Remove/install high-pressure fuel pump

AR07.02-S-1028PS

Remove/install high-pressure fuel pump

10.07.2019

Engine

642 in model 470, 471

Modification notes

15.04.2019

Document reference revised.

Operation steps 3, 38

15.04.2019

Method extended

Operation step 43

28.06.2019

Document reference revised.

Operation steps 6, 35

28.06.2019

Method extended

Operation step 41

10.07.2019

Engine oil

BF18.00-N-1001-01PS

1

Coolant hose

8

Electrical connector

12

High pressure pump

2

Noise damper

9

Fuel hose

13

Screw

3

High pressure pipe

10

Screw

14

Oil line

4

Electrical connector

11

Bracket

12

High pressure pump

13

Bolts

Variant I

5

Counterweight

6

Groove

6a

Left edge

7

Gear

A

Tooth

E

Tooth

F

Tooth

Variant II

5

Counterweight

6

Groove

6a

Left edge

7

Gear

A

Tooth

E

Tooth

F

Tooth

 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

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Drain off coolant.

AR20.00-S-1142PS

2

Remove upper engine cover.

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

3

Remove coolant hose (1) from cooler.

AR20.20-P-7441-01RQ

4

Remove noise damper (2).

AR09.40-S-6930PS

5

Turn engine to top dead center (TDC) on cylinder 1 (ignition TDC).

AR01.00-S-0100PS

 The TDC marking of the vibration damper must be flush with the rib of the timing case cover.

6

Remove high-pressure line (3).

AR07.16-S-1004PS

 Counterhold high-pressure fitting of high-pressure pump (12) using a suitable tool.

7

Remove oil line (14) from the oil filter housing.

 Plug openings.

 Record plug

*129589009100

8

Disconnect electrical connection (4).

9

Disconnect electrical connector (8).

10

Remove fuel hoses (9) from the high-pressure pump (12).

 Plug openings.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

11

Remove bracket (11) with fuel pressure sensor from the cylinder head cover.

 Remove screw/bolt (10) to do this.

12

Unscrew bolts (13).

 Dispose of bolts (13).

13

Remove high-pressure pump (12).

 To do this, remove high-pressure pump (12) from the cylinder head and remove upward.

14

Remove O-ring from high-pressure pump (12).

 Dispose of O-ring.

 Assembly tool

*000589936300

15

Remove gearwheel (7) from high-pressure pump (12).

If a new high-pressure pump (12) is installed.

AR07.16-S-1009PS



Check

16

Check sealing cone of high-pressure line (3) for pressure marks.

If pressure mark are visible:



Install new high-pressure line(3).

17

Check fuel hoses (9) for damage.

If there is a problem,



replace damaged fuel hoses (9).



Clean

18

Clean threaded holes of the screws (13) on the cylinder head.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

19

Clean sealing surfaces of the high-pressure pump (12).

 Use lint-free rags.



Install

20

Attach gearwheel (7) to high-pressure pump (12).

If a new high-pressure pump (12) has been installed.

AR07.16-S-1009PS

21

Install new O-ring on high-pressure pump (12).

 Assembly tool

*000589936300

22

Twist gearwheel (7) so that the groove (6) is vertical.

23

Determine the tooth (A) starting from the left edge (6a), as shown.

24

Attach marking to tooth (A) of the gearwheel (7).

25

Determine teeth (E, F) starting from tooth (A), as shown.

 Here, tooth (A) is the 1st tooth, tooth (E) is the 5th tooth, and tooth (F) is the 6th tooth.

26

Apply markings to teeth (E, F).

27

Twist gearwheel (7) relative to the high-pressure pump (12) so that the teeth (E, F) are pointing vertically upward.

28

Position high-pressure pump (12) on cylinder head.


Ensure that the previously adjusted gearwheel (7) is not twisted.
Vibrations will occur otherwise.

29

Screw in new screws (13).

 Screw/bolt, high-pressure fuel pump to cylinder head

*BA07.16-N-1003-03PS

30

Attach fuel hoses (9) to high-pressure pump (12).

 Remove stop plug Replace clamps.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

31

Position bracket (11) of the fuel pressure sensor on the cylinder head cover.

32

Screw in screw (10).

 M61

*BA00.10-N-1002-04A

33

Connect electrical connector (8).

34

Connect electrical connector (4).

35

Install high-pressure line (3).

AR07.16-S-1004PS

 Counterhold high-pressure fitting of high-pressure pump (12) using a suitable tool.

36

Attach oil line (14) to the oil filter housing.

 Remove stop plug

 Oil line to oil filter housing

*BA18.30-N-1003-01Q

 Record plug

*129589009100

37

Install noise damper (2).

AR09.40-S-6930PS

38

Attach coolant hose (1) to cooler.

AR20.20-P-7441-01RQ

39

Fill in coolant.

AR20.00-S-1142PS

40

Read out fault memory.



AD00.00-S-2000-06P

If stored faults exist



Erase the fault memory.

41

Switch on ignition before engine start.


Switch on ignition for a minimum of 15 s before engine start.
The high-pressure pump (12) will be damaged otherwise.

 This causes the new high-pressure pump (12) to be filled with fuel.



Check

42

Check engine oil level.


The engine oil level must not lie above the maximum marking.
Otherwise engine damage may occur.

If there is a problem,



Correct engine oil level .

 Engine oil

*BF18.00-N-1001-01PS

 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

43

Check fuel system for leaks with engine running.

 Visual inspection only.

44

Switch off engine.

45

Install upper engine cover.

 Metric bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-N-1002-04A

M61

Nm

9

13

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1003-03PS

Screw/bolt, high-pressure fuel pump to cylinder head

Nm

14

 Oil cooling

Number

Designation

Engine 642 in model 470, 471

BA18.30-N-1003-01Q

Oil line to oil filter housing

Nm

8

 Filling capacities for engine lubrication system

Number

Designation

Engine 642 in model 470, 471

BF18.00-N-1001-01PS

Engine oil

Filling capacity (oil and filter change)

Liter

8,5

Sheet

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

Sheet

BB00.40-P-0229-52A

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com