High pressure fuel pump intermediate gear (Mercedes-Benz Vito W638)

Removal

1. Disconnect the negative cable from the battery.

2. Remove the Y20-Y23 injectors (see figure 5.58).

Figure 5.58. High pressure fuel pump intermediate gear:
1. Exhaust camshaft,
2. Intake camshaft,
3. Locking finger,
4. Front cylinder head cover,
5. Intake camshaft pulley,
6. Exhaust camshaft pulley,
7, 19. Guide pin,
8. High pressure fuel pump,
9. Chain tensioner,
10. Sealing,
11. Cylinder head cover,
12. Sliding lever,
13, 18. Bolt,
14. Intermediate gear of high pressure fuel pump,
15. Sleeve,
16. Fuel pump,
17. Vacuum pump,
Y20-Y23. Injectors.

3. Remove the cylinder head cover 1.

4. Set the piston of the first cylinder to the TDC position.

5. Lock the flywheel with the lock.

6. Lock the intake camshaft 2.

7. Remove the timing chain tensioner 9.

8. Remove the front cover of the cylinder head 4.

9. Remove the sliding lever in the cylinder head 12.

10. Remove the high pressure fuel pump 8.

11. Mark the relative positions of pulley 6 of the exhaust camshaft and the timing chain.

12. Unscrew and remove pulley 6 of the exhaust camshaft.

13. Unscrew the bolts securing the sleeve 15 of the intermediate gear of the high-pressure fuel pump 14 and remove them together.