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

ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 

Shown on model 204 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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
	Notes about Common-Rail components		AH07.16-P-0002-01TX
	Remove/install
1	Remove exhaust gas recirculation valve	Engine 651 in model 166, 172	AR14.20-P-7662GQ
2	Remove throttle valve actuator		AR09.41-P-1321CD
3	Remove screw/bolts (7) and place bracket (8) with electrical lines to one side	Engine 651 in model 172, 204, 207, 212, 218, 221 Bolt, bracket for electric switchover valves to fastening plate	*BA09.41-P-1006-01N
4.1	Unscrew screw/bolts (9) and remove mounting plate for mixing tube (10)	Engine 651 in model 172, 204, 207, 212, 218, 221 Charge air manifold fastening plate bolt on engine support	*BA09.41-P-1005-01N
4.2	Remove EGR bypass switchover valve with bracket and place to one side	Engine 651 in model 166	AR14.20-P-7660CD
5	Remove charge air pipe downstream of charge air cooler		AR09.41-P-8624CD
6	Release and disconnect electrical connection from quantity control valve (Y94)
7	Release and disconnect electrical connection from fuel temperature sensor (B50)
8	Disconnect vacuum line on vacuum pump	Engine 651 in model 166	AR43.05-P-1320CDA
		Engine 651 in model 172, 204, 207, 212, 218, 221	AR43.05-P-1320CD
9	Remove screw/bolts (2, 3) on high-pressure line (1) bracket
10	Remove high-pressure line (1) from high-pressure pump (4) and rail (5)	Counterhold high-pressure fitting (6) to avoid it from coming loose as the high pressure line (1) is being loosened. Install high-pressure line (1) free of tension. Union nut, pressure line to high-pressure pump/rail	*BA07.16-P-1002-01H
		Box wrench bit	Fig 1
11	Seal connections with stop plugs	Ensure utmost cleanliness. The high pressure components will be damaged otherwise. Repeated usage of stop plugs is not allowed. Record plug	Fig 2
12	Disconnect fuel line (11) from high-pressure pump (4)	Check hose clamps for damage and replace if necessary.
13	Seal connections with stop plugs	Record plug	Fig 2
14	Remove screw/bolt (12)	Screw/bolt, high-pressure pump to cylinder crankcase	*BA07.16-P-1001-01H
15	Unhook engine wiring harness on exhaust gas recirculation tract bracket from crankcase and detach high-pressure pump (4)	The high-pressure pump (4) must not be opened. The driver (14) can be taken off.
16	Clean sealing surfaces	Replace sealing ring (13) and grease lightly with special grease.	*BR00.45-Z-1028-04A
		Assembly cleaner Special grease	*BR00.45-Z-1036-06A
17	Remove drive pinion from high-pressure pump (4)	When replacing the high-pressure pump (4). Replace drive pinion and nut. Nut, coupling flange to high-pressure pump	*BA07.16-P-1007-01H
18	Install in the reverse order
19	Switch on ignition for 15 seconds	The fuel pump fills the high-pressure pump (4) with fuel.
	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. Check fuel system for leaks with engine 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
20	Check fuel system for leaks with engine running

Fig 1: Identifying Box Wrench Bit (000 589 69 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA