Remove/install gear of high-pressure fuel pump

AR07.16-S-1009EA

Remove/install gear of high-pressure fuel pump

11.10.2019

Engine

654.9 in model 447

Modification notes

26.09.2019

Tension tensioning rail for bush chain and secure, added.

Operation step 6

26.09.2019

Release tensioning rail for bush chain and slacken, added.

Operation step 14

1

Gear

4

Timing case cover

7.1

Thrust piece

2

Glow output stage

5

Screw

7.2

Pressure screw

3

Cap

6

Bush chain

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Remove engine with transmission.

AR01.10-S-2401EA

2

Remove glow output stage (2).

AR15.20-S-4500EA

3

Pierce cap (3) in center with suitable tool and pry out.


Do not damage seat of cap (3) on timing case cover (4).
Timing case cover (4) will otherwise leak.

4

Have a helper counterhold engine at crankshaft and remove screw (5).

 Counterholder

*654589004000

5

Remove timing case cover (4).

AR01.40-S-8000EA

6

Tension tensioning rail for bush chain (6) and secure.

AR05.10-S-8426-02EA

 As a result of the tensioning rail being tensioned, the bush chain (6) is slackened.

7

Remove timing chain from gearwheel (1).

8

Screw thrust piece (7.1) of special tool into gearwheel (1) as far as it will go.

 Sleeve

*654589001400

9

Screw in pressure screw (7.2) until the gearwheel (1) is released from the high-pressure fuel pump.

 Sleeve

*654589001400

10

Take off bush chain (6) and remove gearwheel (1) together with thrust piece (7.1).

11

Remove thrust piece (7.1) from gearwheel (1).



Install

12

Place bush chain (6) on gearwheel (1).

13

Install gearwheel (1) on high-pressure fuel pump and tighten screw (5) lightly by hand.

 Replace screw (5)

 Observe the guide notch.

14

Release tensioning rail for the bush chain (6) and slacken.

AR05.10-S-8426-01EA

 As a result of the tensioning rail being slackened, the bush chain (6) is tensioned.

15

Place timing chain on gearwheel (1).

16

Install timing case cover (4).

AR01.40-S-8000EA

 Do not install glow output stage (2) yet.

17

Have a helper counterhold engine at crankshaft and tighten screw (5).

 Bolt, sprocket to high-pressure pump

*BA07.16-P-1006-04A

 Counterholder

*654589004000

18

Install new cap (3) on timing case cover (4).

19

Install glow output stage (2).

AR15.20-S-4500EA

20

Install engine with transmission.

AR01.10-S-2401EA

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1006-04A

Bolt, sprocket to high-pressure pump

Nm

60