Shimming method D4D/D5D

Changing Unit Injector Pumps

on mechanically controlled
D4D and D5D Engines

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Shimming method D4D/D5D

When replacing injection pumps on mechanically controlled

D4D/D5D the thickness of the shim between the pump and the
roller tappet has to be calculated.

The calculation method is described in this presentation.

During the procedure several value tables are used.

Different value tables are to be used depending on engine type

and whether the engine is equipped with ”Injection Timer” or
not.

All the value tables needed are included last in this presentation

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How do I know if the engine is equipped with

Injection Timer; “White Smoke Kit”?

D4D: If the EP-code on the engine ID-plate is between 600 to 699,

the engine is equipped with a ”White Smoke Kit”.

D5D: If the EP-code on the engine ID-plate is between 700 to 799,

the engine is equipped with a ”White Smoke Kit”.

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 Shimming method D4D/D5D

What is an Injection Timer (White Smoke Kit)?

To meet Tier 2 / Stage 2 emission legislations the injection timing has
to be retarded in comparison with Tier 1 /Stage 1 engines.
Retarded injection timing reduces the NOx emissions, but increases
the white smoke emitted during engine cold start up.
NOx emissions increases with higher combustion temperatures, thus
during cold running conditions the NOx levels are quite low
Solution:
¾Advanced (early) injection timing during cold start up to reduce
white smoke

¾Retarded (later) injection timing during normal running, when the

engine is warm to reduce NOx
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Injection Timer (White Smoke Kit)

Unit injection pump Fuel delivery Shim
Fuel inlet channel

Pump piston
Pump piston control edge

Main oil gallery

Injection Timer; Hydraulic Roller Tappet

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Hydraulic Roller Tappet

Housing Lock ring
Drain channel
Timing spool
Return spring for non return valve Non return valve

Spring
Control spool

Return spring for control

Bushing
spool
Bolt

Lock pin

Roller
Memory spring

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 Shimming method D4D/D5D
What is a “Memory Spring”?
Shape memory alloys (SMA's) are metals,
which exhibit two very unique properties,
pseudo-elasticity, and the shape memory
effect

The two unique properties described above are made possible through a solid state phase change

The two phases, which occur in shape memory alloys, are Martensite, and Austenite.

Martensite, is the relatively soft and easily deformed phase of shape memory alloys, which exists at
lower temperatures. In this phase, the spring is inactive.

Austenite, the stronger phase of shape memory alloys, occurs at higher temperatures. In this phase
the spring is active.

In most shape memory alloys, a temperature change of only about 10°C is necessary to initiate this
phase change.
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 Shimming method D4D/D5D
Hydraulic Roller Tappet, Cold Engine Operation
Oil temperature < 40°C 1 Memory spring plastic / not in force

2 Return spring overcomes the memory

spring and forces the control spool
downwards
6 3 Oil from the main gallery may now
5 enter via the non return valve into
4 the upper chamber underneath the
timing spool

3 4 The timing spool is forced upwards

advancing the injection timing by 6
crank angle degrees
2
5 The timing spool is kept in it’s upper
position by the hydraulic lock
1 maintained by the non return valve.
6 Even if some of the oil is drained via
the drain channel, the hydraulic lock
remains as new oil is continuously
refilled via the non return valve
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Hydraulic Roller Tappet, Warm Engine Operation
Oil temperature > 50°C
1 Memory spring elastic / working
5 4
2 Memory spring overcomes the return
spring and forces the control spool
upwards closing the passage to the
upper chamber
3 Oil from the main gallery can no
longer enter via the non return valve
3 to the upper chamber
4 Any remaining oil trapped in the
upper chamber underneath the
2 timing spool is drained via the drain
channel
5 The timing spool is not lifted, thus
1 in it’s lowest position and the timing
is again retarded

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 Shimming method D4D/D5D

Example: Change UIP for cylinder no. 3 on Engine D4D

with ”Injection Timer”

Read off EP code for cylinder no. 3 on the engine identification plate
under column ”EP”.

(Reading sequence: line 1 = cyl. 1, line 2 = cyl. 2, etc.)

EP-code for cylinder no. 3 = e.g. 653

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 Shimming method D4D/D5D

D4D / D5D
Firing order 1-3-4-2

Flywheel end
Note! The cylinders are numbered 1
to 4, starting at the flywheel end

Direction of rotation: As seen from the

flywheel counter-clockwise

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 Shimming method D4D/D5D

Take corrected injection pump installation dimension (EK)

from table 3.1 according to EP code, e.g. 117.225 mm.

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Read off code for injection pump length (A) from new injection pump, e.g. 39.

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What does the A-code stand for?

In this position - commencement of delivery position of the
injection pump plunger - the distance between pump contact
surface and tappet foot contact surface is called LFB.

The injection pump must be compressed to this length in order to

arrive at its commencement of delivery position.

Due to manufacturing tolerances this length varies from pump to

pump.

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 Shimming method D4D/D5D

What does the A-code stand for?

The length LFb is always some hundreds of a millimeter
longer than a certain standard dimension Lo of the pump.

Those hundreds of a millimeter which must be added to Lo in

order to obtain LFb are called A.

LFb = Lo + A / 100 [mm] ;(Lo = standard length)

These hundreds of a millimeter are measured and etched on

the pump body by means of an electro sensitive pen.

The minimum value which can be found is zero. A pump will

be scrapped if its LFb value drops below Lo; that is if
A < 0.

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Shimming method D4D/D5D

Read off commencement of delivery (°C/A BTDC), e.g. 3.0

And camshaft type, e.g. P

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Shimming method D4D/D5D

Take basic dimension of injection pump (L0)

from table 1, e.g. 111.15 mm

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 Shimming method D4D/D5D

Determine theoretical shim thickness (TS):

TS = EK - (L0 + A/100)

TS = 117.225 mm - (111.15 mm + 39/100 mm)

TS = 5.685 mm

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 Shimming method D4D/D5D

Select shim thickness (SS)

from table 2.1

TS = 5.685 mm ⇒ SS = 5.7 mm

Hydraulic roller tappet Shim

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 Shimming method D4D/D5D
How to reinstall the unit injector pumps……
While installing the injection pumps, the fuel rack has to be kept in “stop”
position with a locking device.

Either special tool No. 9998684 or 9998682 can be used to lock the fuel rack in
stop position.

9998684 9998682

Note! Please disregard that the pumps are already installed on the pictures in this presentation
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Shimming method D4D/D5D
When special tool 9998684 is to be used……
Remove the UIP stop solenoid Remove the fuel governor

9998684 Install special tool 9998684 and tighten the

screw until the fuel rack is locked in “stop”
position

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Shimming method D4D/D5D
When special tool 9998682 is to be used……

Remove the UIP stop solenoid

9998682 Install special tool 9998682 and tighten the

screw until the fuel rack is locked in
“stop” position

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Shimming method D4D/D5D

5 Installation of injection pumps

1 5 2 34
Check that the UIP roller tappet is placed
against the cam shaft base circle for the
Stop relevant cylinder

Special tool No. 9998682 or 9998684 keeps

the fuel rack in stop position (1)

Turn the injection pump linkage lever (3) to the middle of its
travel and insert he single injection pump so that the linkage
lever (3) can be introduced into the notch (4) of the fuel rack. Oil
O-rings of the injection pumps

Preload the flange screws (5) of the single injection pump -

chamfer pointing towards injection pump body - with 5 Nm.
Thereafter the screws are slackened by 60°.

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Shimming method D4D/D5D

Stop

11668403

Carefully turn the UIP counter-clockwise. Use a torque wrench

(2) with gauge and socket 11668403. Make a note of the
reading on the gauge on the torque required to turn the UIP,
e.g. 3.5 Nm.

Stop turning the torque wrench when the UIP has reached its
stop position, which is reached when the torque required has
increased by 1 Nm, e.g. 3.5 + 1 = 4.5 Nm

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Shimming method D4D/D5D

5 5

Stop

Thereafter tighten the UIP flange screws (5) alternately in steps:

Step 1 7 Nm
Step 2 10 Nm
Step 3 30 Nm

After installation of each single injection pump the fuel rack

must be checked for free move ability.

Reinstall fuel governor, stop solenoid and other disassembled parts.

NOTE! Always fit NEW fuel pressure pipes!
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Shimming method D4D/D5D

Tables

D4D; With Injection Timer D4D; No Injection Timer

D5D; With Injection Timer D5D; No Injection Timer

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 Shimming method D4D/D5D
Tables D5D; No Injection Timer (continues on next slide)

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Shimming method D4D/D5D

Tables D5D; No Injection Timer

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Shimming method D4D/D5D

Tables D5D; With Injection Timer

(continues on next slide)

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Shimming method D4D/D5D

Tables D5D; With Injection Timer

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 Shimming method D4D/D5D

Tables D4D; With Injection Timer

(continues on next slide)

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Shimming method D4D/D5D

Tables D4D; With Injection Timer

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 Shimming method D4D/D5D

Tables D4D; No Injection Timer (continues on next slide)

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 Shimming method D4D/D5D

Tables D4D; No Injection Timer

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