Page 777 of 2053
1F3 -- 20 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL PUMP
1 Fuel Injection Pump
2 Pressure Line 13N∙m (10 lb-ft) ..............
3 Suction Line
4 Hose Clip Replace........................5 Gasket Replace..........................
6 Spring Lock Washer
7 Hexagon Nuts
8 Fuel Pump
Page 778 of 2053
OM600 ENGINE CONTROLS 1F3 -- 21
D AEW OO M Y_2000
INJECTION NOZZLE TEST
Preceding Work : Removal of fuel injection nozzle
1 Fuel Injection Nozzle New : 115-- 125 bar....
Used : min. 100bar
A Closed Spray = good
B Stringy Spray = poor2Tester
3Valve
Page 779 of 2053
1F3 -- 22 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
Tools Required
000589142700 Tester
Notice
When testing the injection nozzle, do not place your
hand into the spray of a nozzle. The spraywill penetrate
deep into the skin and destroy the tissue.
1. Connect the fuel injection nozzle to the tester (2).
Tester 000 589 14 27 00
2. Close the valve (3) and pump 5 times strongly.
3. Chatter test :
Slowly operate the hand lever at tester (approx. 1
stroke per second). The nozzlemust spray with a
gentle chattering.
4. Spray pattern test :
Operate the hand lever at tester rapidly (approx.
2~3 strokes per second).
DGood
The spray pattern shows closed and well atom-
ized.
DPoor
The spray pattern shows split, too wide and
stringy.
(Repair the fuel injection nozzle)
Page 780 of 2053
OM600 ENGINE CONTROLS 1F3 -- 23
D AEW OO M Y_2000
5. Opening pressure test :
Open the valve (3) and slowly operate the hand le-
ver at tester (approx. 1 stroke / second) and mea-
sure opening pressure.
New Nozzle115 -- 125bar
Used NozzleMin. 100bar
Difference Between NozzlesMax. 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.
Page 781 of 2053
1F3 -- 24 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
INJECTION NOZZLES
1 Fuel Injection Nozzle 35-- 40N∙m(26--30 lb-ft) .
2 Fuel Return Hose
3Plug
4 Nozzle Washer Replace...................
5 Fuel Injection Pipe 18N∙m (13 lb-ft) ..........
Page 782 of 2053
OM600 ENGINE CONTROLS 1F3 -- 25
D AEW OO M Y_2000
Tools Required
001 589 65 09 00 Serration Wrench
Removal & Installation Procedure
1. Remove the plastic clip from the injection pipe
2. Remove the fuel return hose.
3. Disconnect the injection pipes from the injection
nozzles and push them to theside.
4. Remove the fuel injection nozzle.
Serration Wrench 001 589 65 09 00
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.
Page 783 of 2053
1F3 -- 26 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
INJECTION NOZZLE REPAIR
Preceding Work : Removal of fuel injection nozzle
1 Nozzle Holder
2 Steel Washer
3 Compression Spring
4 Thrust Pin5 Intermediate Disc
6 Nozzle Needle
7 Nozzle Body
8 Nozzle Tensioning Nut 80 N∙m (59 lb-ft) .....
Page 784 of 2053
OM600 ENGINE CONTROLS 1F3 -- 27
D AEW OO M Y_2000
Tools Required
001 589 65 09 00 Socket Wrench Insert
000 589 00 68 00 Cleaning Set
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.
Socket Wrench Insert 001 589 65 09 00
3. Clean the nozzle needle (6) and nozzle body (7) with
an abradant.
4. Clean the nozzle seat with cleaning cutter.
Cleaning Set 000 589 00 68 00
5. Immerse nozzle needle (6) and nozzle body (7) in
filtered diesel fuel. When the nozzle body is held
vertical, the weight of the nozzle needle must cause
it to slide down toward the nozzle needle seat.
6. Assemble the injection nozzle so that the tip of the
thrust (4) pin is facing toward the nozzle holder.
Tightening Torque80 N∙m (59 lb-ft)
Notice
Nozzle needle (6) and nozzle body (7) should al-
ways be replaced as a pair.