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TABLE OF CONTENTS
Specifications. . . . . . . . . . . . . . . . . . . . . . . 1F3-1
Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
N m
28 - 47
13
35 - 40
18
80
30
46
1F3-16
1F3-18
1F3-21
1F3-22
1F3-25
1F3-27
1F3-30
1F3-35
1F3-37
1F3-46
ON-VEHICLE SERVICE
FUEL SYSTEM
1
2
3
4
5
6
7
8
9
10
Component Location
1.
2.
3.
4.
5.
6.
FUEL TANK
1
2
3
4
5
6
7
Fuel Tank
The Sender of Fuel Tank
2-way Check Valve
Pre Filter
Front Fuel Filler Neck
Rear Fuel Filler Neck
Fuel Supply Tube
8
9
10
11
12
13
2
3
4
5
6
7
8
9
10
11
12
30 Thermovalve
Fuel Injection Pump
Filter with Restriction
Check Valve
Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase
Permissible Pressure Drop of System
Tester Connection
YES
NO
NO
YES
Stop the engine Seal the air admission line with plug.
Connect the vacuum pump to line to thermovalve and
pressurize the line with vacuum.
Vacuum is built up.
YES
NO
YES
NO
Faulty thermovalve
Fit the line onto air admission filter. Built up vacuum with
vacuum pump. Detach the plug from air admission line.
Vacuum drops.
YES
NO
Go to test step 2.
YES
NO
Faulty thermovalve.
Defective filter with restriction.
YES
NO
1 Fuel Filter
2 Vacuum Line
Tools Required
201 589 13 21 00 Vacuum Tester
3 Ancillaries Connection
4 Vacuum Tester
> 70 mbar
Notice
If out of standard, replace the vacuum pump.
5. Remove the vacuum tester.
6. Connect the vacuum line to the ancillaries connection.
7. Install the fuel filter.
VACUUM PUMP
Preceding Work : Remove the poly V-belt
10 Nm
Notice
Clean the gasket residues of sealing surface of vacuum
pump and replace the gasket(5).
5. Connect the vacuum line (3, 4).
1
2
3
4
5
Bracket
Bolt
Vacuum Unit
Vacuum Line
Seal .............................................. Replace
Idle Speed
750 - 850 rpm
720 - 820 rpm
Tools Required
667 589 00 21 00 TDC Pulse Generato
Commercial Tool
e.g. Bosch, MOT 001.03
Sun, DIT 9000
Digital Tester
Adjustment Procedure
1. Connect the digital tester (1) and TDC pulse sender unit
(11).
2. Run the engine and warm up the coolant to 60~80C.
3. Disconnect the vacuum hose (4) from the PLA unit to check
idle speed with tester.
4. Check idle speed with tester.
OM 661LA Engine
750 - 850rpm
OM 662LA Engine
720 - 820rpm
Notice
To adjust idle speed, loosen the locking nut (6) of PLA unit.
RPM Decrease
Counterclockwise
RPM Increase
Notice
Do not rotate the PLA unit over turn from the position
marking. If do, idle spring in the governor will be severely
damaged.
2. Insert the plastic hose (5) and put the end into the measuring
beaker (6).
4. Start the engine and read off the fuel pressure on tester
(5).
Notice
At Idle Speed
> 0.3bar
At Full load
> 0.5bar
FUEL PUMP
1
2
3
4
5
6
7
8
2 Tester
3 Valve
l Poor
115 - 125bar
Used Nozzle
Min. 100bar
Max. 5bar
Notice
If out of standard, repair the injection nozzle.
6. Leak test
Slowly operate the hand lever at the tester until get a
pressure of approx. 90bar. Maintain this pressure for more
than
20 seconds and within this period no drop of fuel should
build up at the nozzle tip.
INJECTION NOZZLES
1
2
3
4
5
Notice
Replace the washers.
5. Installation should follow the removal procedure in the
reverse order.
Notice
Pay attention to the installation position of new nozzle washer
and tightening torque
1
2
3
4
Nozzle Holder
Steel Washer
Compression Spring
Thrust Pin
5
6
7
8
Intermediate Disc
Nozzle Needle
Nozzle Body
Nozzle Tensioning Nut ................................ 80Nm
Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzle
tensioning nut (8).
Notice
Use protective jaws for clamping.
2. Disassemble the fuel injection nozzle.
3. Clean the nozzle needle (6) and nozzle body (7) with an
abradant.
4. Clean the nozzle seat with cleaning cutter.
80 Nm
Notice
Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Washer
Bolt (Left-Hand Thread) ............................. 46Nm
Camshaft Sprocket
Washer
12-Sided Stretch Bolt ............ Check, 25Nm + 90
Timing Chain
Seal
Chain Tensioner......................................... 80Nm
Flange
Locking Screw
Sliding Hammer
Threaded Bolt
Retaining Plate
10 Nm
Notice
Replace the gasket.
Rotate the engine 1 revolution by hand and check TDC
marking of the crankshaft and camshaft.
25Nm + 90
Notice
If max. length of bolt exceeds 53.6mm, replace it.
5. Remove the plug (6) and seal (5) from the fuel injection
pump and collect oil in a suitable vessel.
Installation Notice
Tightening Torque
30 Nm
Notice
Replace the seal.
80 Nm
Notice
Replace the seal (16).
9. Pull out the 12-sided stretch bolt (14) and washer and
remove the camshaft sprocket (12).
46 Nm
11. Using special tool (24, 25), remove the locking pin (8).
Sliding Hammer 116 589 20 33 00
Threaded Bolt 116 589 02 34 00
2. Pull out the compression springs (5) and cam sprocket (1)
from the segment flange (4).
1 Position Sensor
2 Battery
3 Fuel Injection Pump
Service Data
Start of Delivery (RIV)
ATDC 14 - 16
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a
suitable vessel.
ATDC 14 - 16
Notice
If only lamp A lights up, repeat the test and if out of
specification, adjust start of delivery.
Service Data
Start of Delivery (RIV)
Idle Speed
ATDC 14 - 16
OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm
Item
With Pulse Generator
Without Pulse Generator
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable
vessel.
5.
6.
7.
8.
ATDC 14 - 16
Notice
If out of standard, adjust the start of delivery.
Stop the engine.
Remove the Rl sensor, digital tester and TDC pulse sender
unit.
Replace the seal and tighten the plug.
Check engine oil level and adjust if necessary.
Tightening Torque
30 Nm
Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875
1 Adjusting Screw
2 Bolt ............................................................ 23Nm
3 Fuel Injection Pump
Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15
Notice
Do not rotate the engine in opposite direction of engine
rotation.
Notice
If the adjustment range is not adequate, remove the injection
pump and reinstall.
Position Sensor 617 589 08 21 00
Service Data
Start of Delivery (RIV)
ATDC 14 - 16
Ldling Speed
Tools Required
617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester
667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Digital Tester
Item
With Pulse Generator
Without Pulse Generator
Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875
18
19
20
21
22
23
Tools Required
000 589 77 03 00
601 589 00 08 00
601 589 05 21 00
601 589 05 14 00
24
25
26
27
28
Oil Pan
Fuel Injection Pump
Seal ....................................................... Replace
Screw Plug ................................................. 30Nm
Square Nut
12. Remove the bolt (12) and pull off the washer (11).
13. Remove the bolt (22) and pull off the square nut (28).
14. Pull out the fuel injection pump (25) and seal (23).
23 Nm
23 Nm
9. Insert the washer (21) and tighten the bolts (20) and then
remove the assembly cage (29).
Tightening Torque
46 Nm
46 Nm
18 Nm
13 Nm
13 Nm
Notice
Replace the seal.
Box Wrench Insert 000 589 77 03 00
15.
16.
17.
18.