Remove/install high-pressure fuel pump

AR07.16-G-1005NA

Remove/install high-pressure fuel pump

12.02.2019

Engine

470.9, 471.9## ## as of 032691 in model 800.110/112

Modification notes

09.10.2018

Work procedure completely revised.

1

Bracket

7

Fuel system high pressure pump

13

Sealing rings

2

Electrical connector

8

Fuel line

Y642

Quantity control valve

3

Clip

9

Engine wiring harness

A

Without 2nd generation engine OM470/OM471

4

Fuel lines

10

Electrical connector

B

With 2nd generation engine OM470/OM471

5

Fuel lines

11

High-pressure lines

6

Flange

12

Seal

1

Bracket

7

Fuel system high pressure pump

9

Engine wiring harness

14

Coolant line

15

Coolant line

 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

 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

 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

 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

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

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

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Drain off coolant completely.

AR20.00-G-1142N

2

Drain off fuel from fuel filter module.

AR07.03-G-1460-03N

3

Clean engine in the area of the fuel high-pressure pump (7) and the fuel filter module.

4

Remove resonator box.

Only for engine 471.9

AR13.10-G-5840N

5

Remove air intake line from compressor and place to one side.

6

Remove high-pressure lines (11) to rail.

AR07.16-G-1004NA

7

Remove power-steering pump and place to one side.

AR46.30-G-0500-02N

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

8

Disconnect electrical connector (10) from fuel temperature sensor.

9

Remove fuel lines (5) from fuel filter module.

10

Remove fuel line (8) from metering device.

11

Remove flange (6) with attached fuel lines (5) and attached fuel line (8).

12

Remove fuel lines (4).

13

Mount turning device onto timing case.

AR03.30-G-1600-03N

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

14

Position engine at TDC on cylinder 1 and lock in place.

AR07.16-W-1005-02H

 Drift

*470589001500

 Turning device

*904589046300

15

Disconnect electrical connector (2) from quantity control valve (Y642) and expose engine wiring harness (9).

16

Remove clamp (3) from fuel filter module.

17

Remove coolant line (14) from engine.

Only for engine 471.9

18

Remove bracket (1).

19

Remove fuel high-pressure pump (7).

 To pry out the coolant line (15) and the engine wiring harness (9), press to one side.

20

Check gearwheel of fuel high-pressure pump (7) for damage.

Engine 471.9

AR05.10-G-4660N

ENGINE 470.9

AR05.10-G-4660NA

If the gearwheel is damaged,



also check the mating gear in the crankcase for damage and replace if necessary.

21

Pull out drift for engaging the engine on the timing case.

Only if the gearwheel of the fuel high-pressure pump (7) is damaged.

 Drift

*470589001500

22

Turn engine with the attached turning device through two full revolutions and check mating gear in crankcase for damage.

Only if the gearwheel of the fuel high-pressure pump (7) is damaged.

 Turning device

*904589046300

23

Again, engage engine in TDC for cylinder 1 with drift on the timing case.

Only if the gearwheel of the fuel high-pressure pump (7) is damaged.

 After exactly two full revolutions (2   x360°), the engine is again in TDC for cylinder 1.

 Drift

*470589001500

24

Remove gearwheel of fuel high-pressure pump (7).

Only if the fuel high-pressure pump (7) or gearwheel is renewed.

Up to engine end number 168337

AR07.16-G-1006N

As of engine end number 168338

AR07.16-G-1006NA



Clean

25

Clean sealing surfaces on the fuel high-pressure pump (7) and on crankcase.



Install

26

Install gearwheel of fuel high-pressure pump (7).

Only if gear was removed.

Up to engine end number 168337

AR07.16-G-1006N

As of engine end number 168338

AR07.16-G-1006NA

27

Insert both inner screws/bolts of the fuel high-pressure pump (7).

28

Install fuel high-pressure pump (7).

AR07.16-W-1005-01H


The engine must be at TDC for cylinder 1 or be locked there before installation of the fuel high-pressure pump (7).
Malfunctions during operation of the engine can occur otherwise.

 Screw, fuel high-pressure pump to crankcase

*BA07.16-N-1008-03A

29

Thread in new cable tie on the bracket (1).

30

Install bracket (1).

 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

31

Check sealing ring for coolant line (14) for damage; if necessary.

32

Attach coolant line (14) on the engine.

Only for engine 471.9

33

Attach clamp (3) with coolant line (15) to fuel filter module.

 Engine 470.9, 471.9## ## as of 032691 in model 800.110/112Bolt, coolant line to fuel filter module

*BA20.00-N-1010-02D

34

Attach engine wiring harness (9) to bracket (1) and connect electrical connector (2) to quantity control valve (Y642).

35

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

36

Pull out drift for engaging the engine on the timing case.

37

Replace O-ring on crankshaft position sensor.

38

Install crankshaft position sensor and connect electrical plug.

 Bolt, crankshaft position sensor to timing case

*BA07.04-N-1001-01H

39

Replace O-rings of the fuel lines (4).

40

Install fuel lines (4).

 Flange, low pressure fuel line to fuel high-pressure pump

*BA07.16-N-1014-03A

 Bolt, flange for fuel line to fuel filter module

*BA07.16-N-1042-03A

41

Replace O-rings of the fuel lines (5).

42.1

Check seal (12) on flange (6); install new flange (6) if necessary.

For engine OM470/OM471 without 2nd generation

42.2

Install new seals (13) on flange (6).

For engine OM470/OM471 with 2nd generation

43

Replace sealing rings at the fuel line (8).

44

Install flange (6) with attached fuel lines (5) and attached fuel line (8).

 Banjo bolt, fuel line from flange for fuel high-pressure pump to fuel metering device

*BA07.16-N-1026-03A

 Flange, low pressure fuel line to fuel high-pressure pump

*BA07.16-N-1014-03A

 Bolt, flange for fuel line to fuel filter module

*BA07.16-N-1042-03A

45

Connect electrical connector (10) to the fuel temperature sensor.

46

Install high-pressure lines (11) to rail.

AR07.16-G-1004NA

47

Attach power-steering pump.

AR46.30-G-0500-02N

 Screw/bolt, power steering pump to control housing

*BA01.60-N-1008-01N

48

Attach air intake line to compressor.

49

Install resonator box.

Only for engine 471.9

AR13.10-G-5840N

50

Fill in coolant.

AR20.00-G-1142N

51

Fill fuel low-pressure circuit on engine.

AR07.16-G-1007N

52

Connect vehicle diagnosis system, start diagnosis and perform quick test.

Only if the fuel system high pressure pump (7) was replaced.

 See information from body manufacturer.

53

Reset "adaptation range for quantity control valve".

Only if the fuel system high pressure pump (7) was replaced.

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

54

End diagnosis and remove vehicle diagnosis system.

Only if the fuel system high pressure pump (7) was replaced.

 See information from body manufacturer.

55

Start engine and perform an engine test run.

 Allow the engine to run at a higher engine speed.
See information from body manufacturer.

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



Fill fuel low-pressure circuit again.

AR07.16-G-1007N

56

Switch off engine.

57

Check area of the fuel high-pressure pump (7), fuel filter module, coolant hoses, and the fuel line (5) for leak tightness.

 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 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1008-03A

Screw, fuel high-pressure pump to crankcase

Nm

60

60

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1009-03A

Screw/nut, holder to fuel high-pressure pump

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1010-03A

Screw, fuel high-pressure pump holder to crankcase

M12x1.5

Nm

100

100

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1014-03A

Flange, low pressure fuel line to fuel high-pressure pump

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1026-03A

Banjo bolt, fuel line from flange for fuel high-pressure pump to fuel metering device

M12x1.5

Nm

25

25

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1042-03A

Bolt, flange for fuel line to fuel filter module

Nm

30

30

 Engine cooling, general

Number

Designation

Engine 470.9

Engine 471.9

BA20.00-N-1010-02D

Bolt, coolant line to fuel filter module

Nm

30

30