Remove/install high-pressure fuel pump

AR07.16-G-1005H

Remove/install high-pressure fuel pump

14.01.2019

Engine

471.9## ## up to 032690 in model 800.310/320

1

Fuel system high pressure pump

5

Coolant line

9

Power steering pump

2

Electrical connector

6

Compressor

Y642

Quantity control valve

3

Bracket

7

Bracket

4

Engine wiring harness

8

High pressure pipe

 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

 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-0001-01B

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Remove

1

Drain off coolant

AR20.00-G-1142H

2

Clean engine in the area of fuel system high pressure pump (1) and the fuel filter module

3

Remove resonator

AR13.10-G-5840HA

4

Remove air intake duct on compressor (6) and place to one side

5

Remove high-pressure line (8) to rail

AR07.16-G-1004H

6

Remove power steering pump (9) and place to one side

Only for engine with power steering pump on the timing case

AR46.30-G-0500-02H

 Do not disconnect the lines of the power steering pump (9) in the process.

7

Remove fuel filter module

AR47.20-G-5511H

8

Attach turning device to timing case

AR03.30-G-1600-03N

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

9

Set engine to TDC for cylinder 1 and lock in place

AR07.16-W-1005-02H

 Drift

*470589001500

 Turning device

*904589046300

10

Remove coolant line (5) from compressor (6) and from crankcase

 Collect escaping coolant using suitable vessel.

11

Disconnect electrical connector (2) at quantity control valve (Y642)

12

Expose engine wiring harness (4) on holder (3)

13

Remove bracket (3)

14

Remove fuel system high pressure pump (1)

 To lift out the engine wiring harness, press (4) with holder (7) to the side.

15

Check gear of the fuel system high pressure pump (1) for damage

For damage



Also check the mating gear in crankcase for damage and if necessary install a new one.

AR05.10-G-4660H

16

Pull out drift for locking the engine on timing case

Only if the gear of the fuel system high pressure pump (1) is damaged.

17

Turn engine with the attached turning device through exactly two full revolutions (2 x 360°) and check the counter gear wheel for fuel system high pressure pump (1) in the process

Only if the gear of the fuel system high pressure pump (1) is damaged.

18

Engine in the TDC of cylinder 1 with a drift

Only if the gear of the fuel system high pressure pump (1) is damaged.

 The engine is again in TDC for cylinder 1 after exactly two full revolutions (2 x 360°).

 Drift

*470589001500

19

Remove gear of fuel system high pressure pump (1)

Only if the fuel system high pressure pump (1) or the gear is renewed.

AR07.16-G-1006H



Clean

20

Clean all sealing surfaces on the fuel system high pressure pump (1) and on crankcase



Install

21

Install gear of fuel system high pressure pump (1)

Only if gear was removed.

AR07.16-G-1006H

22

Install fuel system high pressure pump (1)

AR07.16-W-1005-01H


The engine must stand or be locked at TDC for cylinder 1 before installation of the fuel system high pressure pump (1).
Malfunctions during operation of the engine can occur otherwise.

 Push bracket (7) and engine wiring harness (4) to the side.

 Screw, fuel high-pressure pump to crankcase

*BA07.16-N-1008-03A

23

Install bracket (3)

 Lead in a new cable tie before installing bracket (3).

 Screw/nut, holder to fuel high-pressure pump

*BA07.16-N-1009-03A

 Screw, fuel high-pressure pump holder to crankcase

*BA07.16-N-1010-03A

24

Attach engine wiring harness (4) at bracket (3)

25

Connect electrical connection (2) to quantity control valve (Y642)

26

Attach coolant line (5) to compressor (6) and crankcase

27

Remove turning device from timing case

AR03.30-G-1600-03N

 Screw/bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01N

28

Pull out drift for locking the engine on timing case

29

Install crankshaft position sensor with new O-ring and connect electrical connector

 Bolt, crankshaft position sensor to timing case

*BA07.04-N-1001-01H

30

Install fuel filter module

AR47.20-G-5511H

31

Attach power steering pump (9)

Only for engine with power steering pump on the timing case

AR46.30-G-0500-02H

 Screw/bolt, power steering pump to control housing

*BA01.60-N-1008-01N

32

Install high-pressure line (8) to rail

AR07.16-G-1004H

33

Attach air intake duct on compressor (6)

34

Install resonator

AR13.10-G-5840HA

35

Pour in coolant

AR20.00-G-1142H

36

Fill fuel low-pressure circuit on engine

AR07.16-G-1007H

37

Connect diagnostic system and perform quick test

Only if the fuel system high pressure pump (1) was replaced.

 See information from body manufacturer.

38

Reset "Adaptation area for quantity control valve" (Y642)

Only if the fuel system high pressure pump (1) was replaced.

 The process is completely menu-assisted under:
MCM­engine management  (A4) 
Adaptations 
Parameterization 
Resetting the calibration settings 
Adaptation range for quantity control valve

39

Remove diagnostic system

Only if the fuel system high pressure pump (1) was replaced.

40

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

If engine fails to start or only runs for a brief period.



Fill fuel low-pressure circuit again.

AR07.16-G-1007H

41

Shut off engine and check area around fuel system high pressure pump (1), the fuel filter module and the coolant line (5) for leaktightness

 Visual inspection.

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1001-01N

Screw/bolt, cap of TDC inspection hole to timing case

Nm

30

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1002-01N

Bolt, turning device to timing case

Nm

30

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1008-01N

Screw/bolt, power steering pump to control housing

Nm

55

 Sensors

Number

Designation

Engine 470.9, 471.9, 473.9

BA07.04-N-1001-01H

Bolt, crankshaft position sensor to timing case

Nm

10

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1008-03A

Screw, fuel high-pressure pump to crankcase

Nm

60

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1009-03A

Screw/nut, holder to fuel high-pressure pump

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1010-03A

Screw, fuel high-pressure pump holder to crankcase

M12x1.5

Nm

100