Remove/install high-pressure pump

AR07.02-P-1020FF

Remove/install high-pressure pump

18.04.2019

Engine

639.9 in model 454.0

Modification notes

07.11.2005

Remove gearwheel at high-pressure pump, added

Operation step 11.1

AR07.02-P-1020-01FF

1

Connector

5

Fuel line

8

Banjo bolt

2

Connector

6

High pressure pump

B50

Fuel temperature sensor

3

High pressure pipe

7

Sealing ring

Y94

Quantity control valve

4

Bolts

 

Remove/install

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Remove paneling on center piece in front of the windshield

AR88.00-P-2792FF

2

Remove air filter housing

AR09.10-P-1150FG

3

Remove connectors (1, 2)

4

Remove high pressure line (3)

 Installation: Install new high-pressure line(3).

 Nut, pressure line on high pressure pump

*BA07.16-P-1003-01G

 Nut, pressure line to rail

*BA07.16-P-1004-01G

5

Remove banjo bolt (8)

 Installation: Replace sealing rings (7).

 Banjo bolt to high pressure pump

*BA07.16-P-1006-01G

6

Remove fuel line (5) at high-pressure pump (6)

7

Unscrew fuel temperature sensor (B50)

When replacing high-pressure pump (6).

 Installation: Replace sealing ring.

 Fuel temperature sensor to high-pressure pump

*BA07.16-P-1011-01G

8

Remove the quantity control valve (Y94)

When replacing high-pressure pump (6).

 Installation: Replace sealing ring.

9

Remove screws (4) of high-pressure pump (6)

 Installation: Replace screws/bolts (4).

 Bolt, high-pressure pump to cylinder head

*BA07.16-P-1007-01G

10

Remove high-pressure pump (6)

 Installation: Replace seal of high-pressure pump (6).

11

Remove gearwheel at high-pressure pump (6)

When replacing high-pressure pump (6) or when replacing gearwheel of high-pressure pump (6).

AR07.02-P-1020-01FF

 Nut, gearwheel to high pressure pump

*BA07.16-P-1012-01G

 Puller

*001589503300

 Counterholder

*454589044000

 Bell-type puller

*640589013300

If gearwheel of high-pressure pump (6) will be replaced, intake camshaft must also be replaced.



Remove/install camshaft

AR05.20-P-6292FG

12

Install in the reverse order

 Warning

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

13

Perform engine test run and check leaktightness of fuel system in area of high-pressure pump (6)

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1003-01G

Nut, pressure line on high pressure pump

Nm

22

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1004-01G

Nut, pressure line to rail

Stage 1

Nm

20

Stage 2

°

60

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1006-01G

Banjo bolt to high pressure pump

Nm

20

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1007-01G

Bolt, high-pressure pump to cylinder head

Nm

20

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1011-01G

Fuel temperature sensor to high-pressure pump

Nm

15

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1012-01G

Nut, gearwheel to high pressure pump

Nm

70