Repair high-pressure pump

AR07.02-P-1022A

Repair high-pressure pump

22.1.07

 

Disassemble/assemble

 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 systems when they are under pressure

AS07.16-Z-0001-01A



When working on the common rail system, absolute cleanliness at the workplace must be observed since ingressed dirt particle can lead to destruction of components

1

Remove high-pressure pump (1)

Engine 668

AR07.02-P-1020GD

Engine 611, 612, 613 except 612.965/966/990

AR07.02-P-1020HB

Engine 612.965/966

AR07.02-P-1020GS

Engine 612.990

AR07.02-P-1020PF

2

Clamp high-pressure pump (1) in vise

 Use protective jaws.

The pump cylinder head (3) must point upwards in the process.

3

Slacken bolts (2)

 Thoroughly clean screw heads, suction off loose dirt particles otherwise ingressed dirt particles can destroy the high-pressure pump (1).

(Do not use any compressed air)

Engine 611, 612, 613

*BA07.16-P-1018-01A

Engine 668

*BA07.16-P-1012-01B

4

Unscrew bolt (2)

Press pump cylinder head (3) against the spring force in the process.

 Installation: Tighten bolts (2) evenly diagonally.

5

Remove pump cylinder head (3)

Firmly hold pump element (4) in the process so that the barrel gasket (6) does not fall out.

 Installation: Ensure correct seating of the pump element (4).

6

Remove pump element (4)

Ensure that valve group (5) does not fall out.

Do not lay pump cylinder head (3) on flange face.

 Installation: Install pump element (4) together with pump cylinder head (3) while firmly holding the pump element (4).

The spring on pump element (4) must sit correctly in the cage.

7

Remove barrel gasket (6)

 Installation: Pay attention to installation position when replacing barrel gasket (6), see picture.

8

Remove fastener (9)

 Replace sealing rings (8) and support rings (7)

 Installation: Mount support ring (7) and sealing rings (8) together with fastener (9).

Wet sealing rings (8) with diesel.

9

Check seats for traces of corrosion

Observe damage profile

If traces of corrosion are discovered on the seat (a major or critical fault) then the high-pressure pump (1) must be replaced.

AR07.02-P-1022-01A

10

Assemble in the reverse order

Both other pump cylinder heads are to be sealed in the same way.

11

Carry out leak checks

 To do this apply chalk to the high-pressure pump (1).

Number

Designation

Engine 611.960/
961

Engine 611.962

BA07.16-P-1018-01A

Bolt, pump cylinder head to pump housing

Nm

25

25

Number

Designation

Engine 612.961/
963

BA07.16-P-1018-01A

Bolt, pump cylinder head to pump housing

Nm

25

Number

Designation

Engine 612.962/
967

Engine 612.965/
966

BA07.16-P-1018-01A

Bolt, pump cylinder head to pump housing

Nm

25

25

Number

Designation

Engine 612.990

Engine 613.960/
961

BA07.16-P-1018-01A

Bolt, pump cylinder head to pump housing

Nm

25

25

Number

Designation

Engine 668.914

Engine 668.940/
941/942

BA07.16-P-1012-01B

Bolt, pump cylinder head to pump housing

Nm

25

25