Remove/install drive gear of high-pressure pump

AR07.02-P-1027MFF

Remove/install drive gear of high-pressure pump

04.02.2020

Engine

654 in model 118, 177, 247

Modification notes

04.02.2020

Document completely revised.

1

Drive gear

6

Pressure screw

2

Cap

7

Hexagon

3

Timing case cover

8

Screw

5

Thrust piece

Position of high pressure pump 700 before ignition TDC (top dead center)

1

Drive gear

8

Screw

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes on coolant level

AH20.00-P-1142-01CW



Remove

1

Remove glow output stage (N14/2).

AR15.20-P-4500MFF

2

Remove cap (2) in timing case cover (3).


Do not damage seat of cap (2).
Leaks can occur otherwise.

3

Release screw (8) and counterhold using counterholder at crankshaft.

 Counterholder

*654589004000

4

Remove lower slide rail.

AR05.10-P-8420MFF

5

Mark running direction of timing chain and major assembly chain.

6

Take off timing chain.

7

Remove screw (8).

8

Attach thrust piece (5) of sleeve to drive gear (1).

 Sleeve

*654589001400

9

Counterhold thrust piece (5) at hexagon (7) and pressure screw (6).

 Screw in pressure screw (6) until drive gear (1) detaches from shaft of fuel high-pressure pump.

 Sleeve

*654589001400

10

Remove major assembly chain and drive gear (1) with thrust piece (5).

11

Remove thrust piece (5) from drive gear (1).



Install

12

Position major assembly chain on drive gear (1).

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

13

Position drive gear (1) and tighten screw(8) lightly by hand.

 Replace bolt (8).

 Observe the guide notch.

14

Remove retaining lock at crankshaft.

AR03.30-P-5001MFF

15

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

 Counterholder

*654589004000

16

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

 Hole in drive gear (1) and crankcase marking must be in alignment (arrows in picture).

17

Mount timing chain.

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

18

Install lower slide rail.

AR05.10-P-8420MFF

 Only install camshaft housing with camshafts if engine is at top dead center of cylinder 1 (ignition TDC) and retaining lock has been reinstalled.

19

Tighten screw (8) and counterhold using counterholder at crankshaft.

 Bolt, sprocket to high-pressure pump

*BA07.16-P-1006-04A

 Counterholder

*654589004000

20

Install cap (2) on timing case cover (3).

 Replace cap (2).

21

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.

 0° marking must be in alignment with TDC marking.

22

Install retaining lock on crankshaft.

AR03.30-P-5001MFF

23

Install camshaft housing with camshafts.

AR05.20-P-6997MFF

 Only install lower engine compartment paneling after leak test.

24

Install glow output stage (N14/2).

AR15.20-P-4500MFF

 Only install upper engine cover after the 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

25

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

26

Install lower engine compartment lining.

AR61.20-P-1105MFE

27

Install upper engine cover.

AR01.10-P-2405MFF

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1006-04A

Bolt, sprocket to high-pressure pump

Nm

60