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

Engine 256.9 in model 167

MODIFICATION NOTES

11.12.2019

Union nut, high-pressure line to fuel distributor/fuel high-pressure pump

BA07.03-P-1001-01MRT

Fig 1: High Fuel Pressure Pump Components Location - Engine 256.9 In Model 167

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 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
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/install
1	Remove charge-air distributor.		AR09.41-P-8683MSC
		: Only install upper engine cover and lower engine compartment paneling after the performing a leak test.
2	Rotate engine in direction of engine rotation to a crank angle of 120° after ignition TDC.	The 120° marking on the vibration damper must match with marking on crankcase.
		Counterholder	Fig 5
3	Unscrew screw (5).	Bolt, holder for low-pressure line to shield/supporting plate	*BA07.03-P-1007-01MRT
4	Remove coolant hose from coolant line (9) and seal openings with protective covers.		AR20.20-P-7441-01RQ
		Set of protective covers	Fig 2
5	Remove screws (3) and remove supporting plate (2).	Screw, shield to fuel high-pressure pump housing/support plate	*BA07.02-P-1006-01MRT
6	Unscrew screw (8), remove coolant line (9) and seal opening at cylinder head (14) with suitable stop plug.	: Replace sealing ring.
		Screw, coolant feed pipe to cylinder head/crankcase	*BA20.20-P-1001-02MRT
		Set of plugs	Fig 3
7	Remove noise insulation (6).
8	Clean the environment around the high-pressure pump (1), low-pressure line (7) and high-pressure line (10).	Assembly cleaner	*BR00.45-Z-1028-04A
9	Release and disconnect quantity control valve (Y94) electrical connector.
10	Remove fuel pressure via the service connection.		AR07.03-P-1460-04MSC
		Cap on service connection	*BA07.03-P-1009-01MRT
		Pressure hose	Fig 7
11	Relieve fuel pressure from the fuel high-pressure circuit.		AR07.03-P-1460-02MM
		Box wrench bit	Fig 6
12	Remove high-pressure line bracket from rear cylinder head cover.	Bolt, holder for high-pressure line to camshaft housing/cylinder head	*BA07.03-P-1004-01MRT
13	Remove high-pressure line (10) from high-pressure pump (1), collect escaping fuel with lint-free rag and seal openings with suitable stop plugs.	Do not kink or bend high-pressure line (10). Leaks can occur otherwise.
		Union nut, high-pressure line to fuel distributor/fuel high-pressure pump	*BA07.03-P-1001-01MRT
		Box wrench bit	Fig 6
		Record plug	Fig 4
14	Remove screw (13).	Bolt, holder for low-pressure line to shield/supporting plate	*BA07.03-P-1007-01MRT
15	Remove low-pressure line (7) from high-pressure pump (1) and seal openings with suitable stop plugs.	Do not bend of kink low-pressure line (7). Leaks can occur otherwise.
		Union nut, low-pressure line to fuel high-pressure pump	*BA07.03-P-1006-01MRT
		Box wrench bit	Fig 6
		Record plug	Fig 4
16	Remove screws (11).	Remove screws (11) alternately by half a revolution each. The high-pressure pump (1) may otherwise be damaged. : Replace screws (11).
		Screw/bolt, high pressure fuel pump to housing	*BA07.02-P-1001-01MRT
17	Remove high-pressure pump (1).	: Replace sealing ring.
	Check
18	Check high-pressure line (10).		AR07.03-P-1010-03MRT
		Assembly cleaner	*BR00.45-Z-1028-04A
19	Check low-pressure line (7).		AR07.03-P-1010-03MRT
		Assembly cleaner	*BR00.45-Z-1028-04A
20	Install in the reverse order.
	Check
21	Switch on ignition.	Prior to starting the engine, switch on the ignition for 5 s and fill the high-pressure pump (1) with fuel. High-pressure pump (1) will otherwise be damaged.
22	Check high-pressure fuel circuit.
			AD00.00-P-2000-06ME
			AR07.03-P-1010-04MM
23	Carry out engine test run and check engine for proper operation and leak tightness.
24	Install lower engine compartment lining.		AR61.20-P-1105ME
25	Install upper engine cover.		AR01.10-P-2405MSC

HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING

Number	Designation		Engine 256.9
BA07.02-P-1001-01MRT	Screw/bolt, high pressure fuel pump to housing	Nm	8

HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING

Number	Designation		Engine 256.9
BA07.02-P-1006-01MRT	Screw, shield to fuel high-pressure pump housing/support plate	Nm	8