Remove high pressure pump, install · ar0702d1020na · Mercedes-Benz WIS

AR07.02-D-1020NA

Remove high pressure pump, install

15.1.01

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

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

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

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

D07.02-1101-06

1 High-pressure pump

2 Connector

3 Bracket

4 Pressure line

5 Threaded union

6 Bolts

7 Screw

8 Bracket

9 Fuel return line

10 Sealing ring

11 Sealing ring

12 Adapter piece

13 Sealing ring

14 Sealing ring

15 Sealing ring

16 Driver

Modification notes

25.9.03

Value changed from 22 Nm to 23 Nm

Value in series 1002 changed for engine 612.981

*BA07.16-P-1002-01A

 	Remove/Install
 Danger!	Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.	No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Remove viscous fan clutch		AR20.40-D-5660NA
2	Remove electric shutoff valve	 Cover poly-V-belt, otherwise feathering-out fuel can cause damage.	AR07.16-D-1040NA
3	Unplug connector (2) at high pressure pump (1)
 Danger!	Risk of explosion. Fuel may ignite and explode. Risk of injury. Fuel may stream out and cause injury to eyes or skin.	Keep all ignition sources out of hazardous area. Do not carry out any work on systems when they are under pressure	AS07.16-Z-0001-01A
4	Detach bracket (3) and take off pressure line (4) at high pressure pump (1)	 Never slacken threaded unions (5), otherwise this can lead to leakage.  When slackening and tightening the union nut, counterhold at threaded union (5) with wrench.On no account exceed the tightening torque in order to avoid also slackening the threaded union (5) the next time.
		Do not squeeze or bend pressure line (4). Ensure scrupulous cleanliness.
		 Installation: Ensure exact seating of the pressure line (4). Check sealing cone at pressure line (4) and replace pressure line (4) if there are pressure marks.
			*BA07.16-P-1002-01A
5	Detach bracket (8) for fuel return line (9) and intermediate piece (12) at the high pressure pump (1)		*BA07.16-P-1008-01A
6	Detach fuel return flow line (9) at high pressure pump (1)	 Installation: Replace sealing rings (10, 11)
7.1	Detach intermediate piece (12) at high pressure pump (1)	Only when replacing the high pressure pump (1)
		 Installation: Replace sealing rings (13, 14)
8	Take off high pressure pump (1) at cylinder head	 Bottom bolt (6) is not easily accessible. High pressure pump must not be opened. The driver (16) can be taken off.
			*BA07.16-P-1009-01A
		Installation: Replace seal (15). Clean sealing surface. Pay attention to position of driver (16) relative to intermediate gear of high pressure pump (arrow).
		If driver is worn (16), also replace the intermediate gear of high pressure pump.	AR05.10-D-4650NA
9	Install in the reverse order
10	Bleed low pressure fuel circuit		AR07.16-D-0100A
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
 Danger!	Risk of explosion from fuel igniting. Risk of injury. Fuel may stream out and cause injury to eyes or skin.	Keep all ignition sources out of hazardous area. Do not carry out any work on the system when it is pressurized.	AS07.16-Z-0001-01A
11	Inspect fuel system for leaks	 Run engine, switch off and inspect for leaks.

 Common rail diesel injection (CDI)

Number	Designation		Engine 612.981


BA07.16-P-1002-01A	Nut of pressure line to high pressure pump/rail	Nm	23
BA07.16-P-1008-01A	Bolt of bracket to high pressure pump	Nm	9
BA07.16-P-1009-01A	Bolt of high pressure pump to cylinder head	Nm	14

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