Remove/install high-pressure pump

AR07.02-S-1020SE

Remove/install high-pressure pump

18.04.2019

Engine

642 in model 639

Modification notes

13.02.2018

Method and work procedure revised

Operation steps 1 to 32

Shown on engine 642.9

1

Fuel hose

5

Pressure line

M41

Common rail high pressure pump

3

Fuel hose

B50

Fuel temperature sensor

Y94

Quantity control valve

4

Bolts

Variant I

6

Groove

6a

Left edge

7

Gear

A

Tooth

E

Tooth

F

Tooth

Variant II

6

Groove

6a

Left edge

7

Gear

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

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Remove air filter housing

AR09.10-S-1150SE

2

Remove fan

AR20.40-S-5614SE

3

Remove bracket from the pressure sensor and fuel hose (3)

Engine 642.8 in model 639

 To do this, unscrew screw and place bracket to one side.

4

Disconnect electrical connection at quantity control valve (Y94)

5

Separate electrical connection at the fuel temperature sensor (B50)

6

Remove fuel hoses (1, 3) from common rail high-pressure pump M41


Close off fuel hoses (1, 3).
This prevents foreign matter from entering.

 Collect escaping fuel.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

7

Remove pressure line (5) from high-pressure fitting of common rail high-pressure pump (M41) and press upward slightly

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


Counterhold high-pressure fitting on common rail high-pressure pump (M41) and do not crush or bend the pressure line (5).
Leaks can occur on the fuel system otherwise.

 Collect escaping fuel.

 Record plug

*129589009100

8

Unscrew high-pressure fitting from common rail high-pressure pump (M41)

If the high-pressure fitting of the common rail high-pressure pump (M41) is loose or leaky.

9

Position piston of cylinder 1  at 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

10

Remove bolts (4)

11

Remove common rail high-pressure pump (M41)

12

Remove gearwheel (7) from common rail high-pressure pump (M41)

If installing a new common rail high-pressure pump (M41).

AR07.02-S-1021SE



Clean

13

Clean sealing surfaces of the common rail high-pressure pump (M41)

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A



Install

14

Attach gearwheel (7) to common rail high-pressure pump (M41)

If a new common rail high-pressure pump (M41) has been installed.

AR07.02-S-1021SE

15

Install new sealing ring on common rail high-pressure pump (M41)

 Coat sealing ring with engine oil.

16

Attach marking to tooth (A) of the gearwheel (7)

 For this purpose, the common rail high-pressure pump (M41) must be stopped in the removed state in the installation position on the cylinder head.

 Place groove (6) vertically, determine from the left edge (6a) of the groove (6) vertically to the upper tooth (A) and mark.

17

Attach markings to teeth (E, F) of the gearwheel (7)

 For this purpose, the common rail high-pressure pump (M41) 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.

18

Adjust gearwheel (7) relative to common rail high-pressure pump (M41)

 For this purpose, the common rail high-pressure pump (M41) 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.

19

Attach common rail high-pressure pump (M41) to cylinder head


Do not twist adjusted gearwheel (7).
Otherwise, vibrations will occur during operation.

20

Screw in new screws (4)

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

21

Screw high-pressure fitting into common rail high-pressure pump (M41)

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

 Replace sealing ring.

 High-pressure fitting to high-pressure pump

*BA07.16-N-1017-01B



Check

22

Check clamps and fuel hoses (1, 3)

If there is damage



Replace damaged clamps and/or fuel hoses (1, 3).

23

Check sealing cone of the pressure line (5)

If there is damage



Install new pressure line (5).

24

Attach pressure line (5) to high-pressure fitting on the common rail high-pressure pump (M41)

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 on common rail high-pressure pump (M41) and do not crush or bend the 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

25

Attach fuel hoses (1, 3) to common rail high-pressure pump (M41)

 Pliers for click clamps

*171589003700

26

Connect electrical connector to fuel temperature sensor (B50)

27

Connect electrical connector to quantity control valve (Y94)

28

Attach bracket to pressure sensor and fuel hose (3)

Engine 642.8 in model 639

29

Install fan

AR20.40-S-5614SE

30

Install air filter housing

AR09.10-S-1150SE

31

Switch on ignition before engine start

If a new common rail high-pressure pump (M41) has been installed.


Do not start engine yet; leave ignition switched on for at least 15 s.
Otherwise, new common rail high-pressure pump (M41) will be damaged.

 As a result of this, the new common rail high-pressure pump (M41) 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

32

Check for leak tightness with engine running

 Visual inspection only.

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.890/990 in model 639

BA07.16-N-1004-01B

Bolt, high-pressure pump to cylinder head

Nm

14

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.890/990 in model 639

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

Stage 1

Nm

33

Stage 2

°

–

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.890/990 in model 639

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