OM 617 – Removal and installation of injection pump

A. Engine 615,616 M-injection pump with pneumatic governor

If lower fastening nut of injection pump (oil filter flange without recess) i s poorly accessible, unscrew
upper fastening screw from oil filter flange first. For this purpose, remove lefthand front wheel and unscrew fastening screw by means of an extended socket wrench. In addition, on engines 615.912 and 616, unscrew oil hoses from air-oil cooler on oil filter top.

Starting with the following chassis end numbers, an oil filter flange with recess is installed for better access to bottom fastening nut of injection pump on models 115.

1. Unscrew injection lines, vacuum line and fuel lines on injection pump. Plug closing caps on connections for injection lines and fuel hoses on injection pump.
2. Disconnect connecting rod on tickler.

3. Disconnect start-stop cable control on adjusting lever (1) of injection pump. For this purpose, remove
cotter pin, washer (5), screw (3) on angle bracket and remove wire coil (4) with clamp.

4. Unscrew hex nut on supporting bell and fastening nuts of injection pump, then pull injection pump out of cylinder crankcase. Remove coupling sleeve from driver of injection pump or from drive shaft.

Note: When replacing a driver, apply counterhold for loosening hex nut by means of notched tooth wrench, then pull driver from injection pump shaft by means of puller. Clean shaft stub and driver; the two cones should be absolutely clean and free of grease.
When mounting a new driver, pay attention to Woodruff key and markings (arrows).

Prior to installing injection pump, check control rod for easy operation. I f required, make operable as follows:
a) Remove closing cap (arrow) of control rod.
b) Push adjusting lever from stop to start position.
Control rod should return automatically.

c) If control rod is hard to move, which i s caused by resinification, fill clean gasoline into fuel feed connection and permit to act for a short period on elements.
d) Move control rod back and forth until it is freely operating.

5. Set crankshaft to the following values in compression stroke of firqt cylinder.

6. Slip coupling sleeve on intermediate gear shaft.
7. Set injection pump to begin of delivery. For this purpose, rotate pump shaft until tooth gap on driver
and marking on injection pump are in alignment (arrows).

8. Mount new gasket.
9. Introduce injection pump in such a manner that the studs are in center of oblong holes (slots). This
will permit swivelling in both directions for precision adjustment.

Note: Following precision adjustment, a distance of approx. 80 mm should be available from cylinder crankcase to center of pipe connection for injection lines to remove glow plugs.

10. Mount washers and slightly tighten injection pump by means of hex nuts.
11. Check begin of delivery and adjust (07.1-1 10 and 1 1 5).
12. Tighten fastening nuts on front flange and on supporting bell.

13.  Check oil level of injection pump and correct, if required. For this purpose, unscrew check plug (1).
If oil level is too high, loosen governor cover and raise slightly so that the fuel-oil mixture can flow out. When the oil level is too low, unscrew filter (2) and add engine oil up to check bore.

1. Check plug
2. Filter

14. Check position of overflow pipe and correct according to illustration, if required. For this purpose,
loosen hollow screw and correct overflow pipe according to illustration.

15.  Mount start-stop cable control and adjust (07.1-340).
16. Run engine and check all connections for leaks.
17. Check idle speed and adjust, if required (07.1 – 100).



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