Remove/install high-pressure pump

AR07.02-P-1020OLD

Remove/install high-pressure pump

17.9.15

Engine

651 in model 205, 253

1

Screw/bolts

15

Screw/bolts

2

Bracket

16

Driver

3

Screw/bolts

17

Sealing ring

4

Mounting plate

18

Bracket

5

Bracket

B50

Fuel temperature sensor

9

High-pressure pump

Y93

Exhaust flap switchover valve

12

Hose

Y94

Quantity control valve

6

Screw/bolt

7

Screw/bolt

8

High-pressure line

9

High-pressure pump

10

Rail

11

High-pressure fitting

13

Fuel hose

14

Fuel hose

 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



Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove rear and center engine compartment paneling downwards

AR61.20-P-1105LW

2

Remove throttle valve actuator

AR07.51-P-1401OLD

3

Remove screw/bolts (1) and bracket (2)

 Place holder (2) together with exhaust gas recirculation cooler bypass switchover valve with attached lines to one side.

 Bolt, bracket for electric switchover valves to fastening plate

*BA09.41-P-1006-01N

4

Remove screw/bolts (3) and remove mounting plate (4)

 Charge air manifold fastening plate bolt on engine support

*BA09.41-P-1005-01N

5

Detach engine wiring harness on holder (5)

6

Remove bracket (18)

7

Detach fuel hose (14) from high-pressure pump (9)

 Seal connections after separation with suitable  grommets.

 Installation: Check clamp for damage.

 Record plug

*129589009100

8

Remove exhaust flap switchover valve (Y93)

AR09.40-P-1010OLD

9

Detach holder (5) from exhaust gas recirculation valve and crankcase and remove

 Bolt, exhaust gas recirculation valve bracket to cylinder crankcase

*BA14.20-P-1015-01K

 Bolt, exhaust gas recirculation valve bracket to exhaust gas recirculation valve

*BA14.20-P-1014-01K

10

Remove exhaust gas recirculation valve

AR14.20-P-7662OLD

11

Disconnect electrical connection at quantity control valve (Y94)

12

Disconnect electrical connection on fuel temperature sensor (B50)

13

Remove screw/bolts (6, 7) on high-pressure line (8) bracket

14

Remove high-pressure line (8)


After disassembly of the high-pressure line (8) close off connections on the high-pressure pump (9) and rail (10) with grommets and ensure the highest levels of cleanliness.
The high pressure components will be damaged otherwise.

 Grommets are available as an replacement part of the fuel injection system; see EPC Group 07. Multiple use of the grommet is not permissible. Counterhold high-pressure fitting (11) to avoid it from coming loose as the high-pressure line (8) is being detached.

 Installation: Install high-pressure line (8) free of tension.

 Union nut, pressure line to high-pressure pump/rail

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

15

Detach hose (12) from high-pressure pump (9)

16

Detach fuel hose (13) from high-pressure pump (9)

 Seal connections after separation with suitable  grommets.

 Installation: Check clamp for damage.

 Record plug

*129589009100

17

Remove screw/bolt (15)

 Screw/bolt, high-pressure pump to cylinder crankcase

*BA07.16-P-1001-01H

18

Remove high-pressure pump (9)

 The high-pressure pump (9) must not be opened. The driver (16) can be taken off.

 Installation: Clean sealing surfaces, replace sealing ring (17) and coat sealing ring (17) with special grease.

Special grease

*BR00.45-Z-1036-06A

19

Detach gear from high-pressure pump (9)

When reinstalling the high-pressure pump (9).

 Installation: Replace gear and nut.

 Nut, coupling flange to high-pressure pump

*BA07.16-P-1007-01H

 Counterholder

*651589044000

20

Install in the reverse order

21

Switch on ignition for 15 seconds

 so that the fuel pump fills the high-pressure pump (9) with fuel.



Check

 Danger !

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

22

Check fuel system for leaks with engine running

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1001-01H

Screw/bolt, high-pressure pump to cylinder crankcase

Nm

20

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1002-01H

Union nut, pressure line to high-pressure pump/rail

Nm

33

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1007-01H

Nut, coupling flange to high-pressure pump

Nm

70

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1005-01N

Charge air manifold fastening plate bolt on engine support

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1006-01N

Bolt, bracket for electric switchover valves to fastening plate

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1014-01K

Bolt, exhaust gas recirculation valve bracket to exhaust gas recirculation valve

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1015-01K

Bolt, exhaust gas recirculation valve bracket to cylinder crankcase

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10