Removal and installation of the injection pump - ra07016028410x(8410)

Engines 602.96, 603.96/97 TURBO in Models 124, 126, 140, 201 

Operation no. of operation texts and work units or standard texts and flat rates: 07-8410 or 07-8411

Fig 1: Identifying Injection Pump Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Bottom section of noise encapsulation	remove, fit (94-0050).
Belt tensioning device	remove, install (13-340).
Fan cowl and fan	remove, install (20-335).
Vacuum pump (67)	remove, install (43-618). Renew gasket (67).
Assembly sleeve (067)	install, remove, so that engine can be turned over properly. Special tool 601 589 05 14 00 (engines effective 09/89).
Radiator	remove, install (20-470). Model 201.128 only.
Actuator of cruise control	remove, install (54-541), Engine 603 only.
Central fastening bolt (19) with washer (20)	unscrew, screw in, tightening torque 40-50 Nm. Left-hand thread
Crankshaft	in direction of rotation turn to 15° ATDC of no. 1 cylinder.
Chain tensioner (156)	remove, install (05-310). Special tool 001 589 65 09 00.
Injection lines (54-59) at injection pump	disconnect, connect. Tightening torque 10-20 Nm. Special tool 000 589 77 03 00.
Fuel lines (80, 82, 83)	disconnect, connect, renew seals. Do not mix up hollow screw (27) and overflow orifice (15).
Fuel thermostat (86) and fuel line (89)	disconnect, connect.
Pressure lines at ALDA unit (103) and vacuum lines	disconnect, connect.
Electric cables	disconnect, connect at control rod travel sensor (L7) and at actuator (Y22).
Accelerator control linkage	detach, attach. Check setting (30-1010).
Injection pump (1)	unscrew bolt (13 and 13a), tightening torque 20-25 Nm. Withdraw injection pump to the rear; hold injection timer tight  when performing this step.
O-ring (10)	renew.
Start of delivery adjusting device (8)	remove, install; unscrew bolt (8a) for this step.
Spring (25)	detach, attach.
Screw plug (11)	remove and turn removed injection pump with serrated wrench (027) until lug is visible in the governor housing hole. In this position, push in locking bolt (023) until it is felt to engage. Remove locking bolt (023) after installing injection pump and re-fit screw plug (11).
Start of delivery	check (07.1-8240 or 8244), set if necessary (07.1-8300).
Vacuum control valve (65)	remove, install, set (07.1-1826).

Special tools 

Fig 2: Identifying Special Tools (001 589 66 21 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tools (601 589 05 21 00 07)

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Fig 4: Identifying Special Tools (001 589 65 09 00 03 07 32)

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Fig 5: Identifying Special Tools (000 589 77 03 00 07)

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Fig 6: Identifying Special Tools (601 589 00 08 00 07)

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Fig 7: Identifying Special Tools (601 589 05 14 00 07)

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Removal and installation 

1. Slacken central fastening bolt (19), unscrew while holding crankshaft tight.

   Left-hand thread.

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

   Fig 8: Identifying Central Fastening Bolt

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Turn crankshaft in direction of rotation to 15° ATDC of no.1 cylinder.
   Fig 9: Identifying 15° ATDC Of No. 1 Cylinder

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove chain tensioner (05-310).
   Fig 10: Identifying Chain Tensioner

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   156 Wrench socket

   Special tool 001 589 65 09 00

4. Detach injection and fuel lines at the injection pump.
   Fig 11: Removing Injection And Fuel Lines

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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; unscrew fastening bolts (arrows) and bolt on mounting bracket for this step. Withdraw injection pump to the rear, holding timing device in place.
    Fig 12: Locating Injection Pump Fastening Bolts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Remove fuel thermostat (86) complete; unscrew bolts (arrows) for this step.
    Fig 13: Identifying Fuel Thermostat Bolts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12. Check whether the engine is positioned at 15° ATDC of no. 1 cylinder; adjust if necessary.

    Engine must only be cranked in direction of rotation!

    Fig 14: Identifying 15° ATDC Of No. 1 Cylinder

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13. Unscrew plug (11).
    Fig 15: Identifying Plug

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14. Use serrated wrench (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.
    Fig 16: Identifying Serrated Wrench

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    Remove locking bolt (023) after installing injection pump, otherwise the injection pump will be damaged when starting the engine.

    Fig 17: Identifying Locking Bolt

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15. Fit remaining parts to engine.
    NOTE: When starting engine, the injection system is automatically bled.
16. Check start of delivery (07.1-8240 or 8244); set start injection if necessary (07.1-8300).
17. Install vacuum control valve and set (07.1-1826).