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-1020EL

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

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 276 in MODEL 212, 218 

MODIFICATION NOTES

24.9.14 Union nut, fuel line to high-pressure pump   BA07.03-P-1002-01D
24.9.14 Union nut, fuel line to fuel distributor   BA07.03-P-1001-01D

Shown on engine 276.9 

Fig 1: Bulkhead Center Section
G09974564Courtesy of MERCEDES-BENZ USA
Fig 2: High-Pressure Pump, Quantity Control Valve, Housing & Screws/Bolts
G09974565Courtesy of MERCEDES-BENZ USA

Shown on engine 276.8 

Fig 3: Crash Plate, Insulation, Bracket & Screw/Bolt
G09974566Courtesy of MERCEDES-BENZ USA

Shown on engine 276.9 

Fig 4: Crash Plate, Insulation & Screw/Bolts
G09974567Courtesy of MERCEDES-BENZ USA
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING Remove     
1 Drain coolant   AR20.00-P-1142EL
NOTES Notes on coolant   AH20.00-N-2080-01A
2 Detach ground line from battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
3.1 Remove both air filter housings ENGINE 276.8 in MODEL 212, 218  
      AR09.10-P-1150ELS
3.2 Remove air filter housing ENGINE 276.9 in MODEL 212, 218  
4 Take off and remove insulation from right rail   AR07.03-P-1010EL
5 Remove intake manifold ENGINE 276.9 in MODEL 212, 218  
      AR09.20-P-1961EL
6 Detach engine wiring harness on crash plate (10) ENGINE 276.8 in MODEL 212, 218 AR01.00-P-2410-02ELS
    ENGINE 276.9 in MODEL 212, 218 AR01.00-P-2410-02EL
7 Disconnect left electrical connection at ME-SFI [ME] control unit and unclip electrical line at bracket (13) and place to one side ENGINE 276.8 in MODEL 212, 218 AR07.08-P-7008ELS
8 Unclip ME-SFI [ME] control unit from bracket and place to one side with attached lines ENGINE 276.8 in MODEL 212, 218 AR07.08-P-7008ELS
9 Remove center section of the bulkhead (78) ENGINE 276 in MODEL 212, 218  
    ENGINE 276.8 in MODEL 212 AR61.25-P-6600EW
10 Remove bracket at crash plate (10) and vacuum pump ENGINE 276.8 in MODEL 212, 218  
11 Rotate engine at crankshaft center bolt in direction of engine rotation to a 40°crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC)   AR05.10-P-7620-04MM
12 Remove screw/bolt (12) and press the bracket (13) to one side.    
13 Remove screw/bolts (10a) and remove crash plate (10)    
14 Remove insulation (11, 14)    
15 Unclip engine wiring harness on exhaust gas recirculation positioner bracket ENGINE 276.9 in MODEL 212, 218  
16 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA
    TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1007-01D 
    SPECIAL TOOL Pressure hose Fig 5
17 Relieve fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM
18 Unscrew union nuts for fuel lines on rails and high-pressure pump (1) NOTES Thoroughly clean area around the fuel lines at points to separated.
Failure of the fuel system can occur otherwise.
NOTES Do not kink or bend fuel lines. Otherwise leaks and damage may occur.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
19 Disconnect electrical connection on quantity control valve (Y94)    
20 Remove high-pressure pump (1) screw/bolts (1s) and the high-pressure pump (1) NOTES Screw/bolts (1s) must  be removed alternately each by half a revolution each time when removing the high-pressure pump (1). Damage could occur to the high-pressure pump (1) otherwise.
NOTES Thoroughly clean area around the fuel high-pressure circuit.
Failure of the fuel system can occur otherwise.		  
21 Pull tappet element (4) out of high-pressure pump housing (2)    
22 Detach engine wiring harness bracket on high-pressure pump housing (2)    
23 Remove screw/bolts (2a) of the high-pressure pump housing (2) and high-pressure pump housing (2) upwards    
INSPECT Check     
24 Check tappet element (4) If wear is found:
↓
Replace tappet element (4)		  
INSTALLING Install     
25 Place high-pressure pump housing (2) and tighten screw/bolts (2a) of high-pressure pump housing (2 Tightening procedure for housing of fuel system high pressure pump
NOTES Observe tightening procedure.
Damage can occur otherwise to the camshaft and cylinder head.
IMPORTANT Replace seal.		 AR07.02-P-1020-02MM 
    TORQUE SPECIFICATION Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover *BA07.02-P-1002-01C 
26 Detach engine wiring harness bracket on high-pressure pump housing (2) TORQUE SPECIFICATION Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing *BA07.03-P-1006-01D 
27 Push tappet element (4) in high-pressure pump housing (2) NOTES The tappet element (4) must be installed in such a way that the drive roller for the tappet element (4) sits on the camshaft.
Damage can occur to the camshaft otherwise.		  
28 Clean mount for high-pressure pump (1) in high-pressure pump housing (2).    
29 Replace sealing rings of the high-pressure pump (1). IMPORTANT There are two variants of the sealing rings which can be differentiated between based on their color. Dry green sealing ring coated with low-friction paint and insert the black sealing ring wet with oil into the high-pressure pump housing (2).
Replace sealing ring by an same colored sealing ring.		  
30 Attach high-pressure pump (1) to high-pressure pump housing (2) and tighten screw/bolts (1s) for high-pressure pump (1) NOTES Screw/bolts (1s) must  be screwed in alternately each by half a revolution each time when installing the high-pressure pump (1). Damage could occur to the high-pressure pump (1) otherwise.
IMPORTANT Replace screw/bolts (1s) with new ones.
IMPORTANT The high-pressure pump (1) must  lie flat on the high pressure pump housing (2) after tightening the screw/bolts (1s).		  
    Assembly cleaner *BR00.45-Z-1028-04A 
    TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing *BA07.02-P-1001-01C 
31 Place electrical connection on quantity control valve (Y94)    
INSPECT Check     
32 Check fuel lines   AR07.03-P-1010-03MM
33 Attach union nuts for fuel lines to rails and high-pressure pump (1)   AR07.03-P-1010-02MMA
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1002-01D 
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1001-01D 
34 Clip in engine wiring harness on exhaust gas recirculation positioner bracket ENGINE 276.9 in MODEL 212, 218  
35 Attach insulation (11, 14)    
36 Attach crash plate (10) and screw/bolts (10a) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
37 Screw in screw/bolt (12) and tighten down bracket (13)    
38 Remove bracket at crash plate (10) and vacuum pump ENGINE 276.8 in MODEL 212, 218  
39 Install center section of the bulkhead (78) ENGINE 276.8 in MODEL 212, 218
ENGINE 276.8 in MODEL 212
IMPORTANT Ensure correct seating of the center section of the bulkhead (78).		 AR61.25-P-6600EW
40 Clip ME-SFI [ME] control unit into bracket ENGINE 276.8 in MODEL 212, 218 AR07.08-P-7008ELS
41 Place left electrical connection on ME-SFI [ME] control unit and clip in electrical line on bracket (13) ENGINE 276.8 in MODEL 212, 218  
      AR07.08-P-7008ELS
42 Attach engine wiring harness to crash plate (10) ENGINE 276.9 in MODEL 212, 218 AR01.00-P-2410-02EL
    ENGINE 276.8 in MODEL 212, 218 AR01.00-P-2410-02ELS
43 Install intake manifold ENGINE 276.9 in MODEL 212, 218 AR09.20-P-1961EL
44 Attach insulation to right rail   AR07.03-P-1010EL
45.1 Install air filter housing ENGINE 276.9 in MODEL 212, 218
TORQUE SPECIFICATION Bolt, air filter to air intake pipe support brace		 *BA09.10-P-1002-01M 
    TORQUE SPECIFICATION Bolt, air filter to cylinder head cover *BA09.10-P-1001-01M 
45.2 Install both air filter housings ENGINE 276.8 in MODEL 212, 218  
      AR09.10-P-1150ELS
46 Attach ground line to battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
47 Switch on ignition NOTES The ignition must be switched on for 5 s before the engine start in order to fill the high-pressure pump (1) with fuel.
Damage could occur to the high-pressure pump (1) otherwise.		  
48 Pour in coolant   AR20.00-P-1142EL
NOTES Notes on coolant   AH20.00-N-2080-01A
INSPECT Check     
49 Check fuel high-pressure circuit.   AR07.03-P-1010-04MM
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
50 Perform an engine test run and check fuel system for proper operation and leaktightness    
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1001-01C Bolt, high-pressure pump to high-pressure pump drive housing Nm 14
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1002-01C Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover Stage 1 Nm 1
Stage 2 Nm 9
HIGH PRESSURE PUMP

Number Designation ENGINE 276
BA07.02-P-1003-01C Bolt, shield to high-pressure pump drive housing Nm 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1001-01D Union nut, fuel line to fuel distributor Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1002-01D Union nut, fuel line to high-pressure pump Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1006-01D Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1007-01D Cap on service connection Plastic Nm 2
Metal Nm 15
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1001-01M Bolt, air filter to cylinder head cover Nm 9
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1002-01M Bolt, air filter to air intake pipe support brace Nm 9
Fig 5: Identifying Pressure Hose (119 589 04 63 00)
G09974568Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
scientia non olet · About LEMON Manuals