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

ENGINE 157, 278 in MODEL 216, 221 

MODIFICATION NOTES

5.4.13 Tightening procedure for housing of the fuel system high pressure pump, added Operation step 24  
Fig 1: Identifying High-Pressure Pump Remove/Install Components (1 Of 3)
G10107844Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying High-Pressure Pump Remove/Install Components (2 Of 3)
G10107845Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying High-Pressure Pump Remove/Install Components (3 Of 3)
G10107846Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
1 Set DIRECT SELECT gear selector switch to position "N" and release parking brake    
2 Detach ground line from battery   AR54.10-P-0003SX
NOTES Notes on battery AH54.10-P-0001-01A
3 Remove both air filter housings    
4 Remove ME-SFI [ME] control unit   AR07.08-P-7008MMB 
5 Remove insulation on rails    
6 Remove crankcase breather line (8) and boot (9) IMPORTANT The crankcase breather line (8) and boot (9) must not  be separated from each other.  
7 Detach engine wiring harness on intake manifold and cylinder head covers   AR01.00-P-2410-02MMB
8 Remove center bulkhead on firewall    
9 Unclip engine wiring harness on firewall    
10 Disconnect electrical connections on right quantity control valve (Y94/2) and pressure sensor downstream of throttle valve actuator (B28/7)    
11 Unscrew screw/bolts (10a) and remove crash plate (10) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
12 Remove insulation (11) on high-pressure pumps (1l, 1r)    
13 Remove bottom engine compartment paneling   AR61.20-P-1105SX
14 Rotate engine at crankshaft center bolt in direction of engine rotation to a 40°crank angle (CA) after top dead center (TDC) on cylinder 1 (ignition TDC)   AR05.10-P-7620-04MM
15 Relieve fuel pressure through service valve   AR07.03-P-1460-01VA
IMPORTANT Open tank filler cap for a short time in order to remove the overpressure in the fuel tank.
TORQUE SPECIFICATION Protective cap on service valve *BA07.03-P-1007-01E 
SPECIAL TOOL Pressure hose Fig 4
16 Remove high-pressure lines which are mounted on the high-pressure pumps NOTES Do not kink or bend high-pressure lines. Leaks and damage can occur otherwise.
The sealing cone for high-pressure lines must be checked before assembly. The work instructions absolutely must be observed for assembly work. Checking of fuel high-pressure circuit must be carried out after assembly:
↓		  
Check high-pressure lines AR07.03-P-1010-03MM
Mount high-pressure lines. AR07.03-P-1010-02MMB
Check fuel high pressure circuit. AR07.03-P-1010-04MM
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01E 
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01E 
TORQUE SPECIFICATION Bolt, fuel line service valve to cylinder head cover *BA07.03-P-1003-01E 
TORQUE SPECIFICATION Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head *BA07.03-P-1004-01E 
TORQUE SPECIFICATION Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase *BA07.03-P-1005-01E 
TORQUE SPECIFICATION Bolt, fuel line clamp to charge air distribution line *BA07.03-P-1006-01E 
Assembly cleaner *BR00.45-Z-1028-04A 
17 Remove screw/bolts (1s) for high-pressure pump(s) (1r, 1l) NOTES Screw/bolts (1s) must  be screwed in and out by half a revolution alternately for removal or installation of the high-pressure pump(s) (1r, 1l)..
Damage can occur to the high-pressure pump(n) (1r, 1l) otherwise.
IMPORTANT Replace screw/bolts (1s) with new ones.
IMPORTANT The high-pressure pump(s) (1r, 1l) must  lie flat on the high pressure pump housing (2) after tightening the screw/bolts (1s) under the screw/bolts (1s)..		  
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing *BA07.02-P-1001-01C 
18 Raise high-pressure pump on the left (1l) somewhat and disconnect electrical connection on left quantity control valve (Y94/1)    
19 Remove high-pressure pump(s) (1r, 1l) NOTES
Dry green sealing ring (3) coated with low-friction paint and insert the black sealing ring (3) wet with oil into the high pressure pump housing (2).
Leakage can occur otherwise.
IMPORTANT Clean mount(s) for the high-pressure pump(s).
IMPORTANT Replace sealing ring (3). There are two variants of the sealing rings (3) which can be differentiated between based on their color.		  
20 Pull tappet elements (4) out of the high-pressure pump housing (2) NOTES
The tappet elements (4) must be installed in such a way that the drive rollers for the tappet elements (4) sit on the camshaft.
Damage can occur to the camshaft otherwise.		  
INSPECT Check     
21 Check tappet elements (4) for wear, check for damage and replace if necessary    
  Only perform operation steps 22 to 25 to remove the high-pressure pump housing (2)     
22 Remove centrifuge vacuum line (7) on intake manifold    
23 Remove bracket for high-pressure pump housing (2) on cylinder head cover    
24 Remove screw/bolts (2a) for high-pressure pump housing (2)   AR07.02-P-1020-02MM
NOTES
Observe assembly specification and tightening sequence.
Damage will occur to the camshaft and cylinder head otherwise.
TORQUE SPECIFICATION Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover *BA07.02-P-1002-01C 
25 Take out high-pressure pump housing (2) upwards IMPORTANT Replace seals (5, 6)  
26 Install in the reverse order    
27 Switch on ignition NOTES The ignition must  be switched on for 5 s before the engine start in order to fill the high-pressure pump (1l, 1r) with fuel.
Damage can occur to the high-pressure pumps (1r, 1l) otherwise.		  
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
28 Perform an engine test run and check fuel system for proper operation and leaktightness AR07.03-P-1010-04MM
HIGH PRESSURE PUMP

Number Designation ENGINE 157 ENGINE 278
BA07.02-P-1001-01C Bolt, high-pressure pump to high-pressure pump drive housing Nm 14 14
HIGH PRESSURE PUMP

Number Designation ENGINE 157 ENGINE 278
BA07.02-P-1002-01C Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover Stage 1 Nm 1 1
Stage 2 Nm 14 14
HIGH PRESSURE PUMP

Number Designation ENGINE 157 ENGINE 278
BA07.02-P-1003-01C Bolt, shield to high-pressure pump drive housing Nm 14 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1001-01E Union nut, fuel line to fuel distributor Nm 22 22
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1002-01E Union nut, fuel line to high-pressure pump Nm 22 22
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1003-01E Bolt, fuel line service valve to cylinder head cover Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1004-01E Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head Nm 14 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1005-01E Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1006-01E Bolt, fuel line clamp to charge air distribution line Nm 5 5
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1007-01E Protective cap on service valve Plastic Nm 2 2
Metal Nm 15 15
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G07449508Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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