Remove/install high-pressure pump

AR07.02-P-1020MRT

Remove/install high-pressure pump

30.03.2020

Engine

256.9 in model 222

Modification notes

11.12.2019

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

BA07.03-P-1001-01MRT

1

High pressure pump

2

Support plate

3

Bolts

4

Crash plate

5

Screw

6

Noise insulation

7

Low pressure pipe

8

Screw

9

Coolant line

10

High pressure pipe

11

Bolts

13

Screw

14

Cylinder head

Y94

Quantity control valve

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

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

AH00.00-P-0020-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Remove charge-air distributor.

AR09.41-P-8683MRT

 Cover openings with suitable rags.

 Installation: Only install upper engine cover after the leak test.

 Installation: Only install lower engine compartment paneling after leak test.

2

Turn engine in direction of engine rotation to 120° after ignition TDC.

 The 120° marking on the vibration damper must match with marking on crankcase.

 Counterholder

*654589004000

3

Remove screw (5).

 Bolt, holder for low-pressure line to shield/supporting plate

*BA07.03-P-1007-01MRT

4

Remove screws (3) and remove supporting plate (2).

 Screw, shield to fuel high-pressure pump housing/support plate

*BA07.02-P-1006-01MRT

5

Remove coolant hose from coolant line (9).

AR20.20-P-7441-01RQ

6

Remove screw (8), remove coolant line (9), and seal openings with protective covers or suitable stop plugs.

 Installation: Replace sealing ring.

 Screw, coolant feed pipe to cylinder head/crankcase

*BA20.20-P-1001-02MRT

 Set of protective caps

*001589009100

 Set of plugs

*199589009800

7

Remove noise insulation (6).

8

Clean area around the high-pressure pump (1), low-pressure line (7), and high-pressure line (10).

Assembly cleaner

*BR00.45-Z-1028-04A

9

Release and disconnect electrical connector at quantity control valve (Y94).

10

Remove high-pressure line (10) from high-pressure pump (1) and seal openings with suitable stop plugs.


Do not kink or bend high-pressure line (10).
Leaks can occur otherwise.

 Use rags to catch escaping fuel.

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

*BA07.03-P-1001-01MRT

 Box wrench bit

*000589690300

 Record plug

*129589009100

11

Unscrew screw (13).

 Bolt, holder for low-pressure line to shield/supporting plate

*BA07.03-P-1007-01MRT

12

Remove low-pressure line (7) from high-pressure pump (1) and seal openings with suitable stop plugs.


Do not bend or kink low-pressure line (7).
Leaks can occur otherwise.

 Use rags to catch escaping fuel.

 Union nut, low-pressure line to fuel high-pressure pump

*BA07.03-P-1006-01MRT

 Box wrench bit

*000589690300

 Record plug

*129589009100

13

Remove screws (11).


Remove screws (11) alternately by half a revolution each.
The high-pressure pump (1) may otherwise be damaged.

 Screw/bolt, high pressure fuel pump to housing

*BA07.02-P-1001-01MRT

14

Remove high-pressure pump (1).

 Installation: Replace sealing ring.
Replace bolts (11).



Check

15

Check the tappet for driving the high-pressure pump (1) for damage.

If damage is present:



Replace the tappet for driving the high-pressure pump (1).

16

Check high-pressure line(10).

AR07.03-P-1010-03MRT

Assembly cleaner

*BR00.45-Z-1028-04A

17

Check low-pressure line (7).

AR07.03-P-1120-01MRT

Assembly cleaner

*BR00.45-Z-1028-04A

18

Install in the reverse order.



Check

19

Switch on ignition.


Prior to starting the engine, switch on the ignition for 5 s and fill the high-pressure pump (1) with fuel.
The high-pressure pump (1) will be damaged otherwise.

 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

20

Check the fuel high-pressure circuit.



AD00.00-P-2000-04B

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

21

Carry out engine test run and check engine for proper leaktightness and leaktightness.

22

Install lower engine compartment lining.

AR61.20-P-1105LF

23

Install upper engine cover.

AR01.10-P-2405MRT

 High pressure fuel pump, high pressure fuel pump housing

Number

Designation

Engine 256.9

BA07.02-P-1001-01MRT

Screw/bolt, high pressure fuel pump to housing

Nm

8

 High pressure fuel pump, high pressure fuel pump housing

Number

Designation

Engine 256.9

BA07.02-P-1006-01MRT

Screw, shield to fuel high-pressure pump housing/support plate

Nm

8

 High-pressure line, low-pressure line, fuel distributor

Number

Designation

Engine 256.9

BA07.03-P-1001-01MRT

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

In case of reusability

Nm

18

For new lines

Stage 1

Nm

15

Stage 2

°

90

 High-pressure line, low-pressure line, fuel distributor

Number

Designation

Engine 256.9

BA07.03-P-1006-01MRT

Union nut, low-pressure line to fuel high-pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 High-pressure line, low-pressure line, fuel distributor

Number

Designation

Engine 256.9

BA07.03-P-1007-01MRT

Bolt, holder for low-pressure line to shield/supporting plate

Nm

8

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 256

BA20.20-P-1001-02MRT

Screw, coolant feed pipe to cylinder head/crankcase

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01