Remove/install high-pressure pump

AR07.02-P-1020CD

Remove/install high-pressure pump

06.03.2020

Engine

651 in model 166, 172, 204, 207, 212, 218, 221

Shown on model 204

1

High pressure pipe

2

Screw

3

Screw

4

High pressure pump

5

Rail

6

High-pressure fitting

7

Bolts

8

Bracket

9

Bolts

10

Mounting plate for mixing tube

11

Fuel line

13

Sealing ring

B50

Fuel temperature sensor

12

Bolts

14

Driver

Y94

Quantity control valve

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove exhaust gas recirculation valve

Engine 651 in model 166, 172

AR14.20-P-7662GQ

2

Remove throttle valve actuator

AR09.41-P-1321CD

3

Remove screw/bolts (7) and place bracket (8) with electrical lines to one side

Engine 651 in model 172, 204, 207, 212, 218, 221

 Bolt, bracket for electric switchover valves to fastening plate

*BA09.41-P-1006-01N

4.1

Unscrew screw/bolts (9) and remove mounting plate for mixing tube (10)

Engine 651 in model 172, 204, 207, 212, 218, 221

 Charge air manifold fastening plate bolt on engine support

*BA09.41-P-1005-01N

4.2

Remove EGR bypass switchover valve with bracket and place to one side

Engine 651 in model 166

AR14.20-P-7660CD

5

Remove charge air pipe downstream of charge air cooler

AR09.41-P-8624CD

6

Release and disconnect electrical connection from quantity control valve (Y94)

7

Release and disconnect electrical connection from fuel temperature sensor (B50)

8

Disconnect vacuum line on vacuum pump

Engine 651 in model 166

AR43.05-P-1320CDA

Engine 651 in model 172, 204, 207, 212, 218, 221

AR43.05-P-1320CD

9

Remove screw/bolts (2, 3) on high-pressure line (1) bracket

10

Remove high-pressure line (1) from high-pressure pump (4) and rail (5)

 Counterhold high-pressure fitting (6) to avoid it from coming loose as the high pressure line (1) is being loosened.

 Installation: Install high-pressure line (1) free of tension.

 Union nut, pressure line to high-pressure pump/rail

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

11

Seal connections with stop plugs


Ensure utmost cleanliness.
The high pressure components will be damaged otherwise.

 Repeated usage of stop plugs is not allowed.

 Record plug

*129589009100

12

Disconnect fuel line (11) from high-pressure pump (4)

 Installation: Check hose clamps for damage and replace if necessary.

13

Seal connections with stop plugs

 Record plug

*129589009100

14

Remove screws (12)

 Screw/bolt, high-pressure pump to cylinder crankcase

*BA07.16-P-1001-01H

15

Unhook engine wiring harness on exhaust gas recirculation tract bracket from crankcase and detach high-pressure pump (4)

 The high-pressure pump (4) must not be opened. The driver (14) can be taken off.

16

Clean sealing surfaces

 Installation: Replace sealing ring (13) and grease lightly with special grease.

Assembly cleaner

*BR00.45-Z-1028-04A

Special grease

*BR00.45-Z-1036-06A

17

Remove drive pinion from high-pressure pump (4)

When replacing the high-pressure pump (4).

 Installation: Replace drive pinion and nut.

 Nut, coupling flange to high-pressure pump

*BA07.16-P-1007-01H

18

Install in the reverse order

19

Switch on ignition for 15 seconds

 The fuel pump fills the high-pressure pump (4) with fuel.

 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

20

Check fuel system for leaks with engine running

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1001-01H

Screw/bolt, high-pressure pump to cylinder crankcase

Nm

20

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1002-01H

Union nut, pressure line to high-pressure pump/rail

Nm

33

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1007-01H

Nut, coupling flange to high-pressure pump

Nm

70

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1005-01N

Charge air manifold fastening plate bolt on engine support

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1006-01N

Bolt, bracket for electric switchover valves to fastening plate

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10