Installing high-pressure pump

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ 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.

→ Perform leak test.

→ 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.

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 

• The fuel high-pressure lines must only be used once.
• The line must be replaced after removing or loosening the union nuts.

Information 

• Following replacement of the high-pressure pump and engine, the values for the high-pressure adaptation must be reset using the PIWIS Tester. Then carry out a test and adaptation drive.

Information 

• The fuel high-pressure lines must only be used once.
• The line must be replaced after removing or loosening the union nuts.

1. Replace fuel lines.

   → 249019 REMOVING AND INSTALLING FUEL LINE (HIGH-PRESSURE) 

2. Install the high-pressure pump.
   1. 2.1. Coat roller tappet with engine oil and fit it.
   2. 2.2. Insert high-pressure pump and tighten screws alternately in several steps. Tightening torque 10 Nm (7.5 ft lb.) 
3. Further installation is performed in reverse order.
   1. 3.1. Observe the specified tightening sequence for high-pressure lines.

      Coat ball/conical joint with Microgleit 977S grease 

   2. 3.2. Check that the quick-connecting locks are latched securely to the high-pressure pump by pulling on them!
4. After removing or replacing the high-pressure pump, the following functions must be run using the PIWIS Tester  .
   1. 4.1. Select "System check for high-pressure pumps" in the Maintenance/repairs menu
   2. 4.2. Select "First start function" in the Maintenance/repairs menu