Installing High-Pressure Pump

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Do not smoke, eat or drink in the work area.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

→ Perform leak test.

Information 

• Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting  .

Information 

• Absorb any escaping fuel using a suitable binding material or a cloth  .
• Cloths which have absorbed fuel must be disposed of according to the applicable national laws  .
• The fuel system must be depressurized before starting work on it  .
• Only work on the fuel system in well-ventilated rooms  .
• Any seals which have been removed must always be replaced  .
• Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors  .

1. Check that the drive tappet -1-  is installed correctly. The drive tappet has a twist lock on the side. -2- 
   Fig 1: Installing Drive Tappet

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2. Check sealing ring of high-pressure pump for signs of damage and replace if necessary. Avoid shearing off the sealing ring during installation.
3. Place high-pressure pump in installation position → High-pressure pump  . Then insert bottom left screw.
   Fig 2: Placing High-Pressure Pump In Installation Position

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4. Connect the lower cable plug for the flow control valve. -arrow- 
   Fig 3: Locating Cable Plug Of Flow Control Valve

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5. Insert the three screws for the high-pressure pump. For the bottom screw, use a thin tool and very carefully press the coolant pipe down -2-  . Press the high-pressure pump against the resistance of the spring and screw in screws (twist crankshaft if necessary until the drive tappet is at its lowest point). Fit screws -1-  . → Tightening Torque: 10 Nm (7.5 ft. lb.) 
   Fig 4: Locating Mount Screw Of High-Pressure Pump

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   Fig 5: Inserting Bottom Screw

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6. Tighten the high-pressure line -A-  uniformly and counter the high-pressure line in -direction of arrow-  at the same time. Once tightened, the high-pressure line -A-  and low-pressure hose -B-  must not be touching.

   Tightening Torque: → Tightening Torque: 28 Nm (21 ft. lb.) 

   Fig 6: Tightening Fuel High-Pressure Pipe

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   Information 

   Always replace the fuel hose as it will be damaged by the corrugated connection piece during removal.

   Information 

   Always replace the fuel hose as it will be damaged by the corrugated connection piece during removal.

7. Fit the fuel supply hose (not shown)  and fuel low-pressure hose -A-  and secure with spring band clamps. Check installation position -arrows-  .
   Fig 7: Locating Fuel Low-Pressure Lines

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8. Connect cable plug for the high-pressure sensor -arrow-  .
   Fig 8: Locating High-Pressure Line On High-Pressure Pump

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9. Inspect high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTION PIPE (FUEL RAIL) ON DFI ENGINES FOR LEAKS