Injection Pump Removal and Installation

PRELIMINARY PROCEDURES





Remove bottom section of noise encapsulation.

Remove belt tensioning device.

Remove fan cowl and fan.

Remove vacuum pump (67). Replace gasket (67).

Install Assembly sleeve (067) with special tool 601 589 OS 14 00 so that engine can be turned over easily.(engines effective 09/89). Remove before installing vaccum pump.

Remove Radiator (Model 201.128 only).

Remove Actuator of cruise control (Engine 603 only).

SPECIAL TOOLS









REMOVAL AND INSTALLATION





1 Loosen central fastening bolt (19), unbolt while holding crankshaft tight. Installation torque 40-50 Nm.

Caution! Left-hand thread

Mount assembly basket using bolts (67b), so that the engine can be cranked easily (on engines effective 09/89).





2 Turn crankshaft in direction of rotation to 15° ATDC of no.1 cylinder.





3 Remove chain tensioner using special tool 001 589 65 09 00.





4 Detach injection and fuel lines at the injection pump using special tool 000 589 77 03 00 with 1/4" ratchet (arrow). Replace seals (78). Installation torque 10-20 Nm.

5 Disconnect vacuum lines at vacuum unit for stop unit and vacuum control valve. Detach 2-pin connector at actuator (Y22) of electronic idle speed control.

6 Disconnect electric cables at control rod travel sensor (L7) and at actuator (Y22).

7 Disconnect pressure line at ALDA unit.

8 Detach accelerator control linkage at control lever and spring.

9 Remove vacuum control valve.





10 Remove injection pump; remove fastening bolts (arrows) and bolt on mounting bracket for this step. Withdraw injection pump to the rear, holding timing device in place. Installation torque 20-25 Nm.

Replace O-ring (10). Remove start of delivery adjusting device(8); remove bolt (8a) for this step. Detach spring (25).





11 Remove fuel thermostat (86) complete; remove bolts (arrows) for this step.





12 Check whether the engine is positioned at 15° ATDC of no.1 cylinder; adjust if necessary.

Caution! Engine must only be cranked in direction of rotation!





13 Unscrew plug (11).





14 Use serrated wrench, special tool 601 589 00 08 00 (027), to turn injection pump on the injection pump crankshaft until the lug of the governor is visible at the hole, i.e. push in locking bolt (023) in this position until it is felt to engage, and tighten by hand.





Caution! Remove locking bolt, special tool 601 589 OS 21 00 (023), after installing injection pump, otherwise the injection pump will be damaged when starting the engine.

15 Reverse procedure to install.

Note: When starting engine, the injection system is automatically bled.

16 Check start of delivery; set start injection if necessary.

17 Install vacuum control valve and set.