Remove/install intermediate gear of high-pressure pump

AR05.10-P-4650A

Remove/install intermediate gear of high-pressure pump

27.10.09

 

Remove/install

1

Remove cylinder head cover trim

Engine 611

AR01.20-P-5014-02A

Engine 612.961/962/963/965/967/990

AR01.20-P-5014-02B

Only with engine 612.966 in model 461.331

AR01.20-P-5014-02GLC

With engine 613

AR01.20-P-5014-02C



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

2

Remove cylinder head cover (11)

AR01.20-P-5014HB

3

Remove viscous fan.

Only for engine 612.965/966

AR20.40-P-5660GP

4

Position piston of cylinder 1 to ignition TDC

 Do not reverse rotate engine otherwise the timing chain could become jammed.

 Do not crank engine at the Bolt, the camshaft sprocket.

5

Lock intake camshaft (2) in place

Lead retaining pin (3) through 1st camshaft bearing cap into hole (A) in the intake camshaft sprocket (5).



*111589031500

6

Remove chain tensioner (9)

Engine 611.960/961, engine 611.962 except in model 203.204, 612.961/962/963/967/990, engine 613.960 except in model 220.126, 613.961

AR05.10-P-7800HB

Engine 612.965/966

AR05.10-P-7800GT

7

Check basic position of camshafts

AR05.20-P-6010HB

8

Remove front cover at cylinder head (4)

AR01.30-P-5700B

9

Remove top slide rail (12)

AR05.10-P-8432B

10

Remove high-pressure pump (8)

Engine 611.960/961/962, 612.961/962/963/967, 613.960/961

AR07.02-P-1020HB

Engine 612.990

AR07.02-P-1020PF

Engine 612.965/966

AR07.02-P-1020GS

11

Mark camshaft sprocket (6) relative to timing chain

12

Remove bolts (13) from camshaft sprocket (6)

 Installation: Install new bolts (13).



*BA05.10-P-1003-01A

13

Remove camshaft sprocket (6)

 Pay attention to dowel pin (7). Detach camshaft sprocket (6) with the timing chain fitted. Ensure that the timing chain does not fall on removing the camshaft sprocket (6).

14

Remove bolt from high-pressure pump intermediate gear (14)



*BA05.10-P-1005-01A

15

Remove intermediate gear of high-pressure pump (14) with cylinder liner (15)

16

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

17

Start engine and run at idling speed

18

Check for oil leaks with engine running

 Danger!

Risk of explosion from 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

19

Check fuel system for leaks with engine running

20

Turn off engine

Number

Designation

Engine 611.960/
961/962

Engine 612.961/
962/967

Engine 612.963

Engine 612.965

Engine 612.966

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

10

10

10

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

10

10

10

Number

Designation

Engine 612.990

Engine 613.960/
961

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

8

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

-

10

Number

Designation

Engine 611.960/
961

Engine 611.962

Engines
612.961/
963

Engine
612.962/
967

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

18

18

18

BA05.10-P-1005-01A

Bolt, intermediate gear of high pressure pump to cylinder head

Nm

40

40

40

40

Number

Designation

Engine
612.965/
966

Engine 613.960/
961

Engine 612.981/
990

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

18

18

BA05.10-P-1005-01A

Bolt, intermediate gear of high pressure pump to cylinder head

Nm

40

40

40