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

ENGINE 276.8 in MODEL 205 

Fig 1: Identifying High-Pressure Pump Remove/Install Components - Shown On Engine 276.8

Courtesy of MERCEDES-BENZ USA

Shown on engine 276.8 

Shown on engine 276.9 

Fig 2: Identifying High-Pressure Pump Remove/Install Components - Shown On Engine 276.9

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying High-Pressure Pump Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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 contactwith 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
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove/install
1	Detach ground line from battery		AR54.10-P-0003LW
2	Drain off coolant		AR20.00-P-1142LW
3	Detach charge air cooler and place with attached coolant lines to one side		AR09.41-P-6819MMV
4	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
5	Remove both air filter housings		AR09.10-P-1150MMV
6	Detach engine wiring harness on crash plate (10)
7	Remove both insulations of the rails
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-7008MMV
9	Unclip ME-SFI [ME] control unit from bracket and place to one side with attached lines		AR07.08-P-7008MMV
10	Remove center section of bulkhead	Ensure correct seating of the center section of the bulkhead.
11	Remove bracket (13) at crash plate (10) and vacuum pump
12	Unscrew screw/bolts (10a) and remove crash plate (10)	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
		Cap on service connection	*BA07.03-P-1007-01D
		Pressure hose	Fig 4
15	Relieve fuel pressure in fuel high-pressure circuit		AR07.03-P-1460-02MM
16	Clean area around connections of low pressure and high-pressure line	Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system. Failure of the fuel injection system can occur otherwise.
		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)	Do not kink or bend high-pressure line and low-pressure line. This prevents leaks and damage.
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01D
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
		Screw/bolt, fuel line service connection to cylinder head cover	*BA07.03-P-1003-01D
		Screw/bolt, fuel line clamps	*BA07.03-P-1005-01D
		Union nut, fuel line to service connection	*BA07.03-P-1008-01D
		Assembly cleaner The sealing cone of the high-pressure line 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: ↓	*BR00.45-Z-1028-04A
		Mount high-pressure lines.	AR07.03-P-1010-02MMA
		Check high-pressure lines	AR07.03-P-1010-03MM
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
18	Remove screw/bolts (1s) for high-pressure pump (1)	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. The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s). Replace screw/bolts (1s) with new ones.
		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)	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. 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)	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.
	Check
22	Check tappet element (4) for wear and damage, replace if necessary
23	Detach bracket on the high-pressure pump housing (2)	When removing the high-pressure pump housing (2)
		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)
			AR07.02-P-1020-02MM
		Observe assembly specification and tightening sequence. Damage can occur otherwise to the camshaft and cylinder head.
		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	Replace seal.
26	Install in the reverse order
27	Switch on ignition	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.
	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 leak tightness

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

Courtesy of MERCEDES-BENZ USA