ar0702d1020nb

Removing/installing the high pressure pump

Typ ar · temat 07.02 · wersja 0202 · 2005-07-06

Dotyczy: ENGINE 647.981 in MODELS WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA ENGINE 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Niedostępne w języku „pl”; wyświetlono w języku Angielski.

Umiejscowienie

Grupa funkcyjna 1 Silnik › 07 Przygotowanie mieszanki › 07.02 Pompa wtryskowa, pompa nasadzana, pompa wysokociśnieniowa — Seria 647 (modele 981) · Seria 903 (modele 61*, 62*, 66*, 67*) · Seria 904 (modele 61*, 62*, 66*)

EinPAS 15 Silnik › 15.45 Sterowanie pracą silnika › 15.45.51 Pompa wtryskowa/przestawiacz wtrysku — Seria 647 (modele 981) · Seria 903 (modele 61*, 62*, 66*, 67*) · Seria 904 (modele 61*, 62*, 66*)

AR07.02-D-1020NB

Removing/installing the high pressure pump

11.8.03

ENGINE 647.981 in MODELS WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINE 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Removing/installing the high pressure pump

D07.02-1103-06

1 High-pressure pump

2 Sealing ring

3 Driver

4 Fuel-pressure line on high pressure pump

5 Bracket

6 Fuel feed line

7 Fuel return line

8 Bolts

9 Quantity control valve

10 Fuel temperature sensor

11 High pressure pump intermediate gear

Removing/installing

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 contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel jets or leakage.

Keep all ignition sources out of hazard area.

Do not carry out any work on the system when it is pressurized.

AS07.16-Z-0001-01A

1

Remove fan shroud

AR20.40-D-6800NB

2

Disconnect electrical connectors from fuel temperature sensor (10) and quantity control valve (9)

Installation: Ensure that electrical connectors are seated correctly

3

Remove bracket (5) from cylinder head cover

4

Remove fuel pressure line for high pressure pump (4) from high pressure pump (1) and rail

Counterhold threaded sleeves on high pressure pump (1) while detaching the fuel pressure line for high pressure pump (4) and do not bend or squeeze fuel pressure line for high pressure pump (4) otherwise leakage can occur.

Close off all connections after disassembly of the fuel pressure line for high pressure pump (4). Ensure scrupulous cleanliness.

Installation: Check sealing cone on the fuel pressure line for high pressure pump (4) and replace if there are any pressure marks on the fuel pressure line for high pressure pump (4).

Ensure exact seating of the fuel pressure line for high pressure pump (4).

*BA07.16-N-1001-01A

*611589000300

5

Remove fuel feed line (6) and fuel return line (7) on high pressure pump (1)

Collect escaping fuel.

Installation: Check hose clamps, fuel feed line (6) and fuel return line (7); replace if necessary.

6

Unscrew bolts (8) for high pressure pump (1)

*BA07.16-N-1005-01A

7

Remove high pressure pump (1) and drive plate (3)

The high pressure pump (1) must not be disassembled.

Installation: Clean the sealing surface and install new sealing ring (2). Pay attention to the position of the driver (3) at the intermediate gear of the high pressure pump (11). If the driver is worn (3), also replace the intermediate gear of the high pressure pump (11). Refer to:

Removing/installing the intermediate gear on the high pressure pump (11)

AR05.10-D-4650NB

8.1

Remove fuel temperature sensor (10)

Only when replacing the high pressure pump (1).

9

Install in reverse order

10

Bleed fuel system

Switch on ignition three times for approx. 6 seconds without starting the engine.

When replacing high pressure pump (1):

Switch on ignition twice for
approx. 15 seconds without starting the engine to ensure that the new high pressure pump (1) is adequately or fully filled with fuel.

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 engine

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

11

Let engine run, switch it off and check leaktightness of the fuel system

Common rail diesel injection (CDI)

Number

Designation

Engine
647.981

BA07.16-N-1001-01A

Nut for pressure line on high pressure pump/rail

Nm

23

BA07.16-N-1005-01A

Bolt for high pressure pump on cylinder head

Nm

14

Removing/installing the high pressure pump

611 589 00 03 00

Socket wrench

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