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

ENGINE 157, 278 in MODEL 217, 222 

MODIFICATION NOTES

04.07.2016 Union, nut fuel line to fuel rail   BA07.03-P-1001-01E
04.07.2016 Union, nut Fuel line to high-pressure pump   BA07.03-P-1002-01E
Fig 1: High Pressure Pump Remove/Install Components (1 Of 2)
G11131929Courtesy of MERCEDES-BENZ USA
Fig 2: High Pressure Pump Remove/Install Components (2 Of 2)
G11131930Courtesy 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
REMOVINGINSTALLING Remove/install     
1 Set DIRECT SELECT gear selector switch to position "N" and release parking brake    
2 Detach ground line from battery   AR54.10-P-0003LF
3 Remove both air filter housings   AR09.10-P-1150LFB
4 Remove ME-SFI [ME] control unit   AR07.08-P-7008LFB 
5 Remove soundproofing on rails    
6 Remove vent line (8) together with boot (9) IMPORTANT The vent line (8) and boot (9) not must not be separated from each other.  
7 Detach engine wiring harness on charge air distributor and cylinder head covers   AR01.00-P-2410-02LFB
8 Disconnect electrical connections on right quantity control valve (Y94/2) and pressure sensor downstream of throttle valve (B287)    
9 Unscrew screw/bolts (10a) and remove crash plate (10) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
10 Remove insulation (11) on high-pressure pumps (1l, 1r)    
11 Remove bottom engine compartment paneling   AR61.20-P-1105LF
12 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
13 Relieve fuel pressure over diagnostic socket IMPORTANT Open tank cap for a short time in order to remove the overpressure in the fuel tank. AR07.03-P-1460-01VA
    TORQUE SPECIFICATION Protective cap on service valve *BA07.03-P-1007-01E 
    SPECIAL TOOL Pressure hose Figure
14 Remove high-pressure lines which are mounted on the high-pressure pumps NOTES Do not kink or bend high-pressure lines. This avoids damage and leaks.
Assembly cleaner		 *BR00.45-Z-1028-04A 
    TORQUE SPECIFICATION Bolt, fuel line clamp to charge air distribution line *BA07.03-P-1006-01E 
    TORQUE SPECIFICATION Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase *BA07.03-P-1005-01E 
    TORQUE SPECIFICATION Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head *BA07.03-P-1004-01E 
    TORQUE SPECIFICATION Bolt, fuel line service valve to cylinder head cover *BA07.03-P-1003-01E 
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01E 
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01E 
    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 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
15 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.
INSTALLATION 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). Replace screw/bolts (1s) with new ones.
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing		 *BA07.02-P-1001-01C 
16 Raise high-pressure pump on the left (1l) somewhat and disconnect electrical connection on left quantity control valve (Y94/1) When removing left high-pressure pump (1l)  
17 Remove high-pressure pump(s) (1r, 1l) INSTALLATION NOTES
The green sealing ring (3) coated with low-friction paint must be inserted dry in the high pressure pump housing (2). Leakage can occur otherwise.
INSTALLATION IMPORTANT Replace sealing ring (3).
IMPORTANT Clean mount(s) for the high-pressure pump(s).		  
18 Pull tappet elements (4) out of the high-pressure pump housing (2) INSTALLATION 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 may occur to the camshaft otherwise.		  
19 Check tappet elements (4) for wear, check for damage and replace if necessary    
20 Detach centrifuge vacuum line (7) on centrifuge at charge air distributor When removing the high-pressure pump housing (2).  
21 Remove bracket for high-pressure pump housing (2) on cylinder head cover When removing the high-pressure pump housing (2).  
22 Remove screw/bolts (2a) for high-pressure pump housing (2) When removing the high-pressure pump housing (2).
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 
23 Take out high-pressure pump housing (2) upwards When removing the high-pressure pump housing (2).
INSTALLATION IMPORTANT Replace seals (5, 6).		  
24 Install in the reverse order    
25 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
26 Perform an engine test run and check fuel system for proper operation and leaktightness    
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 In case of reusability   Nm 22 22
For new lines Stage 1 Nm 15 15
Stage 2 ∠° 90 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1002-01E Union nut, fuel line to high-pressure pump In case of reusability   Nm 22 22
For new lines Stage 1 Nm 15 15
Stage 2 ∠° 90 90
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 3: 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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