Remove high pressure pump, install

AR07.02-D-1020A

Remove high pressure pump, install

16.4.99

9.3.00

Figure modified from 20 Nm to 22 Nm

Figure in BA07.16-P-1002-01A for engine 611.981/987, 612.981 modified

*BA07.16-P-1002-01A

25.9.03

Value changed from 22 Nm to 23 Nm

Value in series 1002 modified for engine 611.981/983/987,
612.981

*BA07.16-P-1002-01A

 

Remove/Install

Danger!

Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, naked flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove viscous fan clutch

AR20.40-D-5660E

2

Remove electric shutoff valve

 Cover over poly V-belt. Feathering-out fuel can cause damage.

AR07.16-D-1040A

3

Unplug connector (2) at high pressure pump (1)

4

Detach bracket (3) and take off pressure line (4) at high pressure pump (1)

 Never slacken threaded connection (5)!

Use a wrench to counterhold at the threaded connection when slackening and tightening the union nut. On no account exceed the tightening torque in order to avoid also slackening the threaded connection the next time.

Do not crimp or bend line.

Ensure scrupulous cleanliness!

 Ensure line is exactly located. Inspect sealing cone at the line. Replace line if compression points exist.



*BA07.16-P-1002-01A

5

Take off fixture (8) for fuel lines at high pressure pump (1)



*BA07.16-P-1008-01A

6

Detach fuel return flow line (9) at high pressure pump (1)

 Installation: Replace sealing rings (10, 11).

7

Detach intermediate piece (12) at high pressure pump (1)

 Only if high pressure pump is replaced.

Installation: Replace sealing ring (13, 14).

8

Take off high pressure pump (1) at cylinder head

 Bottom torx bolt (6) is not easily accessible.



*BA07.16-P-1009-01A

High pressure pump must not be opened. The driver (16) can be taken off.

Installation: Replace sealing ring (15). Clean sealing surface.

Pay attention to position of driver relative to intermediate gear (arrow). If driver (16) is worn, also replace intermediate gear. Refer to:

Remove/install intermediate gear of high pressure pump.

AR05.10-D-4650A

9

Install in the reverse order

10

Bleed low pressure fuel circuit

AR07.16-D-0100A

 Danger!

Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury. Crushing and burn injuries may result while working on engine during when it is being started or when it is in operation.

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

 Danger!

Risk of explosion from fuel igniting. Risk of injury. Fuel may stream out and cause injury to eyes or skin.

Keep all ignition sources out of hazardous area.

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

AS07.16-Z-0001-01A

11

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

Number

Designation

Engine 611.981/
987

engine 612.981

BA07.16-P-1002-01A

Nut of pressure line to high pressure pump/rail

Nm

23

23

BA07.16-P-1008-01A

Bolt of bracket to high pressure pump

Nm

9

9

BA07.16-P-1009-01A

Bolt of high pressure pump to cylinder head

Nm

14

14

Number

Designation

Engine 611.983

BA07.16-P-1002-01A

Nut of pressure line to high pressure pump/rail

Nm

23

BA07.16-P-1008-01A

Bolt of bracket to high pressure pump

Nm

9

BA07.16-P-1009-01A

Bolt of high pressure pump to cylinder head

Nm

14