Remove/install high-pressure pump - AR07.02-P-1020GZB

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2011 Mercedes-Benz ML350, 2010 Mercedes-Benz ML350, 2009 Mercedes-Benz ML320, 2009 Mercedes-Benz GL320, and 2008 Mercedes-Benz ML320. However, it is still accessible from the selected car via links, so may be relevant.

ENGINES 642 in MODEL 164, 251

Fig 1: Identifying High-Pressure Pump Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Risk of explosion from 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 injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
1	Removes strut tower brace	Model 164.8 only Remove strut tower brace from strut tower mounts.	AR62.30-P-2500GY
2	Remove engine cover	Model 164	AR01.10-P-2405GZB
2	Remove engine cover	Model 251	AR01.10-P-2405RTB
3	Remove bracket from fuel pressure sensor on cylinder head cover	Model 251 Lay fuel pressure sensor down to side with bracket and lines connected.	AR07.04-P-0030SXI
4	Remove pressure line (19/2)	Seal off pressure line (19/2) to prevent the ingress of foreign bodies. Counterhold threaded union of pressure line (19/2) when removing and installing using a suitable tool.
4	Remove pressure line (19/2)		*BA07.16-P-1025-01C
5	Remove fuel hoses (1, 3) from high-pressure pump (2)	Seal off fuel hoses (1, 3) to prevent the ingress of foreign bodies. Installation: Check condition of hose clamps and fuel hoses (1, 3); replace if necessary.
5	Remove fuel hoses (1, 3) from high-pressure pump (2)	Set of stop plugs	Fig 2
6	Disconnect electrical connector at quantity control valve (Y94)
7	Disconnect electrical connector at the fuel temperature sensor (B50)
8	Remove bolts (4) for high pressure pump (2)	Installation: Replace bolts (4) due to micro-encapsulation.
8	Remove bolts (4) for high pressure pump (2)		*BA07.16-P-1021-01C
9	Detach high pressure pump (2) from the cylinder head	Installation: When replacing the high pressure pump (2) the ignition must be switched on for at least 15 seconds before the engine is started. The high pressure pump (2) would be damaged otherwise. Installation: Clean sealing surfaces of high-pressure pump (2), replace the O-ring and apply engine oil. Installation: The high pressure pump (2) must not be disassembled or opened. The drive pinion gear must be modified when replacing the high pressure pump (2). ↓
9	Detach high pressure pump (2) from the cylinder head	Remove/install high-pressure pump drive gear	AR07.02-P-1021GZB
10	Install in the reverse order
	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 moving off. Wear closed and close-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
11	Check fuel system for leaks with engine running

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation			Engine 642
BA07.16-P-1021-01C	Bolt, high-pressure pump to cylinder head		Nm	15
BA07.16-P-1025-01C	Pressure line to high-pressure pump	M14	Nm	33

Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.