Remove/Install High-Pressure Pump - AR07.02-P-1020MMV

Engine 276.8 in model 205 

Engine 276.8 in model 253 

Shown on model 205.066 

Fig 1: High-Pressure Fuel Pump And Housing Components Location - Engine 276.8 In Model 205 (Shown On Model 205.066)

Courtesy of MERCEDES-BENZ USA

Shown on model 205.066 

Courtesy of MERCEDES-BENZ USA

Shown on model 205.066 

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 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 on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove
1	Detach ground line from battery		AR54.10-P-0003LW
2	Drain off coolant	Engine 276.8 in model 205 up to model year 2016	AR20.00-P-1142LW
3	Detach charge air cooler and place to one side with attached coolant lines		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 1st cylinder (ignition TDC)		AR05.10-P-7620-04MM
		Socket wrench bit	Fig 2
5	Remove left and right air filter housing		AR09.10-P-1150MMV
6	Detach engine wiring harness on crash plate (10)
7	Remove soundproofing of the left and right rail
8	Release and disconnect left electrical connection at engine management control unit	Engine 276.8 in model 205	AR07.08-P-7008MMV
9	Unclip electrical wiring harness of engine management control unit at holder (13) and lay to one side
10	Unclip engine management control unit from the holder and place with the attached electrical wiring harness to one side		AR07.08-P-7008MMV
11	Unclip vacuum line at bracket (13)
12	Remove center section of bulkhead	Engine 276.8 in model 205 up to model year 2016
13	Detach bracket (13) at crash plate (10) and vacuum pump
14	Unclip electrical connection for right oxygen sensor upstream of CAT from holder	Engine 276.8 in model 205 as of model year 2016 Engine 276.8 in model 253	AR07.04-P-0083MMV
15	Unclip electrical connection for right oxygen sensor upstream of CAT from holder	Engine 276.8 in model 205 as of model year 2016 Engine 276.8 in model 253	AR07.04-P-0084MMV
16	Remove screw/bolts (10a) and remove crash plate (10)
17	Unclip wiring harness of the right oxygen sensor upstream of CAT and the right oxygen sensor downstream of CAT at soundproofing (11)
18	Remove soundproofing (11)
19	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Cap on service connection	*BA07.03-P-1007-01D
		Pressure hose	Fig 3
20	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
21	Clean area around connections of low pressure high-pressure line and high-pressure pump (1)	Thoroughly clean area around connections 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
22	Remove high-pressure line from high-pressure pump (1) at right rail and close off openings with stop plugs	Do not kink or bend high-pressure lines. Leaks and damage can occur otherwise. Record plug	Fig 4
23	Detach low-pressure line at high-pressure pump (1) and close off openings with stop plugs	Do not kink or bend low-pressure lines. Leaks and damage can occur otherwise. Record plug	Fig 4
24	Release and disconnect electrical connection on quantity control valve (Y94)
25	Remove screw/bolts (1) and take out high-pressure pump (1)	Screw/bolts (1s) must be removed alternately each by half a revolution each time when removing the high-pressure pump (1). Otherwise damage could occur to the high-pressure pump (1).
26	Pull tappet element (4) out of high-pressure pump housing (2)
27	Check tappet element (4) for damage	If damage is present ↓ Replace tappet element (4).
28	Check high-pressure line		AR07.03-P-1010-03MM
		Assembly cleaner	*BR00.45-Z-1028-04A
29	Clean mount for high-pressure pump (1) in high-pressure pump housing (2)	Assembly cleaner	*BR00.45-Z-1028-04A
	Install
30	Push tappet element (4) in 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.
31	Replace sealing ring of the high-pressure pump (1)
32	Attach high-pressure pump (1) to high-pressure pump housing (2) and tighten screw/bolts (1s) for high-pressure pump (1)	Screw/bolts (1s) must be screwed in alternately each by half a revolution each time when installing the high-pressure pump (1). Otherwise damage could occur to the high-pressure pump (1). 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). Bolt, high-pressure pump to high-pressure pump drive housing	*BA07.02-P-1001-01C
33	Push together electrical connection on quantity control valve (Y94) until it is locked
34	Remove stop plug at high-pressure line and low-pressure line	Record plug	Fig 4
35	Mount low-pressure line at high-pressure pump (1)	Do not kink or bend low-pressure lines. Leaks and damage can occur otherwise. Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
36	Install high-pressure line on high-pressure pump (1) on right rail		AR07.03-P-1010-02MMA
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01D
37	Install soundproofing (11) on high-pressure pump (1)
38	Clip in wiring harness of the right oxygen sensor upstream of CAT and the right oxygen sensor downstream of CAT at soundproofing (11)
39	Position crash plate (10) and tighten down screw/bolts (10a)	Bolt, shield to housing for high-pressure pump drive/bracket	*BA07.02-P-1003-01C
40	Clip electrical connection for right oxygen sensor downstream of CAT into holder	Engine 276.8 in model 205 as of model year 2016 Engine 276.8 in model 253	AR07.04-P-0084MMV
41	Clip electrical connection for right oxygen sensor upstream of CAT into holder	Engine 276.8 in model 205 as of model year 2016 Engine 276.8 in model 253	AR07.04-P-0083MMV
42	Mount holder (13) on crash plate (10) and vacuum pump
43	Install center section of the bulkhead	Engine 276.8 in model 205 up to model year 2016
44	Clip in vacuum line at bracket (13)
45	Clip engine management control unit into the holder		AR07.08-P-7008MMV
46	Clip in electrical wiring harness of engine management control unit on holder (13)
47	Put left electrical connection on engine management control unit and lock it		AR07.08-P-7008MMV
48	Remove soundproofing of the left and right rail
49	Mount engine wiring harness on crash plate (10)
50	Install left and right air filter housing		AR09.10-P-1150MMV
51	Install charge air cooler		AR09.41-P-6819MMV
52	Fill in coolant	Engine 276.8 in model 205 up to model year 2016	AR20.00-P-1142LW
53	Mount ground line to battery		AR54.10-P-0003LW
54	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. Otherwise damage could occur to the high-pressure pump (1).
55	Check fuel high-pressure circuit		AR07.03-P-1010-04MM
	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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
56	Perform an engine test run and check fuel system for proper operation and leaktightness

Fig 2: Identifying Socket Wrench Bit (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA