Remove/Install High-Pressure Fuel Pump - AR07.02-P-1028MND

Engine 276.8 in model 213, 238 

Shown on engine 276.823 

Fig 1: High-Pressure Fuel Pump Components Location - Engine 276.823 In Model 213

Courtesy of MERCEDES-BENZ USA

Shown on model 276.823 

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove
1	Disconnect ground line at battery	Engine 276.8 in model 213	AR54.10-P-0003LW
		Engine 276.8 in model 238	AR54.10-P-0003LWO
2	Remove the charge air cooler and place with attached coolant line to one side	Only install upper engine cover after the leak test.	AR09.41-P-6817MND
3	Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC)		AR05.10-P-7620-04MM
		Socket wrench bit	Fig 2
4	Remove left-hand air filter housing		AR09.10-P-1151MND
5	Remove right air filter housing		AR09.10-P-1152MND
6	Remove engine wiring harness on crash plate (10)
7	Remove insulation of the left and right rail
8	Release and disconnect left electrical connection at engine management control unit		AR07.08-P-7013MND
9	Unclip electrical line of engine management control unit on holder (13) and place to one side
10	Unclip engine management control unit from bracket and place to one side with attached lines		AR07.08-P-7013MND
11	Unclip vacuum line at firewall and vacuum pump and remove		AR43.05-P-1320MND
12	Remove holder (13) on crash plate (10) and vacuum pump
13	Unscrew screw/bolts (10a) and remove crash plate (10)
14	Remove insulation (11) on the high-pressure pump (1)
15	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Pressure hose	Fig 3
16	Attach cap to service connection	Cap on service connection	*BA07.03-P-1007-01D
17	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
18	Thoroughly clean area around connections of low pressure, high-pressure line and high-pressure pump	Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system. Failure of the fuel injection system can occur otherwise.
		Assembly cleaner	*BR00.45-Z-1028-04A
19	Remove high-pressure line from high-pressure pump (1) on right rail	Do not kink or bend high-pressure lines. Leaks and damage can occur otherwise.
20	Remove low-pressure line at high-pressure pump (1)	Do not kink or bend low-pressure lines. Leaks and damage can occur otherwise.
21	Release and disconnect electrical connection on quantity control valve (20)
22	Remove high-pressure pump (1) screw/bolts (1s) and the high-pressure pump (1)	Screw/bolts (1s) must be removed alternately each by half a revolution each time when removing the high-pressure pump (1). Otherwise damage could occur to the high-pressure pump (1).
23	Pull tappet element (4) out of high-pressure pump housing (2)
24	Check tappet element (4) for damage	If damage is present ↓ Replace tappet element (4).
25	Check high-pressure lines		AR07.03-P-1010-03MM
		Assembly cleaner	*BR00.45-Z-1028-04A
26	Clean mount for high-pressure pump (1) in high-pressure pump housing (2).	Assembly cleaner	*BR00.45-Z-1028-04A
	Install
27	Push tappet element (4) into high-pressure pump housing (2)	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.
28	Replace sealing ring of the high-pressure pump (1).
29	Attach high-pressure pump (1) to high-pressure pump housing (2) and tighten screw/bolts (1s) for high-pressure pump (1)	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). Replace screw/bolts (1 s) with new ones. The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s).
		Bolt, high-pressure pump to high-pressure pump drive housing	*BA07.02-P-1001-01C
30	Push together electrical connection on quantity control valve (20) until it is locked
31	Attach low-pressure line at high-pressure pump (1)	Do not kink or bend low-pressure lines. Leaks and damage can occur otherwise. Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
32	Attach high-pressure line from right rail on high-pressure pump (1)	Do not kink or bend high-pressure lines. Leaks and damage can occur otherwise.
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01D
33	Install insulation (11) on high-pressure pump (1)
34	Remove crash plate (10) and screw in screw/bolts (10a)	Bolt, shield to housing for high-pressure pump drive/bracket	*BA07.02-P-1003-01C
35	Install holder (13) on crash plate (10) and vacuum pump	M6	*BA00.10-P-1002-01A
36	Put together vacuum line on firewall and vacuum pump until this is locked		AR43.05-P-1320MND
37	Clip in electrical line at bracket for the engine management control unit (13)
38	Put on and lock left electrical connection at engine management control unit		AR07.08-P-7013MND
39	Clip engine management control unit into the holder		AR07.08-P-7013MND
40	Install insulation of the left and right rail
41	Attach engine wiring harness on crash plate (10)
42	Install left-hand air filter housing		AR09.10-P-1151MND
43	Install right air filter housing		AR09.10-P-1152MND
44	Install charge air cooler		AR09.41-P-6817MND
45	Connect ground cable to battery	Engine 276.8 in model 213	AR54.10-P-0003LW
		Engine 276.8 in model 238	AR54.10-P-0003LWO
46	Switch on ignition	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).
47	Check fuel high-pressure circuit		AR07.03-P-1010-04MM
	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	Install upper engine cover

Fig 2: Identifying Socket Wrench Bit (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA