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.

Tightening sequence for high-pressure pump: 

Fig 1: High-Pressure Pump Nuts Tightening Sequence

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1. When refitting the high-pressure pump, install it at its original position (rotor position as marked during removal).
   Fig 2: Locating Rotor Mark 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- 

      Fig 3: Locating Deep Groove On Outlet Sprocket (Side 1-3)

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   2. 2.2. Turn the driver so that the high driving journal is flush with the deeper recess.
      1. Driver
      1. Dimension A = 11.5 mm
      2. Dimension B = 7 mm
         Fig 4: Positioning Driver

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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 two external Torx screws (E10, M6 x 25) -3-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

      Fig 5: Identifying High-Pressure Pump And Heat Shield

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4. Tools for fitting fuel lines (two alternatives):
   1. 4.1. Tool set 1: 

      Torque wrench with 3/8-inch head 

      Short 3/8-inch extension 

      Crow foot wrench Nr.195,  a/f 17

      Crow foot wrench Nr.195-1,  a/f 14

      Fig 6: Identifying Fuel Pump And High-Pressure Line

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   2. 4.2. Tool set 2: Position of adapter with joint with respect to torque wrench: 90° 
      1. Torque wrench with 3/8-inch head 
      2. Insert Adapter With 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 7: 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 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 on fuel high-pressure line by hand and then tighten it.

      → Tightening torque: 20 Nm (15 ft. lb.) 

   3. 5.3. Fit union nut (a/f 14) on fuel low-pressure line by hand and tighten it.

      → Tightening torque: 20 Nm (15 ft. lb.) 

   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 for high-pressure pump.
   1. 7.1. Fit external Torx screws (E10) M6 x 25 -1-  and M6 x 40 -2-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

      Fig 8: Identifying High-Pressure Pump And Heat Shield

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8. Fit heat protection panel for high-pressure pump.
   1. 8.1. Position heat protection panel -4-  , screw in three external Torx screws (E10, M6 x 12) -3-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

   2. 8.2. Insert cable plug for flow control valve -2-  and clip in cable -1-  .
      Fig 9: Identifying High-Pressure Pump And Heat Protection Panel

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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. Fit coolant pipe.
   1. 9.1. Replace sealing rings and grease with the prescribed lubricant.
   2. 9.2. Position coolant pipe -2-  , fit external Torx screws (E10, M6 x 12) -1-  and tighten to the prescribed torque.

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

      Fig 10: Identifying Coolant Pipe Mounting

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10. Fit supply hose for coolant line.
    1. 10.1. Attach coolant hose -1-  and tighten spring band clamp -2-  .
       Fig 11: Identifying Coolant Pump And Coolant Hose

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