Installing high pressure pump

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

  The depth gauge (1) is in the deepest 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.
• Rotate the engine with the special tool 0 493 380 (11 6 480)  until the cam of the high-pressure pump drive is at the BDC position. 

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• Guide out and remove gasket (1).

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• Replace gasket (1).

  Parts:  Gasket

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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 enters 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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• Insert and install the gasket (1).
• Make sure that seal (1) is correctly positioned in 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.
  NOTE: TECHNICAL INFORMATION. 
  The sealing surfaces must be free of oil, grease and cleaning agents.
• Clean sealing surface (1).

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• Feed in and install high pressure pump (2).
• Replace the bolts (arrows).

  Parts:  screw

• Bring the screws (arrows) at the high pressure pump (2) into position and tighten in alternating order  in steps of 90°  .

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

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  TIGHTENING TORQUES SPECIFICATION
  
  

  High pressure pump to high pressure pump flange
  M6x25 Replace screws.	Joining torque	12 Nm
  	Tightening torque	90°

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

Follow-up work 

• Install FUEL DELIVERY LINE .
• Install the HIGH-PRESSURE LINE  between the high-pressure pump and the high-pressure rail
• Install all IGNITION COILS .
• Install rear ACOUSTIC COVER .
• Install the upper part COWL .
• Install ACOUSTIC COVER .
• Install windshield panel COVER .
• Install left and right WIPER ARM .
• Install fan COWL .
• Install the rear top CROSS CONNECTION .
• Install the left and right hood gasket SEAL .
• Install left and right FRONT-END STRUT .
• Install front CROSS CONNECTION .
• Install the rear left and right engine compartment COVER PANEL .
• Install the front hood rear SEAL .
• Install the top left and right engine compartment COVER .
• Install the front UNDERBODY PROTECTION .
• Reconnect all battery GROUND LEADS
• Activate the 48 v ELECTRICAL SYSTEM .