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

ENGINE 642 in model 166, 292 

Fig 1: High-Pressure Fuel Pump Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

Shown on model 166 

	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
	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
	Remove/install
1	Remove upper ENGINE cover	: Ensure correct seating of the ENGINE cover.
2	Unclip pipework for Active Roll Stabilization on impact plate	ENGINE 642 in model 166, 292 with code 468 (ACTIVE CURVE SYSTEM) The impact plate is installed in front of the belt drive.
3	Remove impact plate
4	Detach retaining clamp on high-pressure line from cylinder head cover
5	Detach pressure line (19/2) on high-pressure fitting and close off connections	Counterhold threaded sleeve of pressure line (19/2) when releasing using an appropriate tool. : Counterhold threaded sleeve for the pressure line (19/2) when releasing using an appropriate tool. Pressure line to high-pressure pump	*BA07.16-P-1025-01C
		Record plug	Fig 2
6	Remove fuel hoses (1, 3) on high-pressure pump (2)	Seal fuel hoses (1, 3) using suitable stop plugs. : Check condition of hose clamps and fuel hoses (1, 3) and replace if necessary. Record plug	Fig 2
7	Disconnect electrical connection at quantity control valve (Y94)
8	Disconnect electrical connection on fuel temperature sensor (B50)
9	Remove coolant hose from bracket
10	Remove screw/bolts for impact plate holder and remove holder
11	Remove screw/bolts (4) for high-pressure pump (2)	: Replace screw/bolts (4) since these are micro-encapsulated. Clean threads. Bolt, high-pressure pump to cylinder head	*BA07.16-P-1021-01C
		Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
12	Detach high-pressure pump (2) from the cylinder head	: When replacing the high-pressure pump (2), the ignition must be switched on for at least 15 seconds before the ENGINE is started. The high-pressure pump (2) will be damaged otherwise. : Clean sealing surfaces of high-pressure pump (2), replace the O-ring and apply ENGINE oil. The high-pressure pump (2) must not be disassembled or opened. When replacing high-pressure pump (2): ↓ Modify gear	AR07.02-P-1021GZB
13	Install in the reverse order
	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
14	Check fuel system for leaks with ENGINE running

COMMON RAIL DIESEL INJECTION SYSTEM (CDI)

Number	Designation		ENGINE 642
BA07.16-P-1021-01C	Bolt, high-pressure pump to cylinder head	Nm	15

COMMON RAIL DIESEL INJECTION SYSTEM (CDI)

Number	Designation			ENGINE 642
BA07.16-P-1025-01C	Pressure line to high-pressure pump	M14	Nm	33

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

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1051-04A	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	Chemische Werke Kluthe GmbH Gottlieb-Daimler-Str. 12 69115 Heidelberg Germany Tel. +49 6221 5301-0 Fax +49 6221 5301-176 http: //kluthe.com