Remove/Install Housing Of High Pressure Fuel Pump - AR07.02-P-1026MSC

Engine 256.9 in model 167

MODIFICATION NOTES

05.09.2019

Operation step variants added.

Operation steps 2.1, 2.2, 29.1, 29.2

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

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 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
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove
1	Remove fuel high-pressure pump (1).		AR07.02-P-1020MSC
2.1	Remove charge air line.	Engine 256.9 in model 167 except code M016 (Uprated engine)	AR09.41-P-8950MSC
2.2	Remove charge air line from check valve to additional compressor.	Engine 256.9 in model 167 with code M016 (Uprated engine)	AR09.41-P-8952MSC
3	Install retaining lock for crankshaft.		AR03.30-P-5001MSC
4	Unclip line clips (4).
5	Remove low-pressure line from shield (2).		AR07.03-P-1120MSC
6	Remove screws (3) and remove shield (2).
7	Remove noise insulation (5).
8	Pierce cap (19) in center with suitable tool and pry out.	Do not damage seat of cap (19) in timing case cover (25). Leaks can occur otherwise.
9	Remove screw (20).
10	Install sleeve (22) on drive gear (21) and tighten screw (23) at timing case cover (25).	Sleeve	Fig 2
11	Screw in thrust piece of sleeve (22) at drive gear (21) and slightly manually tighten pressure screw (24).	Sleeve	Fig 2
12	Remove screws (17) in reverse numerical sequence of tightening procedure.	Tightening procedure for housing of fuel system high pressure pump	AR07.02-P-1020-02MRT
13	Screw in pressure screw (24) until drive gear (21) releases from shaft of high-pressure fuel pump housing (18).	Sleeve	Fig 2
14	Remove high-pressure fuel pump housing (18).
	Clean
15	Clean sealing surfaces at high-pressure fuel pump housing (18) and at crankcase.	Assembly cleaner	*BR00.45-Z-1028-04A
	Install
16	Unscrew pressure screw (24).
17	Position high-pressure fuel pump housing (18) at crankcase and drive gear (21).	Guide pin of drive gear (21) must engage in shaft of high-pressure fuel pump housing (18). Replace seals and sealing rings.
		Assembly tool	Fig 1
18	Tighten screws (17) in the numerical sequence of tightening procedure.	Tightening procedure for housing of fuel system high pressure pump	AR07.02-P-1020-02MRT
		Screw/bolt, high pressure fuel pump housing to crankcase	*BA07.02-P-1002-01MRT
19	Remove screw (23) and sleeve (22).	Sleeve	Fig 2
20	Tighten screw (20).	Screw/bolt, sprocket to high pressure fuel pump	*BA07.02-P-1003-01MRT
21	Install new cap (19).
22	Install noise insulation (5).
23	Install shield (2) and tighten screws (3).	Screw, shield to fuel high-pressure pump housing/support plate	*BA07.02-P-1006-01MRT
24	Install low-pressure line on shield (2).		AR07.03-P-1120MSC
25	Clip line clips (4) into shield (2).
26	Remove retaining lock for crankshaft.		AR03.30-P-5001MSC
27	Set engine in direction of engine rotation to a crank angle of 120° after ignition TDC.	Turn engine in direction of engine rotation only. Engine damage can occur otherwise. The 120° marking on the vibration damper must match with marking on crankcase.
		Counterholder	Fig 3
28	Install high-pressure fuel pump (1).		AR07.02-P-1020MSC
29.1	Install charge air line.	Engine 256.9 in model 167 except code M016 (Uprated engine)
			AR09.41-P-8950MSC
		Only install upper engine cover and lower engine compartment paneling after the performing a leak test.
29.2	Install charge air line from check valve to additional compressor.	Engine 256.9 in model 167 with code M016 (Uprated engine)
			AR09.41-P-8952MSC
	Concluding tasks
	Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-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
30	Perform engine test run. While doing so, check engine for proper operation and leak tightness
31	Install upper engine cover.		AR01.10-P-2405MSC
32	Install lower engine compartment lining.		AR61.20-P-1105ME