Engine runs irregularly and shakes. Check engine lamp lights up
Topic number

LI03.10-N-071148

Version

3

Function group

03.10 Connecting rods, pistons

Date

06-04-2020

Validity

Model 906 with engine OM651
Model 906, 907 with engine OM642

Reason for change

Operation Codes Updated

Reason for block

Complaint:

Engine runs irregularly and shakes. Check engine lamp lights up.
Information:
Fault codes for injectors and/or combustion misfires may be stored in the CDI control unit:
•
•

On engine 642 cylinder 6 is affected.
On engine 651 cylinder 2 is affected.

Cause:

Charge air from the exhaust gas recirculation is condensed after being introduced into the charge air system.
Information:
Under certain operating conditions, condensation that has collected in the charge air cooler can enter the combustion
chamber to a damaging degree causing a mild hydro lock scenario and the connecting rod(s) to bend.

Remedy:

Perform following testing and diagnosis operations
****************************************************************************************************************************
1.

Attach diagnostic system (see AD00.00-D-2000-04SD in model 906 or AD00.00-D-2000-06TS in model 907).

2.

-------------------------------------------------------------------------------------------------------------------------------Perform initial quick test and save to paperless (see AD00.00-D-2000-04SD in model 906 or AD00.00D-2000-06TS in model 907).
Information: For fault codes (current or stored) on injector and/or combustion misfires in the CDI control unit,
continue with operation step 2.
Information: If there are no fault codes on the injector or combustion misfires in the CDI control unit, conduct further research on the exact reason for the customer complaint and initiate corresponding repair measures.

3.

-------------------------------------------------------------------------------------------------------------------------------Remove charge air hoses from inlet and outlet fittings on charge air cooler (see AR09.41-D-1311-01WE) and
check if there is any condensation in them.
Information: If any condensation is detected, it must be removed.
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4.

Check air filter and air filter housing for ingressed fluid (see AR09.10-D-1050US and AR09.10-D-1150SF in model 906 with engine 642, AR09.10-D-1050US and AR09.10-D-1150WE in model 906 with engine 651, AR09.10D-1050TS and AR09.10-D-1150TSV in model 907 with engine 642).
Information: If any fluid is detected, it must be removed.

5.

-------------------------------------------------------------------------------------------------------------------------------Perform compression test using XENTRY Diagnosis.
Information: If noticeable problems are found (speed deviations), continue with operation step 6.
Information: If no noticeable problems are found, conduct further research on the exact reason for the customer
complaint and initiate corresponding repair measures.

6.

-------------------------------------------------------------------------------------------------------------------------------Check compression pressure using compression pressure recorder (see AR01.00-D-1200SF in model 906 with
engine 642, AR01.00-D-1200WE in model 906 with engine 651, AR01.00-D-1201TSV in model 907 with engine
642).
Information: If, when checking the compression pressure using the compression pressure recorder (on engine
651 this affects cylinder 2 and on engine 642 cylinder 6) a pressure difference is detected to the other 3 or 5 cylinders that is greater than 3 bar, you can assume that the connecting rod is damaged or bent. If noticeable problems are found, continue with operation step 7.
Information: If no noticeable problems are found, conduct further research on the exact reason for the customer
complaint and initiate corresponding repair measures.

7.

8.

-------------------------------------------------------------------------------------------------------------------------------Remove fuel injectors (see AR07.16-D-1000SF in model 906 with engine 651, AR07.16-D-1000WE in model
906 with engine 642, AR07.16-D-1020TSV in model 907 with engine 642).
-------------------------------------------------------------------------------------------------------------------------------Manually turn cylinders, one after the other, to TDC position (see AR01.00-D-0100SF in model 906 with engine
642, AR01.00-D-0100-01TSV in model 907 with engine 642, AR01.10-D-1000-01WE in model 906 with engine
651) and use welding wire or a vernier caliper through the fuel injector slot to measure the distance to the piston
(see Picture 01 and 02).
Information: If noticeable problems are found, continue with operation step 9.
Information: If no noticeable problems are found, conduct further research on the exact reason for the customer
complaint and initiate corresponding repair measures.

9.

-------------------------------------------------------------------------------------------------------------------------------Replace engine (see AR01.10-D-2401SF in model 906 with engine 642, AR01.10-D-2401TSV in model 907 with
engine 642, AR01.10-D-2401WE in model 906 with engine 651) or repair it (see AR03.10-S-7021SE in model
906 with engine 642, AR03.10-D-7021TSV in model 907 with engine 642, AR03.10-D-7021WE in model 906
with engine 651).
Information:
- On vehicles covered by warranty: Replace engine.
- On vehicles not covered by warranty and with a properly operating crankcase and properly operating cylinder
barrel: repair engine or offer replacement engine.
- On vehicles not covered by warranty and with defective crankcase and/or defective cylinder barrel: replace engine (offer replacement engine).
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10.

Check as-built configuration of charge air cooler.
Information: Perform only on model 906, 907 before production date 02/2019.
Information: For an older as-built configuration (fitting in center, see Picture 03), continue with operation step 11.
Information: For a current as-built configuration (see Pictures 03, 04(OM651) and 05(OM642)), do not undertake
any more repair measures.

11.

-------------------------------------------------------------------------------------------------------------------------------Replace charge air cooler (see AR09.41-D-6817SD in model 906 with engine 642, AR09.41-D-6817TS in model
907 with engine 642 or AR09.41-D-6817WE in model 906 with engine 651).
Information: Perform only in accordance with result after checking as-built configuration of charge air cooler (see
operation step 10) and only in model 906, 907 before production date 02/2019.
Information: The new charge air cooler with lowered fitting on the cold side (see AR09.41-D-8619M in model 906
with engine 642, AR09.41-D-8621TSR in model 907 with engine 642 or AR09.41-D-8619WE in model 906 with
engine 651) must be installed (see Picture 04 and 05). Cost acceptance to be checked through advance agreement with regard to goodwill (ESKULAB). The modification of the charge air cooler is to be applied for as additional work through an ESKULAB query for engine damage (Note service information bulletin SI01.10-S-0001A
hereto).
Information: On vehicles in which the charge air cooler and charge air hose were replaced, the following text
must be entered in the "Vehicle Documentation" (VeDoc) as FO texts:
- Text for engine 651: Charge air cooler and charge air hose modified. New part numbers: Charge air cooler A
907 501 16 00, charge air hose A 907 528 23 00.
- Text for engine 642: Charge air cooler and charge air hose modified. New part numbers: Charge air cooler A
907 501 17 00, charge air hose A 907 528 22 00.
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Attachments
File

Description

01.jpeg

Measurement of distance to piston (cylinder 1).

02.jpeg

Measurement of distance to piston (cylinder 2).

03.jpeg

Old as-built configuration of charge air cooler (fitting in
center) (A 906 501 02 01). Standard on model 906.

04.jpeg

New as-built configuration of charge air cooler (with lowered fitting on cold side) (A 907 501 16 00). Model 907 with
engine 651.

05.jpeg

New as-built configuration of charge air cooler (with lowered fitting on cold side) (A 907 501 17 00). Model 907 with
engine 642.

Symptoms
Power generation / Engine management / Engine running / Surges
Power generation / Engine management / Engine running / RPM too high/low
Power generation / Engine noise / Noise
Power generation / Engine management / Engine running / Runs rough/shakes
Power generation / Engine management / Engine running / RPM reduces with delay
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Power transmission / Function / Vibrates
Power generation / Engine management / Indicator lamp / Engine diagnosis / lit
Power generation / Engine management / Indicator lamp / Electronic diesel control / lit
Power generation / Engine management / Engine performance / No/poor output
Power generation / Engine management / Function / Malfunction

Control unit/fault code
Control unit

Fault code

Fault text

N3/28 - Motor electronics
'CDI61NFZ' for combustion engine 'OM642' (CDI)
(CR61NFZ) (Sprinter 907)

P3004DA

Combustion misfiring of cylinder 6 has been detected.

N3/28 - Motor electronics
'CDID3' for combustion engine 'OM651' (CDI) (Code:
MA5|MP6|MP8|MA6|MB6)
(CRD3NFZ) (Sprinter III)

P026685

Teach-in of the operating parameters for cylinder 2 has a malfunction. The correction value for the smooth running control of cylinder 2 is outside the permissible range.

N3/28 - Motor electronics 'CDI- P310179
D3S2' for combustion engine
'OM651' (CDI) (CRD3S2NFZ)
(Sprinter 907)

Teach-in of the operating parameters for cylinder 2 has a malfunction. Calibration is missing.

N3/28 - Motor electronics 'CDI- P3100F9
D3S2' for combustion engine
'OM651' (CDI) (CRD3S2NFZ)
(Sprinter 907)

Teach-in of the operating parameters for cylinder 2 has a malfunction. There is a signal above the permissible limit value.

N3/28 - Motor electronics
'CDI61NFZ' for combustion engine 'OM642' (CDI)
(CR61NFZ) (Sprinter 907)

Combustion misfiring of cylinder 6 has been detected.

P3004C6

Parts
Part number

ES1 ES2 Designation

Quantity Note

EPC

A 907 501 16 00

Charge air cooler

1

Model 907 with engine 651
Information: For old as-built configuration only (fitting in center, see
Picture 03, 04 and 05 and operation
step 10 of remedy).

X

A 907 501 17 00

Charge air cooler

1

Model 907 with engine 642
Information: For old as-built configuration only (fitting in center, see
Picture 03, 04 and 05 and operation
step 10 of remedy).

X

A 907 528 22 00

Charge air hose

1

Model 907 with engine 642
Information: For old as-built configuration only (fitting in center, see
Picture 03, 04 and 05 and operation
step 10 of remedy).

X

A 907 528 23 00

Charge air hose

1

Model 907 with engine 651

X

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Information: For old as-built configuration only (fitting in center, see
Picture 03, 04 and 05 and operation
step 10 of remedy).
Additional necessary replacement
part scopes, small parts and consumable materials must be replaced
according to the information in the repair documents referred to in this document. These are to be determined
according to the vehicle identification
number (VIN) through the XENTRY
Portal Parts Information system.

Operation numbers/damage codes
Op. no.

Operation text

Time

54-1011

PERFORM QUICK TEST