SECTION 1F3

OM600 ENGINE CONTROLS

Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.

TABLE OF CONTENTS
Specifications. . . . . . . . . . . . . . . . . . . . . . . 1F3-1
Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15

Idle Speed Adjustment . . . . . . . . . . . . . . . .

Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Nozzle Test . . . . . . . . . . . . . . . . . .
Injection Nozzles . . . . . . . . . . . . . . . . . . . . .
Injection Nozzle Repair . . . . . . . . . . . . . . . .
Removal and Installation of
Injection Timing Device . . . . . . . . . . . . . .
Injection Timing Device . . . . . . . . . . . . . . . .
Start of Delivery Test
(Position Sensor, RIV Method) . . . . . . . . .
Fuel Injection Pump . . . . . . . . . . . . . . . . . .

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application

N m

Fuel Tank Mounting Nut

28 - 47

Fuel Pump Pressure Line

Fuel Injection Nozzle
Fuel Injection Pipe
Nozzle Tensioning Nut
Screw Plug

13
35 - 40
18
80
30

Left-Hand Thread Bolt

46

1F3-16
1F3-18
1F3-21
1F3-22
1F3-25
1F3-27
1F3-30
1F3-35
1F3-37
1F3-46

1F3-2 OM600 ENGINE CONTROLS

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
FUEL SYSTEM

1
2
3
4
5

Fuel Injection Pump

Fuel Feed Pump
Overflow Valve
Injection Nozzle
Pre-filter

6
7
8
9
10

Fuel Return Hose

Injection Line
Fuel Tank
Fuel Filter
Choke Orifice

OM600 ENGINE CONTROLS 1F3-3

FUEL INJECTION PUMP CODING

Model Code
OM661 LA Engine
OM662 LA Engine

Fuel Injection Pump Code

Example)
P
E
S
5
M
55
C
320
R
S188
RSF
R
S
F

PES 5M 55C 320 RS 168

Pump
Self-Driven
End Flange Mounting
Number of Cylinders (5EA)
Pump Size
Element Diameter
Modification Letter
Assembly Number
Direction of Rotation (clockwise)
Special Version
Governor
Governor
Coil Spring
Drive Governor

Component Location
1.
2.
3.
4.
5.
6.

Fuel Injection Pump

Vacuum Unit (Stop Unit)
Control Lever
PLA Vacuum Unit (Idle Speed Adjustment)
Governor
Fuel Pump

PES 4M 55C 320 RS 167

PES 5M 55C 320 RS 168

1F3-4 OM600 ENGINE CONTROLS

FUEL TANK

1
2
3
4
5
6
7

Fuel Tank
The Sender of Fuel Tank
2-way Check Valve
Pre Filter
Front Fuel Filler Neck
Rear Fuel Filler Neck
Fuel Supply Tube

8
9
10
11
12
13

Fuel Return Tube

Filter Hose
Fuel Tank Hose
Fuel Filler Cap
Clip
Clip

OM600 ENGINE CONTROLS 1F3-5

VACUUM CONTROL SYSTEM TEST

2
3
4
5
6
7

Engine Cut-Off Valve (Ignition Key Switch)

Auto-locking Hub Solenoid Valve
Engine Stop Valve Unit
PLA Vacuum Unit (Idle Speed Adjustment)
Engine
Vacuum Pump

8
9
10
11
12

30 Thermovalve
Fuel Injection Pump
Filter with Restriction
Check Valve
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.

1F3-6 OM600 ENGINE CONTROLS

Tools Required
001 589 73 21 00 Vacuum Pump
201 589 13 21 00 Vacuum Tester
667 589 00 21 00 TDC pulse generator
Commercial Tools
Digital tester
Temperature measuring instrument with test probe
WB24

Tester Connection

11 TDC Pulse Sender Unit

12 Digital Tester

e.g. Bosch MOT 001.03

Sun DIT 9000
e.g. Ahlborn, Therm 2263-2
Eichenfeldstrabe 1 - 3
D-8150 Holzkirchen

OM600 ENGINE CONTROLS 1F3-7

Test step 1
Connect vacuum pump (14) with Y adapter to PLA
vacuum unit (5). Run engine at idle speed.
Vacuum >
= 500 mbar

YES

NO

Lines and connections leaking.

Faulty PLA vacuum unit.

(Remove the connection hose from vacuum pump)

Connect vacuum pump (14) direct to PLA vacuum unit

(5) and pressurize with vacuum.
Vacuum is built up and idle speed increases approx.
150-200 rpm

NO

YES

Faulty PLA vacuum unit

(Coolant Temperature 30C)

Stop the engine Seal the air admission line with plug.
Connect the vacuum pump to line to thermovalve and
pressurize the line with vacuum.
Vacuum is built up.

YES

NO

Lines and connectors leaking.

Faulty thermovalve.

1F3-8 OM600 ENGINE CONTROLS

Detach line downstream of air admission filter (13).

Vacuum drops.

YES

NO

Faulty thermovalve

Fit the line onto air admission filter. Built up vacuum with
vacuum pump. Detach the plug from air admission line.
Vacuum drops.

YES

NO

Faulty filter with restriction.

Go to test step 2.

OM600 ENGINE CONTROLS 1F3-9

Test step 2
Connect vacuum pump (14) with Y adapter to PLA
vacuum unit (5). Run the engine at idle speed.
Vacuum drops to 0 at approx. 30 C of the thermovalve.

YES

NO

Faulty thermovalve.
Defective filter with restriction.

Stop the engine. Detach the filter with restriction.

Filter with restriction is clear.

YES

NO

Defective filter with restriction.

OM600 ENGINE CONTROLS 1F3-11

VACUUM PUMP TEST

1 Fuel Filter
2 Vacuum Line

Tools Required
201 589 13 21 00 Vacuum Tester

3 Ancillaries Connection
4 Vacuum Tester

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.
Standard

> 70 mbar

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.

OM600 ENGINE CONTROLS 1F3-13

VACUUM PUMP
Preceding Work : Remove the poly V-belt

1 Bolt ............................................................ 10Nm

2 Vacuum Pump
3 Vacuum Line (Ancillaries)

4 Vacuum Line (Brake Booster)

5 Gasket ................................................... Replace

1F3-14 OM600 ENGINE CONTROLS

Removal & Installation Procedure
1. Remove the vacuum line (3, 4).

2. Remove the bolts (1) evenly.

Notice
If necessary, rotate the engine until the pressure on the
tappet of the vacuum pump is released.

3. Remove the vacuum pump (2).

4. Install the vacuum pump (2).
Tightening Torque

10 Nm

Notice
Clean the gasket residues of sealing surface of vacuum
pump and replace the gasket(5).
5. Connect the vacuum line (3, 4).

OM600 ENGINE CONTROLS 1F3-15

VACUUM UNIT REPLACEMENT

1
2
3
4
5

Bracket
Bolt
Vacuum Unit
Vacuum Line
Seal .............................................. Replace

1F3-16 OM600 ENGINE CONTROLS

IDLE SPEED ADJUSTMENT

Service Data
Engine
OM661LA Engine
OM662LA Engine

Idle Speed
750 - 850 rpm
720 - 820 rpm

Tools Required
667 589 00 21 00 TDC Pulse Generato

Commercial Tool
e.g. Bosch, MOT 001.03
Sun, DIT 9000

Digital Tester

Adjustment Procedure
1. Connect the digital tester (1) and TDC pulse sender unit
(11).
2. Run the engine and warm up the coolant to 60~80C.

TDC pulse generator 667 589 02 21 00

3. Disconnect the vacuum hose (4) from the PLA unit to check
idle speed with tester.
4. Check idle speed with tester.
OM 661LA Engine

750 - 850rpm

OM 662LA Engine

720 - 820rpm

Notice
To adjust idle speed, loosen the locking nut (6) of PLA unit.

OM600 ENGINE CONTROLS 1F3-17

5. Ensure not to damage the idle spring in the governor and
adjust idle speed by turning the PLA unit (5) slowly.
Clockwise

RPM Decrease

Counterclockwise

RPM Increase

Notice
Do not rotate the PLA unit over turn from the position
marking. If do, idle spring in the governor will be severely
damaged.

6. After adjustment, tighten the locking nut and place the

position marking with different color of paint.
Notice
If there are no changes in idle speed with PLA unit
adjustment, perform the service at a BOSCH Service Center.
7. Connect the vacuum pump to the PLA vacuum unit and
build up vacuum approx. 500mbar. If engine rpm increases
by approx. 100rpm, It is normal.

Vacuum Pump 001 589 73 21 00

8. Connect the vacuum line (4).

9. Switch on all ancillaries and check the idle speed.

1F3-18 OM600 ENGINE CONTROLS

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.
Min. volume

150cm for 30 seconds

OM600 ENGINE CONTROLS 1F3-19

Fuel Pressure Test

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 and
remove 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
At Idle Speed

> 0.3bar

At Full load

> 0.5bar

If out of standard, replace the fuel feed pump.

Tester 617 589 04 21 00

5. Stop the engine.

6. Remove the tester.
7. Replace the seal and connect the fuel line (2).

OM600 ENGINE CONTROLS 1F3-21

FUEL PUMP

1
2
3
4

Fuel Injection Pump

Pressure Line ............................................ 13Nm
Suction Line
Hose Clip ............................................... Replace

5
6
7
8

Gasket ................................................... Replace

Spring Lock Washer
Hexagon Nuts
Fuel Pump

1F3-22 OM600 ENGINE CONTROLS

INJECTION NOZZLE TEST

Preceding Work : Removal of fuel injection nozzle

1. Fuel Injection Nozzle ............. New : 115 - 125bar

Used : min. 100bar
A Closed Spray = good
B Stringy Spray = poor

2 Tester
3 Valve

OM600 ENGINE CONTROLS 1F3-23

Tools Required
000 589 14 27 00 Tester
Notice
When testing the injection nozzle, do not place your hand into
the spray of a nozzle. The spray will 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 nozzle must spray with a gentle chattering.
4. Spray pattern test :
Operate the hand lever at tester rapidly (approx. 2~3 strokes
per second).
l Good
The spray pattern shows closed and well atomized.

l Poor

The spray pattern shows split, too wide and stringy.

(Repair the fuel injection nozzle)

1F3-24 OM600 ENGINE CONTROLS

5. Opening pressure test :
Open the valve (3) and slowly operate the hand lever at
tester (approx. 1 stroke / second) and measure opening
pressure.
New Nozzle

115 - 125bar

Used Nozzle

Min. 100bar

Difference Between Nozzles

Max. 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.

OM600 ENGINE CONTROLS 1F3-25

INJECTION NOZZLES

1
2
3
4
5

Fuel Injection Nozzle ............................. 35-40Nm

Fuel Return Hose
Plug
Nozzle Washer ....................................... Replace
Fuel Injection Pipe ..................................... 18Nm

1F3-26 OM600 ENGINE CONTROLS

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 the side.

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

OM600 ENGINE CONTROLS 1F3-27

INJECTION NOZZLE REPAIR

Preceding Work : Removal of fuel injection nozzle

1
2
3
4

Nozzle Holder
Steel Washer
Compression Spring
Thrust Pin

5
6
7
8

Intermediate Disc
Nozzle Needle
Nozzle Body
Nozzle Tensioning Nut ................................ 80Nm

1F3-28 OM600 ENGINE CONTROLS

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 Torque

80 Nm

Notice
Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.

OM600 ENGINE CONTROLS 1F3-29

7. Check the fuel injection nozzle and adjust opening pressure
if necessary.
Opening pressure adjustment
Disassemble the fuel injection nozzle and replace the steel
washer (2).
Notice
Each 0.05mm thickness of the washer results in a pressure
difference of approx. 3bar.

1F3-30 OM600 ENGINE CONTROLS

REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE

Preceding Work : Removal of vacuum pump

1
2
3
4
5
6
7
8
9

Cylinder Head Cover

Bolt ............................................................ 10Nm
Gasket ................................................... Replace
Fuel Injection Pump
Seal ....................................................... Replace
Screw Plug ................................................. 30Nm
Oil Pan
Locking Pin
Injection Timing Device

10
11
12
13
14
15
16
17

Washer
Bolt (Left-Hand Thread) ............................. 46Nm
Camshaft Sprocket
Washer
12-Sided Stretch Bolt ............ Check, 25Nm + 90
Timing Chain
Seal
Chain Tensioner......................................... 80Nm

OM600 ENGINE CONTROLS 1F3-31

Tools Required
601 589 00 08 00
601 589 05 21 00
116 589 20 33 00
116 589 02 34 00
667 589 04 63 00

Flange
Locking Screw
Sliding Hammer
Threaded Bolt
Retaining Plate

Removal & Installation Procedure

1. Remove the bolts (2) and then remove the cylinder head
cover (1) and gasket (3).
Installation Notice
Tightening Torque

10 Nm

Notice
Replace the gasket.
Rotate the engine 1 revolution by hand and check TDC
marking of the crankshaft and camshaft.

2. Loosen the camshaft sprocket bolt (14).

Notice
Do not remove the bolt.
Installation Notice
Tightening Torque

25Nm + 90

Notice
If max. length of bolt exceeds 53.6mm, replace it.

3. Loosen the bolt (11) (left-hand thread).

Notice
Do not remove the bolt.

1F3-32 OM600 ENGINE CONTROLS

4. Position the no.1 cylinder at ATDC 15.
Notice
Do not rotate the engine with camshaft sprocket bolt or
opposite direction of the engine rotation.

5. Remove the plug (6) and seal (5) from the fuel injection
pump and collect oil in a suitable vessel.
Installation Notice
Tightening Torque

30 Nm

Notice
Replace the seal.

6. Install the locking screw (18) into the injection pump.

Notice
Before tightening the bolts for the injection timing device
and the camshaft sprocket, always remove the locking screw
from the injection pump and reinstall the plug.

Locking Screw 601 589 05 21 00

7. Place alignment marks (arrow) on the timing chain (12) and

camshaft sprocket (15).

OM600 ENGINE CONTROLS 1F3-33

8. Remove the chain tensioner (17).
Installation Notice
Tightening Torque

80 Nm

Notice
Replace the seal (16).

9. Pull out the 12-sided stretch bolt (14) and washer and
remove the camshaft sprocket (12).

10. Pull out the bolt (11) and washer (10).

Notice
Be careful that the bolt is left-hand thread.
Installation Notice
Tightening Torque

46 Nm

11. Using special tool (24, 25), remove the locking pin (8).
Sliding Hammer 116 589 20 33 00
Threaded Bolt 116 589 02 34 00

1F3-34 OM600 ENGINE CONTROLS

12. Push back the timing chain with retaining plate (26) and
remove the injection timing device (9).

Retaining Plate 667 589 04 63 00

13. Installation should follow the removal procedure in the

reverse order.
14. After assembling the engine, check start of delivery and
adjust if necessary.

OM600 ENGINE CONTROLS 1F3-35

INJECTION TIMING DEVICE

Preceding Work : Removal of injection timing device

1 Cam Sprocket ........................................... Check

2 Bushing .................................................... Check
3 Governor Weights

4 Segment Flange and Drive Hub

5 Compression Springs

1F3-36 OM600 ENGINE CONTROLS

Disassembly & Assembly
1. Remove the governor weights (3).

2. Pull out the compression springs (5) and cam sprocket (1)
from the segment flange (4).

3. Knock out the bushing with a proper drift.

4. Installation should follow the removal procedure in the
reverse order.

OM600 ENGINE CONTROLS 1F3-37

START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD)

1 Position Sensor
2 Battery
3 Fuel Injection Pump

4 Seal ....................................................... Replace

5 Screw Plug ................................................. 30Nm

Service Data
Start of Delivery (RIV)

ATDC 14 - 16

1F3-38 OM600 ENGINE CONTROLS

Tools Required
617 589 08 21 00 Position Sensor

Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a
suitable vessel.

2. Install the position sensor (1) into the governor housing of

the injection pump to be the guide pin of the position sensor
facing up.
3. Connect the battery terminal of position sensor (1) to positive
terminal (+) of battery.

Position Sensor 617 589 08 21 00

4. Rotate the crankshaft by hand (in direction of engine rotation)

until the lamp B lights up. Rotate the crankshaft carefully
further until both lamps A and B come on. In this position,
check the Rl value on the crankshaft vibration damper.
Specification

ATDC 14 - 16

Notice
If only lamp A lights up, repeat the test and if out of
specification, adjust start of delivery.

OM600 ENGINE CONTROLS 1F3-39

Digital Tester, RIV Method
(Connection Diagram for Testers Without Adapter)

1 Fuel Injection Pump

2 Rl Sensor
3 Digital Tester

4 TDC Pulse Sender Unit

5 Battery

1F3-40 OM600 ENGINE CONTROLS

(Connection Diagram for Testers With Adapter)

1 Fuel Injection Pump

2 Rl Sensor
3 Digital Tester

Service Data
Start of Delivery (RIV)
Idle Speed

4 TDC Pulse Sender Unit

5 Battery
6 Rl Pulse Generator

ATDC 14 - 16
OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

OM600 ENGINE CONTROLS 1F3-41

Tools Required
617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester
667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Digital Tester

Item
With Pulse Generator
Without Pulse Generator

Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable
vessel.

2. Install the Rl sensor into the governor housing of injection

pump (1).

Rl Sensor 617 589 10 21 00

3. Connect the digital tester and TDC pulse sender unit

according to connection diagram.
4. Run the engine at idle speed and check the Rl value on the
digital tester
Rl value

5.
6.
7.
8.

ATDC 14 - 16

Notice
If out of standard, adjust the start of delivery.
Stop the engine.
Remove the Rl sensor, digital tester and TDC pulse sender
unit.
Replace the seal and tighten the plug.
Check engine oil level and adjust if necessary.
Tightening Torque

30 Nm

Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875

1F3-42 OM600 ENGINE CONTROLS

After Testing
Preceding Work : Start of delivery test
Position Sensor (RIV method)

1 Adjusting Screw
2 Bolt ............................................................ 23Nm
3 Fuel Injection Pump

4 Bolt ............................................................ 23Nm

5 Scale.......... Rl start of delivery = 14 - 16 ATDC

OM600 ENGINE CONTROLS 1F3-43

Tools Required
617 589 08 21 00 Position Sensor

Adjustment Procedure
1. Position the No. 1 cylinder at ATDC 15
Notice
Do not rotate the engine in opposite direction of engine
rotation.

2. Remove the bolt (2) at the supporting bracket.

3. Remove the bolt (4).

4. Turn the adjusting screw (1) until both lamps A + B on

the position sensor light up.
To the right
To the left

Start of delivery retarded

Start of delivery advanced

Notice
If the adjustment range is not adequate, remove the injection
pump and reinstall.
Position Sensor 617 589 08 21 00

5. After adjusting, retighten all the bolt to the specified torque.

1F3-44 OM600 ENGINE CONTROLS

Digital tester (RIV Method)

1 Bolt ............................................................ 23Nm

2 Adjusting
Screw ....... To the right : start of delivery retarded
To the left : start of delivery advanced

3 Bolt ............................................................ 23Nm

Service Data
Start of Delivery (RIV)

ATDC 14 - 16

Ldling Speed

OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

Tools Required
617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester
667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Digital Tester

Item
With Pulse Generator
Without Pulse Generator

Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875

OM600 ENGINE CONTROLS 1F3-45

Adjustment Procedure
1. Remove the bolt (3) at the supporting bracket.

2. remove the bolts (1) at the timing case cover.

3. Run the engine at idle speed.

4. Turn the adjusting screw (2) until the specification (15 1
ATDC) is indicated on the digital tester.
To the Right
To the Left

Start of Delivery Retarded

Start of Delivery Advanced

1F3-46 OM600 ENGINE CONTROLS

FUEL INJECTION PUMP

Preceding Work : Removal of vacuum pump
Removal of air cleaner housing
Removal of intake manifold

18
19
20
21
22
23

Chain Tensioner ......................................... 80Nm

Seal ....................................................... Replace
Bolt(Left-Hand Thread) .............................. 46Nm
Washer
Bolt ............................................................ 23Nm
Seal ....................................................... Replace

Tools Required
000 589 77 03 00
601 589 00 08 00
601 589 05 21 00
601 589 05 14 00

Box Wrench Insert

Flange
Locking Screw
Assembly CageRemoval

24
25
26
27
28

Oil Pan
Fuel Injection Pump
Seal ....................................................... Replace
Screw Plug ................................................. 30Nm
Square Nut

OM600 ENGINE CONTROLS 1F3-47

Removal Procedure
1. Position then no.1 cylinder at 15 ATDC.
Notice
Do not rotate the engine in opposition direction of engine
rotation.

2. Remove the connecting rod (9).

3. Disconnect the vacuum lines (13, 14).
4. Remove the accelerator control damper (10).
(Manual transmission vehicle)

5. Remove the suction line (16) and pressure line (4).

6. Remove the banjo bolt (1) and then remove the seal (2)
and fuel line (3).
7. Remove the plastic clip (8) on the injection line.

8. Disconnect the injection lines (15) from the injection pump

(25).
9. Remove the banjo bolt (1) and then remove the seal (7)
and return line (5).

1F3-48 OM600 ENGINE CONTROLS

10. Install the assembly cage (29) and remove the bolt (20)
and pull off the washer (21).
Notice
Be careful that the bolt (20) is left hand thread.

Assembly Cage 601 589 05 14 00

11. Remove the chain tensioner (18) and seal (19).

12. Remove the bolt (12) and pull off the washer (11).

13. Remove the bolt (22) and pull off the square nut (28).
14. Pull out the fuel injection pump (25) and seal (23).

OM600 ENGINE CONTROLS 1F3-49

Installation Procedure
1. Remove the screw plug (27) and seal (26) and collect oil in
a vessel.

2. Insert flange (31) onto the injection pump camshaft and

turn until the cam of the governor is visible in the hole.

Flange 601 589 00 08 00

3. Tighten the locking screw.

Locking Screw 601 589 05 21 00

4. Ensure that the No.1 cylinder is positioned at ATDC 15.

1F3-50 OM600 ENGINE CONTROLS

5. Coat the new seal (23) with engine oil and install it.
6. Insert the fuel injection pump (25) and tighten the bolts
(22).
Tightening Torque

23 Nm

7. Remove the locking screw (32).

8. Tighten the bolt(12).

Tightening Torque

23 Nm

9. Insert the washer (21) and tighten the bolts (20) and then
remove the assembly cage (29).
Tightening Torque

46 Nm

10. Connect the fuel pipes

Return Line

46 Nm

Fuel Injection Line

18 Nm

Fuel feed Line

13 Nm

Suction and Pressure Line

13 Nm

Notice
Replace the seal.
Box Wrench Insert 000 589 77 03 00

OM600 ENGINE CONTROLS 1F3-51

11.
12.
13.
14.

Assemble the plastic clip (8).

Connect the vacuum line (13, 14).
Connect the connecting rod (9).
Connect the accelerator control damper (10).
(Manual transmission vehicle)

15.
16.
17.
18.

Install the chain tensioner.

Install the vacuum pump.
Check the start of delivery.
Adjust the idle speed.