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1F3-2 OM600 ENGINE CONTROLS
FUEL SYSTEM
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre-filter 6 Fuel Return Hose
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
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1F3-4 OM600 ENGINE CONTROLS
FUEL TANK
1 Fuel Tank
2 The Sender of Fuel Tank
3 2-way Check Valve
4 Pre Filter
5 Front Fuel Filler Neck
6 Rear Fuel Filler Neck
7 Fuel Supply Tube 8 Fuel Return Tube
9 Filter Hose
10 Fuel Tank Hose
11 Fuel Filler Cap
12 Clip
13 Clip
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OM600 ENGINE CONTROLS 1F3-5
VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch)
3 Auto-locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)
6 Engine
7 Vacuum Pump830
° Thermovalve
9 Fuel Injection Pump
10 Filter with Restriction
11 Check V alve
12 Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx. 500mbr
400 - 500mbar approx. 1 min.
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OM600 ENGINE CONTROLS 1F3-11
VACUUM PUMP TEST
1 Fuel Filter
2 Vacuum Line3 Ancillaries Connection
4 Vacuum Tester
Tools Required
201 589 13 21 00 Vacuum Tester
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1F3-12 OM600 ENGINE CONTROLS
Test Procedure
1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine.
2. Remove the vacuum line (2) from ancillaries connection (3).
3. Connect the vacuum tester (4) to the ancillaries connection (3).
Vacuum Tester 201 589 13 21 00
4 Run the engine at idle and check vacuum pressure after 30 sec. 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.
Standard > 70 mbar
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1F3-18 OM600 ENGINE CONTROLS
Min. volume 150cm for 30 seconds
FUEL PUMP TEST Notice
Before test, replace the fuel filter cartridge and fuel prefilter.
Fuel Feed Test
1. Disconnect the fuel return line (1) and seal up it with plug.
2. Insert the plastic hose (5) and put the end into the measuring
beaker (6).
3. Disconnect the vacuum line (4) from vacuum unit (engine stop) (5) and connect the vacuum pump (7) to the vacuum unit.
4. To avoid the engine starting, build up vacuum (approx. 500 mbar).
5. Operate the starter motor for exactly 30 seconds and measure fuel volume in the beaker.
3
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1F3-20 OM600 ENGINE CONTROLS
Tools Required
617 589 04 21 00 Tester
1. Disconnect the fuel line (2) from the fuel filter.
2. Remove the banjo bolt (4) from the fuel injection pump andremove the seals (3) and fuel line (2).
3. Connect the tester (5).
4. Start the engine and read off the fuel pressure on tester (5). Notice If out of standard, replace the fuel feed pump.
Tester 617 589 04 21 00
5. Stop the engine. At Idle Speed
At Full load
> 0.3bar > 0.5bar
6. Remove the tester.
7. Replace the seal and connect the fuel line (2).
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1F3-28 OM600 ENGINE CONTROLS
Tools Required 001 589 65 09 00 Socket Wrench Insert000 589 00 68 00 Cleaning Set Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzletensioning 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 thenozzle needle seat.
6. Assemble the injection nozzle so that the tip of the thrust (4) pin is facing toward the nozzle holder.
Tightening Torque 80 Nm
Notice Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.
