ar0510d4650a

Remove/install intermediate gear of high-pressure pump

Type ar · topic 05.10 · version 0107 · 2009-11-12

Applies to: ENGINES 611.981 /987 in MODEL 901.6, 902.6, 903.6, 904.6 ENGINES 612.981 in MODEL 902.6, 903.6, 904.6, 905.6 ENGINES 611.983 in MODEL 690.6

Where it sits

Function group 1 Engine › 05 Engine timing › 05.10 Timing chain drive, toothed belt drive — Series 611 (models 981, 983, 987) · Series 690 (models 6**) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**) · Series 905 (models 6**)

EinPAS 15 Engine › 15.17 Engine timing › 15.17.34 Chain drive/toothed belt/gearwheel drive — Series 611 (models 981, 983, 987) · Series 690 (models 6**) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**) · Series 905 (models 6**)

EinPAS 15 Engine › 15.45 Engine management › 15.45.51 Injection pump/injection timer — Series 611 (models 981, 983, 987) · Series 690 (models 6**) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**) · Series 905 (models 6**)

Also applies to engines/gearboxes: 612 981

AR05.10-D-4650A

Remove/install intermediate gear of high-pressure pump

27.10.09

ENGINES 611.981 /987 in MODEL 901.6, 902.6, 903.6, 904.6

ENGINES 612.981 in MODEL 902.6, 903.6, 904.6, 905.6

ENGINES 611.983 in MODEL 690.6

Remove/install intermediate gear of high-pressure pump

D05.10-1101-06

1 High pressure pump intermediate gear

2 Bush

3 Screw

4 High-pressure pump

5 Camshaft sprocket

6 Dowel pin

7 Bolts

8 Slide rail

9 Front cover

10 Cylinder head cover

11 Exhaust camshaft

12 Intake camshaft

13 Driver

14 Retaining pin

A Bore

Removing

1

Remove cylinder head cover (10)

AR01.20-D-5014E

2

Position piston of cylinder 1 to ignition TDC

Rotate engine at crankshaft in clockwise direction. Do not crank engine at camshaft and do not crank back

3

Lock intake camshaft (12) in place

*111589031500

Insert retaining pin (14) at

1st camshaft bearing cap into the hole (A) in intake camshaft sprocket

4

Remove front cover (9) at cylinder head

AR01.30-D-5700D

5

Unscrew driver (13) at the intake camshaft, take off slide rails (8)

17 mm hexagon socket 3/8 inch square

*BA05.20-P-1002-01F

6

Remove high-pressure pump (4)

AR07.02-D-1020A

7

Mark camshaft sprocket (5) relative to timing chain

8

Detach camshaft sprocket (5) at the exhaust camshaft (11) and take off with timing chain fitted on.

Counter-hold exhaust camshaft, if necessary, with open-end wrench.

Pay attention to dowel pin (6). Secure timing chain to prevent it dropping down after removing the camshaft sprocket

Installation: Replace bolts (7)

*BA05.10-P-1003-01A

9

Unscrew bolt (3) at intermediate gear of high pressure pump (1)

*BA05.10-P-1005-01A

10

Take intermediate gear of high pressure pump (1) together with liner (2) up and out through the timing chain shaft

11

Install in the reverse order

Installation: Check basic position of camshafts, after testing if necessary

AR05.20-D-6010D

Correct basic position of camshafts

AR05.20-D-6025D

Timing chain, chain tensioner

Number

Designation

Engine
611.981/
983/987

Engine 612.981/
990

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

18

BA05.10-P-1005-01A

Bolt, intermediate gear of high pressure pump to cylinder head

Nm

40

40

Camshaft

Number

Designation

Engine
611.960/961/962/980/
981/983/987
612.961/962/963/965/
966/967/981/990
613.960/961

BA05.20-P-1002-01F

Bolt, driver to inlet camshaft

Nm

50

Remove/install intermediate gear of high-pressure pump

Retaining pins

111 589 03 15 00

Referenced documents