Remove/install high-pressure pump

AR07.02-S-1020EA

Remove/install high-pressure pump

12.06.2019

Engine

654.9 in model 447

1

High pressure pump

7

Electrical connector

10

Screw

2

Screw

8

Fuel feed line

11

Bracket

6

Electrical connector

9

Fuel return line

12

Screw

1

High pressure pump

2

Bolts

3

Drive gear

4

Screw

4

Screw

16

Sleeve

18

Thrust piece

14

Timing case cover

17

Screw

19

Pressure screw

15

Cap

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove high-pressure line.

AR07.16-S-1002EA

2

Release and disconnect electrical connectors (6, 7).

3

Remove bracket (11).

 Bolt, bracket for high-pressure pump to crankcase

*BA07.16-P-1007-04A

 Bolt, bracket for high-pressure pump to high-pressure pump

*BA07.16-P-1008-04A

4

Remove leak oil line from high-pressure pump(1).

AR07.03-S-9105EA

5

Remove the bolt (10).

 Screw, vacuum line bracket to crankcase

*BA09.20-N-1003-01EA

6

Remove screw (12) and remove fuel return line (9) and fuel feed line (8) on high-pressure pump (1).

 Installation: Replace O-rings.

 Bolt, fuel line to high-pressure pump

*BA07.16-P-1009-04A

7

Remove the glow output stage.

AR15.20-S-4500EA

8

Remove cap (15).

 Installation: Replace the cap(15).

9

Remove resonator box.

AR09.20-S-0010EA

10

Set engine in direction of engine rotation to 290° after top dead center(TDC).

 The 290° marking on belt pulley/vibration damper must align with the marking on crankcase.

 Counterholder

*654589004000

11

Unscrew bolt (4).

 Counterhold engine on crankshaft.

 Bolt, sprocket to high-pressure pump

*BA07.16-P-1006-04A

 Counterholder

*654589004000

12

Insert sleeve(16) with vinyl ring and tighten screw(17) on timing case cover(14).

 Sleeve

*654589001400

13

Screw in thrust piece(18) at drive gear(3) and tighten pressure screw(19) slightly by hand.

 Sleeve

*654589001400

14

Remove screws (2).

 Bolt, high-pressure pump to crankcase

*BA07.16-P-1001-04A

15

Screw in pressure screw (19) until drive gear (3) on high-pressure pump (1) is unfastened.

16

Remove high-pressure pump(1).


The drive gear (3) with  sleeve remain on engine and should not be removed.
Otherwise the drive gear (3) falls down with the major assembly chain.

 Installation: Turn back pressure screw (19) somewhat.

17

Install in the reverse order.

18

Switch on ignition for 15 s.

 This fills the high-pressure pump (1) with fuel.



Check

 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

19

Start engine and check high-pressure pump (1) for leaks.

 Visual inspection only.

20

Switch off engine.

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1001-04A

Bolt, high-pressure pump to crankcase

Nm

20

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1006-04A

Bolt, sprocket to high-pressure pump

Nm

60

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1007-04A

Bolt, bracket for high-pressure pump to crankcase

Nm

8

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1008-04A

Bolt, bracket for high-pressure pump to high-pressure pump

Nm

8

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1009-04A

Bolt, fuel line to high-pressure pump

Nm

8

 Intake manifold

Number

Designation

Engine 654.9 in model 447

BA09.20-N-1003-01EA

Screw, vacuum line bracket to crankcase

Nm

8