AR05.10-S-4650A | Remove/install intermediate gear of high-pressure pump | 29.1.09 |
ENGINES 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINES 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
S05.10-2507-09
1 Exhaust camshaft
2 Intake camshaft
3 Retaining pin
4 Front cover on cylinder head
5 Inlet camshaft sprocket
6 Exhaust camshaft sprocket
7 Guide bolts
8 High-pressure pump
17 Vacuum pump
18 Screw
19 Dowel pin
Y20 Injector 1
Y21 Injector 2
Y22 Injector 3
Y23 Injector 4
9 Chain tensioner
10 Sealing ring
11 Cylinder head cover
12 Slide rail in cylinder head
13 Screw
14 High pressure pump intermediate gear
15 Bush
16 Fuel pump
| Remove, Install | ||
1 | Disconnect ground line from battery | ||
2 | Remove injectors (Y20, Y21, Y22, Y23) | ||
3 | Remove cylinder head cover (11) | ||
4 | Position piston of cylinder 1 to ignition TDC | Crank engine at crankshaft, do not crank the engine at the screw of the camshaft sprocket. Crank engine in direction of rotation. | |
5 | Install retaining lock for crankshaft/starter ring gear | ||
6 | Lock intake camshaft (2) | Insert the retaining pin (3) through the 1st camshaft bearing cap into the hole (A) in the inlet camshaft sprocket (5). | |
| |||
7 | Remove chain tensioner (9) | Installation: Replace sealing ring (10). | |
8 | Remove front cover at cylinder head (4) | ||
9 | Remove slide rail (12) in cylinder head | ||
10 | Remove high-pressure pump (8) | ||
11 | Mark camshaft sprocket (6) relative to timing chain | ||
12 | Unbolt camshaft sprocket (6) from exhaust manifold (1) | Installation: Replace bolts for camshaft sprocket (13). | |
| |||
| |||
13 | Take off exhaust camshaft sprocket (6) | Observe guide pins (7). | |
14 | Unscrew bolt from high pressure pump intermediate gear (14) | | |
| |||
15 | Remove high pressure pump intermediate gear (14) with cylinder liner (15) | ||
16 | Install in the reverse order | ||
| Checking | ||
17 | Check basic position of camshafts, adjust if necessary | ||
18 | Set basic position of camshafts | ||
Danger! | Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running | Secure vehicle to prevent it from moving by itself. | |
19 | Check for oil leaks with engine running | ||
Danger! | Risk of explosion from 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. | |
20 | Check fuel system for leaks with engine running |
Timing chain, chain tensioner
Number | Designation | Engine | |
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 |
602 589 00 33 00
Extraction claw
Impact extractor
Retaining pins
Round brush
111 589 03 15 00
611 589 00 33 00
611 589 00 68 00
001 589 76 09 00
External Torx set
Brake caliper brush
000 589 26 68 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1036-06A | Special grease | A 001 989 42 51 10 |
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