. Needs a turbo. 1968 Ford F750 truck. 6-354 diesel conversion. Other toys ~J.D.,Cat & GM ~ mainly earth moving
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#5
11-02-2010, 04:32 AM
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Cam
Look at the cam lobes through the oil-filler hole.
Jay.
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On the road, currently: '83 300D (German spec.) 168k mi. - - Wolfgang (tucked snugly away for the winter!) '87 300D 375k mi. - finally went over to "The Dark Side" '87 300TD 225k mi. Cannondale 66cm CAAD5 w/Campy/Jamis Aurora Hujsak Custom Fixie/Landshark Track Shark Custom/Ahearne Custom 29'er
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#6
11-02-2010, 08:47 AM
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Quote:
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!!  1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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#7
11-02-2010, 08:52 AM
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Quote:
Algae?
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http://superturbodiesel.com/images/sig.04.10.jpg 1995 E420 Schwarz 1995 E300 Weiss #1987 300D Sturmmachine #1991 300D Nearly Perfect #1994 E320 Cabriolet #1995 E320 Touring #1985 300D Sedan OBK #42
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#8
11-02-2010, 09:52 AM
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You really need to test the boost pressure IMO. You can tee-in at the ALDA port.
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-Louis '87 300D Anthracite 
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#9
11-02-2010, 11:46 AM
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Remember I said I had tons of parts laying around? I have a good crank from another 603 sitting on the floor. Blinding flash of insight: pull the harmonic balancer in the troublesome car, and compare crankshafts. The keyhole should be at the same angle at TDC on both the reference crankshaft and the one in the car. I'll compare them and post results later.
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Josh Ace Taxi Bangor, ME Cab 2: '87 300D Cab 3: '92 300D Cab 4: '90 300E 4Matic Wagon Cab 6: '96 E300D Cab 7: '87 300TD Cab 8: '91 300E 4Matic Wagon Cab 9: '98 E320 4Matic Wagon Cab 10: '98 E300D Cab 11: '98 E320 4Matic Wagon '96 Suburban 6.5 Turbodiesel
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#10
11-02-2010, 12:02 PM
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Quote:
Checking boost is simple, should have been done before tearing into Turbo. What is the cars 0-60 time? A rough estimate is fine.
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1987 300TDT - 195,000 (Original #14 head) 1993 190E 2.3 - 105,000 1981 300D - 250,000
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#11
11-02-2010, 12:41 PM
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Quote:
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CC: NSA All things are burning, know this and be released. 82 Benz 240 D, Kuan Yin 12 Ford Escape 4wd You're four times It's hard to more likely to concentrate on have an accident two things when you're on at the same time. a cell phone. www.kiva.org It's not like there's anything wrong with feeling good, is there?
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#12
12-22-2010, 02:46 AM
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Any update on this?
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1987 300TDT - 195,000 (Original #14 head) 1993 190E 2.3 - 105,000 1981 300D - 250,000
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