Remove/install high-pressure pump

AR07.02-D-1020SF

Remove/install high-pressure pump

18.04.2019

Engine

642.896/898/992/993 in model 906

Modification notes

13.02.2018

Method and work procedure revised

Operation steps 1 to 30

Shown on engine 642.896/898

1

High pressure pump

6

High-pressure fitting

11

Sealing ring

2

Fuel hose

7

Electrical connector

12

Gear

3

Fuel hose

8

Screw

15

Fuel temperature sensor

4

Electrical connector

9

Coolant hose

16

Quantity control valve

5

Pressure line

10

Bracket (engine 642.896/898)

Variant I

12

Gear

13

Groove

13a

Left edge

A

Tooth

E

Tooth

F

Tooth

Variant II

12

Gear

13

Groove

13a

Left edge

A

Tooth

E

Tooth

F

Tooth

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Remove fan shroud

Engine 642.896/898/992/993 in model 906
except code XM0 (Facelift)

AR20.40-D-6800SF

Engine 642.896/898/992/993 in model 906
with code XM0 (Facelift)

AR20.40-D-6800M

2

Remove coolant hose (9) from bracket (10) and press toward the rear

Engine 642.896/898 in model 906

3

Disconnect electrical connector (7) from quantity control valve (16)

 To do this, expose electric line.

4

Remove electrical connector (4) from fuel temperature sensor (15)

5

Remove fuel hoses (2, 3) from high-pressure pump (1)


Seal fuel hoses (2, 3).
This prevents foreign matter from entering.

 Collect escaping fuel.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

6

Remove pressure line (5) from high-pressure fitting (6) and press upward slightly


Seal pressure line (5).
This prevents foreign matter from entering.


Counterhold high-pressure fitting (6) and do not crush or bend pressure line (5).
Leaks can occur on the fuel system otherwise.

 Collect escaping fuel.

 Record plug

*129589009100

7

Remove high-pressure fitting (6)

If the high-pressure fitting (6) is loose or leaky.

8

Set piston of cylinder 1 at the crankshaft to ignition TDC


Do not turn engine against its direction of rotation.
The timing chain can skip otherwise and engine damage can occur.

 Observe marking on belt pulley.

 Socket wrench bit

*001589650900

9

Remove screws/bolts (8)

10

Remove high-pressure pump (1)

11

Remove gear (12) for high-pressure pump (1)

If installing a new high-pressure pump (1).

AR07.02-D-1021SF



Clean

12

Clean sealing surfaces of the high-pressure pump (1)

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A



Install

13

Fix gear (12) for high-pressure pump

If a new high-pressure pump (1) has been installed.

AR07.02-D-1021SF

14

Install new sealing ring (11)

 Coat sealing ring (11) with engine oil.

15

Attach marking to tooth (A) of the gearwheel (12)

 For this purpose, the high-pressure pump (1) must be stopped in the removed state in the installation position on the cylinder head.

 Place groove (13) vertically, determine tooth (A) from the left edge (13a) of the groove (13) vertically upward and mark.

16

Attach markings to teeth (E, F) of the gearwheel (12)

 For this purpose, the high-pressure pump (1) must be stopped in the removed state in the installation position on the cylinder head.

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

17

Adjust gearwheel (12) relative to high-pressure pump (1)

 For this purpose, the high-pressure pump (1) must be stopped in the removed state in the installation position on the cylinder head.

 Teeth (E, F) must be positioned in the center at the top.

18

Attach high-pressure pump (1) to cylinder head


Do not twist adjusted gearwheel (12).
Otherwise, vibrations will occur during operation.

19

Screw in new screws (8)

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Bolt, high-pressure pump to cylinder head

*BA07.16-N-1004-01B

20

Screw high-pressure fitting (6) into high-pressure pump (1)

If loose or leaky high-pressure fitting (6) has been removed.

 Replace sealing ring.

 High-pressure fitting to high-pressure pump

*BA07.16-N-1017-01B



Check

21

Check clamps and fuel hoses (2, 3)

If there is damage.



Replace damaged clamps and/or fuel hoses (2, 3).

22

Check sealing cone of the pressure line (5)

If there is damage.



Install new pressure line (5).

23

Attach pressure line (5) to high-pressure fitting (6)

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW


Counterhold high-pressure fitting (6) and do not crush or bend pressure line (5).
Leaks can occur on the fuel system otherwise.

 Ensure correct seating of pressure line (5).

 Pressure line to high-pressure pump

*BA07.16-N-1008-01B

 Box wrench bit

*000589690300

24

Attach fuel hoses (2, 3) to high-pressure pump (1)

 Pliers for click clamps

*171589003700

25

Connect electrical connector (4) to fuel temperature sensor (15)

26

Connect electrical connector (7) to quantity control valve (16)

27

Attach coolant hose (9) to bracket (10)

Engine 642.896/898 in model 906

28

Install fan shroud

Engine 642.896/898/992/993 in model 906
with code XM0 (Facelift)

AR20.40-D-6800M

Engine 642.896/898/992/993 in model 906
except code XM0 (Facelift)

AR20.40-D-6800SF

29

Switch on ignition before engine start

If a new high-pressure pump (1) has been installed.


Do not start engine yet; leave ignition switched on for at least 15 s.
Otherwise, the new high-pressure pump (1) will be damaged.

 Because of this, the new high-pressure pump (1) is filled with fuel.



Check

 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

 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

30

Check for leak tightness with engine running

 Visual inspection only.

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1004-01B

Bolt, high-pressure pump to cylinder head

Nm

14

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

Stage 1

Nm

20

Stage 2

°

60

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1017-01B

High-pressure fitting to high-pressure pump

Nm

55

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