Remove/install high-pressure pump

AR07.02-P-1020EVO

Remove/install high-pressure pump

16.5.11

 

Remove/install

 Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Thoroughly clean area surrounding fuel line to be opened so that no dirt finds its way into the injection system since failure will occur otherwise

 The ground line on the battery must always be detached before beginning work on the fuel system otherwise pressure will be built up in the fuel system through opening a vehicle door or the trunk lid

1

Detach ground line from battery

Model 204

AR54.10-P-0003CW

Model 172

AR54.10-P-0003W

Model 207, 212

AR54.10-P-0003EW



Notes on battery

AH54.10-P-0001-01A

2

Remove engine trim panel

 Grasp with both hands and pry off. Check gasket, replace if necessary.

 Installation: When placing the engine cover, ensure that the seal is correctly seated at the oil filler neck. The seal should not be pressed down by the engine cover, but must lie against the engine cover .

3

Rotate engine at the center bolt on the crankshaft in the direction of rotation to 52° marking on the belt pulley (A) before ignition TDC

 The 52° marking on the belt pulley (A) (color coding: white) must be flush with the positioning edge (B) on the timing case cover .

4

Disconnect electrical line (5) for high-pressure pump (1) at the connecting point on the intake manifold

5

Remove intake manifold

AR09.20-P-1310EVO

6

Reduce pressure from the fuel system at the service valve

AR07.03-P-1460-01EVO



*119589046300

7

Remove high pressure line (3)

 In order to avoid leakage, do not crush or bend the high pressure lines (3). After disassembly, close the connections. Ensure scrupulous cleanliness! Check sealing cone at high-pressure line (3) and replace high-pressure line (3) if pressure marks are detected. Ensure the high pressure line (3) is seated exactly.



Check high-pressure lines

AR07.03-P-1010-03MM



*BA07.02-P-1008-01B



*129589009100

Cleaner from package

*BR00.45-Z-1028-04A

8

Remove bolts (2) for high pressure pump (1)



*BA07.02-P-1007-01B

9

Lift high-pressure pump (1) and remove drive plate for high-pressure pump (1) from camshaft

 Installation: Replace sealing ring. When inserting the high-pressure pump (1) observe position of the high-pressure pump drive (1) relative to the drive plate.

10

Remove fuel hose (7) at high-pressure pump (1)

 Installation: Replace clamp (4).

11

Remove high-pressure pump (1) upwards

12

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

13

Carry out an engine test run and check fuel system for leaks with engine running

Number

Designation

Engine 271.8

BA07.02-P-1007-01B

Bolt, high-pressure pump to camshaft bearing housing

Stage 1

Nm

6

Stage 2

Nm

13

BA07.02-P-1008-01B

Union nut, high-pressure line to high-pressure pump and rail

Stage 1

Nm

15

Stage 2

°

90

Number

Designation

Order number

BR00.45-Z-1028-04A

Cleaner from package

Adolf Würth GmbH & Co. KG
Reinhold-Würth-Str. 12-17
74653 Künzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de