07.1 - 8410 Removing and installing injection pump -...

07.1 - 8410 Removing and installing injection pump

Preceding work:Removing cylinder head cover (01-5014).

1 Injection pump pour in engine oil.

2 Coolant line

3 Coolant line

4 Heater (fuel preheater)

5 Hexagon bolt

6 Bracket

7 Fuel line and leak oil line

8 Bracket with fuel prefilter and priming pump

(as of engine end no. 010 284)

9 Seals replace.

10 Banjo bolt 35 Nm, secure with Loctite 221.

11 Bracket with solenoid valve (flame starting system)

12 Fuel lines

13 Electrical connection

14 Fuel filter

15 Hexagon bolt

16 Fuel return line 35 Nm.

/20© Daimler AG, 11/14/09, G/10/09 / ra0703d841000x / 8410 - Removal and installation of injection pump Engines 364, 364 A/LA - T2

17 Banjo bolts 35 Nm.

18 Seals replace.

19 Overflow valve 35 Nm.


20 Engine stop cylinder grease ball socket with longlife grease.

21 Vacuum line or pressure line

22 Securing clip

23 Banjo bolt

24 Seals replace.

25 Manifold pressure compensator line

26 Injector line 25 Nm; screw union M22; M16: 10 Nm; secure with

Omnifit Forte 150 M.

27 Seal replace, install slot facing up.

28 Clip

29 Woodruff key

30 Seal replace.

31 Hexagon bolt 20 to 40 Nm, seal with Hylomar SQ 32 M.

32 Carrier

33 Gasket (OM 364 up to engine end no. 013 163) replace.

34 Seals replace.

35 Drive gear backlash 0.07 to 0.18 mm.

36 Spring lock washer


80 Nm.37 Hexagon nut M14 15105 Nm.M18 15

38 Stud bolt secure in carrier (32) with Loctite 221.

39 Washer

40 Hexagon nut 40 Nm.

41 Seals replace.

42 Oil pressure line

43 Banjo bolt 15 Nm.

OM 364 A, LA


41 Seals replace.

42 Oil pressure line

43 Banjo bolts 15 Nm.

44 Oil filter with oil cooler

up to engine end no. 118 047

45 Oil filter with oil cooler

as of engine end no. 118 048

46 Hexagon bolt 55 Nm.

47 Gasket replace.


48 Coolant hose

up to engine end no. 118 047

49 Coolant lineas of engine end no. 118 048

50 Coolant line

as of engine end no. 118 048

51 Electrical connection (oil pressure sensor)

Special tools

Removal

-------------------------------

1 Unscrew banjo bolt (43), detach oil pressure line (42) at the injection pump.

2 OM 364 A, LA: oil filter with attached oil cooler.

2.1 Drain coolant (radiator, oil cooler) and collect.

2.2 Up to engine end no. 118 047 detach coolant hoses at oil cooler.


2.3 As of engine end no. 118 048 unscrew coolant lines (49, 50) at the bracket and oil cooler.

2.4 Detach electrical connection (51) at the oil pressure sensor.

2.5 Unscrew hexagon bolts (46), take off oil filter (44, 45) together with oil cooler and gasket.

3 If fuel preheating system fitted.

3.1 Unscrew both coolant lines (2, 3) at the heater.

3.2 Unscrew coolant line (3) at the crankcase.

3.3 Detach coolant line (2) at coolant thermostat housing and mounting.

3.4 Detach fuel line depending on installation position.

3.5 Remove heater (4).


4 Detach leak oil line (7) at connection of cylinder 4.

5 Unscrew banjo bolt (10) and take off fuel line together with leak oil line (7) at the fuel priming pump.

Note

Up to engine end no. 010 283

Fuel priming pump attached to injection pump.

As of engine end no. 010 284

Fuel priming pump attached to main fuel filter.

6 Unscrew fuel return line (16) at the fuel filter.

7 Unscrew banjo bolt (17) and pressure relief valve (19), take off fuel lines.


8 Take off fuel filter (14).

9 Take off fuel pre-filter together with priming pump and bracket (8) (as of engine end no.

010 284).

10 If flame starting system fitted.

10.1 Separate electrical connection at solenoid valve and temperature switch.

10.2 Unscrew fuel lines (12) at solenoid valve.

10.3 Take off solenoid valve together with bracket (11).

11 Take off injection lines (26) at injection pump.

000 589 07 03 00


12 Remove clips (28) at the injection lines.

13 Unscrew injection lines at injector holders of cylinders 3 and 4.

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14 Slacken screw unions at the through-holes of cylinders 3 and 4 and turn injection lines away from injection pump.

Note

Do not bend injection lines.


15 Remove securing clip (22) at ball socket.

16 Pull off vacuum line (21) at engine stop cylinder (20), or unscrew pressure line, respectively.

17 Press off engine stop cylinder (20) at throttle control lever and injection pump lever.

18 Unscrew bush pressure indicator line (25) at the injection pump.

19 If vacuum system fitted:

- Unscrew vacuum line at air compressor.


19.1 If compressed air system fitted:

- Unscrew suction line at air compressor.

20 Remove oil dipstick guide tube.

21 Unscrew hexagon bolts (31). Take injection pump (1) together with carrier off the timing case, remove injection pump (1) upward over air compressor.


22 Take gasket or seal (33, 34) off the carrier.

23 Unscrew hexagon nut (37) for drive gear.

24 Pull drive gear off the injection pump.

25 Pull Woodruff key off the injection pump camshaft.

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26 Unscrew hexagon nuts (40) and washers (39) and take carrier (32) off injection pump. Remove seal (30).

Note

OM 364 flange with 4-hole attachment.

OM 364 A, LA flange with 3-hole attachment.


Installation

-------------------------------

1 Insert new seal (30) into injection pump flange.

2 Attach injection pump to carrier (32).

3 Tighten hexagon nuts (40) and washers (39) only loosely.

4 Insert Woodruff key into injection pump camshaft.

5 Fit drive gear onto the injection pump.

6 Tighten hexagon nut (37),

M14 1.5; 80 Nm,

M18 1.5; 105 Nm.

7 Insert new gasket or seal (33, 34) into carrier.

8 Replace seal on connection fitting of dipstick guide tube.


9 Rotate engine at front of crankshaft.

001 589 43 09 00

10 Turn crankshaft in direction of rotation to FB marking.


11 Remove plug on timing case.

12 Insert injection pump with carrier into timing case so that the FB marking on the injection pump gear is aligned with the point in the timing case (kidney-shaped cover).

Note

Injection timer must be in 0 position.

13 Seal hexagon bolts (31) with Hylomar SQ

32 M and screw tight, 20 to 40 Nm.

14 Fill up engine oil at governor of injection pump (1). Wait for transfer time of 10 minutes.

15 Test start of delivery (07.1-8234).

Note

The start of delivery of a newly attached injection pump should be tested with the pressure limiting valves fitted.

442 589 00 91 00


16 Adjust start of delivery (07.1-8300).

17 Tighten hexagon nuts at the injection pump, 40 Nm.

Note

OM 364 injection pump with 4-hole flange.

OM 364 A, LA injection pump with 3-hole flange.

18 Screw vacuum line, or if compressed air system suction line, to the air compressor.

19 Screw manifold pressure compensator line (25) with new seals to the injection pump.

20 Install dipstick guide tube.


21 Press engine stop cylinder (20) onto injection pump lever and throttle control lever. Fit on vacuum line (21) or screw compressed air line tight, respectively.

Note

Grease ball sockets with longlife grease.

22 Install securing clip (22) at ball socket.

23 Install injection lines of cylinders 3 and 4.


24 Secure M22 1.5 screw unions (26a) with Omnifit Forte 150 M, screw tight, 10 Nm.

25 Install new seals (27) with slot facing up.

26 Screw washer (26c) with M16 1.5 unions (26b) tight, 10 Nm.

Note

Lay injection lines (26) free of stress.

27 Screw injection lines to injector holders of cylinders 3 and 4, 25 Nm.

000 589 68 03 00

28 Detach pressure limiting valves and screw injection lines (267) tight at the injection pump, 25 Nm.

000 589 68 03 00


29 Fit on clips (28) at the injection lines.

Note

Lay injection lines free of chafing and tension.

30 If flame starting system fitted:

30.1 Attach bracket with solenoid valve (11) together with fuel filter.

30.2 Screw fuel lines (12) tight at solenoid valve.

30.3 Attach electrical connection to solenoid valve and temperature switch.

31 Attach fuel prefilter with priming pump and bracket (8) together with fuel filter (14) to carrier (as of engine end no. 010 284).


32 Attach fuel lines with new seals, screw banjo bolts (17) and pressure relief valve (19) tight,

35 Nm.

33 OM 364 A, LA: oil filter with attached oil cooler.

33.1 Attach oil filter (44, 45) with new gasket.

33.2 Screw hexagon bolts (46) tight, 55 Nm.

33.3 Attach electrical connection (51) to oil pressure sensor.

33.4 Up to engine end no. 118 047 attach coolant hoses to oil cooler.

33.5 As of engine end no. 118 048 screw coolant lines (49, 50) tight to bracket and oil cooler.

34 Attach oil pressure line (42) with new seals, screw banjo bolt (43) tight, 15 Nm.


35 Attach leak oil line (7) to connection of cylinder 4.

36 If fuel priming pump attached to main fuel filter, attach fuel line (7) with new seals, secure banjo bolts (10) with Loctite 221 and screw tight,

35 Nm.

37 Screw fuel return line (16) tight to fuel filter, 35 Nm.

38 If fuel preheating system fitted:

38.1 Attach heater (4).

38.2 Screw fuel line tight to heater.

38.3 Screw coolant line (3) tight to crankcase.

38.4 Screw both coolant lines (2, 3) tight to heater.

38.5 Screw coolant line (2) tight to coolant thermostat housing and to mounting.

39 Pour in coolant, test cooling system for leaks with tester 001 589 83 21 00.

40 Adjust engine oil to correct level.

41 Bleed fuel system.

42 Start engine and run at idling speed. Keep a check on engine pressure gauge. Pressure must be indicated after about 10 seconds. Switch off engine and check for leaks.


07.1 - 8410 Removing and installing injection pump -...

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Transcript of 07.1 - 8410 Removing and installing injection pump -...