Remove/install high-pressure fuel pump

AR07.16-W-1005H

Remove/install high-pressure fuel pump

14.01.2019

Engine

471.9## ## up to 032690 in model 963, 964

Modification notes

27.06.2013

Work procedure completely modified.

1

Fuel system high pressure pump

5

Coolant line

9

Power steering pump

2

Electrical connector

6

Compressor

Y642

Quantity control valve

3

Bracket

7

Bracket

4

Engine wiring harness

8

High pressure pipe

 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

 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

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

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-N-5000-01H

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A



Remove

1

Tilt cab

2

Remove soundproofing

3

Drain coolant at expansion reservoir

Drain/fill coolant in expansion reservoir
Only for vehicles with code F1P(S-cab) or code F1Qcode (M (medium-length) cab) and rear expansion reservoir.

AR20.00-W-1142-01H

 Clamp

*000589543700

 Clamp

*000589403700

4

Remove cab mounting

Only for vehicles with code F1P(S-cab) or code F1Q(M (medium-length) cab)

AR60.80-W-0075-01HB

5

Clean engine in the area of fuel system high pressure pump (1) and the fuel filter module

6

Remove resonator

AR13.10-W-5840HA

7

Remove air intake duct on compressor and place to one side

8

Remove high-pressure line (8) to rail

AR07.16-W-1004H

9

Remove power steering pump (9) and place to one side

AR46.30-W-0500-02H

 Do not disconnect the lines of the power steering pump (9) in the process.

10

Remove fuel filter module

AR47.20-W-5511H

11

Attach turning device to timing case

AR03.30-W-1600-03H

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

12

Position engine at ignition TDC on cylinder 1 and lock in place

AR07.16-W-1005-02H

 Drift

*470589001500

 Turning device

*904589046300

13

Remove coolant line (5) from compressor (6) and from crankcase

 Collect coolant which flows out.

14

Disconnect electrical connector (2) at quantity control valve (Y642)

15

Expose engine wiring harness (4) at bracket (3)

16

Remove bracket (3)

17

Remove fuel system high pressure pump (1)

 To lift out the engine wiring harness, press (4) with holder (7) to the side.

18

Check drive gear of fuel system high pressure pump (1) for damage

If the drive gear is damaged, the counter gear wheel must also be checked in the crankcase for damage. To do this:



 pull out drift for locking the engine on timing case,

 turn engine with the attached turning device through exactly two full revolutions (2 x 360 °),

 in doing do check the counter gear and

 again lock engine in TDC of cylinder 1 with drift on timing case.

 The engine is again in TDC for cylinder 1 after exactly two full revolutions (2 x 360°).

19

Remove drive gear for fuel system high pressure pump (1)

Only if the fuel system high pressure pump (1) or the drive gear is renewed.

AR07.16-W-1006H



Clean

20

Clean all sealing surfaces on the fuel system high pressure pump (1) and on crankcase



Install

21

Install drive gear for fuel system high pressure pump (1)

Only if drive gear was removed.

AR07.16-W-1006H

22

Install fuel system high pressure pump (1)

AR07.16-W-1005-01H


The engine must stand or be locked at TDC for cylinder 1 before installation of the fuel high-pressure pump (1).
Malfunctions during operation of the engine can occur otherwise.

 Push bracket (7) and engine wiring harness (4) to the side.

 Screw, fuel high-pressure pump to crankcase

*BA07.16-N-1008-03A

23

Install bracket (3)

 Lead in a new cable tie before installing bracket (3).

 Screw/nut, holder to fuel high-pressure pump

*BA07.16-N-1009-03A

 Screw, fuel high-pressure pump holder to crankcase

*BA07.16-N-1010-03A

24

Attach engine wiring harness (4) at bracket (3)

25

Attach electrical connection (2) to quantity control valve (Y642)

26

Attach coolant line (5) to compressor (6) and crankcase

27

Remove turning device from timing case

AR03.30-W-1600-03H

 Screw/bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01N

 Screw/bolt, bracket for position sensor to skewback crossbeamBracket for front axle travel sensor to crescent-shaped crossmember

*BA32.30-N-1005-04B

28

Pull out drift for locking the engine on timing case

29

Install crankshaft position sensor and connect Electrical connection

 Replace O-ring.

 Bolt, crankshaft position sensor to timing case

*BA07.04-N-1001-01H

30

Install fuel filter module

AR47.20-W-5511H

31

Attach power steering pump (9)

AR46.30-W-0500-02H

 Screw/bolt, power steering pump to control housing

*BA01.60-N-1008-01N

32

Install high-pressure line (8) to rail

AR07.16-W-1004H

33

Install cab mounting

Only for vehicles with code F1P(S-cab) or code F1Q(M (medium-length) cab)

AR60.80-W-0075-01HB

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

 Screw/bolt, mounting console of rear cab carrier console to vehicle frameBolt, rear cab support mounting console to vehicle frame

*BA60.80-N-1025-01B

34

Attach air intake duct to compressor

35

Install resonator

AR13.10-W-5840HA

36

Pour in coolant at expansion reservoir

Drain/fill coolant in expansion reservoir
Only for vehicles with code F1P(S-cab) or code F1Qcode (M (medium-length) cab) and rear expansion reservoir.

AR20.00-W-1142-01H

 Coolant

*BF20.00-N-1001-01M

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

37

Fill low-pressure fuel circuit at engine

AR07.16-W-1007H

38

Connect diagnostic system, start XENTRY and perform quick test

Only if the fuel system high pressure pump (1) was replaced.

39

Reset "Adaptation area for quantity control valve"

Only if the fuel system high pressure pump (1) was replaced.

 The process is completely menu-assisted under:
 "MCM - engine management (A4)"
 "Adaptations"
 "Parameterization"
 "Reset the calibration settings"
 "Adaptation range for quantity control valve"

40

End Xentry and disconnect diagnostic system

Only if the fuel system high pressure pump (1) was replaced.

41

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

If engine fails to start or only runs for a brief period:



Fill low-pressure fuel circuit again.

AR07.16-W-1007H

42

Stop engine and check for leaktightness in the area of the fuel system high pressure pump (1) and the fuel filter module and the coolant hoses.

 Visual inspection.

43

Install soundproofing

44

Tilt back cab

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1001-01N

Screw/bolt, cap of TDC inspection hole to timing case

Nm

30

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1002-01N

Bolt, turning device to timing case

Nm

30

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1008-01N

Screw/bolt, power steering pump to control housing

Nm

55

 Sensors

Number

Designation

Engine 470.9, 471.9, 473.9

BA07.04-N-1001-01H

Bolt, crankshaft position sensor to timing case

Nm

10

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1008-03A

Screw, fuel high-pressure pump to crankcase

Nm

60

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1009-03A

Screw/nut, holder to fuel high-pressure pump

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1010-03A

Screw, fuel high-pressure pump holder to crankcase

M12x1.5

Nm

100

 Level control

Number

Designation

Model 963, 964

BA32.30-N-1005-04B

Bracket for front axle travel sensor to crescent-shaped crossmember

M10

Nm

50

 Cab mounting

Number

Designation

Model 963, 964

BA60.80-N-1025-01B

Bolt, rear cab support mounting console to vehicle frame

M14x1.5

Nm

­

M18x1.5

Stage 1

Nm

330

Stage 2

°

90

 Engine cooling

Number

Designation

ENGINE 471.9 in MODEL 963, 964 except CODE B3H

Engine 471.9 in model 963, 964
with code B3H (Water-type secondary retarder)

BF20.00-N-1001-01M

Coolant

Total filling capacity

Liter

60,0

80,0

Anticorrosion/antifreeze agent down to –37°C

Liter

30,0

40,0

Anticorrosion/antifreeze agent down to –45°C

Liter

33,5

44,5

Specifications for Operating Fluids, Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Specifications for Operating Fluids, Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67