Fuel Injection Pump, Remove and Install
Important: For Y
20 DTH as of MY 2003, Y 22 DTR: Security code must be reset using
TECH2 before removal when replacing or swapping injection pump -
see relevant test instruction
Remove
1. |
Remove inlet manifold upper section
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For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
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For Y 20 DTH as of MY 2003, Y 22 DTR
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2. |
Remove intake manifold lower part
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3. |
Remove air cleaner housing with hot film mass air flow meter
and air intake hose
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Y 20 DTH as of MY 2003 and Y 22 DTR
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4. |
Lock engine on no. 1 cylinder "Ignition TDC"
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5. |
Detach fuel lines from fuel injection pump
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Important: To avoid bending the
pins and thus replacing the injection pump, protective caps KM-6154 must be fitted on the injection pump
immediately after removing the wiring harness plug and removed
again just before attaching the wiring harness plugs
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6. |
For Y 20 DTH from MY 2003, Y 22 DTR engine: Detach wiring
harness plugs (2) and attach KM-6154 (1)
to injection pump
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7. |
Remove Simplex chain tensioner (3)
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Note installation position.
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Important: Use sheet metal plate
or suitable heat shielding to avoid damaging the guide rails
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8. |
Heat fastening bolts (1) intensively with hot air blower and
remove
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9. |
Remove guide rail for simplex timing chain upwards
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Note installation position.
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10. |
Clean thread for the fastening bolts (1) in cylinder head
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11. |
Remove duplex chain tensioner (2)
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Note installation position.
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12. |
Remove test gauge KM-932 from
cylinder head and injection pump locking pin KM-927 from retaining bore
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13. |
Remove camshaft sprocket from camshaft
Note: To simplify
installation, suspend simplex timing chain at suitable point
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Counterhold with open-ended wrench on the hex nut of the
camshaft
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14. |
Remove fastening bolts (1) and simplex injection pump gear
Note: For Y 20 DTH from
MY 2003 and Y 22 DTR: 5 fastening bolts
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15. |
Remove simplex timing chain upwards from cylinder head
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16. |
Remove fastening bolts (1) from injection pump with MKM-604-D
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17. |
Detach fuel injection pump bracket (2) from cylinder block and
fuel injection pump. Remove fuel injection pump towards rear out of
cylinder block and remove upwards out of engine compartment
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Install
Important: The spacer disc (1) on
the fuel injection pump flange (3) must not be removed, as this
disc compensates for manufacturing tolerances and therefore
corresponds to a precisely defined axial dimension
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18. |
Replace gasket (2)
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19. |
Insert injection pump in cylinder block
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Ensure that the duplex sprocket sits straight on the injection
pump flange without tilting
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20. |
Injection pump to cylinder block
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Tightening torque 25 Nm / 18.5 lbf.
ft.
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21. |
Injection pump bracket to injection pump
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Tightening torque 20 Nm / 15 lbf.
ft.
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22. |
Fuel injection pump bracket to cylinder block
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Tightening torque 20 Nm / 15 lbf.
ft.
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23. |
Guide simplex timing chain through timing case, and insert
simplex injection pump gear in simplex timing chain
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Arrow (2) must align with recess in injection pump flange and
retaining bore (3) in injection pump
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24. |
Loosely hand-tighten new fastening bolts (1) with bolt strength
10.9 of the simplex injection pump gear
Note: For Y 20 DTH from
MY 2003 and Y 22 DTR: 5 fastening bolts
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25. |
Insert injection pump locking pin KM-927 (4) in retaining bore of fuel injection
pump
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26. |
Insert camshaft sprocket in simplex timing chain and fasten
hand-tightened to camshaft with new fastening bolt
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Ensure that the camshaft sprocket is not askew on the
camshaft
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Camshaft sprocket must lie flat on the camshaft
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Important: A distinction must be
made between versions with and without release bolts (1). In
versions with release bolts, the chain tensioner must be
untightened using the release bolt after installation
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27. |
Insert duplex chain tensioner (4) in timing case
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The closed side of chain tensioner must point to tension rail.
Install duplex chain tensioner closure bolt (2) with new seal ring
(3)
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Tightening torque 60 Nm / 44 lbf.
ft.
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28. |
Press in the release pin with a hammer shaft until a click is
heard
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29. |
It must be possible to push in release bolt up to stop with
thumb and for it to slide back to its original position
automatically
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The release bolt can no longer be pushed in once the oil
pressure has built up
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30. |
Remove injection pump locking pin KM-927
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31. |
Tighten fastening bolts (1) for simplex injection pump gear
Note: For Y 20 DTH from
MY 2003 and Y 22 DTR: 5 fastening bolts
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Tightening torque 28 Nm / 20.6 lbf.
ft.
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32. |
Re-insert injection pump locking pin KM-927 into injection pump retaining bore
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33. |
Position test gauge KM-932 (3) on
cylinder head
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Pin (2) must engage in hole (1) of camshaft
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34. |
Insert and install simplex timing chain guide rail (1)
Note: Check
installation position
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Use new fastening bolts (2)
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Tightening torque 8 Nm / 6 lbf.
ft.
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35. |
Insert carrier (1) of adjuster KM-933
(4) vertically into camshaft sprocket. Mount adjuster KM-933 on cylinder head
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36. |
Use toggle (2) to exert slight pressure on the carrier in the
direction of arrow (counter to direction of engine rotation) and
fix in place with locking bolt (3)
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37. |
Injection pump locking pin KM-927
must be able to be installed and removed under suction. If this is
not possible, decrease the pressure on the carrier disc slightly
using the locking screw.
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38. |
Fasten camshaft sprocket to camshaft
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Tightening torque 90 Nm / 66 lbf. ft. +
60° + 30°
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Important: A distinction must be
made between versions with and without release bolts (1). In
versions with release bolts, the chain tensioner must be
untightened using the release bolt after installation
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39. |
Insert simplex chain tensioner (4) in cylinder head
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The closed side of the chain tensioner must point to tension
rail. Install simplex chain tensioner closure bolt (2) with new
seal ring (3)
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Tightening torque 60 Nm / 44 lbf.
ft.
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40. |
Press in the release pin with a hammer shaft until a click is
heard
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41. |
It must be possible to push in release bolt up to stop with
thumb and for it to slide back to its original position
automatically
• |
The release bolt can no longer be pushed in once the oil
pressure has built up
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42. |
Remove all locking and adjusting tools
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43. |
At fastening bolt of torsional vibration damper, turn
crankshaft two turns (approx. 720°) in direction of engine
rotation to just before "1st cylinder TDC"
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The mark (3) on the torsional vibration damper is located just
before the lug (2) on the timing case
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44. |
In this position, the cams (1) of the 1st cylinder are just
before TDC (both cams point upwards)
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45. |
Insert crankshaft locking pin KM-929
(1) in aperture for crankshaft pulse pick-up, and simultaneously
slowly turn crankshaft further in engine rotational direction at
fastening bolt of torsional vibration damper until crankshaft lock
pin engages to stop in cylinder block or crank web
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46. |
Insert fuel injection pump locking pin KM-927 (2) into injection pump retaining bore and
test gauge KM-932 (3) into cylinder
head
Note: If a tool cannot
be inserted, then the adjustment procedure must be completely
repeated
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47. |
Remove all locking tools
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48. |
Clean sealing surfaces on timing case cover and timing case
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Cover aperture in timing case with lint-free cloth
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49. |
Apply an approx. 2 mm (Dimension I) thick bead of silicone
sealing compound to timing case cover.
Note: The silicone
sealing compound must be applied and the timing case must be
installed (including torque checking) within 10 minutes
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50. |
Attach timing case cover to timing case with new fastening
bolts
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Use 2 threaded pins (M6) to fasten
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Tightening torque 6 Nm / 4.5 lbf.
ft.
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51. |
Fit fuel lines on injection pump with new seal rings
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Tightening torque 25 Nm / 18.5 lbf.
ft.
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52. |
Attach crankshaft pulse pick-up to cylinder block with new
O-ring
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Tightening torque 8 Nm / 6 lbf.
ft.
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53. |
Install ribbed V-belt tensioner
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55. |
Install cylinder head cover
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56. |
Install air cleaner housing with hot film mass air flow meter
and air intake hose
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Y 20 DTH as of MY 2003 and Y 22 DTR
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57. |
For Y 20 DTH as of MY 2003, Y 22 DTR: Detach KM-6154 from injection pump and attach wiring harness
plug
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58. |
Install intake manifold lower part
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59. |
Install inlet manifold upper section
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For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
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• |
For Y 20 DTH as of MY 2003, Y 22 DTR
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