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

Engine 276.8 in model 217, 222 

Shown on engine 276.8 without code ME05 (HD 80KW VARIANT (INCLUDING plug-in)) 

Fig 1: High Pressure Fuel Pump Components Location - Engine 276.8 In Model 222 (Shown Without Code ME05)

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Shown on vehicle with code ME05 (HD 80KW-variants (INCLUDING PLUGIN)) 

Courtesy of MERCEDES-BENZ USA

	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 death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
Topical note	Notes on battery		AH54.10-P-0001-01A
Topical note	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove/install
1	Perform enable for the high voltage on-board electrical system	Engine 276.8 in model 222.163
			AR54.10-P-1150LF
2	Detach ground line from battery		AR54.10-P-0003LF
3	Detach charge air cooler and place with attached coolant lines to one side		AR09.41-P-6819LFA
4	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
5	Remove left and right air filter housing		AR09.10-P-1150LFA
6	Detach engine wiring harness on crash plate (10)
7	Remove left and right insulation on rail		AR07.03-P-1010LFA
8	Disconnect left electrical connection at ME-SF [ME] control unit and unclip electrical line at bracket (13) and place to one side		AR07.08-P-7008LFA
9	Unclip ME-SFI [ME] control unit from bracket and place to one side with attached lines		AR07.08-P-7008LFA
10	Remove center section of bulkhead	: Ensure correct seating of the center section of the bulkhead.
11.1	Remove bracket (13) at crash plate (10) and vacuum pump	Engine 276.8 in model 217, 222 (except 222.163)
11.2	Remove bracket (15)	Engine 276.8 in model 222.163
12	Unscrew screw/bolts (10a) and remove crack plate (10)	Bolt, shield to housing for high-pressure pump drive/bracket	*BA07.02-P-1003-01C
13	Remove insulation (11) on the high-pressure pump (1)
14	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Cap on service connection	*BA07.03-P-1007-01D
		Pressure hose	Fig 2
15	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
16	Clean area around connections of low pressure and high-pressure line	Assembly cleaner	*BR00.45-Z-1028-04A
17	Detach low-pressure line and high-pressure line on the rails and on the high-pressure pump (1)	Do not kink or bend high-pressure line and low-pressure line. This prevents leaks and damage. The sealing cone for the high-pressure line and low-pressure line must be checked before assembly. Checking of fuel high-pressure circuit must be carried out after assembly ↓
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
		Mount high-pressure lines.	AR07.03-P-1010-02MMA
		Check high-pressure lines	AR07.03-P-1010-03MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Union nut, fuel line to service connection	*BA07.03-P-1008-01D
		Screw/bolt, fuel line clamps	*BA07.03-P-1005-01D
		Screw/bolt, fuel line service connection to cylinder head cover	*BA07.03-P-1003-01D
		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
18	Remove screw/bolts (1s) for high-pressure pump (1)	Screw/bolts (1s) must be screwed in or 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). : The high-pressure pump (1) must lie flat on the high-pressure pump housing (2) after tightening the screw/bolts (1s). : Replace screw/bolts (1s) with new ones.
		Bolt, high-pressure pump to high-pressure pump drive housing	*BA07.02-P-1001-01C
19	Disconnect electrical connection at quantity control valve (Y94)
20	Remove high-pressure pump (1)	: Replace sealing ring of the high-pressure pump (1). 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). Leakage can occur otherwise. : Clean mount for high-pressure pump (1) in high-pressure pump housing (2).
21	Pull tappet element (4) out of 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.
	Check
22	Check tappet element (4) for wear, check for damage and replace if necessary
23	Remove bracket on the high-pressure pump housing (2)	When removing the high-pressure pump housing (2). Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing	*BA07.03-P-1006-01D
24	Remove screw/bolts (2a) for high-pressure pump housing (2)	When removing the high-pressure pump housing (2). Tightening procedure for housing of fuel system high pressure pump Observe assembly specification and tightening sequence. Damage can occur otherwise to the camshaft and cylinder head.	AR07.02-P-1020-02MM
		Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover	*BA07.02-P-1002-01C
25	Take out high-pressure pump housing (2) upwards	When removing the high-pressure pump housing (2). : Replace seal.
26	Install in the reverse order
27	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).
	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
28	Perform an engine test run and check fuel system for proper operation and leaktightness

Fig 2: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA