Remove/install drive gear of high-pressure pump

AR07.02-P-1027OID

Remove/install drive gear of high-pressure pump

04.02.2020

Engine

656 in model 167

Modification notes

04.02.2020

Document completely revised.

1

Drive gear

4

Screw

7

Cap

2

Major assembly chain

5

Screw

8

Screw

3

Sleeve

6

Timing case cover

High-pressure pump position 700 before ignition TDC (top dead center)

1

Drive gear

8

Screw

a

Fitting sleeves

 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



Remove

1

Remove engine with front axle carrier.

AR01.10-P-2500OID

2

Remove glow output stage (N14/2).

AR15.20-P-4500OID

3

Pierce cap (7) in the center and pry out.


Do not damage seat of cap (7) at timing case cover (6).
Non-observance will result in leaks at timing case cover (6).

4

Remove screw (8) and counterhold with counterholder at the crankshaft.

 Counterholder

*654589004000

5

Install sleeve (3) on drive gear (1) and tighten screw (4) on timing case cover (6).

 Sleeve

*654589001400

6

Install thrust piece of the sleeve (3) together with the screw (5) on the drive gear (1).

 Sleeve

*654589001400

7

Screw in screw (5) and release drive gear (1) from high-pressure pump.

 Screw in screw (5) only until the drive gear (1) on the high-pressure pump is released.

 Sleeve

*654589001400

8

Remove sleeve (3).

 Sleeve

*654589001400

9

Remove lower slide rail.

AR05.10-P-8420OID

10

Mark running direction of timing chain and remove timing chain.

11

Mark running direction of major assembly chain (2).

12

Remove major assembly chain (2) and remove drive gear (1).



Install

13

Fit major assembly chain (2) on drive gear (1).

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

14

Position drive gear (1) on the high-pressure pump and tighten screw (8) slightly by hand.

 Replace bolt (8).

 Observe the guide notch.

15

Remove retaining lock from the crankshaft.

AR03.30-P-5001OID

16

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

 Counterholder

*654589004000

17

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

 The hole in the drive gear (1) and the marking in the crankcase must be flush (arrows in the picture).

18

Mount timing chain.

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

19

Install lower slide rail.

AR05.10-P-8420OID

 Install the camshaft housing with the camshafts only once the engine is at top dead center at cylinder 1 (ignition TDC) and the retaining lock is reinstalled.

20

Tighten screw (8) and counterhold with the counterholder at the crankshaft.

 Bolt, sprocket to high-pressure pump

*BA07.16-P-1006-04A

 Counterholder

*654589004000

21

Install cap (7) on timing case cover (6).

 Replace cap (7).

22

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.

 The 0° marking must be flush with the TDC marking.

23

Install retaining lock for crankshaft.

AR03.30-P-5001OID

24

Install camshaft housing with camshafts.

AR05.20-P-6997OID

25

Install glow output stage (N14/2).

AR15.20-P-4500OID

 Only install upper engine cover after the leak test.

26

Install engine with front axle carrier.

AR01.10-P-2500OID

 Only install lower engine compartment paneling after 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

27

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

28

Install lower engine compartment lining.

AR61.20-P-1105ME

29

Install upper engine cover.

AR01.10-P-2405OID

 Common rail diesel injection system

Number

Designation

Engine 656

BA07.16-P-1006-04A

Bolt, sprocket to high-pressure pump

Nm

60