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Home >> Mercedes Benz >> 2014 >> S550 Base >> Repair and Diagnosis >> Engine Performance >> Tune-Up >> Mixture Formation - 222 Chassis >> Testing & Repair >> Remove/install high-pressure pump >> Remove/install high-pressure pump - AR07.02-P-1020LFA

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

ENGINE 276.8 in MODEL 217, 222 

Shown on engine 276.8 without code ME05 (HD 80KW-VARIANTS (INCLUDING PLUGIN)) 

Fig 1: High Pressure Pump Remove/Install Components - Shown On Engine 276.8 Without Code ME05 (1 Of 3)
G11131924Courtesy of MERCEDES-BENZ USA
Fig 2: High Pressure Pump Remove/Install Components - Shown On Engine 276.8 Without Code ME05 (2 Of 3)
G11131925Courtesy of MERCEDES-BENZ USA
Fig 3: High Pressure Pump Remove/Install Components - Shown On Engine 276.8 Without Code ME05 (3 Of 3)
G11131926Courtesy of MERCEDES-BENZ USA

Shown on vehicle with code ME05 (HD 80KW-variants (INCLUDING PLUGIN)) 

Fig 4: High Pressure Pump Remove/Install Components - Shown On Vehicle With Code ME05
G11131927DANGERDANGERNOTESIMPORTANTIMPORTANTREMOVINGINSTALLINGINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONNOTESINSTALLATION IMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSTALLATION NOTESINSTALLATION IMPORTANTINSTALLATION NOTESINSPECTTORQUE SPECIFICATIONNOTESTORQUE SPECIFICATIONINSTALLATION IMPORTANTNOTESDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of death  when touching components on vehicles with high-voltage on-board electrical system Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems. AS54.00-Z-0001-01A
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
NOTES Note on high-voltage on-board electrical system   AH54.00-P-0010-01A
IMPORTANT Evaluation of high-voltage components   AH54.00-P-6500-01SXH
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVINGINSTALLING Remove/install     
1 Perform enable for the high voltage on-board electrical system Engine 276.8 in model 222.163 AR54.10-P-1150LF
2 Detach ground line from battery   AR54.10-P-0003LF
3 Detach charge air cooler and place with attached coolant lines to one side   AR09.41-P-6819LFA
4 Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC)   AR05.10-P-7620-04MM
5 Remove left and right air filter housing   AR09.10-P-1150LFA
6 Detach engine wiring harness on crash plate (10)    
7 Remove left and right insulation on rail   AR07.03-P-1010LFA 
8 Disconnect left electrical connection at ME-SFI [ME] control unit and unclip electrical line at bracket (13) and place to one side   AR07.08-P-7008LFA 
9 Unclip ME-SFI [ME] control unit from bracket and place to one side with attached lines   AR07.08-P-7008LFA 
10 Remove center section of bulkhead INSTALLATION IMPORTANT Ensure correct seating of the center section of the bulkhead.  
11.1 Remove bracket (13) at crash plate (10) and vacuum pump Engine 276.8 in model 217, 222 (except 222.163)  
11.2 Remove bracket (15) Engine 276.8 in model 222.163  
12 Unscrew screw/bolts (10a) and remove crash plate (10) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
13 Remove insulation (11) on the high-pressure pump (1)    
14 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 5
15 Relieve fuel pressure in fuel system high-pressure circuit   AR07.03-P-1460-02MM
16 Clean area around connections of low pressure and high-pressure line Assembly cleaner *BR00.45-Z-1028-04A 
17 Detach low-pressure line and high-pressure line on the rails and on the high-pressure pump (1) NOTES Do not kink or bend high-pressure line and low-pressure line.
This prevents leaks and damage.
The sealing cone for the high-pressure line and low-pressure line must be checked before assembly. Checking of fuel high-pressure circuit must be carried out after assembly
↓
Check fuel high pressure circuit.		 AR07.03-P-1010-04MM
    Mount high-pressure lines. AR07.03-P-1010-02MMA
    Check high-pressure lines AR07.03-P-1010-03MM
    Assembly cleaner *BR00.45-Z-1028-04A 
    TORQUE SPECIFICATION Union nut, fuel line to service connection *BA07.03-P-1008-01D 
    TORQUE SPECIFICATION Screw/bolt, fuel line clamps *BA07.03-P-1005-01D 
    TORQUE SPECIFICATION Screw/bolt, fuel line service connection to cylinder head cover *BA07.03-P-1003-01D 
    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 
18 Remove screw/bolts (1s) for high-pressure pump (1) NOTES Screw/bolts (1s) must be screwed in or out by half a revolution alternately for removal or installation of the high-pressure pump (1). Damage could occur to the high-pressure pump (1) otherwise.
INSTALLATION IMPORTANT The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s).
INSTALLATION IMPORTANT Replace screw/bolts (1s).
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing		 *BA07.02-P-1001-01C 
19 Disconnect electrical connection at quantity control valve (Y94)    
20 Remove high-pressure pump (1) INSTALLATION NOTES
Replace sealing ring of the high-pressure pump (1). 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).
Leakage can occur otherwise.
INSTALLATION IMPORTANT Clean mount for high-pressure pump (1) in high-pressure pump housing (2).		  
21 Pull tappet element (4) out of high-pressure pump housing (2) INSTALLATION 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.		  
INSPECT Check     
22 Check tappet element (4) for wear, check for damage and replace if necessary    
23 Remove bracket on the high-pressure pump housing (2) When removing the 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 
24 Remove screw/bolts (2a) for high-pressure pump housing (2) When removing the high-pressure pump housing (2).
Tightening procedure for housing of fuel system high pressure pump
NOTES Observe assembly specification and tightening sequence.
Damage can occur otherwise to the camshaft and cylinder head.		 AR07.02-P-1020-02MM
    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 When removing the high-pressure pump housing (2).
INSTALLATION IMPORTANT Replace seal.		  
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 (1) with fuel.
Damage could occur to the high-pressure pump (1) 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    
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-1003-01D Screw/bolt, fuel line service connection to cylinder head cover Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1005-01D Screw/bolt, fuel line clamps Nm 9
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 5: 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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