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

ENGINE 276 in MODEL 231 

MODIFICATION NOTES

24.09.2014 Union nut, Fuel line to service port   BA07.03-P-1008-01D
24.09.2014 Union nut, Fuel line to high pressure pump   BA07.03-P-1002-01D
24.09.2014 Union nut, Fuel line to fuel distributor   BA07.03-P-1001-01D

Shown on engine 276.9 

Fig 1: High-Pressure Pump Remove/Install Components - Shown On Engine 276.9 (1 Of 3)
G11128343Courtesy of MERCEDES-BENZ USA
Fig 2: High-Pressure Pump Remove/Install Components - Shown On Engine 276.9 (2 Of 3)
G11128344Courtesy of MERCEDES-BENZ USA
Fig 3: High-Pressure Pump Remove/Install Components - Shown On Engine 276.9 (3 Of 3)
G11128345Courtesy of MERCEDES-BENZ USA
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
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
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING Remove     
1 Disconnect battery ground line   AR54.10-P-0003RK
NOTES Notes on battery   AH54.10-P-0001-01A
2 Drain coolant ENGINE 276.9 in MODEL 231 AR20.00-P-1142RK
NOTES Notes on coolant   AH20.00-N-2080-01A
3 Remove center section of the bulkhead ENGINE 276.9 in MODEL 231  
4 Remove both air filter housings ENGINE 276.8 in MODEL 231 AR09.10-P-1150RKA
5 Remove intake manifold ENGINE 276.9 in MODEL 231 AR09.20-P-1961RKA
6 Take off and remove insulation from right rail    
7 Remove engine wiring harness on crash plate (10)   AR01.00-P-2410-02RKA
8 Disconnect left electrical connection at ME-SFI [ME] control unit, unclip electrical line at bracket and place to one side ENGINE 276.8 in MODEL 231 AR07.08-P-7008RKA 
9 Unclip ME-SFI [ME] control unit from bracket and place to one side with attached lines ENGINE 276.8 in MODEL 231 AR07.08-P-7008RKA 
10 Remove bracket at crash plate (10) and vacuum pump ENGINE 276.8 in MODEL 231  
11 Position piston of cylinder 1 to a 40° crank angle (CKA) after ignition TDC IMPORTANT To do this turn engine at center bolt of the crankshaft in direction of engine rotation. AR05.10-P-7620-04MM
12 Detach engine wiring harness bracket at crash plate (10) ENGINE 276.8 in MODEL 231  
13 Remove screw/bolts (12a) and remove impact protection (12)    
14 Unscrew screw/bolts (10a) and remove crash plate (10)    
15 Remove insulation (11) on the high-pressure pump (1)    
16 Unclip engine wiring harness on bracket on right exhaust gas recirculation positioner (Y87/1) and remove ENGINE 276.9 in MODEL 231  
17 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA
TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1007-01D 
SPECIAL TOOL Pressure hose Fig 4
18 Relieve fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM
19 Unscrew union nuts for fuel lines on rails and high-pressure pump (1) NOTES Do not kink or bend fuel lines.
Otherwise leaks and damage may occur.
NOTES Thoroughly clean area around fuel line on the locations to be separated.
Failure can occur otherwise to the fuel system.
Assembly cleaner		 *BR00.45-Z-1028-04A 
20 Disconnect electrical connection on quantity control valve (Y94)    
21 Remove high-pressure pump (1) screw/bolts (1s) and the high-pressure pump (1) NOTES Thoroughly clean area around the fuel high-pressure circuit.
Failure can occur otherwise to the fuel system.
NOTES Screw/bolts (1s) must be removed alternately each by half a revolution each time when removing the high-pressure pump (1).
Damage could occur to the high-pressure pump (1) otherwise.
Assembly cleaner		 *BR00.45-Z-1028-04A 
22 Pull tappet element (4) out of high-pressure pump housing (2)    
23 Detach engine wiring harness bracket on high-pressure pump housing (2)    
24 Remove screw/bolts (2a) of high-pressure pump housing (2) and remove high-pressure pump housing (2) and pull out upwards    
INSPECT Check     
25 Check tappet element (4) If wear is found: ↓
Replace tappet element (4)		  
INSTALLING Install     
26 Attach high-pressure pump housing (2) and tighten down screw/bolts (2a) of the high-pressure pump housing (2) Tightening procedure for housing of fuel system high pressure pump
↓ Observe tightening procedure.
Damage can occur otherwise to the camshaft and cylinder head.
INSTALLATION IMPORTANT Replace seal.		 AR07.02-P-1020-02MM
TORQUE SPECIFICATION Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover *BA07.02-P-1002-01C 
27 Detach engine wiring harness bracket on high-pressure pump housing (2) TORQUE SPECIFICATION Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing *BA07.03-P-1006-01D 
28 Push tappet element (4) in high-pressure pump housing (2) NOTES The tappet element (4) must be installed in such a way that the drive roller for the tappet element (4) sits on the camshaft.
Damage can occur to the camshaft otherwise.		  
29 Clean mount for high-pressure pump (1) in high-pressure pump housing (2). Assembly cleaner *BR00.45-Z-1028-04A 
30 Replace sealing rings of the high-pressure pump (1). IMPORTANT There are two variants of the sealing rings which can be differentiated between based on their color. Dry green sealing ring coated with low-friction paint and insert the black sealing ring wet with oil into the high-pressure pump housing (2). Replace sealing ring by a sealing ring of the same color.  
31 Attach high-pressure pump (1) to high-pressure pump housing (2) and tighten screw/bolts (1s) for high-pressure pump (1) NOTES Screw/bolts (1s) must be screwed in alternately each by half a revolution each time when installing the high-pressure pump (1).
Damage could occur to the high-pressure pump (1) otherwise.
IMPORTANT Replace screw/bolts (1s) with new ones. The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s).
Assembly cleaner		 *BR00.45-Z-1028-04A 
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing *BA07.02-P-1001-01C 
32 Put on electrical connection on quantity control valve (Y94)    
INSPECT Check     
33 Check fuel lines   AR07.03-P-1010-03MM
Assembly cleaner *BR00.45-Z-1028-04A 
34 Unscrew union nuts for fuel lines on rails and high-pressure pump (1)   AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Union nut, fuel line to service connection *BA07.03-P-1008-01D 
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
35 Clip in engine wiring harness on exhaust gas recirculation positioner bracket    
36 Install insulation (11) on high-pressure pump (1)    
37 Screw in screw/bolts (10a) and attach crash plate (10) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
38 Screw in screw/bolts (12a) and install impact protection (12)    
39 Attach engine wiring harness bracket at crash plate (10) ENGINE 276.8 in MODEL 231  
40 Install bracket at crash plate (10) and vacuum pump    
41 Clip ME-SFI [ME] control unit into bracket ENGINE 276.8 in MODEL 231 AR07.08-P-7008RKA 
42 Place left electrical connection onto ME-SFI [ME] control unit and clip in electrical line onto bracket ENGINE 276.8 in MODEL 231 AR07.08-P-7008RKA 
43 Attach engine wiring harness on crash plate (10)    
44 Attach insulation to rail on the right    
45 Install intake manifold ENGINE 276.9 in MODEL 231 AR09.20-P-1961RKA
46 Install both air filter housing ENGINE 276.8 in MODEL 231 AR09.10-P-1150RKA
47 Install center section of the bulkhead ENGINE 276.9 in MODEL 231  
48 Connect ground line to battery   AR54.10-P-0003RK
NOTES Notes on battery   AH54.10-P-0001-01A
49 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 (1) with fuel.
Damage could occur to the high-pressure pump (1) otherwise.		  
50 Pour in coolant ENGINE 276.9 in MODEL 231 AR20.00-P-1142RK
NOTES Notes on coolant   AH20.00-N-2080-01A
INSPECT Check     
51 Check fuel high-pressure circuit   AR07.03-P-1010-04MM
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
52 Perform an engine test run and check fuel system for proper operation and leaktightness
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1001-01C Bolt, high-pressure pump to high-pressure pump drive housing Nm 14
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1002-01C Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover Stage 1 Nm 1
Stage 2 Nm 9
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1003-01C Bolt, shield to high-pressure pump drive housing Nm 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1001-01D Union nut, fuel line to fuel distributor Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1002-01D Union nut, fuel line to high-pressure pump Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1006-01D Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1007-01D Cap on service connection Plastic Nm 2
Metal Nm 15
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1008-01D Union nut, fuel line to service connection Stage 1 Nm 15
Stage 2 ∠° 90
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G07742723Courtesy 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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