Removing and installing injection pump

AR07.12-S-8410A

Removing and installing injection pump

4.12.95



Removing

1

Remove radiator

AR20.20-S-3865B

2

Remove vacuum pump

AR43.05-S-1320A

3

Remove dipstick guide tube

AR01.45-S-9600B

4

Remove oil filter element

 Allow oil to flow out of oil filter housing

AP18.00-D-0101A

5

Remove oil filter housing with oil-water heat exchanger attached

 Collect oil which flows out

AR18.20-S-3471A

6

Position engine to 15° after TDC of cylinder 1

 Rotate engine at crankshaft
 Crank engine only in direction of rotation

AR01.00-S-0120B

7

Detach connecting rod (1) at throttle control lever (2)

8

Detach fuel lines (9) at fuel filter

 Inspect seals, replace if necessary. Collect fuel which flows out

AR47.20-S-5510A

9

Detach leak fuel line (5) and return flow fuel line (6) at connection piece (4)

10

Detach vacuum line (7) at engine stop vacuum unit (8)

11.1

Separate vacuum hoses from vacuum control valve (31)

Engine 601.942 with code MS5 (low emission engine stage II) or KD1 (emissions control system (oxidation cat.) up to 01.07.96)

12.1

Unplug connector (32)

Engine 601.970 with code MS5 (low emission engine stage II)

13

Separate plug connection (X114) at the electronic blocking valve (Y30)

With code FZ6 (immobilizer)

14.1

Separate plug connection (30) from microswitch (S70)

Engine 601.942 with code MS5 (low emission engine stage II) or KD1 (emissions control system (oxidation cat.) up to 01.07.96)

15

Detach injection lines at the injection pump

 Do not bend injection lines

AR07.12-S-9230A

16

Detach vacuum line (18) at charge pressure unit (17)

Engine 601.970

17.1

Detach vacuum line (20) at the PISI vacuum unit (19)

On engines with PISI

17.2

Separate plug connection (X120) at the ISC solenoid (Y56)

On engines with ISC (electronic idle speed control)

18

Unscrew bolt (21) at support (22)


 Installation: pay attention to washer (25)

*BA07.11-N-1005-01A

19

Install centering sleeve (14)



*601589051400

20

Unscrew central bolt (11) and take off together with washer (12) and disk spring (13)

 Left-hand thread

Counterhold crankshaft if necessary

21

Remove chain tensioner (10)

AR05.10-S-7800B

22

Unscrew bolts (15) at injection pump flange and take off together with four-point nuts (24)

 Bolt (15) cannot be removed (arrow)

Top bolt (15) can be removed by raising engine

23

Remove injection pump (26)

 Counterhold injection timing device

24

Detach connecting rod (1) at adjusting lever of injection pump

25

Detach fuel lines of injection pump

 Release quick locks

AR07.11-S-8410-01A



Installing

26

Fit on fuel lines of injection pump

 Inspect seals, replace if necessary and secure quick locks

AR07.11-S-8410-01A



*BA07.11-N-1011-01A

27

Block injection pump (26) before installing

 Blocking bolt (29) must be felt to engage. Pay attention to distance (arrow) between collar of stud and bolt

AR07.11-S-8410-02A



*601589000800



*601589052100

 handtight



Check whether engine is at 15° after TDC of cylinder 1, correct if necessary

 Rotate engine only in direction of rotation with centering sleeve (14) installed

AR01.00-S-0120B

28

Insert injection pump (26) and bolt tight to flange

 Replace seal (23) and oil with engine oil



*BA07.11-N-1007-01A

29

Remove blocking bolt (29) and insert screw plug (28)

 Otherwise injection pump will be damaged when starting
 Replace seal (27)



*BA07.11-N-1009-01A

30

Install chain tensioner (10)

 Replace seal

AR05.10-S-7800B

31

Tighten central bolt (11) with washer (12) and disk spring (13)

 Left-hand thread
 Counterhold crankshaft if necessary



*BA07.11-N-1008-01A

32

Remove centering sleeve (14)

33

Install connecting rod (1)

 Pay attention to installation position

34

Fit remaining parts to vehicle

 Injection system bled automatically

35

Check start of delivery

Position sensor GIM method

AR07.11-S-8240A

or

digital tester GIM method

AR07.11-S-8244A

36

Check idle speed, set if necessary

AR07.11-S-2053A

37

Inspect for leaks

Number

Designation

Engine 601.942 601.970

BA07.11-N-1005-01A

Injection pump to support

Nm

23

BA07.11-N-1007-01A

Injection pump to crankcase

Nm

23

BA07.11-N-1008-01A

Central bolt of injection timing device to injection pump  Left-hand thread

Nm

46

BA07.11-N-1009-01A

Screw plug to governor housing

Nm

30

BA07.11-N-1011-01A

Return flow line to injection pump

Nm

13