Remove/install high-pressure pump

AR07.02-D-1020R

Remove/install high-pressure pump

18.11.2013

ENGINE

646 in MODEL 909

1

Poly-V belt

2

High-pressure pump

3

Electrical connection

4

Electrical connection

5

Pressure line

6

Fuel hoses

7

O-ring

8

Driver

 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

 Danger !

Risk of explosion caused by 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.

AS07.16-Z-0001-01A

 

Remove/install

1

Remove viscous fan clutch

AR20.40-D-5660R

2

Cover poly-V belt (1) in area of the high-pressure pump (2) with rags

3

Disconnect electrical connections (3, 4)

4

Detach pressure line (5) at the high-pressure pump (2)


Counterhold connection fitting at the high-pressure pump (2) and do not crush or bend the pressure line (5).
Leaks can occur on the fuel system otherwise.

 Installation: Check sealing cone of the pressure line (5) and replace pressure line (5) if necessary. Ensure correct seating of pressure line (5).

 Seal connections with suitable  stop plug and ensure the greatest cleanliness.

 Nut connecting pressure line on high pressure pump

*BA07.16-N-1015-01A

 Record plug

*129589009100

 Socket wrench

*611589000300

5

Detach fuel hoses (6) from high-pressure pump (2)

 Catch escaping fuel. Mark installation locations of fuel hoses (6) at high-pressure pump (2).

6

Remove high-pressure pump (2) and remove upwards

 Installation: Replace O-ring (7) and align drive plate (8).

 The high-pressure pump (2) is attached to cylinder head by three screw/bolts.

 Bolt, high-pressure pump to cylinder head

*BA07.16-N-1005-01A

7

Install in the reverse order

 Danger !

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

8

Perform engine test run and check the fuel system for leaktightness in the area of the high-pressure pump (2)


Repeat starting procedure until fuel system is bled and the engine starts. Do not actuate starter for longer than 10 s.
The high-pressure pump (2) will otherwise be damaged.

 Common rail diesel injection (CDI)

Number

Designation

ENGINE 646.7 in MODEL 909

BA07.16-N-1005-01A

Bolt, high-pressure pump to cylinder head

Nm

14

 Common rail diesel injection (CDI)

Number

Designation

ENGINE 646.7 in MODEL 909

BA07.16-N-1015-01A

Nut connecting pressure line on high pressure pump

M121.5

Nm

22