Remove/install drive gear of high-pressure pump

AR07.02-P-1027OLI

Remove/install drive gear of high-pressure pump

04.02.2020

Engine

654 in model 205, 253

Modification notes

04.02.2020

Document completely revised.

1

Drive gear

5

Spindle

7

Cap

2

Major assembly chain

6

Timing case cover

8

Screw

High-pressure pump position 700 before ignition TDC (top dead center)

1

Drive gear

8

Screw

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1.1

Remove engine with transmission.

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2401OLI

1.2

Remove engine with front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2500OLI

2

Remove glow output stage (N14/2).

AR15.20-P-4500OLI

3

Pierce cap (7) in the center of the timing case cover (6) and pry out.


Do not damage the seating of the cap (7).
Non-observance will result in leaks at timing case cover (6).

4

Remove screw (8) and counterhold with counterholder at the crankshaft.

 Counterholder

*654589004000

5

Remove lower slide rail.

AR05.10-P-8420OLI

6

Mark running direction of timing chain and of major assembly chain (2).

7

Remove timing chain from drive gear (1).

8

Install spindle (5) with thrust piece on the drive gear (1) and screw in spindle (5) until the drive gear (1) becomes unfastened from the high-pressure pump.

 Sleeve

*654589001400

9

Remove major assembly chain (2) and remove drive gear (1).

10

Remove spindle (5) with thrust piece from the drive gear (1).

 Sleeve

*654589001400



Install

11

Fit major assembly chain (2) on drive gear (1).


Observe marking for the running direction.
Engine damage can occur otherwise.

12

Install drive gear (1) on the high-pressure pump and tighten screw (8) slightly by hand.

 Replace bolt (8).

 Observe the guide notch.

13

Remove retaining lock from the crankshaft.

AR03.30-P-5001OLI

14

Turn engine at the crankshaft with the counterholder in the direction of engine rotation to 700 before top dead center at cylinder 1 (ignition TDC).

 Counterholder

*654589004000

15

Turn drive gear (1) to 700 before top dead center at cylinder 1 (ignition TDC).

 The hole in the drive gear (1) and the marking in the crankcase must be flush (arrows in the picture).

16

Mount timing chain.


Observe marking for the running direction.
Engine damage can occur otherwise.

17

Install lower slide rail.

AR05.10-P-8420OLI

 Install the camshaft housing with the camshafts only once the engine is at top dead center at cylinder 1 (ignition TDC) and the retaining lock is reinstalled.

18

Tighten screw (8) and counterhold with the counterholder at the crankshaft.

 Bolt, sprocket to high-pressure pump

*BA07.16-P-1006-04A

 Counterholder

*654589004000

19

Install cap (7) on timing case cover (6).

 Replace cap (7).

20

Turn engine at crankshaft with counterholder in direction of engine rotation and position piston of cylinder 1 at top dead center (ignition TDC).


Do not turn engine opposite direction of engine rotation.
Otherwise the timing chain jumps and causes engine damage.

 The 0° marking must be flush with the TDC marking.

21

Install retaining lock on the crankshaft.

AR03.30-P-5001OLI

22

Install camshaft housing with camshafts.

AR05.20-P-6997OLI

23

Attach engine to front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2510OLI

24

Install glow output stage (N14/2).

AR15.20-P-4500OLI

 Only install upper engine cover after the leak test.

25.1

Install engine with transmission.

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2401OLI

 Only install lower engine compartment paneling after leak test.

25.2

Install engine with front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2500OLI

 Only install lower engine compartment paneling after leak test.

 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

26

Carry out engine test run and check engine for proper leak tightness and leak tightness.

27

Install lower engine compartment lining.

AR61.20-P-1105LW

28

Install upper engine cover.

AR01.10-P-2405OLI

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1006-04A

Bolt, sprocket to high-pressure pump

Nm

60