07.1-200 Removal, reinstallation of injection pump
Job no. of Job Texts and Work Units or Standard Texts and Flat Rates 07-8410 and 8411 |
Battery | disconnect, connect. |
Bottom part of noise encapsulation | unscrew, screw on. |
Model 202 Intake manifold |
remove, install (14-180). |
All models | |
Belt tensioning device | remove, install (13-340). |
Fan shroud and fan | remove, install (20-310/335). |
Vacuum pump | remove, install (43-618). |
Actuator of Tempomat cruise control | remove, install (54-541). |
Assembly cage | remove, install. Special tool 601 589 05 14 00 Note Assembly cage deleted on all engines as of 09/89 (see table). |
Central mounting bolt (19) | remove, install "left-hand thread" |
Crankshaft | turn in direction of rotation to 15° ATDC of cylinder 1. |
Chain tensioner | remove, install (05-310). |
Models 124, 201 | |
Accelerator control damper (16) | remove, install (only with manual transmission). |
All models | |
Injection lines (54-57) | at injection pump, disconnect, connect, tightening torque 10-20 Nm, special tool 000 589 770 300. |
Fuel lines (80, 82, 83) | disconnect, connect. Replace seals (78). Note model 202 Release quick locks, pull off, fit on, secure. |
Vacuum lines at stop unit | pull off, fit on. |
Couplings at actuators | disconnect, connect. |
Accelerator control linkage | detach, attach. |
Models 124, 201 | |
Vacuum control valve | remove, install, adjust (07.1-170). |
All models | |
Securing bolts (13 and 13a) | remove, install, tightening torques |
Bolt+washer (8a) | slacken. |
Models 124, 201 Fuel thermostat |
remove, install. |
All models | |
Injection pump | pull out to rear, counterhold injection timing device when performing this step. |
O-ring (10) | replace, oil for installing injection pump. |
Engine | check whether postioned at 15° ATDC, or vehicles with code 62/0 at 14° TDC, of cylinder 1; correct if necessary. |
Screw plug (11) | remove. |
Injection pump | when removed, turn with serrated wrench (027) 601 589 00 08 00 and lock with blocking screw (023) 601 589 05 21 00. |
Start of delivery | check (07.1-112), adjust if necessary |
Microswitch | test (07.1-229) |
Special tools
Notes
Until the production breakpoints mentioned, a gasket with oil pocket must be installed when renewing the gasket of the vacuum pump.
As of production breakpoint a gasket without oil pocket will be installed.
Engine model designation | Transmission | As of engine end no. |
601.911 | manual automatic | 157499 015077 |
601.912 | manual automatic | 041801 003380 |
602.911 | manual automatic | 019187 004738 |
602.912 | manual | 029464 004808 |
603.912 | manual automatic | 015367 009219 |
Engine 603.912/913
From April to July 1989 an injection pump with modified tappet spring was installed.
Production breakpoint: April - July 1998
Model | Engine | Engine end no. automatic transmission |
124.130 124.190 | 603.912 | 032890-034028 |
124.330 | 603.913 | 000589-000603 |
Engine 601, 602, 603
Since November 1989 the centering sleever securing bolts has no longer been fitted.
Production breakpoint: November 1989
Model | Engine | Engine end no. manual transmission | Engine end no. automatic transmission | Vehicle ident. end no. |
A/B | F | ||||
124.120 124.180 | 601.912 | 134622 | 011467 | not registered | 130181 |
124.125 124.185 | 602.912 | 149028 | 021904 | 122689 | 129639 |
124.130 124.190 | 603.912 | 055088 | 035826 | 124680 | 129936 |
124.330 | 603.913 | 000668 | 000636 | 131741 | - |
201.122 | 601.911 | 323596 | 025246 | 542109 | 688338 |
201.126 | 602.911 | 085358 | 016711 | 542712 | 684718 |
The assembly cage with the securing bolts at the injection timing device drive is not fitted to engine 601, 602, 603.
Production breakpoint: September 1989 (assembly cage deleted)
Model | Engine | Engine end no. manual transmission | Engine end no. automatic transmission |
124.120 124.180 | 601.912 | 134622 | 011467 |
124.125 124.185 | 602.912 | 149058 | 021904 |
124.130 124.190 | 603.912 | 055088 | 035826 |
124.330 | 603.913 | 000668 | 000636 |
201.122 | 601.911 | 323596 | 025246 |
201.126 | 602.911 | 085358 | 016711 |
Return spring on injection pump engine 601.911/921 with automatic transmission, return spring 601 993 17 10 with smaller outer diameter (arrow).
Production breakpoint: December 1983
Model Engine Engine end no.
automatic transmission
201.122 601.911 000 180
601.921 001 908
Spring chamber cover (1c) at injection pumps of engines 603.912/913/931 (except national version and Standard with ARF) made of aluminium, previously sheet steel.
Reason: improved seal.
Production breakpoint: September 1990 - January 1991
Model | Engine | Engine end no. |
manual transmission | automatic transmission | ||
124.130/190 | 603.912 | 063564 - 066251 | - |
Production breakpoint: September 1990 - February 1991
Model | Engine | Engine end no. |
manual transmission | automatic transmission | ||
124.130/190 | 603.912 | - | 042065 - 044758 |
124.330 | 603.913 | - | 000742 - 000773 |
Engine 601.912
Injection pump modified. Injection pump (AJC) with short servomagnet. Spring chamber cap die cast aluminum (was sheet steel).
Production breakpoint: as of February 1993
Model | Engine | Engine end no. Manual transmission |
124.120 | 601.912 | 195583 |
Engine 601.913
Injection pump modified. Overflow valve with
O-ring groove for increasing sealing properties.
Production breakpoint: as of September 1993
Model | Engine | Engine end no. Manual transmission | Engine end no. Automatic transmission |
202.120 | 601.913 | 007159 | 000404 |
Engine 601.913
Adjusting lever of injection pump modified. Cam contour strengthened and clamping bolt with flat head.
Production breakpoint: as of July 1994
Model | Engine | Engine end no. Manual transmission | Engine end no. Automatic transmission |
202.120 | 601.913 | 021595 | 001545 |
Engine 601.912, only Taxi Germany
Injection pump and fuel tank for vegetable oil methyl ester fuel.
Production breakpoint: as of December 1994
Model | Engine | Engine end no. Automatic transmission |
124.120 | 601.912 | 023765 |
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