Group 22 Service procedures - fuel system
Service procedures
The engine must always be washed prior to starting repairs.
1
Injection pump, removal
1
Carefully clean the injection pump, pipes and the engine near the pump. Remove the protection plate for the pump coupling.
2
Undo the pressure pipe, fuel and lubrication pipes at the pump and the control connections. Fit protective caps.
Remove the plug in the flywheel cover (16 mm hex socket key) and fit rotating tool 999 3590. Remove the inspection cover on the flywheel cover. Remove the inspection cover on the camshaft at the cylinder block’s rear end.
2
Rotate the engine with a ratchet handle to the compression stroke for No. 1’s cylinder (0° marking on the flywheel). The camshaft’s marking hole should be pointing up.
3
3
Undo the clamping screws on the pump coupling. Remove the screws between the pump coupling and the carrier to the pump. Press the pump coupling forwards onto the drive axle.
4
Unscrew the pump’s securing screws and lift the pump out.
Ensure that the steel laminates do not get damaged.
Fitting and adjusting the injection pump
Special tools: 999 3590, 998 9876, 999 6648
Note: Check that there is about 0.2-0.3 liters (0.2-0.3 quarts) of engine oil in the pump and regulator before the injection pump is fitted. Refilling takes place in the regulator housing.
Turn back the flywheel in the opposite direction to the
engine’s direction of rotation about 90° from the starting point. Then turn it forward in the direction of rotation until the correct number of degrees for the pump setting is immediately behind the needle on the flywheel housing. See
”Workshop manual, Technical Data”.
Note: Set the degree marking within the upper half of the tolerance area which is stated in the specifications.
The setting must be accurately carried out, and do not crank the flywheel back against the direction of rotation to finely adjust the setting. If the flywheel has been cranked too far, the setting procedure must be carried out again.
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Service procedures - fuel system
4
Screw the injection pump securely to the engine.
5
Screw the carrier securely to the pump coupling (do not tighten the clamping screws).
6
Group 22
Remove the overflow valve and hex socket plug from the pump so that No. 1’s lifter is visible.
7
Rotate the pump coupling until the lifter is at the base position.
8
Fit tool 999 6848 and dial indicator 998 9876. Adjust the measurement tip so that it rests on the lifter.
9
Set the dial indicator to zero.
10
Rotate the pump coupling in the engine’s rotational di-
rection. Check that the dial test indicator is still at zero when rotation commences.
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Group 22 Service procedures - fuel system
14 11
Continue to rotate until the lifter has moved up until the value of the lift from basic circle is shown on the dial indicator.
See ”Workshop manual, Technical Data” for each engine type. Further rotate the pump coupling until the dial test indicator shows about 1-2 mm (0.04-0,08”) more than the figure specified. See ”Workshop manual, Technical Data”.
12
Tighten the clamping screw sufficiently tight so that the pump coupling can be turned with powerful resistance.
This must be done to eliminate gear-tooth flank play in the timing gears.
13
Torque the clamping screws to 85 Nm (62.7 ft-lb).
15
Check that the correct adjustment has been maintained by again rotate the engine backwards 90°, and forwards to
correct setting angle. The dial test indicator should show the correct value for lift from basic circle. See ”Workshop manual, Technical Data”.
16
Remove the dial indicator and fixture.
17
Fit the hex socket plug and a new copper washer.
18
Screw in the overflow valve securely.
19
Screw in the fuel and lubricating oil pipes together with new washers. Connect the controls.
20
Remove the rotating tool. Fit the plug and inspection covers.
Rotate the pump coupling back against the engine’s ro-
tational direction until the test indicator shows the value for the lift from basic circle. See ”Workshop manual, Technical Data”.
Note: If the pump coupling is turned too far, it is necessary to start over from item 10.
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