Remove/install left high-pressure fuel pump

AR07.02-P-1023MNB

Remove/install left high-pressure fuel pump

06.03.2020

Engine

178 in model 190

Modification notes

20.05.2016

Union nut, fuel line to fuel distributor/fuel system high pressure pump

BA07.03-P-1001-01H

30.01.2017

Union nut, fuel line to fuel distributor/fuel system high pressure pump

BA07.03-P-1001-01H

1

Left fuel system high pressure pump

2

Electrical connector

3

Wiring harness

4

Fuel line

5

Diagnostic socket

6

Rail

7

Bolts

14

Fuel hose

8

Wiring harness

12

Nut

9

Sidewall

13

Rubber grommet

10

Vacuum line

34

Seal

11

Bolts

 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 contactwith 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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A



Remove

1

Set DIRECT SELECT gear selector switch to position "N" and release parking brake

2

Detach ground line from battery

AR54.10-P-0003RG

3

Remove seal (34)

4

Unclip wiring harness (8) at sidewall (9)

5

Detach vacuum line (10) on brake booster and remove upwards

6

Remove screws/bolts (11)

7

Unscrew nut (12), lift sidewall (9) and remove rubber grommet (13)

8

Take out sidewall (9) in an upward direction

9

Remove insulation of the left fuel system high pressure pump (1)

10

Disconnect electrical connection (2)

11

Unclip wiring harness (3) at fuel line (4)

12

Remove lower engine compartment paneling

AR61.20-P-1105RG

13

Rotate engine at crankshaft center bolt in direction of engine rotation to a 40°crank angle (CA) after top dead center (TDC) on cylinder 1 (ignition TDC)

AR05.10-P-7620-04MNA

 Drift

*177589001500

14

Relieve fuel pressure via service connection (5)

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

15

Detach bracket of the fuel line (4) at left cylinder head cover

16

Detach fuel line (4) on rail (6)


Thoroughly clean area around fuel line (4) on the locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend fuel line (4).
Otherwise leaks and damage may occur.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

17

Detach fuel line (4) at left fuel system high pressure pump (1) and place to one side


Thoroughly clean area around fuel line (4) on the locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend fuel line (4).
Otherwise leaks and damage may occur.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

18

Remove bolts(7)


Screw/bolts (7s) must be removed alternately each by half a revolution each time when removing the left fuel system high pressure pump (1).
Damage could otherwise occur to left fuel high-pressure pump (1).


Thoroughly clean area around the fuel high-pressure circuit.
Failure can occur otherwise to the fuel system.

Assembly cleaner

*BR00.45-Z-1028-04A

19

Detach mounting clamp of fuel hose (14) on distributor

20

Remove fuel hose (14) from distributor

21

Remove left fuel system high pressure pump (1) upwards



Install

22

Replace sealing ring of left fuel system high pressure pump (1)



Check

23

Check fuel hose (14) for damage and replace if necessary

24

Push fuel hose (14) onto distributor and close off mounting clamp

 Replace mounting clamp.

25

Attach left fuel system high pressure pump (1) with screw/bolts (7) to left cylinder head cover


Screw/bolts (7s) must be screwed in alternately each by half a revolution each time when installing the left fuel system high pressure pump (1).
Damage could otherwise occur to left fuel high-pressure pump (1).

 After the screws/bolts (7) have been tightened, the left fuel high-pressure pump (1) must rest flat on the left cylinder head cover.

 Replace the screw/bolts (7).

 Bolt, fuel system high pressure pump to cylinder head

*BA07.02-P-1001-01E



Check

26

Check fuel line (4) for damage and replace if necessary

AR07.03-P-1010-03MM


The sealing cones for fuel line (4) must be checked before assembly.
Otherwise leaks and damage may occur.

27

Attach fuel line (4) to left fuel system high pressure pump (1)

AR07.03-P-1010-02MNB


Do not kink or bend fuel line (4).
Otherwise leaks and damage may occur.

 Union nut, fuel line to fuel distributor/fuel system high-pressure pump

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

28

Attach fuel line (4) at rail (6)

AR07.03-P-1010-02MNB


Do not kink or bend fuel line (4).
Otherwise leaks and damage may occur.

 Union nut, fuel line to fuel distributor/fuel system high-pressure pump

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

29

Mount bracket on fuel line (4) at left cylinder head cover

30

Unscrew pressure hose on diagnostic socket (5) and attach dust cap

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

31

Remove stake-out drift from belt pulley/vibration damper

 Drift

*177589001500

32

Clip in the wiring harness (3) of the oxygen sensor to fuel line

33

Connect electrical connection (2)

34

Install insulation of the left fuel system high pressure pump (1)

35

Position sidewall (9) in vehicle

36

Position rubber grommet (13) in sidewall (9)

37

Tighten nut (12)

 Nut, partition wall to body

*BA68.74-P-1002-01D

38

Screw in screws/bolts (11)

 Bolt, partition wall to body

*BA68.74-P-1001-01D

39

Mount vacuum line (10) on the brake booster

40

Clip in wiring harness (8) at sidewall (9)

41

Install seal (34)

42

Mount ground line on battery

AR54.10-P-0003RG



Check

43

Check fuel high-pressure circuit

AR07.03-P-1010-04MM

 Warning

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

44

Perform an engine test run and check fuel system for proper operation and leaktightness

45

Install lower engine compartment paneling

AR61.20-P-1105RG

 Injection pump, high-pressure fuel pump

Number

Designation

Engine 178

BA07.02-P-1001-01E

Bolt, fuel system high pressure pump to cylinder head

Nm

14

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1001-01H

Union nut, fuel line to fuel distributor/fuel system high-pressure pump

In case of reusability

Nm

22

For new lines

Stage 1

Nm

15

Stage 2

°

90

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1005-01H

Dust protection cap to service connection

Nm

1

 Partition wall

Number

Designation

Model 190

BA68.74-P-1001-01D

Bolt, partition wall to body

Nm

7

 Partition wall

Number

Designation

Model 190

BA68.74-P-1002-01D

Nut, partition wall to body

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01