Removal and installation of the injection timer - ra07016028014x(8014)

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

Preceding work:

Vacuum pump removed (43-0618).

Operation no. of operation texts and work units or standard texts and flat rates: 07-8014

Fig 1: Identifying Injection Timer Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Cylinder head cover	detach, attach.
Engine or crankshaft	position on 15° ATDC.
Camshaft gear (154) and timing device (18)	fix in position to timing chain with hose strap.
Chain tensioner (156)	remove, install (05-310). Tightening torque 80 Nm.
Screw (153) for camshaft gear	unscrew, screw in. Tightening torque 45 Nm. Note washer (152).
Camshaft gear (154)	remove, install.
Central fastening bolt (19)	unscrew, screw on, tightening torque 40-50 Nm.
	Left-hand thread
	Check washer (20), renew if necessary.
Locking pin (151)	withdraw with threaded pin (116 589 01 34 00) and impact puller (116 589 20 33 00).
Mounting basket (18a)	remove, install.
Timing chain (155)	press to the outside with metal strips (approx. 0.5 X 70 X 120) and withdraw timing device (18) with universal pliers.
Timing device (18)	remove, install.
	NOTE: If the roller or bearings of the piston vacuum pump are damaged, check whether the drive flange with cam at the injection timing device (18) is damaged. Replace part, if necessary.
Screw plug with seal (11)	unscrew from injection pump (1).
Injection pump	turn with serrated wrench (027) and lock in position with locking bolt (023).
	Remove locking bolt.
Engine or crankshaft	crank 1 revolution by hand and check TDC setting on crankshaft and camshaft.
Start of delivery	check (07.1-112), set if necessary (07.1-117).

Special tools 

Fig 2: Identifying Special Tools 03 07 32 (001 589 65 09 00)

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Fig 3: Identifying Special Tools 00 (001 589 66 21 00)

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Fig 4: Identifying Special Tools 05 (116 589 20 33 00)

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Fig 5: Identifying Special Tools 05 (116 589 01 34 00)

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

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Fig 7: Identifying Special Tools 07 (601 589 05 21 00)

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Segment flange of injection timing device modified from forging to sintered part.

Removal and Installation 

1. Remove cylinder head cover.
2. Turn engine to 15° ATDC of no. 1 cylinder.
   Fig 8: Identifying 15° ATDC Of No. 1 Cylinder

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3. Fix camshaft gear and injection timer in place with cable strap.
   Fig 9: Fixing Camshaft Gear And Injection Timer

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4. Remove chain tensioner (156) for relieving the load on the timing chain (05-310).
   Fig 10: Identifying Chain Tensioner

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5. Unscrew bolt for camshaft gear on camshaft; hold crankshaft in place when performing this step.

   Tightening torque 45 Nm.

   Remove camshaft timing gear.

   Fig 11: Removing Camshaft Timing Gear

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6. Unscrew central fastening bolt (19); hold crankshaft in place when performing this step.

   Left-hand thread

7. Withdraw locking pin (arrow) and remove mounting basket.
   Fig 12: Identifying Central Fastening Bolt And Locking Pin

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Press timing chain out of the way with metal strips and use universal pliers to withdraw ignition timer.

   Shop-made metal strips

   Thickness approx. 0.5 mm

   Length approx. 140 mm

   Width approx. 070 mm

   NOTE: If the roller or bearings of the piston vacuum pump are damaged, check whether the drive flange with cam at the injection timing device (18) is damaged. Replace part, if necessary.
   Fig 13: Identifying Shop-Made Metal Strips

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9. Unscrew plug (11).
   Fig 14: Identifying Plug

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10. Use serrated wrench (027) to turn injection pump on injection pump camshaft until the lug of the governor is visible in the hole. In this position, push in locking bolt (023) until it is felt to engage and tighten union nut by hand.
    Fig 15: Identifying Serrated Wrench

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11. Install injection timer. Tighten central fastening bolt to 40-50 Nm.

    Left-hand thread

12. Remove locking bolt (023) otherwise the injection pump will be damaged when engine is first started.
13. Assemble engine.
14. Test start of delivery with digital tester (07.1-112), set if necessary (07.1-117).
    Fig 16: Identifying Locking Bolt

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