Remove/Install High-Pressure Fuel Pump - Ar07.02-D-1028TSV
Engine 642 in model 907
Variant I
Variant II
| 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 | |
| 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 | |
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Notes about Common-Rail components | AH07.16-P-0002-01TX | ||
| Remove | |||
| 1 | Remove fan shroud. | AR20.40-D-6800TSV | |
| 2 | Remove coolant hose (9) from the bracket (10) and press toward the rear. | ||
| 3 | Detach electrical connector (7). | ||
| 4 | Disconnect electrical connection (4). | ||
| 5 | Remove fuel hoses (2, 3) from fuel high-pressure pump (1). | Seal fuel hoses (2, 3). This prevents foreign matter from entering. |
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| Fig 4 | |||
| Fig 3 | |||
| 6 | Remove high-pressure line (5) from high-pressure fitting (6) and press upward slightly. | Seal high-pressure line (5). This prevents foreign matter from entering. Counterhold high-pressure fitting (6) and do not crush or bend high-pressure line (5). Leaks can occur on the fuel system otherwise. |
|
| Fig 3 | |||
| 7 | Remove high-pressure fitting (6). | If the high-pressure fitting (6) is loose or leaky. | |
| 8 | Position piston of cylinder 1 at crankshaft to ignition TDC. | Do not turn engine against its direction of rotation. The timing chain can skip otherwise and engine damage can occur. |
|
| Fig 2 | |||
| 9 | Remove bolts (8). | ||
| 10 | Remove fuel high-pressure pump (1). | ||
| 11 | Remove gearwheel (12) of the fuel high-pressure pump (1). | If installing a new fuel high-pressure pump (1). | |
| AR07.16-D-1006TSV | |||
| Clean | |||
| 12 | Clean sealing surfaces of the fuel high-pressure pump (1). | Cold degreasing agent/cold cleaning solvent HAKU 1025-920 | *BR00.45-Z-1051-04A |
| Install | |||
| 13 | Attach gearwheel (12) of the fuel high-pressure pump (1). | If a new fuel high-pressure pump (1) has been installed. | |
| AR07.16-D-1006TSV | |||
| 14 | Replace the sealing ring (11). | ||
| 15 | Attach marking to tooth (A) of the gearwheel (12). | ||
| 16 | Attach markings to teeth (E, F) of the gearwheel (12). | ||
| 17 | Adjust gearwheel (12) relative to fuel high-pressure pump (1). | ||
| 18 | Attach fuel high-pressure pump (1) to cylinder head. | Do not twist adjusted gearwheel (12). Otherwise, vibrations will occur during operation. |
|
| 19 | Screw in new screws (8). | *BA07.16-N-1003-03TSV | |
| 20 | Screw high-pressure fitting (6) into fuel high-pressure pump (1). | If loose or leaky high-pressure fitting (6) has been removed. |
|
| *BA07.16-N-1010-03TSV | |||
| Check | |||
| 21 | Check clamps and fuel hoses (2, 3) for damage. | Depending on the findings, ↓ Replace affected clamps and fuel hoses (2, 3) |
|
| 22 | Check sealing cone of the high-pressure line (5) for damage. | Depending on the findings, ↓ Install new high-pressure line (5). |
|
| Remove/install high-pressure line to rail | AR07.16-D-1004TSV | ||
| 23 | Attach high-pressure line (5) to high-pressure fitting (6). | ||
| Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | ||
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
Counterhold high-pressure fitting (6) and do not crush or bend high-pressure line (5). Leaks can occur on the fuel system otherwise |
|||
| *BA07.16-N-1008-03TSV | |||
| Fig 1 | |||
| 24 | Attach fuel hoses (2, 3) to fuel high-pressure pump (1). | Fig 4 | |
| 25 | Connect electrical connector (4) to fuel temperature sensor (15). | ||
| 26 | Connect electrical connector (7) to quantity control valve (16). | ||
| 27 | Attach coolant hose (9) to bracket (10). | ||
| 28 | Install fan shroud. | AR20.40-D-6800TSV | |
| 29 | Switch on ignition before engine start. | If a new fuel high-pressure pump (1) has been installed. Do not start engine yet; leave ignition switched on for at least 15 s. Otherwise, the new fuel high-pressure pump (1) will be damaged. |
|
| Check | |||
| 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 | |
| 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 | |
| 30 | Check for leaktightness when engine is running. |
| Number | Designation | Engine 642 in model 907 | |
|---|---|---|---|
| BA07.16-N-1003-03TSV | Screw/bolt, high-pressure fuel pump to cylinder head | Nm | 14 |
| Number | Designation | Engine 642 in model 907 | ||
|---|---|---|---|---|
| BA07.16-N-1008-03TSV | Union nut, high-pressure line for fuel system high pressure pump to fuel system high pressure pump | Stage 1 | Nm | 20 |
| Stage 2 | ∠ ° | 60 | ||
| Number | Designation | Engine 642 in model 907 | |
|---|---|---|---|
| BA07.16-N-1010-03TSV | Fitting on fuel system high pressure pump | Nm | 55 |
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 |