Diesel MFI Pump: Service and Repair
Removing and installing injection pumpPreceding work:
Removing and installing belt tensioning device. Refer to Engine, Cooling and Exhaust - Engine - Drive Belts, Mounts, Brackets and Accessories - Drive Belt Tensioner - Service and Repair - Procedures Service and Repair
Removing and installing vacuum pump.
Engine 605.911
Remove intake manifold, upon installation replace gasket. Refer to Engine, Cooling and Exhaust - Engine - Intake Manifold - Service and Repair - Procedures Service and Repair
Engine 606.910
Remove variable resonance intake manifold, upon installation, replace gasket. Refer to Engine, Cooling and Exhaust - Engine - Intake Manifold - Service and Repair - Procedures Service and Repair
All models
Disconnect ground cable at battery.
Unbolt bottom part of noise encapsulation.
Remove assembly cage (022). Use special tool 601 589 05 14 00.
Unscrew central securing bolt (40/3).
Attention! "Left-hand thread" Tightening torque 40-50 Nm.
Turn crankshaft in direction of rotation 14° ±0.5° after ignition TDC of cylinder 1.
To do this, open oil filler opening cap.
Rotate crankshaft until the marking (punch point) on the inlet camshaft sprocket is visible through oil filler opening.
Continue to turn crankshaft in direction of rotation to 14° ±0.5° after ignition TDC of cylinder 1.
Use special tool 001 589 65 09 00.
Attention! Crank engine only in direction of rotation.
Remove chain tensioner. Refer to Engine, Cooling and Exhaust - Engine - Timing Components - Timing Chain Tensioner - Service and Repair - Procedures [1][2]Procedures
Unbolt injection lines (55) at injection pump (10).
Seal all connections.
Use special tool 000 589 77 03 00.
Tightening torque 10-20 Nm as reference value.
Attention! To avoid line fractures, the retaining clips must be installed as shown in the illustration (see notes).
Note: When removing an injection pipe, it is necessary to replace the complete retaining clips of the relevant pipe.
Detach all vacuum lines at injection pump.
Note: Pay attention to connection of vacuum line Vacuum and Vapor Hose Diagrams
Unplug coupling (arrow) at microswitch (S27/6).
Vehicles with Tempomat cruise control
Remove cruise control actuator. Service and Repair
Vehicles with atmospheric pressure-dependent full load stop (ARA) unit
Unplug ARA actuator coupling.
Vehicles with electronic idle speed control (ELR)
Unplug ELR actuator coupling.
All models
Unscrew overflow restriction (15).
Detach fuel lines (90/7, 90/8, 90/9).
To do this, release quick-lock, secure.
Examine 0-rings, replace if necessary.
Upon installation ensure correctly seated.
Unscrew bolts (10/1).
Hold square nuts (10/2) tight.
Tightening torque 25 Nm as reference value.
Unscrew bolt (10/3)
Pull injection pump (10) out to the rear.
To do this, counter-hold injection timing device.
Installation note:
Slacken screw plug (10/5).
Turn injection pump with notched wrench (027) 601 589 00 08 00 and block with blocking bolt (023) 601 589 05 21 00, unscrew blocking bolt.
Check whether engine is positioned at 14° ±0.5° after ignition TDC, correct if necessary.
If the injection pump is replaced, adjust microswitch before installing Adjustments
Attention! Crank engine only in direction of rotation. Pay attention to notes (blocking bolt)!
Replace and oil 0-ring (10/4) before installing the in-line injection pump.
check and adjust start of delivery Adjustments
Check and adjust engine oil level
Check for Leaks at all connection points with engine running.
Note: The fuel system is bled automatically when the engine is started.
Special Tools
Notes: Remove blocking bolt (023) after installing the injection pump otherwise the injection pump will be damaged when engine is started.
023 blocking bolt
Special tool 601 569 0521 00
The retaining clips (56) must be installed in accordance with the illustration in order to avoid line fractures.
Shown on engine 605.911
10 In-line injection pump
50 Injection nozzle
55/1 Injection line, cylinder 1
55/2 Injection line, cylinder 2
55/3 Injection line, cylinder 3
5514 Injection line, cylinder 4
55/5 Injection line, cylinder 5
56 Retaining clips
Fuel low-pressure circuit
Shown on engine 606.910
10 Injection pump
13 Fuel pump
15 1.5 mm dia. overflow restriction with non-return valve
50 Nozzle holder combination
55/1 Injection line, cylinder 1
60 Fuel heat exchanger
70/1 Fuel prefilter
70/2 Fuel full-flow filter
70/5 Restriction drilling in top pan of fuel filter
74/1 Cut-off
80 Fuel tank
90/1 Fuel feed line
90/3 Leak oil hoses
90/11 Fuel return hose
Overflow valve modified. Overflow valve with 0-ring for increasing leak tightness.
Production break points: as of September 1993
Fuel hose from top part of oil filter to return flow pipe modified. Non-return valve in fuel return flow hose (immobilizer).
Production break points: as of March 1994
Production break points: as of April 1994
Fuel hose from top part of oil filter to return flow pipe modified to improve starting.
Production break points: as of January 1995
Production break points: as of February 1995
Segment flange of injection timing device modified from forging to sintered part. New injection timing device is installed with washer.
Production break points: as of June 1994
Fuel feed pipe from fuel filter to injection pump converted from plug connection to screw attachment.
Production break points: as of September 1995
Shut-off valve modified.
Production break points: as of November 1995
Bolt+washer for attaching injection pump modified for tolerance reasons.
Production break points: as of December 1995
