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

ENGINES 157 in MODEL 463 

Fig 1: High-Pressure Pump Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: High-Pressure Pump Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: High-Pressure Pump Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury  caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	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. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
		The ground line on the battery must always  before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door.
		Thoroughly area around the fuel high pressure circuit. Dirt can find its way into the injection system otherwise which can lead to failure of the injection system.
1	Detach ground line from battery		AR54.10-P-0003GW
2	Remove both air filter housings		AR09.10-P-1150GW
3	Remove ME-SFI [ME] control unit		AR07.08-P-7008GW
4	Remove insulation on rails
5	Remove crankcase breather line (8) and boot (9)	The crankcase breather line (8) and boot (9) must not  be separated from each other.
6	Remove air plenum chamber and water collector		AR83.10-P-9998GW
7	Detach engine wiring harness on charge air manifold and cylinder head covers		AR01.00-P-2410-02GW
8	Disconnect electrical connectors on right quantity control valve (Y94/2) and pressure sensor downstream of throttle valve (B28/7)
9	Detach wiring harness (12) from bracket (13)		AR01.00-P-2410-02GW
10	Remove bracket (13)
11	Unscrew screw/bolts (10a) and remove crash plate (10)		*BA07.02-P-1003-01C
12	Remove insulation (11) on high-pressure pumps (1l, 1r)
13	Lift/jack up vehicle		AR00.60-P-1000G
14	Remove underride guard	Aid of helper required.
15	Rotate engine at crankshaft center bolt in direction of rotation of engine to a 40°  crankshaft angle after top dead center (TDC) on cylinder 1		AR05.10-P-7620-04MM
16	Reduce fuel pressure through service valve	Open tank cap for a short time in order to remove the overpressure in the fuel tank.	AR07.03-P-1460-01GW
			*BA07.03-P-1007-01E
			Fig 4
17	Remove high-pressure lines which are mounted on the high-pressure pumps	Do not kink or bend high-pressure lines. Do this to avoid leaks and damage. The sealing cone for high- pressure lines must be checked before assembly. The work instructions absolutely must be observed for assembly work. Checking of the high-pressure fuel circuit must  be carried out after assembly: ↓
		Check sealing cone on 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
			*BA07.03-P-1001-01E
			*BA07.03-P-1002-01E
			*BA07.03-P-1003-01E
			*BA07.03-P-1004-01E
			*BA07.03-P-1005-01E
			*BA07.03-P-1006-01E
			*BA07.03-P-1008-01E
		Cleaner from package	*BR00.45-Z-1028-04A
18	Remove screw/bolts (1s) for high-pressure pump(s) (1r, 1l)	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 ((1r, 1l) otherwise. The high-pressure pump (n) (1r, 1l) must  lie on flat the high pressure pump housing (2) after tightening the screw/bolts (1s) under the screw/bolts (1s)
			*BA07.02-P-1001-01C
19	Raise high-pressure pump on the left (1l) somewhat and disconnect electrical connector on left quantity control valve (Y94/1)	When removing left high-pressure pump (1l)
20	Remove high-pressure pump(s) (1r, 1l)	Clean mount(s) for the high- pressure pump(s). Replace sealing ring (3). There are two variants of the sealing rings (3) which can be differentiated between based on their color. 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.
21	Pull tappet elements (4) out of the high- pressure pump housing (2)	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.
	Checking
22	Check tappet elements (4) for wear, check for damage and replace if necessary
	Only perform operation steps 23 to 26 to remove the high-pressure pump housing (2)
23	Remove centrifuge vacuum line (7) on intake manifold
24	Remove bracket for high-pressure pump housing (2) on cylinder head cover
25	Remove screw/bolts (2a) for high-pressure pump housing (2)		*BA07.02-P-1002-01C
26	Take out high-pressure pump housing (2) upwards	Replace seals (5, 6).
27	Install in the reverse order
28	Switch on ignition	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.
	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 from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
29	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
BA07.02-P-1001-01C	Screw/bolt, high-pressure pump to high pressure pump drive housing	Nm	14
BA07.02-P-1002-01C	Screw/bolt, high pressure pump drive housing to cylinder head/cylinder head cover	Nm	14
BA07.02-P-1003-01C	Screw/bolt, shield to high pressure pump drive housing	Nm	14

INJECTORS, INJECTION VALVES, LINES

Number	Designation			Engine 157
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor		Nm	22
BA07.03-P-1002-01E	Union nut, fuel line to high-pressure pump		Nm	22
BA07.03-P-1003-01E	Screw/bolt, fuel line service valve to cylinder head cover		Nm	9
BA07.03-P-1004-01E	Screw/bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head		Nm	14
BA07.03-P-1005-01E	Screw/bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase		Nm	9
BA07.03-P-1006-01E	Screw/bolt, fuel line clamp to charge air distribution line		Nm	6
BA07.03-P-1007-01E	Protective cap on service valve	Plastic	Nm	2
		Metal	Nm	15
BA07.03-P-1008-01E	Fuel line union nut on service valve		Nm	24

Fig 4: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth GmbH & Co. KG