Injection Pump Disassemble Assemble
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ScribdTranslationsInjection Pump Disassemble Assemble
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ScribdTranslationsInjection pump – disassembly and assembly
J491700
Important: On Y 20 DTH engines from MY 2003, Y 22 DTR: In case of replacement or exchange of the
injection pump, before disassembling it, the security code must be reset with TECH 2 - see corresponding
verification instructions
Disassemble, uncouple
1. Remove the upper part of the intake manifold
• On X 20 DTL, Y 20 DTL, Y 20 DTH engines up to AM 2003 [*-
• On Y 20 DTH engines from AM 2003, Y 22 DTR
2. Remove the lower part of the intake manifold [*-
3. Remove the air filter housing with the hot-film air quantity meter and the air intake hose
• X 20 DTL and Y 20 DTL ►
• And 20 DTH until AM 2003 [*-
• And 20 DTH from AM 2003 and Y 22 DTR >-
4. Set the engine to TDC 1 L cylinder ignition-
5. Remove the fuel lines from the injection pump
Important: To prevent bending of the connection pins and consequently having to replace the injection pump,
the protective caps KM-6154 must be fitted to the injection pump immediately after disconnecting the cable
harness plug; the caps
must only be removed just
before reconnecting the
cable harness plug.
6. For Y 20 DTH engines
from MY 2003 and Y
22 DTR: disconnect
the cable harness plug
(2) and connect KM-
6154 (1) to the
injection pump
7. Remove the Simplex
chain tensioner (3).
• Take into account
the mounting
position.
Important: To avoid damage to the guide rail, use a suitable sheet metal or heat shield.
8. Heat the fixing screws (1) intensely with an industrial hairdryer and remove them.
9. Remove the guide rail for the single timing chain upwards
• Take into account the mounting position.
10. Clean the thread for the fixing screws (1)
on the cylinder head
11. Removing the double chain tensioner (2) •
Note the installation position.
F9834
12. Remove the KM-932 check gauge from the cylinder head and the KM-927 injection pump locking pin
from the counterbore.
13. Disengage the camshaft sprocket from the camshaft
Note: To facilitate assembly, hang or tie the Simplex timing chain in a suitable place.
• Hold with spanner wrench on the camshaft hexagon
14. Remove the fixing screws (1) and
remove the injection pump pinion
simple
Note: In Y 20 DTH from AM 2003
and Y 22 DTR: 5 fixing screws
15. Lift and remove the Simplex timing chain from the cylinder head
16. Disengage the fixing screws (1) with MKM-604-D from the injection pump
17. Remove the support (2) from the cylinder head and the injection pump. Remove the injection pump (by
pulling it back) from the cylinder head and (by pulling it up) from the engine compartment.
Mount, couple
Important: The spacer (1) of the injection pump flange (3) must not be removed, as this spacer balances the
manufacturing tolerance and gives an exact shaft dimension.
18. Renew the O-ring (2)
19. Place the injection pump on the engine block
Make sure that the double chain sprocket does not sit out of
position on the injection pump flange.
20. Injection pump to the engine block
• tightening torque 25 Nm
21. Injection pump support to pump
• Tightening torque 20 Nm
22. Injection pump support to engine block • Tightening torque 20 Nm
23. Guide the single timing chain through the timing case and insert the single sprocket of the injection pump
into the single timing chain.
•
The arrow (2) must align with the
recess of the injection pump flange and with the drill
injection pump insert (3)
24. Manually turn the new fixing screws (1) with a tightening force of 10.9 of the injection pump pinion
Note: On Y 20 DTH from AM 2003 and Y 22 DTR: 5 fixing screws
25. Insert the injection pump locking pin KM-
927 (4) into the injection pump mounting
hole.
26. Insert the camshaft sprocket into the single
timing chain and manually engage it with
the new fixing screw on the camshaft.
• Make sure that the camshaft sprocket
does not sit at an angle on the
camshaft.
• The camshaft sprocket should be flat
on the camshaft.
Important: A distinction must be made
between versions with release pin (1) and
without release pin. In the version with release
pin, after assembly, the chain tensioner must be
released using the release pin.
27. Place the double chain tensioner (4) on the
timing case
• The closed side of the chain tensioner
must point towards the tensioner rail. Install the double chain tensioner locking screw (2) with a new
sealing ring (3)
Tightening torque 60
Nm
28. Press the release pin with the handle of a hammer until a click is heard.
29. The release pin must be able to be pressed with the thumb up to the stop and return by itself to the initial
position.
• Once the oil pressure has built up, the
release pin can no longer be pushed
in.
G6754
30. Remove the lock pin from the KM-927 injection pump
31. Tighten the fixing screws (1) for the single injection pump pinion Note: On Y 20 DTH from AM 2003 and
Y 22 DTR: 5 fixing screws
• Tightening torque 28 Nm.
32. Place the locking pin in the
KM-927 injection pump back into the injection pump recess drill
33. Place the KM-932
check gauge (3) on the
cylinder head • The pin
(2) must fit into the hole
(1) in the camshaft
34. Single timing chain guide rail (1) – position and fit
Note: Please note the mounting position.
• Use new fixing screws (2)
• Tightening torque 8 Nm
35. Place the driver (1) of the KM-933 adjustment tool (4) in a vertical position on the camshaft sprocket.
Mount the KM-933 adjustment tool on the cylinder head
36. Using a handle (2), press the driver lightly in the direction of the arrow (counter-clockwise to the motor
rotation) and secure it with an adjusting screw (3).
The locking pin of the KM-927 injection pump shall be able to be disassembled and assembled by suction.
If this is not possible, it is necessary
37.
slightly decrease the pressure on the drag disc on the adjustment disc
38. Fix the camshaft sprocket to the
camshaft
• Tightening torque 90 Nm + 60° + 30°
.
Important: A distinction must be made between versions with release pin (1) and without release pin. In the
version with release pin, after assembly, the chain tensioner must be released using the release pin.
39. Place the single chain tensioner (4) on the cylinder head
• The closed side of the chain tensioner must point towards the tensioner rail. Install the single chain
tensioner locking screw (2) with a new sealing ring (3)
Tightening torque 60
Nm
40. Press the release pin with the handle of a hammer until a click is heard.
41. The release pin must be able to be pressed with the thumb up to the stop and return by itself to the
initial position.
• Once the oil pressure has built up, the
release pin can no longer be pushed in.
42. Remove all fixing or adjustment tools
43. Position the crankshaft next to the vibration
damper fixing screw, two turns
(approximately 720°) in the direction of
engine rotation until just before "Cylinder 1
G0031
at TDC" "ignition"
• The mark (3) on the vibration damper is located just before the cast projection (2) on the distribution
box
44. In this position are the cams (1) shortly before cylinder 1 of the ignition TDC (both cams face up)
45. Insert the KM-929 locking pin (1) into the opening for the crankshaft pulse transmitter and at the same
time turn the crankshaft on the vibration damper fixing screw slowly in the direction of engine rotation
until the crankshaft locking pin abuts the cylinder block or engages the crankshaft guard.
46. Place the injection pump locking pin KM-927 (2) into the injection pump mounting hole and the
verification gauge KM-932 (3) into the cylinder head.
Note: If it is not possible to use
a tool, the entire adjustment procedure will have to be repeated.
47. Remove all locking tools
48. Clean the sealing surfaces of the timing case cover and timing case • Cover the timing case opening
with a lint-free rag
49. Apply to the lid of the box.
spread a bead of approximately 2 mm (measurement I) thick silicone-based sealing putty.
Note: The application of the putty
silicone sealant and assembly of the timing case cover, including checking the torque, must be carried
out within 10 minutes!
50. Attach the timing case cover with new fixing screws to the timing case • Use 2 threaded bolts (M6) to
secure
• tightening torque 6 Nm
51. Attach the fuel lines with new sealing rings to the injection pump
• tightening torque 25 Nm
52. Attach the crankshaft pulse transmitter to the engine block with a new O-ring.
• Tightening torque 8 Nm
53. Mounting the L-belt tensioning device
54. Mount the vacuum pump. L-
55. Install the cylinder head cover L-
56. Assemble the air filter housing with the hot layer air quantity meter and the air intake hose
• X 20 DTL and Y 20 DTL i*-
• And 20 DTH until AM 2003 [*-
• And 20 DTH from AM 2003 and Y 22 DTR
57. For Y 20 DTH engines from MY 2003, Y 22 DTR: disconnect KM-6154 from the injection pump and
connect the cable branch plugs • 2 pcs.
58. Mount the lower part of the intake manifold [*-
59. Mount the upper part of the intake manifold
• On X 20 DTL, Y 20 DTL, Y 20 DTH engines up to AM 2003
• On Y 20 DTH engines from MY 2003, Y 22 DTR L--
60. Bleed the fuel system Las-
