Remove/install high-pressure pump

AR07.02-P-1020MT

Remove/install high-pressure pump

06.03.2020

Engine

270 in model 117, 156, 176, 242, 246.2

1

High pressure pump

1s

Bolts

2

Insulation

3

High pressure pipe

4

Tappet element

5

Rail

6

Cylinder head cover

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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Clean area around the fuel high pressure circuit


Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system.
Failure of the fuel injection system can occur otherwise.

2

Detach ground line from battery

AR54.10-P-0003NKB

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

3

Lift vehicle on vehicle lift

AR00.60-P-1000AK

4

Open service flap on fender liner in right fender

5

Rotate engine at crankshaft center bolt in direction of engine rotation to a 79° crank angle (CKA) after top dead center (ignition TDC) on cylinder 1

 The 79° marking on belt pulley/ vibration damper must be aligned with positioning edge on timing case cover.

6

Remove engine cover

7

Remove insulation (2) on high-pressure pump (1)

8

Disconnect electrical connection at quantity control valve (Y94)

9

Detach engine wiring harness at cylinder head cover and place to one side

AR01.00-P-2410-02MT

 Nut, circuit B+ to alternator

*BA15.40-P-1002-01F

 Nut, connection for terminal designation 30

*BA15.30-P-1001-01J

10

Detach low-pressure line from the high-pressure pump (1)

11

Relieve fuel pressure in fuel system high-pressure circuit

AR07.03-P-1460-02MM

12

Remove high-pressure line (3) between the rail (5) and high-pressure pump (1)

Mount high-pressure line (3).

AR07.03-P-1010-02MT

Check high-pressure line (3)

AR07.03-P-1010-03MM



AD00.00-P-2000-04A


Do not kink or bend high-pressure line (3).
Leaks or damage can occur otherwise.

 Installation: The sealing cone for the high-pressure lines (3) must be checked before assembly. The work instructions absolutely must be observed for assembly work.

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01F

 Union nut, fuel line to high-pressure pump

*BA07.03-P-1002-01F

Assembly cleaner

*BR00.45-Z-1028-04A

Checking of fuel high-pressure circuit must be carried out after repair:



Check fuel high pressure circuit.

AR07.03-P-1010-04MM

13

Remove screw/bolts (1s) for high-pressure pump (1)


The screw/bolts (1s) must screwed in and out by half a revolution alternately for removal or installation of the high-pressure pump (1).
Otherwise damage could occur to the high-pressure pump(1).

 Installation: Replace screw/bolts (1s) with new ones. The high-pressure pump (1) must lie flat on the cylinder head cover (6) after tightening the screw/bolts (1s).

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1003-01D

14

Remove high-pressure pump (1)

 Installation:
Replace sealing ring of the high-pressure pump (1). The sealing ring must not come into contact with the oil before inserting the high-pressure pump (1) in the cylinder head cover (6).
The sealing ring will swell otherwise and leaks will occur.

 Installation: Clean mount for high-pressure pump (1) in cylinder head cover (6) and wet with silicone-free engine oil.

15

Pull tappet element (4) out of cylinder head cover (6)

 Installation:
The tappet element (4) must be installed in such a way that the drive roller for the tappet element (4) sits on the camshaft.
Damage can occur to the camshaft otherwise.



Check

16

Check tappet element (4) for wear, check for damage and replace if necessary

17

Install in the reverse order

18

Switch on ignition


The ignition must be switched on for 5 s before the engine start in order to fill the high-pressure pump (1) with fuel.
Otherwise damage could occur to the high-pressure pump(1).

 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

19

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

 High pressure pump

Number

Designation

Engine 270

BA07.02-P-1003-01D

Bolt, high-pressure pump to cylinder head cover

Nm

14

 Injection nozzles, injection valves, lines

Number

Designation

Engine 270

BA07.03-P-1001-01F

Union nut, fuel line to fuel distributor

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 270

BA07.03-P-1002-01F

Union nut, fuel line to high-pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Starter

Number

Designation

Engine 270

BA15.30-P-1001-01J

Nut, connection for terminal designation 30

Nm

15

 Alternator

Number

Designation

Engine 270

BA15.40-P-1002-01F

Nut, circuit B+ to alternator

Nm

16

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01