Remove/install intermediate gear of high-pressure pump

AR05.10-D-4650NA

27.10.09

ENGINES 612.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINES 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINES 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINES 612.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Remove/install intermediate gear of high-pressure pump

D05.10-1101-06

1 High pressure pump intermediate gear

2 Bush

3 Screw

4 High-pressure pump

5 Camshaft sprocket

6 Dowel pin

7 Bolts

8 Slide rail

9 Front cover

10 Cylinder head cover

11 Exhaust camshaft

12 Intake camshaft

13 Driver

14  Retaining pin

A Locking bore

	Removing
1	Remove cylinder head cover (10)		AR01.20-D-5014NA
2	Position piston of cylinder 1 to ignition TDC	 Rotate engine at crankshaft in clockwise direction (arrows). Do not turn engine backwards; do not turn intake camshaft (12) or exhaust camshaft (11), otherwise engine timing can be damaged.  The cams on the intake camshaft (12) and exhaust camshaft (11) of the 1st cylinder must point upward.
3	Lock intake camshaft (12) in place	 Insert retaining pin (14) at Install 1st camshaft bearing cap in arresting hole (A) in camshaft sprocket on intake camshaft (12).
			*111589031500
4	Remove front cover (9) at cylinder head		AR01.30-D-5700NA
5	Unscrew driver (13) at the intake camshaft (12), and take off slide rail (8)		*BA05.20-P-1002-01F
		17 mm hexagon socket 3/8 inch square
6	Remove high-pressure pump (4)		AR07.02-D-1020NA
7	Mark camshaft sprocket (5) relative to timing chain
8	Detach camshaft sprocket (5) at the exhaust camshaft (11) and take off with timing chain fitted on.	 If necessary, counterhold exhaust camshaft (11) with open end wrench. Pay attention to dowel pin (6). After removing secure timing chain on camshaft sprocket (5) against falling down.
		 Installation: Check basic adjustment of exhaust camshaft (11) and intake camshaft (12), if necessary: 	AR05.20-D-6010NA
		Correct basic adjustment of exhaust camshaft (11) and intake camshaft (12).	AR05.20-D-6025NA
		Replace bolts (7).
			*BA05.10-P-1003-01A
9	Unscrew bolt (3) at intermediate gear of high pressure pump (1)		*BA05.10-P-1005-01A
10	Take intermediate gear of high pressure pump (1) together with liner (2) up and out through the timing chain shaft
11	Install in the reverse order

 Timing chain, chain tensioner

Number	Designation		Engine 612.981/ 990


BA05.10-P-1003-01A	Bolt, camshaft sprocket to exhaust camshaft	Nm	18
BA05.10-P-1005-01A	Bolt, intermediate gear of high pressure pump to cylinder head	Nm	40

 Camshaft

Number	Designation		Engine 611.960/961/962/980/ 981/983/987 612.961/962/963/965/ 966/967/981/990 613.960/961


BA05.20-P-1002-01F	Bolt, driver to inlet camshaft	Nm	50

Retaining pins

111 589 03 15 00

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