07.1-200 Removal, Reinstallation of Injection Pump

07.
1-200
Removal, reinstallation of injection pump
Job no. of Job Texts and Work Units or Standard Texts

and Flat Rates
07-8410 and 8411
Battery
Bottom part of noise encapsulation
disconnect, connect.
unscrew, screw on.
Model 202
Intake manifold
remove, install (14-180).
All models
Belt tensioning device
Fan shroud and fan
Vacuum pump
Actuator of Tempomat cruise control

remove, install (20-310/335).
Replace gasket (pay attention to table).
Daimler AG, 10/11/09, G/09/09 / ra07016010200x / 0200 - Removal and installation of injection pump Engines 601, 602.91, 603.91 (note deviations for off-road vehicles)
Page 1/7
Assembly cage
remove, install.
Special tool 601 589 05 14 00
Chain tensioner
Note
Assembly cage deleted on all engines as of
09/89 (see table).
remove, install "left-hand thread"
Tightening torque 40-50 Nm.
turn in direction of rotation to 15 ATDC of
cylinder 1.
Vehicles with code 62/0 14 ATDC.
Models 124, 201

Accelerator control damper (16)
remove, install (only with manual transmission).
Central mounting bolt (19)

Crankshaft
All models
Injection lines (54-57)
Fuel lines (80, 82, 83)
Vacuum lines at stop unit

Couplings at actuators
Accelerator control linkage
Models 124, 201
Vacuum control valve
All models
Securing bolts (13 and 13a)
at injection pump, disconnect, connect, tightening

torque 10-20 Nm,
special tool 000 589 770 300.
disconnect, connect. Replace seals (78).
Note model 202
Release quick locks, pull off, fit on, secure.
Examine O-rings for damage.
pull off, fit on.
disconnect, connect.
detach, attach.
remove, install, adjust (07.1-170).
Bolt+washer (8a)
remove, install, tightening torques

20-25 Nm.
slacken.
Models 124, 201

Fuel thermostat
remove, install.
All models
Injection pump
O-ring (10)
Engine
Screw plug (11)
pull out to rear, counterhold injection timing

device when performing this step.
replace, oil for installing injection pump.

check whether postioned at 15 ATDC, or
vehicles with code 62/0 at 14 TDC, of cylinder
1; correct if necessary.
Crank engine only in direction of rotation.

remove.
Page 2/7
Injection pump
when removed, turn with serrated wrench (027)

601 589 00 08 00 and lock with blocking screw
(023) 601 589 05 21 00.
check (07.1-112), adjust if necessary
(07.1-117).
test (07.1-229)
Start of delivery
Microswitch
Special tools
Notes
Until the production breakpoints mentioned, a
gasket with oil pocket must be installed when
renewing the gasket of the vacuum pump.
As of production breakpoint a gasket without oil
pocket will be installed.
Engine model designation

601.911
601.912
602.911
602.912
Transmission
manual
automatic
manual
automatic
manual
automatic
manual
automatic
As of engine end no.

157499
015077
041801
003380
019187
004738
029464
004808
Page 3/7
603.912
manual
automatic
015367
009219
Engine 603.912/913
From April to July 1989 an injection pump with
modified tappet spring was installed.
Production breakpoint: April - July 1998

Model
Engine
Engine end no.

automatic transmission
124.130
124.190
124.330
603.912
032890-034028
603.913
000589-000603
Engine 601, 602, 603

Since November 1989 the centering sleever
securing bolts has no longer been fitted.
Production breakpoint: November 1989

Model
124.120
124.180
124.125
124.185
124.130
124.190
124.330
201.122
201.126
Engine
Engine end no.

manual
transmission
Engine end no.

automatic
transmission
Vehicle ident. end no.
601.912
134622
011467
A/B
not registered
F
130181
602.912
149028
021904
122689
129639
603.912
055088
035826
124680
129936
603.913
601.911
602.911
000668
323596
085358
000636
025246
016711
131741
542109
542712
688338
684718
Page 4/7
The assembly cage with the securing bolts at the

injection timing device drive is not fitted to engine
601, 602, 603.
Production breakpoint: September 1989 (assembly cage deleted)

Model
Engine
601.912
Engine end no.

manual transmission
134622
Engine end no.

011467
124.120
124.180
124.125
124.185
124.130
124.190
124.330
201.122
201.126
602.912
149058
021904
603.912
055088
035826
603.913
601.911
602.911
000668
323596
085358
000636
025246
016711
Return spring on injection pump engine

601.911/921 with automatic transmission, return
spring 601 993 17 10 with smaller outer diameter
(arrow).
Production breakpoint: December 1983
Model
Engine
Engine end no.

201.122
601.911
000 180
601.921
001 908
Page 5/7
Spring chamber cover (1c) at injection pumps of

engines 603.912/913/931 (except national version
and Standard with ARF) made of
aluminium, previously sheet steel.
Reason: improved seal.
Production breakpoint: September 1990 - January 1991

Model
124.130/190
Engine
Engine end no.
manual transmission
063564 - 066251
603.912
-
Production breakpoint: September 1990 - February 1991

Model
Engine
124.130/190
124.330
603.912
603.913
Engine end no.
manual transmission
-
042065 - 044758
000742 - 000773
Engine 601.912
Injection pump modified. Injection pump (AJC)
with short servomagnet. Spring chamber cap die
cast aluminum (was sheet steel).
Production breakpoint: as of February 1993

Model
Engine
124.120
601.912
Engine end no.

Manual transmission
195583
Page 6/7
Engine 601.913
Injection pump modified. Overflow valve with
O-ring groove for increasing sealing properties.
Production breakpoint: as of September 1993
Model
Engine
202.120
601.913
Engine end no.

Manual transmission
007159
Engine end no.

Automatic transmission
000404
Engine end no.

Manual transmission
021595
Engine end no.

001545
Engine 601.913
Adjusting lever of injection pump modified. Cam
contour strengthened and clamping bolt with flat
head.
Production breakpoint: as of July 1994

Model
Engine
202.120
601.913
Engine 601.912, only Taxi Germany

Injection pump and fuel tank for vegetable oil
methyl ester fuel.
Production breakpoint: as of December 1994
Model
Engine
124.120
601.912
Engine end no.

023765
Page 7/7

07.1-200 Removal, Reinstallation of Injection Pump

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07.1-200 Removal, Reinstallation of Injection Pump

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07.

Removal, reinstallation of injection pump

Job no. of Job Texts and Work Units or Standard Texts

remove, install (14-180).

remove, install (13-340).

Models 124, 201

remove, install (only with manual transmission).

Central mounting bolt (19)

Fuel lines (80, 82, 83)

Vacuum lines at stop unit

at injection pump, disconnect, connect, tightening

remove, install, tightening torques

Models 124, 201

Screw plug (11)

pull out to rear, counterhold injection timing

replace, oil for installing injection pump.

Crank engine only in direction of rotation.

when removed, turn with serrated wrench (027)

Engine model designation

As of engine end no.

Production breakpoint: April - July 1998

Engine end no.

Engine 601, 602, 603

Production breakpoint: November 1989

Engine end no.

Engine end no.

Vehicle ident. end no.

The assembly cage with the securing bolts at the

Production breakpoint: September 1989 (assembly cage deleted)

Engine end no.

Engine end no.

Return spring on injection pump engine

Engine end no.

Spring chamber cover (1c) at injection pumps of

Production breakpoint: September 1990 - January 1991

Engine end no.

Production breakpoint: September 1990 - February 1991

Engine end no.

Production breakpoint: as of February 1993

Engine end no.

Engine end no.

Engine end no.

Engine end no.

Engine end no.

Production breakpoint: as of July 1994

Engine 601.912, only Taxi Germany

Engine end no.

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