Remove/Install Right High-Pressure Fuel Pump - AR07.02-P-1024MNA

Engine 176 in model 463

up to model year 2019

Engine 177 in model 205

Modification notes

14.06.2022

Special tool 177 589 00 03 00 added.

Operation step 15.

Shown on engine 177

Courtesy of MERCEDES-BENZ USA

Shown on engine 177

Fig 1: Right High-Pressure Fuel Pump Component Location - Model 205 With Engine 177

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
	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 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 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 to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove
1	Place transmission in neutral position and release parking brake.
2	Disconnect ground line from on-board electrical system battery (G1).	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205 Engine 176 in model 463 (except 463.234) as of model year 2013 up to model year 2019	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
3	Remove left and right air filter housing.		AR09.10-P-1150MNA
4	Remove side heat shield (13) of left exhaust gas turbocharger.	Engine 177 in model 205	AR09.40-P-6026MNA
5	Remove fuel pressure via the service connection.		AR07.03-P-1460-01MNA
		Pressure hose	Fig 7
6.1	Unclip electrical connectors (1) on crash plate (2).	Engine 177 in model 205
6.2	Unclip electrical lines from crash plate (2).	Engine 176 in model 463 up to model year 2019
7	Release and disconnect electrical connector (4).
8	Remove insulation (5).
9	Remove screws (6).
10	Remove vacuum line (7) from vacuum pump and place to one side.	Record plug	Fig 4
11	Remove screws (8) and place crash plate (2) to one side.
12	Remove position sensors of camshafts.	Engine 176 in model 463 up to model year 2019	AR15.12-P-2144MNF
		Engine 177 in model 205	AR15.12-P-2144MNA
13	Remove bottom engine compartment lining.	Engine 176 in model 463 as of model year 2016 up to model year 2019 except code ZQ0 (G 500 4x4² )	AR61.20-P-1105GW
		Engine 177 in model 205	AR61.20-P-1105LW
14	Detach circulation pump for low-temperature water circuit and place to one side with lines and hoses attached.	Engine 176 in model 463 up to model year 2019	AR09.41-P-6925MNF
15	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).	Only turn engine at the center bolt of the crankshaft in the direction of engine rotation using the specified box wrench. Otherwise, damage to the engine or even failure of the engine may occur.	AR01.10-P-1000-01SZ
		Ring wrench	Fig 5
		Drift	Fig 3
16	Remove brackets of fuel lines (9, 10) from right cylinder head cover.
17	Remove fuel line (10) on rail (11).	Thoroughly clean area around fuel line (10) at the locations to be separated. Failure can occur otherwise to the fuel system Do not kink or bend fuel line (10). Otherwise leaks and damage may occur.
		Assembly cleaner	*BR00.45-Z-1028-04A
		Record plug	Fig 4
		Box wrench bit	Fig 6
18	Remove fuel lines (9, 10) from right high-pressure fuel pump (3) and place to one side.	Thoroughly clean area around fuel lines (9, 10 at the locations to be separated. Failure can occur otherwise to the fuel system. Do not kink or bend the fuel lines (9, 10). Otherwise leaks and damage may occur. When pulling out fuel lines (9, 10) from the right high-pressure fuel pump (3) ensure that the position sensor of the right intake camshaft is not damaged.
		Assembly cleaner	*BR00.45-Z-1028-04A
		Record plug	Fig 4
		Box wrench bit	Fig 6
19	Remove screws (14) and remove right high-pressure fuel pump (3) in upward direction.	When removing the right high-pressure fuel pump (3), remove the screws (14) alternately by half a revolution each. Otherwise, damage to the right high-pressure fuel pump (3) will occur. Thoroughly clean area around high-pressure fuel circuit. Failure can occur otherwise to the fuel system.
		Assembly cleaner	*BR00.45-Z-1028-04A
	Install
20	Replace sealing ring of right high-pressure fuel pump (3).	Assembly tool	Fig 2
21	Install right high-pressure fuel pump (3) with screws (14) on right cylinder head cover.	When installing the right high-pressure fuel pump (3), insert the screws (14) alternately by half a revolution each. Otherwise, the right high-pressure fuel pump (3) will be damaged. The high-pressure fuel pump (3) must lie flat on the cylinder head cover after the screws (14) are tightened. Replace screws (14).
		Bolt, fuel system high pressure pump to cylinder head	*BA07.02-P-1001-01E
	Check
22	Check fuel lines (9, 10) for damage.	Engine 176 in model 463 up to model year 2019	AR07.03-P-1010-03MM
		Engine 177 in model 205 Check sealing cones of fuel lines (9, 10) before assembly. This prevents leaks and damage. If there is a problem, ↓ Replace corresponding fuel line (9, 10).	AR07.03-P-1010-03MNA
23	Attach fuel lines (9, 10) to right high-pressure fuel pump (3).		AR07.03-P-1010-02MNA
		Do not kink or bend the fuel lines (9, 10). Otherwise leaks and damage may occur.
		Union nut, fuel line to fuel distributor/fuel system high-pressure pump	*BA07.03-P-1001-01H
		Record plug	Fig 4
		Box wrench bit	Fig 6
24	Attach fuel line (10) to rail (11).		AR07.03-P-1010-02MNA
		Do not kink or bend fuel line (10). Otherwise leaks and damage may occur. Union nut, fuel line to fuel distributor/fuel system high-pressure pump	*BA07.03-P-1001-01H
		Record plug	Fig 4
		Box wrench bit	Fig 6
25	Attach the bracket for fuel lines (9, 10) to right cylinder head cover.
26	Attach front circulation pump for low-temperature water circuit.	Engine 176 in model 463 up to model year 2019	AR09.41-P-6925MNF
27	Install lower engine compartment lining.	Engine 176 in model 463 as of model year 2016 up to model year 2019 except code ZQ0 (G 500 4x4² )	AR61.20-P-1105GW
		Engine 177 in model 205	AR61.20-P-1105LW
28	Install position sensors of camshafts.	Engine 176 in model 463 up to model year 2019	AR15.12-P-2144MNF
		Engine 177 in model 205	AR15.12-P-2144MNA
29	Position crash plate (2) and screw in screws (8).	Bolt, shield to cylinder head/cylinder head cover	*BA07.02-P-1002-01E
30	Attach vacuum line (7) to vacuum pump.	Record plug	Fig 4
31	Screw in bolts (6).	Engine 176 in model 463 up to model year 2019Bolt, vacuum pump to cylinder head	*BA43.05-P-1002-01B
		Engine 177 in model 205Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump	*BA43.05-P-1002-01O
32	Install insulation (5).
33	Connect and lock electrical connector (4).
34.1	Attach electrical connectors (1) on crash plate (2).	Engine 177 in model 205
34.2	Attach electrical lines to crash plate (2).	Engine 176 in model 463 up to model year 2019
35	Install side heat shield (13) of left exhaust gas turbocharger.	Engine 177 in model 205	AR09.40-P-6026MNA
36	Install left and right air filter housing.		AR09.10-P-1150MNA
37	Connect ground line to on-board electrical system battery (G1).	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205 Engine 176 in model 463 (except 463.234) as of model year 2013 up to model year 2019	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
38	Switch on ignition.	In order to fill the high-pressure fuel pump (3) with fuel, switch on the ignition for 5 s before the engine start. Otherwise, damage to the right high-pressure fuel pump (3) will occur.
	Check
39	Check high-pressure fuel circuit.
		Engine 176 in model 463 up to model year 2019	AD00.00-P-2000-04A
		Engine 177 in model 205	AD00.00-P-2000-04B
			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
40	Perform engine test run and check fuel system for proper operation and leak tightness.

INJECTION PUMP, HIGH-PRESSURE FUEL PUMP

Number	Designation		Engine 176	Engine 177
BA07.02-P-1001-01E	Bolt, fuel system high pressure pump to cylinder head	Nm	14	14

INJECTION PUMP, HIGH-PRESSURE FUEL PUMP

Number	Designation		Engine 176	Engine 177
BA07.02-P-1002-01E	Bolt, shield to cylinder head/cylinder head cover	Nm	10	10

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation				Engine 176	Engine 177
BA07.03-P-1001-01H	Union nut, fuel line to fuel distributor/fuel system high-pressure pump	In case of reusability		Nm	22	22
		For new lines	Stage 1	Nm	15	15
		For new lines	Stage 2	∠°	90	90