Remove/install high-pressure pump

AR07.02-P-1020LFD

Remove/install high-pressure pump

04.09.2018

Engine

642 in model 222

1

Screw/bolts

2

Engine wiring harness guide

3

High-pressure line

B4/7

Fuel pressure sensor

B50

Fuel temperature sensor

Y94

Quantity control valve

Variant A

5

Correctional weight

6

Groove

6a

Left edge

7

Gear

A

Tooth

E

Tooth

F

Tooth

Variant B

5

Correctional weight

6

Groove

6a

Left edge

7

Gear

A

Tooth

E

Tooth

F

Tooth

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



Remove

1

Remove engine cover

2

Unclip engine wiring harness guide (2) in the front area

3

Disconnect electrical connections to quantity control valve (Y94) and fuel temperature sensor (B50)

4

Detach bracket for fuel pressure sensor (B4/7)

5

Detach high-pressure line (3) on high-pressure fitting and close off connections


Close off high-pressure line (3) with suitable  stop plugs.
In this way ingress of foreign bodies is avoided.

 Counterhold threaded sleeve for high-pressure line (3) using a suitable tool.

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

 Record plug

*129589009100

6

Disconnect fuel hoses from high-pressure pump


Seal fuel hoses using suitable  stop plugs.
In this way ingress of foreign bodies is avoided.

 Check condition of hose clamps and fuel hoses and replace if necessary.

 Record plug

*129589009100

7

Position piston of cylinder 1 on crankshaft to ignition TDC


The engine must not be turned back against the direction of rotation.
The timing chain can skip otherwise and engine damage can occur.

8

Remove screw/bolts (1) for high-pressure pump

 Clean threads.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

9

Remove high-pressure pump from the cylinder head



Check

10

Check sealing cone on high-pressure line (3).

 In the case of visible pressure marks on the high-pressure line (3), replace it.



Install

11

Modify gear (7)

When replacing high-pressure pump.

AR07.02-P-1021LFD

12

Clean sealing surfaces of the high-pressure pump

13

Replace O-ring on high-pressure pump

 Apply engine oil to the O-ring.

14

Attach marking to tooth (A) of the gear (7)

 In order to apply the markings in the operation steps 14 and 15 and to adjust in operation step 16, the high-pressure pump () is brought into (for example held in) the installation position in a removed condition.

 Place the groove (6) vertically, determine from the left edge (6a) of the groove (6) vertically to the upper tooth (A) and mark.

15

Attach markings to teeth (E, F)

 Determine the teeth (E, F) from the tooth (A) counterclockwise. Here tooth (A) is the 1st tooth and the teeth (E, F) are the 5th and 6th tooth.

16

Adjust position of gear (7) relative to high-pressure pump

 The teeth (E, F) must stand vertically upwards.

17

Place high-pressure pump on cylinder head


Ensure that the previously adjusted gear (7) is not twisted.
Vibrations will occur otherwise.

18

Screw on high-pressure pump with screw/bolts (1)

 Replace screw/bolts (1) due to micro-encapsulation.

 Bolt, high-pressure pump to cylinder head

*BA07.16-P-1021-01C

19

Mount fuel hoses at high-pressure pump

 Check condition of hose clamps and fuel hoses and replace if necessary.

20

Mount high-pressure line (3) on high-pressure fitting

 Counterhold threaded sleeve for high-pressure line (3) using a suitable tool.

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

21

Mount bracket for fuel pressure sensor (B4/7)

22

Mount electrical connections on quantity control valve (Y94) and fuel temperature sensor (B50)

23

Unclip engine wiring harness guide (2) in the front area

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

24

Check fuel system for leaks with engine running


When replacing the high-pressure pump () the ignition must be switched on for at least 15 seconds before the engine is started.
The high-pressure pump would be damaged otherwise.

25

Fit engine cover

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1021-01C

Bolt, high-pressure pump to cylinder head

Nm

15

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1025-01C

Pressure line to high-pressure pump

M14

Nm

33

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com