Remove/Install High-Pressure Fuel Pump - AR07.02-P-1028MRH
Engine 264 in model 213, 238, 257
| Risk of explosion
caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure |
Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. |
AS07.16-Z-0001-01A | |
| 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 | Relieve fuel pressure using diagnostic system. | ||
| Engine 264 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in model 257 | AD00.00-P-2000-06FR | ||
ME-SFI [ME] control unit → Actuation → Actuate the fuel pump. |
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| 2 | Disconnect ground line from battery. | Engine 264 in model 238 | AR54.10-P-0003LWO |
| Engine 264 in model 213 | AR54.10-P-0003LW | ||
| Engine 264 in model 257 | AR54.10-P-0003FR | ||
| 3 | Remove rear engine cover. | Engine 264 in model 213, 238, 257 | AR01.10-P-2408MRH |
| 4 | Remove right charge air line. | AR09.41-P-6817MRH | |
| 5 | Remove the charge air cooler and place it at the front with the lines connected. | AR09.41-P-6817MRH | |
| 6 | Rotate engine at crankshaft center bolt in direction of engine rotation to a 79° crank angle (CKA) after top dead center (ignition TDC) on cylinder 1 | Fig 4 | |
| 7 | Remove the cable duct from the cylinder head cover and shielding (1). | ||
| 8 | Unclip the electrical cable from the shielding (1). | ||
| 9 | Release and disconnect electrical connection of high-pressure pump (4). | ||
| 10 | Remove shielding (1). | Tightening procedure for high-pressure pump shielding |
AR07.02-P-0815-01MRH |
| 11 | Remove soundproofing (2). | ||
| 12 | Clean the environment around the high-pressure pump (4), high-pressure line (7), and low-pressure line (6). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 13 | Release fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| 14 | Remove high-pressure line (7) and seal connections with suitable stop plugs. | Do not kink or bend high-pressure line (7). Leaks can occur otherwise. |
|
| Fig 3 | |||
| Fig 2 | |||
| 15 | Remove the low-pressure line (6) from the cylinder head cover and high-pressure pump (4) and seal the openings using suitable stop plugs. | Fig 3 | |
| Fig 2 | |||
| 16 | Remove screw/bolts (3). | Remove screws (3) alternately by half a turn each. Damage may occur otherwise to the high-pressure pump (4). |
|
| 17 | Remove high-pressure pump (4). | ||
| 18 | Remove the tappet element (5) from the cylinder head cover. | ||
| Check | |||
| 19 | Check the tappet element (5) for wear and damage and replace if necessary. | ||
| 20 | Check the high-pressure line (7). | AR07.03-P-1010-03MM | |
| Assembly cleaner If damage is present, ↓ Replace the high-pressure line (7). |
*BR00.45-Z-1028-04A | ||
| 21 | Check low-pressure line (6). | AR07.03-P-1120-01MNE | |
| Assembly cleaner If damage is present, ↓ Replace low-pressure line (6). |
*BR00.45-Z-1028-04A | ||
| AR07.03-P-1120MRH | |||
| Clean | |||
| 22 | Clean mount for high-pressure pump (4) in the cylinder head cover. | Assembly cleaner | *BR00.45-Z-1028-04A |
| Install | |||
| 23 | Position the tappet element (5) in the cylinder head cover. | The drive roller of the tappet element (5) must point towards the camshaft. The camshaft can get damaged otherwise. |
|
| 24 | Replace sealing ring of the high-pressure pump (4). | ||
| 25 | Position high-pressure pump (4) in cylinder head cover. | ||
| 26 | Tighten new bolts (3). | Screw in screws (3) alternately by half a turn each. Damage may occur otherwise to the high-pressure pump (4). The high-pressure pump (4) must be fully in contact with the cylinder head cover after having tightened the screws (3). Leaks can occur otherwise. |
*BA07.02-P-1001-02A |
| 27 | Install the low-pressure line (6) at the high-pressure pump (4) and cylinder head cover. | *BA07.03-P-1002-011 | |
| *BA07.03-P-1001-01I | |||
| Fig 3 | |||
| 28 | Install high-pressure line (7). | AR07.03-P-1010-02MRH | |
| *BA07.03-P-1001-01I | |||
| Fig 3 | |||
| 29 | Install soundproofing (2). | ||
| 30 | Install shielding (1). | Tightening procedure for high-pressure pump shielding | AR07.02-P-0815-01MRH |
| *BA07.02-P-1002-02A | |||
| 31 | Install the cable duct at the cylinder head | *BA00.10-P-1002-04A | |
| cover and shielding (1). | |||
| 32 | Clip in the electrical cables at the shielding (1). | ||
| 33 | Connect electrical connection of high-pressure pump (4) until it is locked. | ||
| 34 | Install the charge air cooler. | AR09.41-P-6817MRH | |
| 35 | Install right charge air pipe. | AR09.41-P-6817MRH | |
| 36 | Remove the engine cover at the rear. | Engine 264 in model 213, 238, 257 | AR01.10-P-2408MRH |
| 37 | Connect ground line to battery. | Engine 264 in model 238 | AR54.10-P-0003LWO |
| Engine 264 in model 213 | AR54.10-P-0003LW | ||
| Engine 264 in model 257 | AR54.10-P-0003FR | ||
| 38 | Switch on ignition. | Switch on the ignition for 5 s to fill the high-pressure pump (4) with fuel prior to starting the engine. Damage may occur otherwise to the high-pressure pump (4). |
|
| 39 | Check the fuel high-pressure circuit. | AR07.03-P-1010-04MM | |
| Engine 264 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in model 257 | AD00.00-P-2000-06FR | ||
| 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 | |
| 40 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 41 | Install engine cover. | AR01.10-P-2405MRH |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6X1 | Nm | 9 | 13 |
FUEL SYSTEM HIGH PRESSURE PUMP
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA07.02-P-1001-02A | Bolt, high-pressure pump to cylinder head cover | Nm | 9 |
FUEL SYSTEM HIGH PRESSURE PUMP
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA07.02-P-1002-02A | Bolt for high-pressure pump shielding | Nm | 20 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 264 | ||
|---|---|---|---|---|
| BA07.03-P-1001-01I | Union nut, fuel line to high-pressure pump/fuel distributor | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA07.03-P-1002-011 | Screw, low-pressure line holder to cylinder head/crankcase/holder | Nm | 8 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |