Injection system 07.

352/352 A

Contents

Chapter Page

1 General
Installation survey, injection system 1.1/1
Sectional view, EP/RSV governor 1.1/2
Sectional view RQV governor 1.1/3
Installation survey, fuel supply system 1.1/4
- Sectional view, fuel lift pump 1.1/4
Test values for injection pump and governor, engine 353.961 1.2/1
engine 353.961 with RQV governor (special 16457) 1.2/2
engine 353.959/977 1.3/1
Special tools 1.4/1
Consumibles 1.4/1
Tightening torques 1.4/1
Exploded view 1.5/1

2 Reconditioning injection pump

Removal and installation of injection pump 2.1/1
Removal and installation of pressure relief valve on injection pump 2.2/1

3 Checking and adjusting start of delivery 3.1/1

4 Reconditioning injector nozzles

Removal and installation of injector nozzles 4.1/1
Testing injector nozzle 4.2/1
Disassembly and assembly of nozzle holder and injector nozzle 4.3/1

5 Reconditioning advance unit

Removal and installation of advance unit from the injection pump dirve gear 5.1/1
Removal and installation of advance unit from camshaft 5.2/1
Disassembly and assembly of advance unit 5.3/1

6 Bleeding uel system 6.1/1

7 Removal and installation of fuel lift pump 7.1/1

8 Disassembly, cleaning and assembly of fuel filter 8.111

UKD 30 402 21 42-02

 General 07.8
3521352 A

Installation Survey - Injection System

Engine type 352 352 A

Engine model 353.961 353.959 353.977

Injection pump Type PES 6 A 90 0 410 RS 2293 PES 6 AD 410 RS 2293 'I PES 6 A 900410 RS 2293
with charging with charging
pressure balance pressure balance
PES6A900410RS2596"
with charging
pressure balance

Certification No. - , EP 330 -

Manufacturer Bosch

Model 6-cylinder in· line pump

Injection sequence 1-5-3-6-2-'4

.

Governor Type EPI RSV 350- EPI RSV 350 . 'I EP/HSV 350-
1400 A 0 B 1080 OL 1400 A 0 B 788 OL 1400 A 0 B 788 OL

RQV 300-1425 AB 740 L" EPI RSV 350 • "

1400AOB 1141 L

Certification No. - RS 3301 'I -

RS 3303"

Manufacturer Bosch

Test values Sheet designation MB 5,7 q MB 5,7 q 5' 1 MB 5,7 q 5

Edition 2nd edition 3rd edition 3rd edition
MB 5,7 n 3) MB 5,7 v 7"
5th edition 3rd edition

Injection timing device 4) Mechanical centrifugal segment plate system

Injection nozzles Type OLLA 150 S 187 OLLA 150 S 2120 'I
OLLA 150 S 2120
OLLA 142 S 792 "
Manufacturer Bosch

Opening pressure (bar) 200. 10 min. 180

Start of delivery before TOC 18' 210 1) 190 2) 21'

Fuel filter element Felt tube filter element

Fuel pump Type FPI KE 22 AD 11212

Manufacturer Bosch

1) To engine end No. 691 149.

2) From engine end No. 691 150.
3) Special vehicles SW (SA 16 457)
4) From engine end No. 470 428 attached to camshaft

UKO 30 402 21 42 • 04
1.1/1
07.8 General
352/352 A

Sectional View

"W_---6
-::..1------7

13

UZ07-Q020

EPI RSV Governor

1 Starting spring 10 Control lever

2 Tensioning lever 11 Guide bushing
3 Governpr cover 12 Flyweight
4 Guide lever 13 Swivel lever
5 Shut-off or idle stop 14 Rocker
6 Control spring 15 Link
7 Auxiliary idle spring 16 Control rod
8 Compression spring for idle adjustment 17 Governor housing
9 Full load stop (delivery)

1.1/2
 General 07.8

352
SA 16457

Sectional view

1 2 3

15

14 13 UZ07... 0021

RQV governor

Compensating spring 9 Plate cam

2 Spring cap 10 Oil indicator
3 Clevis 11 Adjusting pin
4 Control lever 12 Sliding block
5 Adjusting lever 13 Bell crank
6 Stop lug 14 Flyweights
7 Floating block 15 Injection pump control rod
8 Linkage lever

UKD 30 402 21 42-02 1.1/3

General 07.8

352/352 A

Installation survey
Fuel supply system

Engine model 352 352 A

model designation 353.961 353.959/977
Fuel filter model KS/ESF 3 FB 616/5 CM H 06 K
(optional)
manufacturer Bosch Knecht Hengst
Filter element Felt tube filter element
.

Fuel supply model FP/~E 22 AD 112/2

pump manufacturer Bosch

Sectional view

3 2 1

UZ09-0009!1

Fuel supply pump

A Inlet 5 Non-return valve (pressure sidel

B Outlet 6 Roller tappet
1 Strainer 7 Plunger chamber
2 Plunger·spring chamber 8 Hand primer
3 Plunger spring 9 Non-return valve (suction sidel
4 Plunger

1.1/4
 General 07.8
352
Test Values for Injection Pump and Governor WPP 00114 MS 5,7 g
2nd Edition

PES 6 A 90 D 410 RS 2293 RSV 350 - 1400 AOS 1080 DL Replaces 12.74
Firm: Daimler - Senz
Engine: 353.961
96 kW (130 HP)
Test oil- ISO 4113
All test values apply only to Bosch injection pump test rigs and equipment

A. Injection Pump Setting Values

Start of delivery at preliminary stroke 2.15 - 2.25 mm (2.10 - 2.30 mm from SDC)

Speed Control rod Delivery Difference Control rod Delivery Spring preload
travel travel (adjusting valve)
min'\ mm cm'!100 Strokes cm'!100 Strokes mm cm'!100 Strokes mm
1 2 3 4 2 3 6

1000 9 4,5 - 5,0 0,3 (0,45)

6 1,8 - 2,6
12 7,3 - 8,2
200 9 2,0- 2,8

B, Governor Setting Values

Q) Upper nominal speed Medium nominal speed @) Lower nominal speed @Balance

Adjusting Control rod Adjusting Control rod Adjusting Control rod Control rod
lever travel lever travel lever travel travel
deflection deflection deflection
degrees min" mm degrees . min'! mm degrees min-' mm min-' mm
1 2 3 4 5 6 7 8 9 10 11

approx. 67 1400 16,0 approx. 20 350 9,2

1450 11,4 without auxiliary spring
100 19 - 21 1380 0
1500 5,5
350 8,9 - 9,5 600 0,2 - 0,3
® 1470 8,0 - 10,4 500 3,6- 6,2
1520 3,8 - 6,8 with auxiliary spring 700 0-1
1640 0,3 -1,0

C, Setting Values for Injection Pump with Governor Attached

@ Full-load stop ® Speed ® Delivery curve Starting quantity ® Idle stop

limitation Idle speed
(Test oil temperature 40')
(changed to ... ) CRT
min-' cm'!1000 Strokes min-' min-' cm'!1000 Strokes min:' cm'!1000 Strokes min-' mm
1 2 3 4 5 6 7 8

1400 63,0- 64,0 1450 -1460' 600 51,0 - 53,0 100 14,7 - 15,3
(61,0- 66,0) (49,0- 55,0) 1520- 4,0
1540

Set balanced delivery according to the framed values c:::::::J

o The numbers indicate the test sequence.
Checking values in brackets!
'I mm control rod travel less than column 2.

UKD 30 402 21 42 - 04 1.2/1

07.8 General
352
SA 16457

Test Values for Injection Pump and Governor WPP 00114 MS 5,7 n
5th Edition

PES 6 A 90 D 410 RS 2293 ROV 300 - 1425 FROM 740 L Replaces 4.77
Firm: Daimler - Senz
Engine: 353.961
96 kW (130 HP)
Test oil- ISO 4113
All test values apply only to Bosch injection pump test rigs and equipment

A. Injection Pump Setting Values

Start of delivery at preliminary stroke 2.15 - 2.25 mm (from SDC)

Speed Control rod Delivery Difference Control rod Delivery Spring preload
travel travel (adjusting valve)
min-! mm cm '/100 Strokes cm'!100 Strokes mm cm'!100 Strokes mm
1 2 3 4 2 3 6

1000 9 4,5 - 5,0 0,4

6 1,8-2,6
12 7,3 - 8,3
200 9 2,0- 2,8

S. Governor Setting Values

Upper rated speed , Medium rated speed Lower rated speed Adjusting travel

Adjusting Control rod Adjusting Control rod Adjusting Control rod

lever travel lever travel lever travel
deflection deflection deflection
degrees min-' mm degrees min-1 mm degrees min-' mm min-' mm
1 2 3 4 5 6 7 8 9 10 11

approx. 66 1425 16,0-19,4 - - - approx. 10 100 6,6 -7,8

400 1,4-2,2
1500 11,6-16,0 300 4,9 - 6,4
1425 8,1
1550 8,2 - 13.4 450 3,0 -4,2
1650 1,4- 8,0 600 1,3 - 2,8
1790 0 760 0

C. Setting Values for Injection Pump with Governor Attached

Full·load quantity Speed limitation Delivery curve Starting quantity Intermediate

Control rod stop Idle speed speed
(Test oil temperature 40') Note: Switchover paint Adjusting
travel
(changed to ... ) Control
rod
min-' cm'!1000 Strokes min-1 min-! cm'l1 000 Strokes min-' cm'!1000 Strokes min-' travel
1 2 3 4 5 6 7 8 mm

1400 61,5 - 62,5 1455 - 1465' 100 71,0 - 81,0 13,9-14,3

(59,5- 64,S)
250-180

Set balanced delivery to framed values t==l

Checking values in brackets!
'1 mm control rod travel less than column 2.

1.2/2
 General 07.8
352 A

Test Values for Injection Pump and Governor WPP 00114 MB 5,7 g 5
3rd Edition

PES 6 A 90 D 410 RS 2293 RSV 350 - 1400 AOB 788 DL Replaces 8.82
Firm: Daimler - Benz
Engine: 353.959 to engine end No. 691 149
353.977
124 kW (168 HP)
Test oil - ISO 4113
Comb. No. 0 400 876 258 H= 22.5 mm
All test values apply only to Bosch injection pump test rigs and equipment

A. Injection Pump Setting Values

Start of delivery at preliminary stroke 2.15 - 2.25 mm (2.10 - 2.30 mm from BDC)

Speed Control rod Delivery Difference

Control rod Delivery Spring preload
travel travel (adjusting valve)
min-' mm@ cm'Il00 Strokes cm'Il00 Strokes mm cm'Il00 Strokes mm
1 2 3 4 2 3 6.
1400 11,3+0,1 7,4 -7,5 0,30 (0,45)

350 6,7 - 6,9 0,5-1,1 0,20 (0,40)

B. Governor Setting Values

CD Upper rated speed Medium rated speed @ Lower rated speed ® Adjustment
Adjusting Control rod Adjusting Control rod Adjusting Control rod Control rod
lever travel lever travel lever travel travel
deflection deflection deflection
degrees min-' mm degrees' min-' mm degrees min" mm min"' mm
1 2 3 4 5 6 7 8 9 10 11
loose 800 0,3 - 1,0 - - - 19 - 21 350 6,3 1400 11,3-11,4
X= 5,0
100 min. 19,0
500 11,5-11,6
@ 67-70 1440-1450 10,3 350 6,7- 6,9
1500-1530 4,0 530- 2,0
1600 0,3-1,7 590
700 max.l,O

C. Adjustment for Injection Pump with Governor Attached

@ Full-load stop @ Speed @ Delivery curve Starting quantity <ID @ Idle stop
limitation Idle speed
(Test oil temperature 40') Note:
(changed to ... ) Control
rod
min-' cm'Il000 Strokes min-' min"' cm'Il000 Strokes min-' cm'Il000 Strokes min-' travel
1 2 3 4 5 6 7 8 mm
LDA 0,5 bar 1440 - 1450' LDA 0,5 bar 100 13,7 - 14,3 - -
1400 74,0-75.0 500 62,0- 64,0 mmRW
(72,0- 77,0) (60,0- 66,0)
LDA o bar
500 54,0- 56,0
(52,0- 58,0)

Set balanced delivery according to framed values c::::::J

o The numbers indicate the test sequence.
Checking values in brackets I
"1 mm control rod travel less than column 2.

UKD 30 402 21 42 - 04 1.3/1

07.8 General
352 A

O. Adjustment Check for Manifold Pressure Compensator (LOA)

Decreasing
Test at n= 500 min ' - Pressure- in bar overpressure
Increasing

Pump/governor Adjustment Measurement Control rod Reduction

travel Difference
, pO= bar pO= bar mm
PES 6 A 900 410 RS 2293
with °
0,29
10,8 - 10,9
11,1-11,2
RSV 350 - 1400 AOS 788 DL 0,50 11,5-11,6

Checking the hydraulic start lock

Lock at 0,4 - 0,5 bar
Release at 0,15- 0,25 bar

1.3/2
 General 07.8
352 A

Test Values for Injection Pump and Governor WPP 0011 4 MB 5,7 v 7
3rd Edition

PES 6 A 90 D 410 RS 2596 RSV 350 - 1400 AOB 1141 L Replaces 10.81
Firm: Daimler - Benz
Engine: 353.959 from engine end No. 691 150
124 kW (168 HP)
Test oil - ISO 4113
All test values apply only to Bosch injection pump test rigs and equipment

A. Injection Pump Setting Values

Start of delivery at preliminary stroke 2.00 - 2.10 mm (1.95 - 2.15 mm from BDC)
,
Speed Control rod Delivery Difference Control rod Delivery Spring preload
travel travel (adjusting valve)
min" mm cm'!100 Strokes cm'l1 00 Strokes mm cm'!100 Strokes mm
1 2 3 4 2 3. 6

1400 12,3 + 0,1 7,9- 8,0 0,30 (0,45)

350 7,9- 8,1 0,9 - 1,5 0,20 (0,40)

B. Governor Setting Values

CD Upper rated speed Medium rated speed o Lower rated speed @ Adjustment
Adjusting Control rod Adjusting Control rod Adjusting Control rod Control rod
lever travel !ever travel lever travel travel
deflection deflection deflection
degrees min" mm degrees min" mm degrees min" mm min" mm
1 2 3 4 5 6 7 8 9 10 11

loose 800 0,3 -1,0 - - - approx. 14 350 8,0 1400 12,3 + 0,1
X= 5,75 350 7,9 8,1 600 13,3 + 0,1
®approx. 1440-'-1450 11,3 580- 2,0 1175 12,7 + 0,2
70 153s-,.1565 4,0 640
1680 . 0,3-1,7

C. Setting Values for Injection Pump with Governor Attached

@ FulI·loads stop @ Speed @ Delivery curve Starting quantity @ Idle stop

limitation Idle speed
(Test oil temperature 40') Note:
(changed to ... ) Control ro d
min" cm'!1000 Strokes min" min" cm'!1000 Strokes min,l cm'!1000 Strokes min" travel
1 2 3 4 5 6 7 8 mm

LOA 0,7 bar 1440 - 1450' LOA 0,7 bar 100 79,25 - 89,25 - -
1400 79,0 -80,0 500 76,5 -79,5 at 16,4-- 16,8
(n,o-- 82,0) (74,s-,. 81,5) mm control rod
travel
LOA o bar
500 51,5 - 52,5
(49,s-,. 54,5)

Set balanced delivery according to framed values C:=J

o The numbers indicate the test sequence.
Checking values in brackets I
'1 mm control rod travel less than column 2.

UKD 30 402 21 42 - 04 1.3/3

07.8 General
352 A

O. Adjustment Check for Manifold Pressure Compensator (LOA)

Decreasing
Test at n= 500 min ' - Pressure-- in bar overpressure
Increasing

Reduction
Pump/governor Adjustment Measurement Control rod
Difference
travel
pO= bar pO= bar
mm

PES 6 A 90 D 410 RS 2596 0,52 0 13,0-13,1

with 0,70 11,4-11.5
RSV 350·1400 AOS 1141 L 0,21 13,3 -13,4
11,8 - 12,0

Checking the hydraulic start lock

Lock at 0,45 - 0,55 bar
Release at 0,25 - 0,35 bar

1.3/4
 General 07.8

352/352 A

Special tools

Cons. Tool
No. Tool Part No. set

1 Box wrench for injection lines 000 589 07 03 00 A

2 Claw wrench for protective bushing in cylinper heaP 346 589 00 07 00 B
3 30 mm socket for thrust screw in noiile holder 000589750900 B
4 Socket for injection pump drive gear 322 589 00 09 00 B
5 Special wrench for clamping nut in nozzle holder 000589011300 B
6 Mount for nozzle holder 403 589 00 31 00 B
7 Remover for nozzle holder 352 589 00 33 00 8
8 Puller 355 589 00 33 00 B
9 Special wrench to retorque injection lines 000 589 68 03 00 0

Necessary materials

Cons.
No. Description Part No.

1 Fixing compound: Loctite No. 270 0029899371

2 Sealant: Curil K 2 regular

Tightening torques

Thread
Location material Nm

Cylinder head cover M8 25

Protective sleeve, nozzle holder to cylinder head M 14 60
Pressure screw for nozzle holder to cylinder head M 34
---
60 to 70
Injection nozzle in nozzle holder M 24 80
Leak·off line to nozzle holder M8 15t020
Union nut of injectine line to injection pump M 12 25
to nozzle holder M 14 25
Drive gear to injection pump M 14 80
Injection timing device to camshah 1J M 16 300
Engine mount front to frame M 14 140'±20

1) From engine No. 470 428

UKD 30 402 21 42--{)1 1.4/1

 General 07.8
352/352 A

Exploded view

1:1\270
~~72

~
278C

187 ®

192.
34
200 ~ o<O-:l 36
L:l>'~ 40
~
195
@~
~
o
o
I

"o

~~
N

"
C":> ~®®135
I 125
70

127
!@
'0
129
131 133

Injection system

6 Injection pump 62 Lock washer 207 Nozzle

10 Pipe union 64 Nut 209 Sealing ring
13 Sealing ring 66 Lever 211 Bolt
18 Insert 68 Bolt 215 Pipe
21 Compression spring 70 Woodruff key 220 Pipe
24 Washer 125 Lever 225 Pipe
30 Valve cone 127 Sealing ring 230 Pipe
34 Key 129 Bolt 235 Pipe
36 Key 131 Bolt 240 Pipe
40 Lock washer 133 Lock washer 245 Seal
45 Bolt 135 Washer 250 Packing
47 Sealing ring 185 Nozzle holder 255 Clip
50 Bolt 187 Shim 260 Clamp
52 Sealing ring 192 Compression spring 265 Leak·off line
55 Bolt 195 Spacer 270 Sealing joint
57 Delivery valve 200 Thrust pin 272 Union screw
60 Woodruff key 205 Cap nut 278C Screw

1.5/1
 Removal and installation of injection pump 07.8

352/352 A

Removal

Remove engine hood and front panel.

2 Venting line to steering fluid reservoir is to be
detached at timing gear case.
3 Release and remove taper plug in timing gear
case.

4 Move No. 1 cylinder piston to start of delivery

in compression stroke.

Note: The arrow in timing gear case must point to

mark on injection pump drive gear and the FB mark
(start of delivery) on timing pointer must be aligned
with FB mark (start of delivery) on vibration damper.

5 Using special tool No. 1, detach injection line

cap nuts from injection pump.
6 Detach oil supply line and fuel lines at injection
pump.
Note: For engine model 353.959 and 353.977 re-
move connection for manifold pressure compensator
on the injection pump.

7 Release and detach actuating linkage.

UKD 3040221 42-01 2.1/1

07.8 Removal and installation of injection pump
,
352/352 A

8 Detach fuel feed pump.

9 Unscrew and remove injection pump at timing

gear case.

10 Unscrew fastening nut on drive gear, using spe·

cial tool No. 4',

11 Draw drive gear off injection pump camshaft.

12 Detach bracket from injection pump.

13 Clean and check all parts, exchanging if ne-

cessary.

Note: Injection timing device attached to camshaft as

of end engine No. 470 428.

UR07-0241

2.1/2
 Removal and Installation of Injection Pump 07.8
352/352 A

Installation

1 Remove injection pump cover.

2 Piace rubber sealing ring on new injection pump,

slide on bracket and lightly screw in fastening Qolts.

3 Slide drive gear onto injection pump camshaft and

tighten.
For tightening torques, see 1.4/1.

Note: When installing a new injection pump, use the

drive gear from the old injection pump.

The slotted nut has been replaced from engine

end No. 470360 by a hexagon nut. The special tool No. 4
is required only for the slotted nut.

4 Remove cylinder head and check whether thepiston .

of cylinder No. 1 is at start of delivery in compression
stroke.

Note: The valves of the opposite cylinder must be

overlapping at this point and the start of delivery mark
(FS) on the timing pointer must be aligned with the start
of delivery mark (FS) on the vibration damper.

5 Tum injection pump drive gear until cylinder No. 1 is

at the start of delivery.

6 insert injection pump together with bracket and new

gasket in the timing gear case and screw in bolts with
sealing compound No. 2.

Note: The tooth marked on the drive gear must agree

with the arrow in the timing gear case.

UKD 30 402 21 42 - 04 2.1/3

07.8 Removal and Installation of Injection Pump
352/352 A
7 Attach injection pump cover with gasket and tighten
bolts.

8 Install fuel feed pump together new with gasket and

tighten bolts.

9 Attach and secure actuating linkage.

10 Connect fuel lines to fuel feed pump and injection

pump.

Note: For engine models 353.959 and 353.977, attach

connection for manifold pressure compensator to the
injection pump.

11 If necessary, fill injection pump with approx. 0.451 of

engine oil via the oil feed hol and connect oil feed line.

Note: Capacity of RQV governor approx 0.75 I.

12 Check and adjust start of delivery, refer 3.1/1.

13 Attach union nuts of injection lines using special tool

No. 1 and tighten without tension with the aid of special
tool No. 9.
For tightening torques, see 1.411.

14 Fit tapered plug in timing gear case and attach vent

line from steering oil reservoir.

15 Install cylinder head cover, see 01.8 • 3.1/1.

16 Attach front panel and engine hood.

17 Bleed fuel system, see 6.1/1.

2.1/4
 Removal and installation of relief valve at injection pump 07.8
352/352 A

Removal

Prop up engine hood outside.

2 Unscrew relief valve.

3 Disassemble relief valve.

4 Clean and check all parts, exchanging if ne·

cessary.

Installation

Attach relief valve with new sealing ring.

2 Vent fuel system, referring to 6.1/1.

3 Lower engine hood.

UR07-0361

UKD 30 40221 42-02 2.2/1

 Checking and Adjusting Start of Delivery 07.8
352/352 A

Checking, Adjusting

1 Remove engine hood and front panel.

2 Unscew. No. 1 cylinder injection line at injection pump,

using s~ecial tool No. 9.

3 Unscrew pipe union for No. 1 cylinder of injection pump.

Remove valve cone. Screw pipe union back in again.

4 Remove cylinder head cover, see 01.8-3.1/1.

5 Attach overflow pipe to injection pump at pipe union of

No. 1 cylinder. Fit fuel tank to intake.

6 Remove fastening bolt from front engine mount. Detach

metal cover.

7 Unscrew venting line at timing case to steering fluid

reservoir.

8 Release and remove taper plug at timing gear case.

UKO 30 402 21 42·03 3.1/1

07.8 Checking and Adjusting Start of Delivery
352/352 A

9 Turn crankshaft clockwise in direction of engine rota-

tion until No. 1 cylinder piston is at start of delivery (FB) on
compression stroke.

10 The arrow in the timing gear case must point to the

mark on the injection pump drive gear, and the FB mark
on timing pointer to FB mark on vibration damper
(FB = start of delivery).

11 Release and detach actuating linkage.

12 Move injection pump control lever to no-load and

open shut-off cock valve on fuel tank.

Note: Set to full load if RQV governor (SA 16 457) is

fitted.

13 If setting is correct, fuel must now drip out of overflow

pipe at intervals of about 15 to 20 s. If there is too much or
none at all, release injection pump at fastening bolts and
swivel in oblong holes until specified quantity is obtained.
For this purpose, it is necessary to unscrew all injection
lines at the injection pump.

Note: Swivelling towards engine retards start of deli-.

very.

Swivelling away from engine advances start of delivery.

14 An additional adjustment is provided in injection

pumps with a built on injection adjuster (up to engine end
No. 470 428) in that the screws are loosened and the
injection adjuster turned.

3.1/2
 Checking and adjusting start of delivery 07.8

352/352 A

15 Tighten injection pump fastening bolts. Check

start of delivery.
16 Fit guard plate and fastening bolt to the front
engine mounting.
Tightening torque, see 1.4/1.

17 Fit tapered plug to timing case and attach vent·

ing line from the steering fluid reservoir.

18 Remove spill pipe and fuel reservoir, fit fuel

line.
19 Unscrew the pipe union (4) from the injection
pump and attach the insert (3), compression spring
(2) and valve cone (1).

20 Attach the injector pipe to No. 1 cylinder of

the injection pipe with special tool No. 1 and tighten
without tensioning using special tool No. 9.
Tightening torque, see 1.4/1.
21 Bleed fuel system, see 6.1/1.
22 Fit front cover and engine bonnet.

UK 0 30 402 21 42-01 3.1/3

 Removal and installation of injection nozzle 07.8
352/352 A

Removal

Remove cylinder head cover,

referring to 01.8-3.111.

2 Unscrew injection line cap nut at injection

nozzle, using special tool No. 1.

3 Release bolts (1) on cylinder head and force

injection line to one side.

4 Detach leak·off line (2) from injection nozzle.

5 Remove thrust screw from injection nozzle,

using special tool No. 3.

6 Remove injection nozzle using

special tool No. 7.

UKD 30 402 21 42-<>2 4.1/1

07.8 Removal and installation on injection nozzle

352/352 A

7 Drain coolant.
8 Remove protective bushing from cylinder head,
using special tool No. 2.
9 Test injection nozzle, referring to 4.2/1.

Installation

Introduce new sealing ring for protective bush-

ing into cylinder head.

Note: The injector nozzle protrusion from the under-

side of the cylinder head is determined through a
0.5 or 1.0 mm thick seal.
Nozzle protrusion, see 01.8-1.2/3.

2 Insert and tighten protective bushing with

special tool No. 2.
See 1.4/1 for tightening torque.

3 Insert new nozzle holder seal into protective

bushing.
4 Introduce nozzle holder and nozzle into cylin-
der head, noting lock on nozzle holder and groove
in cylinder head.

Important:
Do not knock nozzle.

4.1/2
 Removal and installation of injection nozzle 07.8

352/352 A

5 Insert thrust screw, tightening with special tool

No. 3 and torque wrench.
See 1.4/1 for tightening torque.

6 Attach and secure leak·off line with new sealing

joints.
See 1.4/1 for tightening torque.

7 Attach injection line to injection nozzle, using

special tool No. 9.
See 1.4/1 for tightening torque.

8 Tighten retaining bolt in cylinder head.

9 Attach cylinder head cover,

referring to 01.8-3.1/1.

10 Fill system with coolant,

referring to 01.8-1.3/2 for quantitiy.

Note: The reservoir ought to be two th irds fu 11.

12 Vent fuel system, referri ng to 6.1/1.

UKO 30 402 21 42...{)1 4.1/3

 Testing injection nozzle 07.8
352/352 A

Testing

1 Remove injection nozzle, referring to 4.1/1.

2 Carefully remove carbon deposits from nozzle.
J Attach nozzle and nozzle holder to nozzle tes·
ter.

Testing injection nozzle for leakage

4 Slowly press pump lever downwards until pres·

sure gage shows 20 bar below opening pressure setting.
Failure of fuel to escape from nozzle mouth within
10 seconds means nozzle is tight.
Disassemble and clean injection nozzle in case of lea·
kage. See 4.3/1 for disassembly.
Renew nozzle should careful cleaning of nozzle body
seats and needle valve still fail to stop leakage,

Note: Never use anything but clean testing oil or

filtered diesel fuel fcir testing operation.

Danger:
On no account allow jet of fuel to strike your hand.
Jet will go deep into your body and damage tissue.
Fuel entering your bloodstream may lead. to blood
poisoning.

Testing the nozzle opening and injection pressures

5 Having connected pressure gage, slowly press

hand pump lever of nozzle tester downwards (1 stroke
per second) and note pressure when nozzle opens and
begins to discharge.

Caution: While pressure gage is set, always remember

to increase and lower pressure slowly because gage
may otherwise be damaged.
Should injection pressure be too high or too low, dis·
mantle injection nozzle, clean and correct setting.
See 4.3/1 for disassembly of injection nozzle.

Jet test

6 Disconnect pressure gage for this test. Press

pump lever up and down four to six times per second.
Nozzle will produce quiet rattling noise. Atomization
is good when all four jets are fine, even and closed;
they must not disparse sideways. Minor ranges with·
out rattling noise (with straight, non·atomized jets)
are of no consequence. Testing oil is ejected in the
form of a straight, non·atomized jet until rattling
region is reached.

7 Install injection nozzle, referring to 4.1/1.

4.2/1
 Disassembly and assembly of nozzle holder and'injection nozzle 07.8
352/352 A

Disassembly

Remove injection nozzle, referring to 4.1/1.

2 Introduce nozzle holder into special tool No. 6.

3 Remove nozzle clamping nut from nozzle hol·

der using special tool No. 5.

4 Disassemble nozzle

Nozzle holder 5 Spacer with locating

2 Washer pins
3 Compression spri ng 6 Nozzle
4 Thrust pin 7 Nozzle body
8 Thrust nut

5 Using a wood stick dipped in diesel fuel, clean

interior and exterior surfaces of dismantled nozzle,
especially valve seat and annular groove.

6 Nozzle body injection ports are to be cleaned

with a special needle.

7 Dip needle valve and nozzle body in clean diesel

fuel, dropping to check for smooth movement.

Dropping test: Having lifted needle valve by one third

out of nozzle body, release so that it returns to its
seat under its own weight. Should it fail to do so, re-
new nozzle and nozzle body.

UKO 30 402 21 42--01 4.3/1

07.8 Disassembly and assembly of nozzle holder and injection nozzle

352/352 Pi

Assembly

Assemble injection nozzle. Note locating pins

on spacer.

Nozzle holder 5 Spacer with locating

2 Washer pins
3 Compression spring 6 Nozzle
4 Thrust pin 7 Nozzle body
8 Thrust nut

2 Introduce nozzle holder into special tool No. 6 ..

3 Tighten thrust nut using special tool Ni>. 5.

See 1.4/1 for tightening torque.

4 Remove nozzle holder and attach to nozzle

tester.

5 Test injection pressure and jet, checking nozzle

for leakage. See 4.2/1.

Note: Fit appropriate washer (see section 1, item 2)

should nozzle tests show inadequate or excessive in·
jection pressure.
Excessive pressure is to be counteracted by thinner
washer, and inadequate pressure by thicker one.

6 Install injection nozzle, referring to 4.1/1.

4.3/2
 Removal and installation of injection timing device at injection pump drive gear 07.8

352/352 A

Removal

Note: Up to engine No. 470 428

Remove injection pump, referring to 2.1/1.

2 Mark injection pump drive gear relative to inject-

ion timing device. Release and remove bolts.

3 Remove lock washer.

4 Remove injection timing device, taking thrust

washer out of drive gear.

5 Clean and check all parts, exchanging if neces-

sary.

Installation

Note: Up to end engine No. 470 428

Install injection timing device in drive gear.

Note: Coat fly-weights and bearing surfaces with

Molykote.

2 Fit thrust washer in drive gear.

3 F it lock washer.

4 Turn drive gear to mark on injection timing

device. Insert and secure bolts.

5 Install injection pump, referring to 2.1/1.

UKD 30 402 21 42-01 5.1/1

 Disassembly and assembly of camshaft 07.8

352/352 A

Removal

Note: From end engine No. 470428.

Remove timing gear case cover, referring to

03.8-3.1/1 or 03.8-3.2/1.

2 Turn crankshaft, positioning crankshaft gear

and injection timing device at mark "1·1" (H.

3 Detach cover or duty hour counter from timing

gear case and mark position of injection pump drive
gear (2).

4 Release bolt holding injection timing device and

detach the latter using special tool No. 8.

5 Disassemble injection timing device, referring

to 5.3/1.

Installation

Note: From end engine No. 470 428.

Position injection timing device on camshaft,

noting marks on crankshaft gear and injection pump
gear.

2 Insert and tighten center fastening bolt.

See 1.4/1 for tightening torque.

3 Attach cover or duty hour counter to timing

gear case.

4 Attach timing gear case cover, referring to

03.8-3.1/1 or 03.8-3.2/1.

5 Check and adjust start of delivery, referring to

3.1/1.

UKO 30 402 21 42-01 5.2/1

 Disassembly and assembly of injection timing device 07.8

352/352 A

Disassembly
From engine No. 470 428

1 Remove injection timing device, referring to

5.211.

2 Clamp injection timing device and force cam·

shaft gear off.

3 Remove springs, pins and centrifugal weights.

4 Clean and check all parts, exchanging if neces·

sary.

Assembly
From engine No. 470 428

Attach camshaft gear and insert springs with

pins.

2 Clamp injection timing device, slightly lift and

turn camshaft gear, and press centrifugal weights into
position.

Note: Coat centrifugal weights and bearing surfaces

with Molykote.

3 Install injection timing device, referring to

5.2/1.

UKD 30 402 21 42-01 © www.buchundbild.de 5.3/1

 Bleeding Fuel System 07.8
352/352
Bleeding

1 Release handwheel (2) on hand pump.

2 Pump until slight resistance is felt.

3 Slacken both bleeder screws successively on the

main filter by 1 to 2 turns.

4 Continue pumping until bubble-free fuel emerges

from the bleeder screws.

5 Tighten bleeder screws.

6 Slacken bleeder screw (1) on injection pump by

1 to 2 turns.

7 Continue pumping until bubble-free fuel emerges.

8 Tighten bleeder screw (1).

9 Tighten handwheel (2) on hand pump.

10 Remove cylinder head cover, refer to 01.8 - 3.1/1.

11 Detach injection line on nozzle holder.

12 Remove injection pump cover.

13 Set adjusting lever to full-load and pump at relevant

pump element until bubble-free fuel emerges from the
injection line.

Note: The relevant pump element must be at BDC.

14 Attach injection line to nozzle holder and tighten.

For tightening torques, see 1.4/1.

15 Pump at the pump element until considerable resist-

ance is felt and the nozzles inject audibly.

Note: Bleed the remaining injection lines as described in

points 11 to 15.

16 Attach injection pump cover.

17 Install cylinder head cover, see 01.8 - 3.1/1.

UKD 30 402 21 42 - 04 6.1/1

 Removal and installation of fuel supply pump 07.8

352/352 A

Removal

Detach fuel lines.

2 Detach fuel supply pump from injection pump.

3 Clean and check all parts, exhanging if neces·

sary.

Installation

Place new gasket in position.

2 Attach and fasten fuel supply pump.

3 Attach fuel lines.

4 Vent fuel system. referring to 6.1/1.

UKO 30 402 21 42-01 7.1/1

 Disassembly, cleaning and assembly of fuel filter 07.8

352/352 A

Disassembly

Release filter bowls.

2 Remove "filter bowls and take out filter ele-

ments.

Note: The prefilter has a felt element and the fine

filter a paper one.

Cleaning

Note: Clean fuel filter elements with reference to

maintenance chart, exchanging if necessary.
When replacing fuel filter elements. use only felt tube
elements.

Clean filter bowls with fuel.

2 Close openings in filter elements, place elements

in fuel and allow to soak.
3 Using compressed air, blowout filter elements
from inside. Repeat cleaning process until ejected
fuel is clean.

Assembly

Exchange seals on filter bracket.

2 Attach filter bowls with filter elements.
3 Vent fuel filter, referring to 6.1/1, operations
1 to 5.

UKD 30 402 21 42-02 8.1/1