Remove/install high-pressure pump

AR07.02-P-1020MTA

Remove/install high-pressure pump

06.03.2020

Engine

133 in model 117, 156, 176

1

Bracket

2

Coolant return line

3

Cable duct

4

High pressure pipe

5

Bracket

6

Screw

7

High pressure pump

 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


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

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 the belt pulley must be aligned with the positioning edge on the timing case cover.

6

Empty low-temperature circuit

AR20.00-P-1144MTA

7

Remove upper engine cover

8

Remove insulation on high-pressure pump (7)

9

Disconnect electrical connector from the high-pressure pump (7)

10

Detach bracket (1) for electrical connection for oxygen sensor from cylinder head cover and place to one side

11

Detach coolant return line (2) from charge air cooler

12

Unclip engine wiring harness at charge air cooler

AR01.00-P-2410-02MTA

13

Detach cable duct (3) for engine wiring harness from cylinder head cover; to do this remove two screw/bolts and lift carefully

AR01.00-P-2410-02MTA

 Installation: Ensure that the side retaining tab of the cable duct (3) sits correctly in the pin on the cylinder head cover.

 For removal the side retaining tab of the cable duct (3) must be carefully lead out of the pin on the cylinder head cover, without this being damaged.

14

Detach low-pressure line at high-pressure pump (7)

 Installation: Replace snap clamp.

15

Relieve fuel pressure in fuel system high-pressure circuit

AR07.03-P-1460-02MM

16

Remove high-pressure line (4); to do this unscrew nut on rail and high-pressure pump (7) and detach bracket (5) from cylinder head cover

Mount high-pressure line (4)

AR07.03-P-1010-03MM

Check the high-pressure line (4)

AR07.03-P-1010-02MT



AD00.00-P-2000-04A


Do not kink or bend high-pressure line (4).
Leaks or damage can occur otherwise.

 Installation: The sealing cone for the high-pressure line (4) 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

17

Remove screw/bolts (6) on the high-pressure pump (7) at cylinder head cover


The screw/bolts (6s) must be screwed in or out by half a revolution alternately for removal or installation of the high-pressure pump (7).
Otherwise damage could occur to the high-pressure pump (7).

 Installation: Replace screws (6). The high-pressure pump (7) must lie flat on the cylinder head cover after tightening the screw/bolts (6).

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1003-01D

18

Remove high-pressure pump (7)

 Installation:
Replace sealing ring of the high-pressure pump (7). The sealing ring must not come into contact with the oil before inserting the high-pressure pump (7) into the cylinder head cover.
The sealing ring will swell otherwise and leaks will occur.

 Installation: Clean mount for high-pressure pump (7) in cylinder head cover and wet with silicone-free engine oil.

19

Pull tappet element from the cylinder head cover

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



Check

20

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

21

Install in the reverse order

22

Switch on ignition


The ignition must be switched on for 5 s before the engine start in order to fill the high-pressure pump (7) with fuel.
Otherwise damage could occur to the high-pressure pump (7).

 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

23

Carry out an engine test run, checking the engine for proper operation and leaktightness

 High pressure pump

Number

Designation

Engine 133

BA07.02-P-1003-01D

Bolt, high-pressure pump to cylinder head cover

Nm

14

 Injection nozzles, injection valves, lines

Number

Designation

Engine 133.980

BA07.03-P-1001-01F

Union nut, fuel line to fuel distributor

Stage 1

Nm

15

Stage 2

°

90

Stage 3

°

–

 Injection nozzles, injection valves, lines

Number

Designation

Engine 133.980

BA07.03-P-1002-01F

Union nut, fuel line to high-pressure pump

Stage 1

Nm

15

Stage 2

°

90

Stage 3

°

–

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01