Removal and installation of injection pump

07.1—200 Removal and installation of injection pump

Job no. of flat rates or standard texts and flat rates data 8410 or 8411, 8430, 8431.

Model          Engine

123.193 617.952

PES 5 MW 55/320 RS 16

RW 375/2200 MW 28-1

FP/K 22 MW 22

3.0 g

5th edition

123.193 617.952

PES 5 MW 55/320 RS 16

RW 375/2200 MW 28-3³)

FP/K 22MW8

3.0 g

1st edition

(usa) 1978/1979         Identification: Green type rating plate

116.120 617.950

PES 5 MW 55/320 RS 16

RW 375/2200 MW 22

FP/K 22MW8

3.0 g

4th edition

RW 375/2200 MW 22

116.120 617.950

PES 5 MW 55/320 RS 16

RW 375/2200 MW 28²

FP/K 22 MW 22

3.0 g

4th edition

123.193 617.952

PES 5 MW 55/320 RS 16

RW 375/2200 MW 28-1

FP/K 22MW22

3.0 g

5th edition

126.120 617.951

<@) starting model year 1982

123.133

123.153 617.952

123.193

PES 5 MW 55/320 RS 16

FP/K 22MW22

3.0 m

1st edition

126.120 617.951

07.1.8-200/1 F3

123.133

123.153 617.952

123.193

PES 5 MW 55/320 RS 16-1

RW 375/2200 MW28-3³)

FP/K 22 MW 22

3.0 m

1st edition

126.120 617.951

‘    Accurate checkup and adjustment of injection pump is possible on an injection pump test bench only. For workshops, where

.   such a test bench is installed, test sheets for the different pumps are available.

‘    Entering production starting February 1980.

‘    Reference impulse verification (RIV), dynamic injection timing (begin of delivery) test possible.

Socket 13 mm, 3/8″ drive

Box wrench socket open, 17 mm, 1/2″ drive for injection lines

Overflow pipe

Torque wrench 1/2″ drive, 15-65 Nm

000 589 21 07 22 000 589 68 03 00

636 589 02 23 00

07.1.8-200/2 F3

1        Detach vacuum line 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.

07.1.8-200/3 F2

6 Unscrew hex-head bolts at supporting holder (4) as well as 3 nuts holding injection pump. Release feastening 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 (18-110).

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).

Prior to installing a replacement injection pump, remove screw plug (arrow) and fill with 0.4 I engine oil (first filling).

07.1.8-200/4 F2

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).

1    Control lever

2    Full-load stop

3    Idle speed stop

4   Adjustable knuckle

5   Connecting rod

6   Full-load stop at vacuum control valve

7   Vacuum control valve

8   Operating lever for vacuum control valve

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.

07.1.8-200/5 F2

13      Fit new gasket.

14      Move injection pump to mark, turning injection pump camshaft until mark on camshaft agrees with line on flange (arrow).

On Bosch production code number “251” (November 1982) the mark for begin of delivery may be applied to the wrong spot on bearing cap.

(approx. center of bearing cap screw)

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 24° before TDC, as usual.

(approx. lefthand edge recess of oil overflow)

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 (07.1-110 and 115).

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 8x 16.

18      Reconnect lubricating oil line to injection pump.

07.1.8-200/6 F3

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 (07.1-140).

23  Check throttle linkage and adjust, if required {30-300).

24   Run engine to operating temperature and check all connections for leaks.

25  Check idle speed and adjust, if required (07.1- 100).

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.

6    Damper

7    Counter nut

07.1.8-200/7 F3

1

2 3 4 5 6

Leak-off hose from injection nozzle

Union screw

Sealing ring

Banjo connector

Union screw

Sealing ring

7    Union screw

8   Sealing ring

9   O-ring

10    Hose clamp

11    Expansion hose

12    Return line from bypass valve

13   Bypass valve

14    Fuel line

15    Fuel line

16    Upper part of fuel filter

17    Fuel filter

30    Injection pump

07.1.8-200/8 F3

Mixture Control

Socket

Segment for injection timing device

Centrifugal weight

Pin

Compression spring

Pin

Segmental flange

Waisted bolt

Washer

Nut

Gasket

Hand-operated fuel feed pump

Rubber sealing ring

Socket

Sealing ring

Fuel feed pump

Screwed union

Sealing ring

Compression spring

Delivery and suction valve

Aneroid compensator

Vacuum control valve

07.1.8-200/9 F3