Installing High-Pressure Pump

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. When refitting the high-pressure pump, install it at its original position -arrow-  (rotor position as marked during removal).
   Fig 1: Locating Mark Rotor Position

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   Information 

   Before installing the high-pressure pump, check the position of the driver and move it into installation position by hand if necessary. 

2. Position driver for high-pressure pump.
   1. 2.1. Check position of the outlet sprocket.

      It is important that the deep groove is approx. 13.5 mm -arrow- 

   2. 2.2. Turn the driver so that the high driving journal is flush with the deeper recess -arrow-  .
      Fig 2: Locating Deep Groove On Outlet Sprocket, Side 1-3

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      Information 

      Always replace gaskets and O-rings.

      • Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68). 
3. Fit high-pressure pump.
   1. 3.1. Replace sealing ring on high-pressure pump and grease with the prescribed lubricant.
   2. 3.2. Fit and tighten two external Torx screws (E10, M6 x 25) -1-  . Tightening torque 13 Nm (9.5 ftlb.) 
      Fig 3: Identifying High-Pressure Pump To Cylinder Head Screws

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4. Tool set: Position of adapter with joint with respect to torque wrench: 90° 
   1. Torque wrench with 3/8-inch head 
   2. Insert adapter with universal joint Nr.98-1 Pos.3 
   3. Open-jawed wrench insert Nr.95 Pos.1  or open-jawed wrench insert Nr.95 Pos.2 
      Fig 4: Tightening Union Nuts On Fuel Lines Using Tool

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   Information 

   • Always perform a leak test in the high-pressure area after opening the fuel system. 
   • This is particularly important if components are disassembled and replaced. 
   • The threaded connections of the fuel lines must be coated with OKS 1710 lubricant (Part No. 000.043.303.27) before being screwed back on again. 
   • Always allow a drying time of 60 minutes for the lubricant! 
   • Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation. 
   • The tightening specifications must be strictly observed. 
5. Fit fuel lines on the high-pressure pump.
   1. 5.1. Coat union nuts on fuel lines, cone and high-pressure pump screw sockets with lubricant OKS 1700.
   2. 5.2. Fit union nut (a/f 14) -1-  on fuel high-pressure line -2-  by hand and then tighten it. Tightening torque 25 Nm (19 ftlb.) 
   3. 5.3. Fit union nut (a/f 17) -3-  on fuel low-pressure line -4-  by hand and tighten it. Tightening torque 25 Nm (19 ftlb.) 
      Fig 5: Identifying Fuel Lines On High-Pressure Pump

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      WARNING: Leaking fuel supply lines

      • Emerging fuel
      • Risk of fire

      → Perform leak test.

6. Perform leak test.

   → 200101 CHECKING FUEL SYSTEM (HIGH-PRESSURE SIDE) FOR LEAKS

7. Fit cover -1-  for high-pressure pump.
   1. 7.1. Fit and tighten external Torx screws (E10, M6 x 25) -2-  . Tightening torque 13 Nm (9.5 ftlb.)  .
   2. 7.2. Fit and tighten external Torx screw (M6 x 40) -3-  . Tightening torque 13 Nm (9.5 ftlb.) 
      Fig 6: Identifying High-Pressure Pump With Cover

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8. Fit heat shield for high-pressure pump.
   1. 8.1. Position heat shield -5-  and screw in and tighten three external Torx screws (E10, M6 x 12) -4-  . Tightening torque 13 Nm (9.5 ftlb.) 
   2. 8.2. Connect cable plug for coolant temperature sensor -1-  .
   3. 8.3. Insert cable plug for flow control valve -2-  and clip in cable -3-  (-6-  ).
      Fig 7: Identifying High-Pressure Pump Heat Shield

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      Information 

      Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93). 

9. Secure the coolant pipe -1-  .
   1. 9.1. Replace sealing rings and grease with the prescribed lubricant.
   2. 9.2. Position coolant pipe and tighten screw -2-  . Tightening torque 13 Nm (9.5 ftlb.) 
   3. 9.3. Secure coolant pipe to heat shield -3-  with a screw -2-  . Initial tightening 3 Nm (2 ftlb.) 
      Fig 8: Securing Coolant Pipe

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