Chapter 4 Part A Fuel and exhaust systems Contents <<. See Chapter 1 Fuel injection timing device — removal and r assembly — removal and installatio --. 9 installation ‘See Chapter 1 le speed check and adjustment See Chapter 1 Fuel system bleeding See Chapter 1 See Chapter 1. Fuel system check See Chapter 1 Exhaust system components — removal and instalation 10 Fuel tank — removal and installation 8 Fuel filter assembly — removal and installation 8 Fuel tank — repair 8 iter replacement... --- See Chapter 1. General information 1 Fuel injection pump — check 2 Idle speed adjusting knob — check and Fue! injection pump — removal and installation 4 ‘See Chapter 1 Fue! injection pump start of delivery — check ifold ~ removal and ‘and adjustment 3 _ installation ‘See Chapter 2 Fue! injection nozzles ~ removal and instalation 7 Thvottle linkage check and lubrication See Chapter 1 Specifications Fuel injection pump Start of delivery (degrees Before Top Dead Center) Turbocharged models Non-turbocharged models 615.913/940 615.912/041 616 Torque specifications Exhaust manifold-to-pipe self-locking nut Exhaust pipe U-clamps Fay Exhaust pipe-to-transmission mount brece {turbocharged models) Exhaust pipe clamp nuts Brace-to-transmission nuts Turbocharger flange-to-exhaust pipe nut Fuel injection lines Fuel injection nozzle Fuel tank Jocking retaining nuts \Non-sel-locking retaining nuts ‘Suction hose clamp screw Fuel strainer nut Fuel gauge immersion tube transmitter nut Fuel delivery valve pipe connection 1 General information The fuel systom consists of a rear mounted fuel tank, @ mechanical ‘operated fuel injection pump with injector nozzles mounted in the ‘cylinder head, the injection timer, the intake manifold and an air cleaner ‘assembly. Some models are also equipped with en exhaust gas-driven turbocharger. The turbocharger is covered in Part B of this Chapte ‘The exhaust system includes the muffler and associated pipes and hardware. Fuel is drawn from the tank and through the filter by the injection pump. The fuel is injected directly into the precombustion and then 23° to 25° BTDC 26° BTDC. 24° BTDC. 24° BTDC. Nm Feube 201025 1810 18 7 5 7 5 20 15 20t025 18018 25 18 701080 210 69 261034 190.25 36 t0 43 26 to 32 24032 1810 24 351043 26 to 32 36 to43 26 to 32, 401050 30 to 37, itis ignited by the very high compres: ‘drawn in through the air cleaner and intake {and the point in the engine cycle at which tothe cylinders is controlled by the timing chain-driven, timing device and the internal governor in the fuel injection pump. Because of the complexity of the diesel fue injection system, check- ing (other than for leaks or obvious damage) and adjustment should bbe left to a dealer or a properiy equipped shop. The home mechanic can adjust the fuel injection start of delivery (Section 3) using a simple factory tool. This is roughly similar to adjusting the distributor timing fon a gasoline powered vehiChapter 4 Part A Fuel and exhaust systems ere PP mm a. cle grees ee be une well egy Ie fama Pine hil ond poclton ay wannnany 3.4b ... and remove the valve (A) and spring (B) 15 3.6 The fuel injection start of delivery tool spout must be installed with the spout facing the engine in the direction of the 2. Fuel injection pump — check 1. The fuel injection pump bolts to the cylinder block on the side of the engine 2 The fuel injection pump is a complicated device which operates {at very high pressure, Checking and adjustment (other than start of delivery, Section 3) requires special tools and techniques so this should be left to a dealer or properly equipped shop. Because of the high pressures involved, fuel leaks can seriously affect engine operation and the pump and lines should be checked periodically for leaks by the home mechanic. 3" Make sure that there is fuel in the fuel tank. 4 With the engine running, check for leaks at all fuel line connec: tions between the fuel tank and the fuel pump. Tighten any loose con: nections. Inspect all ines for cracks as well 25 kinks which would restrict the fuel flow. 3 Fuel injection pump start of delivery — check and adjustment Note: This procedure determines the start of fuel delivery of the fuel injection pump number one element when the number one piston is at the start of the the compression stroke. Before beginning this pro Gedure obtain a start of delivery overflow pipe spout too! number 636 589 02 23 00 from your desler. 1 Remove the fuel injection pump-to-injector pipe assembly. 2 Disconnect the vacuum hose from the fuel pump vacuum control nit. 3. Disconnect the throttle linkage from the pump and use a piece of ‘wire to fasten the control lever in the full load position (photo). 4 Remove the number 1 pump element from the pump and then remove the delivery valve and spring from the element (photos) 5. "Reinstall the element, minus the delivery valve and spring. 6 Install the overflow pipe tool in the number 1 pump element withm6: Chapter 4 Part A Fuel and exhaust systems 3.7. The engine timing marks (A) and pointer (B) (the engine is shown at Top Dead Center (TDC) here) are visible behind the drivebelt pulleys at the front of the engine; a flashlight is helpful in locating them 3.83 Loosen the fue! filter union bolt with a wrench while ‘operating the hand pump until bubble-free fuel (arrow) can be ‘seen escaping from the union and 3.10. Rotate the fuel injection pump toward or away from the engine (arrows) to achieve the proper start of delivery 3.9 Fuel must drip from the spout (arrow) at a one droplet per second rate the spout facing toward the engine (photo). 7. Turn the engine over by hand in the normal direction of rotation (clockwise when facing the front of the vehicle) until the compression pressure can be felt beginning to build up. Rotate the engine until the timing pointer on the front of the engine is aligned with the specified Start of delivery degrees on the balancer (refer to Specifications) {photo}, Remove the oll filer cap. Check to see that both camshaft lobes for the front (number 1) cylinder are facing up. With this done, the number 1 piston is at the start of its compression stroke. 8 Loosen the fuel union bolt at the top of the fuel filter and bleed the air from the system by pumping the hand pump until fuel with no tir bubbles issues from the top ofthe filter and the overflow tool spout (photos) 9. Stop pumping the hand pump and the flow from the spout of the overflow tool should slow until a rate of one droplet per second is reached (photo) 10 If the flow is not correct, loosen the fuel injection pump mounting bolts, repeat the procedure and rotate the pump until one droplet per second is achieved (photo) 41 Once the proper start of delivery is obtained, tighten the pump ‘mounting bolts, remove the spout tool and reinstall the delivery valve land spring in the element. Install the fuel pipe assembly and connect the throttle linkage and vacuum hose.Chapter 4 Part A Fuel and exhaust systems Fig. 48.1 Fuel 1 Leak-off (overflow) hose 5 Fuel union screw from injection nozzle 6 Sealing ring 2 Fuel union screw 7. Fuel union screw 3 Sealing ring & Sealing ring 4 Banjo connector 9 Oring 4.2. The oll cooler lines (A) and pressure gauge line (B) Connections are accessible from the engine compartment ‘4 Fuel injection pump — removal and installation Removal 1 Disconnect the cable from the negative battery terminal 2 On some models it will be necessary to remove the ol filter hous- ing assembly. Drain the ol (Chapter 1) and in the engine compartment, disconnect the oil cooler line and the oil pressure gauge connection. Hold the cooler line nut fiting on the housing with a thin backup wrench ‘while unserewing the fitting to avoid twisting the line (photo). 3 If equipped. remove the turbocharger cooler line from under the jection pump and filter assembly component layout (Sec 4 and 8) 10 Hose clamp 14 Fuel line 11. Expansion hose 18 Fuel line 12. Return line from 16 Fuel filter housing bypass vaive 17 Fuel filter cartridge 13 Bypass valve 30. Fuel injection pump 4.3. The turbocharger oll ne is located at the bottom of the oil filter housing {iter housing (photo). Remove the bolts using a suitable Allen head wrench and lift the housing from the engine. It may be necessary to Gut off a short piece of an Allen wrench with @ hacksaw and hold it Wwith locking pliers to remove the bolts on some models because of the restricted working atea around the oll filter housing. 4 Disconnect the throttle linkage at the fuel injection pump. 5 Mark the fuel injection pump vacuum hoses for ease of instal tion and disconnect them. 6 Remove the fuel injection pump-to-njector pipe assembly. Be sure to_hold the fitings inthe injection pump with ¢ back-up wrench to pr vent them from turning.18, Chapter 4 Part A_ Fuel and exhaust systems 4.7. The fuel injection pump lower bolt (A) and throttle return ‘pring (B) are accessible from below 4.10. Slide the fue! injection pump rearward and then lift it from the engine compartment; be sure to get a good grip because the ump is heavy 7. From under the engine, disconnect the throttle return spring and remove the lower pump retaining bolts (photo) 8 Remove the fuel union bolts and disconnect the lines from the in jection pump (photo). 9 Remove the remaining pump retaining bolts. Use a curved wrench to loosen the bottom one. 10 Grasp the pump securely (itis heavy), slide it rearward and then lift it from the engine compartment (photo). Installation 11. Prior to installation, remove the front collar and align the mark on the splines with the mark on the housing (photo). 12 Install the collar on the pump. The engine must be at the spe start of delivery point (24 or 26° BTOC). 13 Install the pump into the engine as near as possible to it’s original ‘angle. A good way to check this is to place the fuel injection pipe ‘assembly temporarily in place to make sure the connections line up. 414 Install the retaining botts (but don’t fully tighten them) and the fuel lines. 15 Bleed the ar from the system with the hand pump and check and adjust the fuel start of delivery (Section 4). Fully tighten the pump ‘mounting bolts. 16 The temainder of installation is the reverse of removal. Note: Loosen the clamps between the fuel injection pipes to ease instalation ‘and prevent cross threading. 5 Fuel tank — removal and installation Warning: While diese! fuel is not as flammable as gasoline, extra preceu: d 4.8. Prior to injection pump removal, the two fuel lines (A) and fone oil feed line (8) must be disconnected peers 4.11. The wide spline and the mark on the fuel injection pump (arrows) must be aligned before the pump is instaled tions should be taken when working on any part of the fuel system Do not smoke or allow open flames or bare light bulbs near the work ‘area. Also, do not work in a garage if @ natural gas-type appliance with 2 pilot light is present. While performing any work on the fuel tank it is advisable to have a fire extinguisher on hand and to wear safety glasses. 1 Remove the cable from the negative battery terminal. 2. Remove the plug at the bottom of the tank and drain the fuel into ’ clean container. Coupe and sedan 3._Loosen the hose clamps on the fuel suction and return hoses and disconnect, plugging the connections. 4 Remove the trunk floor mat and trim panel. 5 Loosen the retaining screws and remove the trunk rear wall panel for access to the fuel tank. 6 Loosen the retaining nuts, unplug the electrical connector and lift the fuel tank from the trunk, making sure the vent line is held in place. 7. Installation is the reverse of removalFig. 48.3. Station wagon Mouring sodan) fuel tank Installation details (Sec 5) 50 50a 50b 0c 55 550 60 600 62 64 640 65 68 69 70 73 730 Fuel tank Reinforcing panel Washer Self-locking nut Later model expansion tank {not all models) Earlier model expansion tank {not ail models) Filler neck Sealing sleeve Closing cover Sealing ring Positive vent lines Negative vent lines Immersion tube transmitter Sealing ring Fue! strainer Sealing ring Feed line Return line Later model venting sleeve Earlier model protective sleeve Sodan and coupe fuel tank installation details 50 508 505 5t 60 60a 62 628 64 65 650 68 680 69 70 1 71a 73 730 7 (Sec 8) Fuel tank Reinforcing panel Washer Vent vatve (not all models) Filler neck Sealing sleeve Closing cover Sealing ring Vent line Immersion tube transmitter Sealing ring Fuel strainer Sealing ring Feed line Return line Gosket Gasket Vent sleeve (later model) Protective sleeve (early ‘model) Damping shim20) Chapter 4 Part A Fuel and exhaust systems Station wagon (touring sedan) 8 Remove the trunk floor and intermediate shelf panels and remove the covers from the fuel quage sender and hose openings. 9 Unplug the sender connector. 10 Loosen the clamps with a screwdriver and disconnect the hoses. 11 From under the vehicle, loosen the clamps, disconnect and plug the fuel hose and return line placing @ suitable container underneath to catch the residual fuel 412. Remove the retaining bolts and lower the fuel tank from the vehicle. 13 Installation is the reverse of removal. Caution: Never perform any repair work involving heat or flame on the tank untilit has been purged of fuel and vapors. All repair work should be performed by a professional {eee the following Section, © Fuel tank — repair 1. Any repairs to the fuel tank or filler neck should be carried out by 2 professional who has experience in this critical and potentially ‘dangerous work. Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of the tank 2. Ifthe fuel tank is removed from the vehicle, it should not be placed inan area where sparks of open flames could ignite the fumes coming from the tank. Be especially careful inside garages where a natural gas type appliance is located, because the pilot light could cause an explosion, 7 Fuel injection nozzles — removal and installation Waring: Although diese! fuel is not as flammable as gasoline, extra precautions must be taken when working on any part of the fuel ‘system. Do not smoke or allow open flames or bare light bulbs near the work ares, Also, do not work in a garage if @ natural gas type ap- pliance with a pilot light is present. 1. Remove the cable from the negative bi 2 Dueto the rigid nature ofthe injection pi all the pipes from the nozzles even if only one nozzle is being serviced. 3. Pull off the overflow tube from the nozzl 4 Unscrew the nozzle from the cylinder head with a socket wrench ‘such as Mercedes too! number 000 589 68 03 00 available at your such a tool is not remove the camshaft cover to ie with a suitable 8 Fuel filter assembly — removal Note: only the fe! filter cartridge is being replaced, refer to Chapter 1 1 Disconnect the negative battery cab! 2. Place newspapers or rags under the filter to catch the fuel 3. Remove the four fuel union serews and disconnect the fuel lines ‘rom the filter housing, 4. Remove the retaining bolts and lft the assembly housing from the engine. 5 _ Installation is the reverse of removal, taking care to tighten the Union screws securely In order to prevent leaks, use new sealing rings. 9 Air cleaner assembly — removal and installation Oil bath-type air filter 1 Loosen the hose clamp and disconnect the air fiter top from the connector hose. 2° Remove the nut retaining the vibration mount to the fender inner panel and lift the housing assembly from the engine compartment. installation is the reverse of remov. Dry-type air filter 4 Remove the top nut and remove the ment. isconnect the intake hose (later models} and if equipped) turbo: i filter cover and filter SS ZILLI ie YN VRE NN WS IY Fig. 4A.4 Fuel injection nozzle installation details (Sec 71 1 Injection nozzle 5 Nozzle plate 2 Collar 6 Glow plug 3 Precombustion chamber 7. Cylinder head gasket 4 Sealing ring Fig. 48.5 Oil bath-type air cleaner assembly component layout (Sec 9) Hose clamp Scoop Intake pipe ‘Scoop Air filter top ‘Sealing ring Air filter element Air filter bottom Vibration mount Domed washer Nut TS eevoaaens ruts located inside the housing and lift the hous- ing from the engit 7" Remove the three bolts and lift the vibration mount from the ‘manifold (photo). On turbocharged models it will be necessary to disconnect the oil pipe. 8 Installation is the reverse of removal, taking care to lubricate the intake manifold sealing ring with clean engine cil48.6 Dry-type air filter ly component layout turbocharged models) (See 9) Early model intake pipe Later model intake pipe Air filter cover Sealing ring Friter element Filter housing Vibration mount Nut Sealing ring ‘Screw Early model intake hood Later model intake hood Early model rubber seal Later model rubber seal Hose clamp Fig. 48.7 Turbocharged model air filter housing assembly ‘component layout (Sec 8) 1 Wing nut 11 Sud 2 Cover 12. Vibration mount bolt Intake hose 13 Washer Filter element 14. Vibration mount Filter housing 21 Screw ‘Sealing ring 22 Early model inteke hood 9.7. The lower vibration mount bolt (ar rccessible with a Clamp 22a Later model intake hood socket on an extension Turbocharger intake pipe 23a Later model rubber seal NutChapter 4 Part A Fuel and exhaust systems 123 Fig. 4A.9. Turbocharged model exhaust system component layout (Sec 10) 10 Exhaust system components — removal and installation The vehicle's exhaust system gener jeratures and should be allowed to coo! completel the components are touched. 1 Raise the vehicle and support it securely on jackstands. 2. Replacement of exhaust system components is basically a matter ‘of removing any heat shields, disconnecting the component and instal- Ting a new one. Do not tighten any bolts or nuts fully until the exhaust ‘suspended from the rubber suspension rings snd exhaust system hangers must be reinstalled Je could result. Due to the high ‘of the exhaust system com- together. Penetrating to help loosen frozen fasteners. However, in some it may be necessary to cut the pieces apart with a hacksaw or ‘cutting torch. The latter method should be employed only by persons. experienced in this work