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Home >> Mercedes Benz >> 2017 >> GLS63 AMG >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Mixture Formation - 166 Chassis 2 Of 5 >> Testing & Repair >> Remove/Install High-Pressure Fuel Pump >> Remove/Install High-Pressure Fuel Pump - AR07.02-P-1020GQ

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

Engine 276 in model 166, 251, 292 

Fig 1: High-Pressure Fuel Pump Components Location - Engine 276 In Model 166 (Shown On Engine 276.9)
G14133732Courtesy of MERCEDES-BENZ USA

Shown on Engine 276.9 

G14133733Courtesy of MERCEDES-BENZ USA

Shown on Engine 276.8 

G14133734Courtesy 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
  General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING Remove     
1 Detach ground line from battery Engine 276 in model 166, 292
Engine 276 in model 251		 AR54.10-P-0003GZ
AR54.10-P-0003RT
2 Remove windshield wiper system Engine 276 in model 251 AR82.30-P-6400RT
3.1 Remove partition wall between wheel wells Engine 276 in model 251 AR62.30-P-2400RT
3.2 Remove right, center and left bulkhead Engine 276 in model 166, 292
INSTALLATION IMPORTANT : Ensure correct seating of the bulkhead.		  
4.1 Remove front upper Engine cover Engine 276.9 in model 166, 251  
4.2 Remove upper Engine cover Engine 276.8 in model 166, 251, 292  
5 Detach charge air cooler with attached lines and coolant hoses and place to one side Engine 276.8 in model 166, 251, 292 AR09.41-P-6819GQC
6 Rotate Engine at crankshaft center bolt in direction of Engine rotation to a 40°crank angle (CA) after top dead center (TDC) on cylinder 1 (ignition TDC)   AR05.10-P-7620-04MM
7 Remove right and left air filter housing Engine 276.8 in model 166, 251, 292 AR09.10-P-1150GQC
8 Remove air filter housing Engine 276.9 in model 166
TORQUE SPECIFICATION Screw/bolt, air filter to cylinder head cover		 *BA09.10-P-1001-01M 
    TORQUE SPECIFICATION Screw/bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
9 Remove insulation over rail on the right Engine 276.8 in model 166, 251, 292 AR07.03-P-1010GQ
10 Remove intake manifold Engine 276.9 in model 166, 251 AR09.20-P-1961GQ
11 Unclip transmission wiring harness electrical connection on crash plate (10) and disconnect    
12 Disconnect electrical connection for right oxygen sensor upstream and downstream of catalytic converter Engine 276.8 in model 166, 251, 292 AR07.52-P-5303GQC
13 Detach Engine wiring harness on crash plate (10) Engine 276.8 in model 166, 292 AR01.00-P-2410-03GQC
    Engine 276.8 in model 251 AR01.00-P-2410-02RTC
    Engine 276.9 in model 166 AR01.00-P-2410-02GQ
    Engine 276.9 in model 251 AR01.00-P-2410-02RTZ
14 Remove screw/bolt (12) and press the bracket (13) to one side Engine 276.8 in model 166, 251, 292  
15 Unscrew screw/bolts (10a) and remove crash plate (10) TORQUE SPECIFICATION Bolt, shield to housing for high-pressure pump drive/bracket *BA07.02-P-1003-01C 
16 Remove insulation (11, 14)    
17 Unclip Engine wiring harness on exhaust gas recirculation positioner bracket Engine 276.9 in model 166, 251  
18 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA
    TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1007-01D 
    SPECIAL TOOL Pressure hose Fig 2
19 Relieve fuel pressure in fuel system high-pressure circuit   AR07.03-P-1460-02MM
20 Unscrew union nuts for fuel lines on rails and high-pressure pump (1) NOTES
Do not kink or bend fuel lines.
Otherwise leaks and damage may occur.
NOTES
Thoroughly clean area around fuel line on the locations to be separated.
Failure can occur otherwise to the fuel system.
Assembly cleaner		 *BR00.45-Z-1028-04A 
21 Disconnect electrical connection at quantity control valve (Y94)    
22 Remove high-pressure pump (1) screw/bolts (1s) and the high-pressure pump (1) NOTES
Thoroughly clean area around the fuel high-pressure circuit.
Failure can occur otherwise to the fuel system.
NOTES
Screw/bolts (1s) must  be screwed in and out by half a revolution alternately for removal or installation of the high-pressure pump (1). Otherwise damage could occur to the high-pressure pump (1).
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing		 *BA07.02-P-1001-01C 
23 Pull tappet element (4) out of high-pressure pump housing (2)    
INSPECT Check     
24 Check tappet element (4) If wear is found:
↓
Replace tappet element (4).		  
INSTALLING Install     
25 Push tappet element (4) in high-pressure pump housing (2) NOTES
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.		  
26 Clean mount for high-pressure pump (1) in high-pressure pump housing (2).    
27 Replace sealing rings of the high-pressure pump (1). IMPORTANT There are two variants of the sealing rings which can be differentiated between based on their color. Dry green sealing ring coated with low-friction paint and insert the black sealing ring wet with oil into the high-pressure pump housing (2).
Replace sealing ring by a sealing ring of the same color.		  
28 Attach high-pressure pump (1) to high-pressure pump housing (2) and tighten screw/bolts (1s) for high-pressure pump (1) NOTES
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).
IMPORTANT The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s).
IMPORTANT Replace screw/bolts (1s) with new ones.
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing		 *BA07.02-P-1001-01C 
29 Put on electrical connection on quantity control valve (Y94)    
INSPECT Check     
30 Check fuel lines   AR07.03-P-1010-03MM
31 Unscrew union nuts for fuel lines on rails and high-pressure pump (1)   AR07.03-P-1010-02MMA
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
32 Unclip Engine wiring harness on exhaust gas recirculation positioner bracket Engine 276.9 in model 166, 251  
33 Install insulation (11, 14)    
34 Put on crash plate (10) and tighten down screw/bolts (10) TORQUE SPECIFICATION Bolt, shield to housing for high-pressure pump drive/bracket *BA07.02-P-1003-01C 
35 Screw in screw/bolt (12) and tighten down bracket (13) Engine 276.8 in model 166, 251, 292  
36 Detach Engine wiring harness on crash plate (10) Engine 276.8 in model 166, 292 AR01.00-P-2410-03GQC
    Engine 276.8 in model 251 AR01.00-P-2410-02RTC
    Engine 276.9 in model 166 AR01.00-P-2410-02GQ
    Engine 276.9 in model 251 AR01.00-P-2410-02RTZ
37 Disconnect electrical connection for right oxygen sensor upstream and downstream of catalytic converter Engine 276.8 in model 166, 251, 292 AR07.52-P-5303GQC
38 Connect transmission wiring harness electrical connection on crash plate (10) and clip in place    
39 Install intake manifold Engine 276.9 in model 166, 251 AR09.20-P-1961GQ
40 Install insulation over rail on the right   AR07.03-P-1010GQ
41 Install air filter housing Engine 276.9 in model 166
TORQUE SPECIFICATION Screw/bolt, air filter to cylinder head cover		 *BA09.10-P-1001-01M 
    TORQUE SPECIFICATION Screw/bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
42 Install right and left air filter housing Engine 276.8 in model 166, 251, 292 AR09.10-P-1150GQC
43 Mount charge air cooler Engine 276.8 in model 166, 251, 292 AR09.41-P-6819GQC
44.1 Install front upper Engine cover Engine 276.9 in model 166, 251  
44.2 Install upper Engine cover Engine 276.8 in model 166, 251, 292  
45.1 Install partition wall between the wheel wells Engine 276 in model 251 AR62.30-P-2400RT
45.2 Install right. center and left bulkhead Engine 276 in model 166, 292
INSTALLATION IMPORTANT : Ensure correct seating of the bulkhead.		  
46 Install windshield wiper system Engine 276 in model 251 AR82.30-P-6400RT
47 Mount ground line on battery Engine 276 in model 166, 292 AR54.10-P-0003GZ
    Engine 276 in model 251 AR54.10-P-0003RT
WARNING 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
48 Perform an Engine test run and check fuel system for proper operation and leaktightness    
49 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 (1) with fuel.
Otherwise damage could occur to the high-pressure pump (1).		  
HIGH PRESSURE PUMP

Number Designation Engine 276
BA07.02-P-1001-01C Bolt, high-pressure pump to high-pressure pump drive housing Nm 14
HIGH PRESSURE PUMP

Number Designation Engine 276
BA07.02-P-1003-01C Bolt, shield to housing for high-pressure pump drive/bracket Nm 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1001-01D Union nut, fuel line to fuel distributor Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1002-01D Union nut, fuel line to high-pressure pump Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1007-01D Cap on service connection Plastic Nm 2
Metal Nm 15
AIR FILTER

Number Designation Engine 276.9
BA09.10-P-1001-01M Screw/bolt, air filter to cylinder head cover Nm 9
AIR FILTER

Number Designation Engine 276.9
BA09.10-P-1002-01M Screw/bolt, air filter to air intake pipe support brace Nm 9
Fig 2: Identifying Pressure Hose (119 589 04 63 00)
G07449508Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
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