Remove/Install High-Pressure Fuel Pump - AR07.02-P-1028MRD
Engine 274.9 in model 213
Engine 274.9 in model 238
Shown on engine 274.9 in model 213 (except 213.050)
| 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 | ||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| 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 | Remove center and rear sections of lower engine compartment lining. | AR61.20-P-1105LWE | |
| 2 | Remove fuel pressure via the service connection. | AR07.03-P-1460-01MR | |
| *BA07.03-P-1003-01F | |||
| Fig 6 | |||
| 3 | Disconnect ground line from battery. | Engine 274.9 in model 238 | AR54.10-P-0003LWO |
| Engine 274.9 in model 213 | AR54.10-P-0003LW | ||
| 4 | Remove upper engine cover. | ||
| 5 | Remove soundproofing. | Engine 274.9 in model 213 except code 920 (Direct fuel injection with stratified charging) Engine 274.9 in model 238 except code 920 (Direct fuel injection with stratified charging) |
AR94.30-P-5410MRD |
| 6 | Remove engine air intake duct upstream of air filter. | ||
| 7 | Rotate engine using center bolt of crankshaft in direction of engine rotation to a crank angle (CKA) of 79° after top dead center (TDC) at cylinder 1. | Fig 5 | |
| 8 | Remove cable duct (1). | ||
| 9 | Release and disconnect electrical connection of high-pressure pump (4). | ||
| 10 | Remove shielding (2). | Tightening procedure |
AR07.02-P-0815-01MR |
| 11 | Remove soundproofing (5). | ||
| 12 | Clean area around the high-pressure pump (4) and high-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 low-pressure line from the high-pressure pump (4) and seal connections with suitable stop plugs. | Fig 2 | |
| Fig 3 | |||
| 15 | Remove high-pressure line (6) and seal connections with suitable stop plugs. | Do not kink or bend high-pressure line (6). Otherwise leaks and damage can occur. |
|
| Fig 2 | |||
| Fig 4 | |||
| 16 | Remove screws (4s). | Remove screw/bolt (4s) alternately respectively by half a revolution. Damage may occur otherwise to the high-pressure pump (4). |
|
| 17 | Remove high-pressure pump (4). | ||
| 18 | Pull tappet element (7) out of the cylinder head cover. | ||
| Check | |||
| 19 | Check tappet element (7) for wear and damage. | If damage or wear is present, ↓ replace tappet element (7). |
|
| 20 | Check high-pressure line (6). | AR07.03-P-1010-03MM | |
| Assembly cleaner If damage is present, ↓ Replace the high-pressure line (6). |
*BR00.45-Z-1028-04A | ||
| Clean | |||
| 21 | Clean mount for high-pressure pump (4) in the cylinder head cover. | ||
| Install | |||
| 22 | Position the tappet element (7) in the cylinder head cover. | The drive roller of the tappet element (7) must sit on the camshaft. The camshaft can get damaged otherwise. |
|
| 23 | Replace sealing ring of the high-pressure pump (4). | ||
| 24 | Position high-pressure pump (4) in cylinder head cover. | ||
| 25 | Screw in new screws (4s). | Screw in screw/bolts (4s) alternately each by half a revolution. Damage may occur otherwise to the high-pressure pump (4). The high-pressure pump (4) must lie flat on the cylinder head cover () after tightening the screw/bolts (4s). Otherwise leaks and damage can occur to the high-pressure pump (4). |
|
| *BA07.02-P-1003-01D | |||
| 26 | Install the high-pressure line (6). | AR07.03-P-1010-02MR | |
| *BA07.03-P-1002-01F | |||
| *BA07.03-P-1001-01F | |||
| Fig 4 | |||
| 27 | Attach low-pressure line with new clamp to the high-pressure pump (4). | Fig 3 | |
| 28 | Install soundproofing (5). | ||
| 29 | Install shielding (2). | Tightening procedure | AR07.02-P-0815-01MR |
| *BA07.02-P-1004-01D | |||
| 30 | Attach cable duct (1). | *BA00.10-P-1002-04A | |
| 31 | Connect electrical connector of the high-pressure pump (4). | ||
| 32 | Install engine air intake duct upstream of air filter. | ||
| 33 | Connect ground line to the battery. | Engine 274.9 in model 238 | AR54.10-P-0003LWO |
| Engine 274.9 in model 213 | AR54.10-P-0003LW | ||
| 34 | Install soundproofing. | Engine 274.9 in model 213 except code 920 (Direct fuel injection with stratified charging) Engine 274.9 in model 238 except code 920 (Direct fuel injection with stratified charging) |
AR94.30-P-5410MRD |
| 35 | Switch on ignition. | Switch on ignition for 5 s before engine start to fill high-pressure pump (4) with fuel. Damage may occur otherwise to the high-pressure pump (4). |
|
| 36 | Check the fuel high-pressure circuit. | AR07.03-P-1010-04MM | |
| Engine 274.9 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 274.9 in model 213 | AD00.00-P-2000-04B | ||
| 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 | |
| 37 | Perform engine test run. While doing so, check engine for proper operation and leak tightness. | ||
| 38 | Install center and rear lower engine compartment lining. | AR61.20-P-1105LWE | |
| 39 | Install upper engine cover. |
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 |
HIGH PRESSURE PUMP
| Number | Designation | Engine 274 | |
|---|---|---|---|
| BA07.02-P-1003-01D | Bolt, high-pressure pump to cylinder head cover | Nm | 14 |
HIGH PRESSURE PUMP
| Number | Designation | Engine 274 | |
|---|---|---|---|
| BA07.02-P-1004-01D | Bolt for high-pressure pump shielding | Nm | 20 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1001-01F | Union nut, fuel line to fuel distributor | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1002-01F | Union nut, fuel line to high-pressure pump | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1003-01F | Dust cap at service connection | Plastic | Nm | 2 |
| Metal | Nm | 15 | ||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |