Remove/install high pressure pump's high pressure fitting

AR07.02-P-0001A

Remove/install high pressure pump's high pressure fitting

5.8.10

 

Remove/install

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1.1

Remove cylinder head cover trim

Engine 611, 646, 647.

AR01.20-P-5014-02A

Engine 612.

AR01.20-P-5014-02B

Engine 613, 648.

AR01.20-P-5014-02C

1.2

Remove air filter

Engine 628 in model 220.

AR09.10-P-1050M

1.3

Remove engine trim panel

Engine 628 in model 211.

AR01.10-P-2405TD

2

Remove bolt (3) from the bracket (4) of the high-pressure line (2)

3

Unscrew and remove the high pressure line (2) from the high pressure pump (6) and rail (7)

 Counterhold high pressure fitting (1) to avoid it from loosing as the high pressure line is being loosened.

In order to avoid leakage, do not squeeze or bend the high pressure line (2). After disassembling the high pressure line (2), seal connections. Ensure scrupulous cleanliness!

 Installation: Check sealing edge on high pressure line (2). If there are any dents, replace high pressure line (2). Ensure the high pressure line (2) is seated exactly.

Nut of pressure line to high pressure pump/rail.

ENGINE 611, 612, 613.

*BA07.16-P-1002-01A

Nut of pressure line to high pressure pump/rail.

Engine 646, 647, 648.

*BA07.16-P-1002-01D

 Nut of pressure line to valve block/ high pressure pump.

Engine 628.

*BA07.16-P-1001-01C

4

Clean high pressure pump (6) in the area of high pressure fitting (1) with cold cleaning solvent and blow dry with compressed air

 Depending on installation position, use an absorbent, lint-free cloth to collect any fuel that runs out.

*BR00.45-Z-1051-04A

5

Remove high pressure fitting (1) from the high pressure pump (6)

 Vacuum up any particles, like paint, from around hole.

 High pressure fitting on the high pressure pump.

ENGINE 611, 612, 613.

*BA07.16-P-1016-01A

 High pressure fitting on the high pressure pump.

Engine 628.

*BA07.16-P-1019-01C

 High pressure fitting on the high pressure pump.

Engine 646, 647, 648.

*BA07.16-P-1015-01D

6

Remove sealing ring (5) from hole

 Installation: The sealing ring (5) must always be replaced.

 Vacuum up any paint and dirt particles, particularly from out of the hole.

7

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

8

Check fuel system for leaks with engine running

 Visual inspection.

Number

Designation

Engine
646.951/
961,
647.961, 648

Engine
646.962/
963/966

BA07.16-P-1002-01D

Nut, pressure line to high-pressure pump/rail

Stage 1

Nm

23

23

Stage 2

Nm

-

-

BA07.16-P-1015-01D

High pressure fitting on the high pressure pump

Nm

55

55

Number

Designation

Engine 612.961/
963

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

BA07.16-P-1016-01A

High pressure fitting on the high pressure pump

Nm

45

Number

Designation

Engine 611.960/
961

Engine 611.962

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

23

BA07.16-P-1016-01A

High pressure fitting on the high pressure pump

Nm

45

45

Number

Designation

Engine 612.962/
967

Engine 612.965/
966

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

23

BA07.16-P-1016-01A

High pressure fitting on the high pressure pump

Nm

45

45

Number

Designation

Engine 612.990

Engine 613.960/
961

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

23

BA07.16-P-1016-01A

High pressure fitting on the high pressure pump

Nm

45

45

Number

Designation

Engine 628.960/962/963

Engine
628.961

BA07.16-P-1001-01C

Nut, pressure line to valve block/ high pressure pump

Nm

23

23

BA07.16-P-1019-01C

High pressure fitting on the high pressure pump

Nm

55

55

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
www.wuerth.de