Fuel Injection Pump and Fuel Injection Pipe

Dismounting of fuel injection pump

1. Dismount the fuel injection pipe pos. 1 fig 1 and the fuel inlet pipe pos 2.

2. Separate the spring loaded lever from the regulating rod on the fuel injection pump.

1 2

Fig 1 View from Control Side

3.Remove the pipe for lub.oil and drain.

4.Remove the screws in the bottom flange (4 pieces) and take the fuel injection pump away.

Separation of fuel injection pump.

5.If necessary, clean the exterior of the injection pump.

6.Mount the injection pump in the clamping bracket PYO-W020 (see plate 52014 item 037), on the test pump.

7. Press the thrust cap (N) fig. 2 downwards and remove the securing ring (P). Remove the thrust cap

(N) with lower spring plate (O) and plunger (M). Be sure not to damage the plunger.

D

A

1. Back-up ring (spirally coiled)

2. O-ring inside dia. 45.7 mm x 2.6 3. O-ring inside dia. 51 mm x 3

4. Back-up ring

5. O-ring inside dia. 43 mm x 3.5 6. O-ring inside dia. 37 mm x 3

8.Take out the plunger spring (L), upper spring plate (K) and pinion (J). If necessary remove the lock ring (R) and guide pin (I) and dismount the regulating rod (H) as well as the cap screw in the opposite end of the regulating rod (H).

9.Unscrew the four screws (A) and remove the connecting piece (B). Take out the valve spring (D) and the non-return valve (F).

10.Loosen and remove the four screws (C) and take out the barrel (E).

11.Remove all the O-rings and back-up rings from the injection pump.

12.All parts must be cleaned, using kerosene or gas oil and a hand brush (not a steel brush).

Blow through the holes for sealing oil in the pump houses and the barrel (E).

Inspection of fuel injection pump:

13. Insert plunger (M) and non-return valve (F) into the barrel (E) after wetting with clean gas oil. Plunger and non-return valve must slide into the barrel by their own weight.

Plunger (M)

Fig 3 Clearance between Lower Spring Plate and Plunger

14.The axial clearance between lower spring plate and plunger foot must not exceed 0.25 mm. The clearance between lower spring plate and plunger foot is 0.05 to 0.1 mm when new. See fig 3.

15.Check the cavitation plugs (G) for wear and renew if necessary.

16.Barrel (E), plunger (M) and non-return valve

(F)are manufactured to very close tolerances. Any attempt to refinish these parts causes alterat-

ions of the tolerances and must therefore NOT be carried out.

If during the visual inspection of the parts, heavy abrasion symptoms or damage can be observed, the part in question must be replaced.

Assembling of fuel injection pump:

17. When assembling the injection pump, proceed in the reverse order to disassembling. Pay attention to the following:

Marking on regulating rod

Tooth with chamfer

Marking on pinion

Fig 4 Mounting of Regulating Rod Mechanism

A.At initial tightening up of new parts the following

(C)for barrel (E).

Tighten screws to 90 Nm, loosen and tighten again to 90 Nm and then tighten to 90 Nm + 10 Nm. Employ the same procedure when tightening the other pump components for the first time.