Mercedes-Benz Cars 2000-05

Injection Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


NOTE
The central fastening bolt uses left-hand threads.

  1. Disconnect the negative battery cable. Remove the cover and loosen the central fastening bolt while holding the crankshaft with a socket wrench. Position the crankshaft pulley at 15 degrees After Top Dead Center (ATDC). Fix the camshaft gear and injection pump in place with a cable strap.
  2.  
  3. Remove or disconnect the following:

    Timing chain tensioner
     
    Fuel lines
     
    Idle Speed Control (ISC) solenoid vacuum lines and electrical connector
     
    Control rod travel sensor and actuator electrical cables
     
    Pump control lever throttle linkage
     
    Vacuum control valve
     
    Injection pump sprocket bolt while holding the crankshaft in place. The bolt is a left-hand thread.
     
    Sprocket bolt
     
    Pump mounting bolts
     
    Injection pump while holding the timing device in place
     

  4.  

To install:

  1. Be sure the crankshaft is still at 15 degrees ATDC.
  2.  
  3. Remove the timing plug from the pump.
  4.  
  5. Using special tool 601 589 00 08 00 (serrated wrench) turn the pump until the lug of the governor is visible through the hole.
  6.  
  7. Install the special tool 601 589 05 21 00 (locking bolt) in the timing plug hole to prevent the pump from turning while it is being installed.
  8.  
  9. Install the pump on the engine. Torque the injection lines to 84 inch lbs.-15 ft. lbs. (10-20 Nm), mounting bolts to 15-18 ft. lbs. (20-25 Nm) and the central bolt to 30-36 ft. lbs. (40-50 Nm).
  10.  
  11. Remove the locking bolt from the side of the injection pump.
  12.  
  13. Install or connect the following:

    Vacuum control valve
     
    Pump control lever throttle linkage
     
    Control rod travel sensor and actuator electrical cables
     
    ISC solenoid vacuum lines and electrical connector
     
    Timing chain tensioner
     

  14.  
  15. Crank the engine 1 revolution and recheck the Top Dead Center (TDC) mark of the crankshaft and camshaft. Check the start of injector (injector pump timing) delivery with a digital tester.
  16.  


    Click image to see an enlarged view

    Fig. Install the locking bolt tool (023) to prevent the pump from turning during installation-Diesel engines


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    The central fastening bolt uses left-hand threads.

  2.  
  3. Disconnect the negative battery cable. Remove the cover and loosen the central fastening bolt while holding the crankshaft with a socket wrench. Position the crankshaft pulley at 15 degrees ATDC. Fix the camshaft gear and injection pump in place with a cable strap.
  4.  
  5. Remove or disconnect the following:

    Timing chain tensioner
     
    Fuel lines
     
    Idle Speed Control (ISC) solenoid vacuum lines and electrical connector
     
    Control rod travel sensor and actuator electrical cables
     
    Pump control lever throttle linkage
     
    Vacuum control valve
     

  6.  
  7. Remove the injection pump sprocket bolt while holding the crankshaft in place. The bolt is a left-hand thread.
  8.  
  9. Remove or disconnect the following:

    Sprocket bolt
     
    Pump mounting bolts
     
    Injection pump while holding the timing device in place
     

  10.  

To install:

  1. Be sure the crankshaft is still at 15 degrees ATDC.
  2.  
  3. Remove the timing plug from the pump.
  4.  
  5. Using special tool 601 589 00 08 00 (serrated wrench) turn the pump until the lug of the governor is visible through the hole.
  6.  
  7. Install the special tool 601 589 05 21 00 (locking bolt) in the timing plug hole to prevent the pump from turning while it is being installed.
  8.  
  9. Install the pump on the engine. Torque the injection lines to 84 inch lbs.-15 ft. lbs. (10-20 Nm), mounting bolts to 15-18 ft. lbs. (20-25 Nm) and the central bolt to 30-36 ft. lbs. (40-50 Nm).
  10.  
  11. Remove the locking bolt from the side of the injection pump.
  12.  
  13. Install or connect the following:

    Vacuum control valve
     
    Pump control lever throttle linkage
     
    Control rod travel sensor and actuator electrical cables
     
    ISC solenoid vacuum lines and electrical connector
     
    Timing chain tensioner
     

  14.  
  15. Crank the engine 1 revolution and recheck the TDC mark of the crankshaft and camshaft. Check the start of injector (injector pump timing) delivery with a digital tester.

    Click image to see an enlarged view

    Fig. Install the locking bolt tool (023) to prevent the pump from turning during installation-Diesel engines

  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The central fastening bolt uses left-hand threads.

  2.  
  3. Disconnect the negative battery cable. Remove the cover and loosen the central fastening bolt while holding the crankshaft with a socket wrench. Position the crankshaft pulley at 15 degrees ATDC. Fix the camshaft gear and injection pump in place with a cable strap.
  4.  
  5. Remove or disconnect the following:

    Timing chain tensioner
     
    Fuel lines
     
    Idle Speed Control (ISC) solenoid vacuum lines and electrical connector
     
    Control rod travel sensor and actuator electrical cables
     
    Pump control lever throttle linkage
     
    Vacuum control valve
     

  6.  
  7. Remove the injection pump sprocket bolt while holding the crankshaft in place. The bolt is a left-hand thread.
  8.  
  9. Remove or disconnect the following:

    Sprocket bolt
     
    Pump mounting bolts
     
    Injection pump while holding the timing device in place
     

  10.  

To install:

  1. Be sure the crankshaft is still at 15 degrees ATDC.
  2.  
  3. Remove the timing plug from the pump.
  4.  
  5. Using special tool 601 589 00 08 00 (serrated wrench) turn the pump until the lug of the governor is visible through the hole.
  6.  
  7. Install the special tool 601 589 05 21 00 (locking bolt) in the timing plug hole to prevent the pump from turning while it is being installed.
  8.  
  9. Install the pump on the engine. Torque the injection lines to 84 inch lbs.-15 ft. lbs. (10-20 Nm), mounting bolts to 15-18 ft. lbs. (20-25 Nm) and the central bolt to 30-36 ft. lbs. (40-50 Nm).
  10.  
  11. Remove the locking bolt from the side of the injection pump.
  12.  
  13. Install or connect the following:

    Vacuum control valve
     
    Pump control lever throttle linkage
     
    Control rod travel sensor and actuator electrical cables
     
    ISC solenoid vacuum lines and electrical connector
     
    Timing chain tensioner
     

  14.  
  15. Crank the engine 1 revolution and recheck the TDC mark of the crankshaft and camshaft. Check the start of injector (injector pump timing) delivery with a digital tester.

    Click image to see an enlarged view

    Fig. Install the locking bolt tool (023) to prevent the pump from turning during installation-Diesel engines

  16.  

 
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