LEMON Manuals: Even more car manuals for everyone
Home >> Smart >> 2015 >> Fortwo Electric Drive, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 43 (Mixture Formation - 212 Chassis - 04 Of 10) >> Testing & Repair >> Remove/install high-pressure pump >> Remove/install high-pressure pump - AR07.02-P-1020CD

Remove/install high-pressure pump - AR07.02-P-1020CD

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 

Shown on model 204 

Fig 1: High-Pressure Pump Remove/Install Components - Shown On Model 204 (1 Of 3)
G09974559Courtesy of MERCEDES-BENZ USA
Fig 2: High-Pressure Pump Remove/Install Components - Shown On Model 204 (2 Of 3)
G09974560Courtesy of MERCEDES-BENZ USA
Fig 3: High-Pressure Pump Remove/Install Components - Shown On Model 204 (3 Of 3)
G09974561Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of explosion  caused by fuel igniting. Risk of injury  to skin and eyes caused by fuel spraying out at high pressure Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. AS07.16-Z-0001-01A
IMPORTANT Notes about Common-Rail components   AH07.16-P-0002-01TX
1 Remove exhaust gas recirculation valve ENGINE 651 in MODEL 166, 172  
    ENGINE 651 in MODEL 166, 172 AR14.20-P-7662GQ
2 Remove throttle valve actuator   AR09.41-P-1321CD
3 Remove screw/bolts (7); place bracket (8) with electrical lines to one side ENGINE 651 in MODEL 172, 204, 207, 212, 218, 221  
    TORQUE SPECIFICATION Bolt, bracket for electric switchover valves to fastening plate *BA09.41-P-1006-01N 
4.1 Unscrew screw/bolts (9) and remove mounting plate for mixing tube (10) ENGINE 651 in MODEL 172, 204, 207, 212, 218, 221  
    TORQUE SPECIFICATION Charge air manifold fastening plate bolt on engine support *BA09.41-P-1005-01N 
4.2 Remove EGR bypass switchover valve with bracket and place to one side ENGINE 651 in MODEL 166  
    ENGINE 651 in MODEL 166 AR14.20-P-7660CD
5 Remove charge air duct to charge air cooler ENGINE 651 in MODEL 172, 204, 207, 212, 218, 221  
    Remove/install engine charge air channel downstream of charge air cooler AR09.41-P-8624CD
6 Disconnect electrical connector from quantity control valve (Y94)    
7 Disconnect electrical connector on fuel temperature sensor (B50)    
8 Disconnect vacuum line on vacuum pump   AR43.05-P-1320CD
9 Remove screw/bolts (2, 3) on bracket for high-pressure line (1)    
10 Remove high pressure line (1) from high pressure pump (4) and rail (5) NOTES After disassembly close off connections on the high pressure line and ensure highest levels of cleanliness.
The high pressure components will be damaged otherwise.
IMPORTANT Stop plugs are available as a replacement part for injection system. Repeated usage of stop plugs is not allowed. Counterhold high pressure fitting (6) to avoid it from coming loose as the high pressure line (1) is being loosened.
INSTALLATION IMPORTANT Install high-pressure line (1) free of tension.		  
    TORQUE SPECIFICATION Union nut, pressure line to high-pressure pump/rail *BA07.16-P-1002-01H 
    SPECIAL TOOL Box wrench bit Fig 4
11 Disconnect fuel line (11) from high-pressure pump (4) IMPORTANT Close off connections after separating.
INSTALLATION IMPORTANT Check hose clamps for damage; replace if necessary.		  
    SPECIAL TOOL Record plug Fig 5
12 Remove screw/bolts (12) TORQUE SPECIFICATION Screw/bolt, high-pressure pump to cylinder crankcase *BA07.16-P-1001-01H 
13 Unhook engine wiring harness on exhaust gas recirculation tract bracket from cylinder crankcase and detach high-pressure pump (4) IMPORTANT The high-pressure pump (4) must not be opened. The driver (14) can be taken off.
INSTALLATION IMPORTANT Clean sealing surfaces, replace sealing ring (13) and grease lightly with special grease.		  
    Special grease *BR00.45-Z-1036-06A 
14 Remove drive pinion from high-pressure pump (4) Only when replacing high pressure pump (4).
INSTALLATION IMPORTANT Replace drive pinion and nut.		  
    TORQUE SPECIFICATION Nut, coupling flange to high-pressure pump *BA07.16-P-1007-01H 
15 Install in the reverse order    
16 Switch on ignition for 15 seconds IMPORTANT so that the fuel pump fills the high pressure pump (4) with fuel.  
DANGER 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
17 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 651
BA07.16-P-1001-01H Screw/bolt, high-pressure pump to cylinder crankcase Nm 20
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 651
BA07.16-P-1002-01H Union nut, pressure line to high-pressure pump/rail Nm 33
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 651
BA07.16-P-1007-01H Nut, coupling flange to high-pressure pump Nm 70
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 651
BA09.41-P-1005-01N Charge air manifold fastening plate bolt on engine support Nm 20
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 651
BA09.41-P-1006-01N Bolt, bracket for electric switchover valves to fastening plate Nm 9
Fig 4: Identifying Box Wrench Bit (000 589 69 03 00)
G09974562Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Record Plug (129 589 00 91 00)
G09974563Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1036-06A Special grease A 001 989 42 51 10
scientia non olet · About LEMON Manuals