Remove/install high-pressure pump drive gear - AR07.02-P-1021CD

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ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221

Fig 1: High-Pressure Pump Drive Gear Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Removing
1	Secure vehicle on vehicle lift	Model 166	AR00.60-P-0100GZ
		Model 172	AR00.60-P-0100T
		Model 204, 207	AR00.60-P-0100CW
		Model 212, 218	AR00.60-P-0100EWS
		Model 221.0/1	AR00.60-P-0100SX
2	Remove timing case cover		AR01.40-P-8000CD
3.1	Remove oil pan bottom section	Model 172, 204 (except 204.9), 212 except 4MATIC Model 207, 218	AR01.45-P-7555CD
3.2	Remove oil pan	Model 166.0	AR01.45-P-7500GQA
		Model 204, 212 - only 4MATIC	AR01.45-P-7500OMD
		Model 221	AR01.45-P-7500SXA
4.1	Set piston of cylinder 1 with a counterholder to Top Dead Center	Except code (B03) ECO start-stop function The engine must not be turned back. The timing chain can skip otherwise and can cause engine damage. Rotate engine at crankshaft using a counterholder in direction of engine rotation until the 0° marking on the belt pulley/vibration damper coincides with the marking on the cylinder crankcase.
		Counterholder	Fig 3
4.2	Set piston of cylinder 1 with a suitable tool to Top Dead Center	With code (B03) ECO start/stop function The engine must not be turned back. The timing chain can skip otherwise and can cause engine damage. Rotate engine at crankshaft using a counterholder in direction of engine rotation until the 0° marking on the belt pulley/vibration damper coincides with the marking on the cylinder crankcase.
		Counterholder	Fig 3
5	Remove chain tensioner		AR05.10-P-7800CD
6	Remove intermediate gear for engine control (6) between crankshaft and high-pressure pump drive gear (4)		AR05.10-P-7620CD
7	Remove bearing pins (1) on slide rail (2)	Impact extractor	Fig 2
8	Remove screws/bolts (3)
9	Detach high-pressure pump drive gear (4) and remove timing chain (5)
	Install
10	Lay timing chain (5) on high-pressure pump drive wheel (4), position high-pressure pump drive wheel (4) on crankcase and tighten down screw/bolts (3)		*BA07.16-P-1006-01H
11	Lock slide rail (2) with bearing pin (1)
12	Mount intermediate gear for engine control (6)		AR05.10-P-7620CD
13	Check basic setting of balance shaft		AR03.20-P-3637CD
14	Install chain tensioner		AR05.10-P-7800CD
15	Check basic setting for camshafts.	Adjust if necessary. See ↓	AR05.20-P-6010CD
		Set basic position of camshafts	AR05.20-P-6020CD
16.1	Install oil pan bottom section	Model 172, 204 (except 204.9), 212 except 4MATIC Model 207, 218	AR01.45-P-7555CD
16.2	Install oil pan	Model 166.0	AR01.45-P-7500GQA
		Model 204, 212 - only 4MATIC	AR01.45-P-7500OMD
		Model 221	AR01.45-P-7500SXA
17	Install timing case cover		AR01.40-P-8000CD
18	Release vehicle on lifting platform	Model 166	AR00.60-P-0100GZ
		Model 172	AR00.60-P-0100T
		Model 204, 207	AR00.60-P-0100CW
		Model 212, 218	AR00.60-P-0100EWS
		Model 221.0/1	AR00.60-P-0100SX
19	Connect STAR DIAGNOSIS, read out fault memory and erase if required	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.	AD00.00-P-2000-04A
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
20	Test run engine and check for leaks

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation		ENGINE 651
BA07.16-P-1006-01H	Screw/bolt, drive wheel for high-pressure pump to cylinder crankcase	Nm	19

Fig 2: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Counterholder (651 589 00 40 00)

Courtesy of MERCEDES-BENZ USA