Installing high pressure pump

• Place the depth gauge (1) flat onto the high pressure pump flange.
• Turn the engine at the central bolt in the direction of engine rotation until the camshaft is in the BDC position.

  The depth gauge (1) is in the lowest position.

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  NOTE: RISK OF DAMAGE
  Damage to the engine. 
  If the engine is manually rotated in the wrong direction of rotation, the engine can be damaged. 

  • Only rotate the engine manually in the correct direction of rotation: a) clockwise when looking at the damper, or b) counterclockwise when looking at the chain drive, b) applies only if the timing chain is installed in the rear.

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• Rotate the engine using special tool  0 493 380 (11 6 480)  until the cam of the high-pressure pump drive is  at the BDC position  .
• Guide out and remove gasket (1).

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• Replace the seal (1).

  Parts:  Seal

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  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
• Check the threads (1) on the high pressure pump flange for sealing compound residue: Remove sealing compound residue as needed.
• Clean the thread (1) with a thread cutter M6  .
• Make sure that no contamination gets into the engine.
• Cover opening at the high pressure pump flange with suitable materials.

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  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
• Clean sealing surface (1).

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• Guide in and install the seal (1).
• Make sure that the seal (1) is positioned correctly in the marked area.

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  NOTE: RISK OF DAMAGE 
  Damage to the surface. 
  The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage. 

  • Do not use any metal-cutting tools.

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  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
• Clean sealing surface (1).
• Feed in and install high pressure pump (2).
• Replace the bolts (arrows).

  Parts:  Screws

• Position the screws (arrows) on the high pressure pump (2) and alternately  in steps of 90°  .

  Compliance with this specification is imperative to make sure that the piston will not break due to twisting.

  TIGHTENING TORQUE SPECIFICATION
  
  

  High pressure pump to high pressure pump flange
  M6x25	Replace screws. Joining torque	2 Nm
  	Tightening torque	90°

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• Connect connectors (1) and lock.
• Make sure the connector (1) engages audibly.

Follow-up work 

• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING ALL IGNITION COILS .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING UPPER CROSS CONNECTION .
• Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
• Refer to IF INSTALLED: INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT (PARTIALLY REMOVED) .
• Refer to INSTALLING THE COVER FOR CENTER ENGINE COMPARTMENT .
• Refer to INSTALLING THE FRONT HOOD SEAL .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE REAR HOOD SEAL .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .