Removal and Installation of Injection Pump
REMOVAL AND INSTALLATION OF INJECTION PUMPTightening torques
Pipe connection for delivery valves 40-50 Nm (30-37 ft lb)
Injection lines 25 Nm (18.5 ft lb)
Special tools
Conventional tool
Torque wrench 1/2" drive, 15-65 Nm
Removal
1. Detach vacuum tine at vacuum control unit and at vacuum control valve for automatic transmission.
2. Unscrew delivery line at aneroid compensator.
3. Disconnect electric cable at temperature sensor, detach control rod, unscrew injection lines and fuel lines at injection pump. Clip caps onto connections for injection lines and fuel hoses at injection pump.
4. Unscrew lubricating oil line (5).
Attention: Prior to removal of lubricating oil line (5), clean connecting points.
5. Unscrew and remove upper part of oil filter so that engine oil can return to oil pan.
6. Unscrew hex-head bolts at supporting holder (4) as well as 3 nuts holding injection pump. Release fastening bolt (3) to provide adjustment within oblong hole.
7. Unscrew all engine oil lines at oil filter body, releasing clamps for this purpose.
8. Unscrew and remove oil filter body from crankcase.
Attention: When removing gasket, make sure that no remains drop into oil passages.
9. Withdraw injection pump from crankcase. Detach coupling sleeve from injection pump driver or from drive shaft.
Note: If driver is to be exchanged, lock driver with serrated wrench and release hexagon nut. Then remove driver from injection pump shaft using puller. Clean axle stub and driver, making sure that both cones are absolutely clean and dry.
When fitting a new driver, note Woodruff key and marks (arrows).
Installation
Attention: Prior to installing a replacement injectian pump, remove screw plug (arrow) and fill with 0.4 l engine oil (first filling).
10. Check whether connecting rod (5) is correctly set, moving control lever (1) to full-load stop (2) for this purpose. Operating lever (8) must have approx. 0.5 mm clearance from full-load stop (6).
If necessary, adjust connecting rod (5) at adjustable knuckle (4).
11. Detach supporting holder (4) from removed injection pump and bolt to injection pump for installation. Do not tighten fastening bolt (3) because adjustment within oblong hole is still necessary.
12. Move crankshaft to start of delivery in compression stroke.
13. Fit new gasket.
14. Move injection pump to mark, turning injection pump camshaft until mark on camshaft agrees with line on flange (arrow).
Attention! On Bosch production code number "251" (November 1982) the mark for begin of delivery may be applied to the wrong spot on bearing cap.
Note: When installing an injection pump with wrong mark on bearing cap, the pinion should be positioned in such a manner that the recess is 3 teeth to the left on the mark of the bearing cap. In this position the injection pump is at begin of delivery (basic position). The engine should be at 240 before TDC, as usual.
15. Slip coupling sleeve onto driver and insert injection pump. Fit washers and slightly tighten fastening nuts of injection pump.
16. Check and adjust start of delivery. Testing and Inspection
17. Tighten injection pump fastening nuts and attach supporting holder (4) to crankcase. Now tighten fastening bolt (3) in oblong hole of supporting holder. Supporting holder is to be fastened with shims as per part No.116 990 14 40 and hex-head bolts M 8 x 16.
18. Reconnect lubricating oil line to injection pump.
19. Fit oil filter and oil filter cover with new seal.
20. Connect all oil lines to oil filter.
21. Attach temperature sensor cable, connect charge air line and vacuum lines to injection pump, and fit all fuel lines.
22. Vent injection system with hand delivery pump. Service and Repair
23. Check throttle linkage and adjust, if required.
24. Run engine to operating temperature and check all connections for leaks.
25. Check idle speed and adjust, if required. Adjustments
26. Adjust damper for regulator. If a damper (6) is installed on regulator of injection pump, adjust at idle against transverse vibrations of engine.
For this purpose, loosen counter nut (7).
Adjust damper (6) at idle speed, screwing damper in until transverse engine vibrations have been remedied. Then tighten counter nut (7) to 20-25 Nm.
Fuel Filter:
Mixture Control:
