Remove/install right high-pressure fuel pump

AR07.02-P-1024MNA

Remove/install right high-pressure fuel pump

06.03.2020

Engine

176 in model 463

up to model year 2019

Engine

177 in model 205

Modification notes

18.04.2016

Bolt, vacuum pump to cylinder head

Model 463

BA43.05-P-1002-01B

20.05.2016

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

BA07.03-P-1001-01H

25.08.2016

Screw/bolt, shield plate to cylinder head

Engine 176

BA07.02-P-1002-01E

25.08.2016

Screw/bolt, shield plate to cylinder head

Engine 177.980

BA07.02-P-1002-01E

30.01.2017

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

BA07.03-P-1001-01H

Shown on ENGINE 177

1

Plug connections

2

Crash plate

5

Insulation

8

Bolts

9

Fuel line

10

Fuel line

Shown on ENGINE 177

3

Right fuel system high pressure pump

4

Electrical connector

6

Bolts

7

Vacuum line

8

Screw

11

Rail

12

Ignition coil

13

Heat shield

14

Bolts

 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

1

Set DIRECT SELECT gear selector switch to position "N" and release parking brake

2

Detach ground line from battery

Engine 176 in model 463
up to model year 2019
Engine 177 in model 205

Engine 176 in model 463 (except 463.234)
as of model year 2013 up to model year 2019

AR54.10-P-0003GW

Engine 177 in model 205

AR54.10-P-0003LW

3

Remove left and right air filter housing

AR09.10-P-1150MNA

4

Remove side heat shield of left ATL

Engine 177 in model 205

AR09.40-P-6026MNA

5

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

6.1

Unclip electrical plug connection (1) on crash plate (2)

Engine 177 in model 205

6.2

Unclip electrical lines from crash plate (2)

Engine 176 in model 463
up to model year 2019

7

Disconnect electrical connection (4)

8

Remove insulation (5)

9

Remove bolts (6)

10

Detach vacuum line (7) from vacuum pump and place to one side

11

Remove screws/bolts (8) and place crash plate (2) to one side

 Bolt, shield to cylinder head/cylinder head cover

*BA07.02-P-1002-01E

12

Remove position sensor of camshafts

Engine 176 in model 463
up to model year 2019

AR15.12-P-2144MNF

Engine 177 in model 205

AR15.12-P-2144MNA

13

Remove lower engine compartment paneling

Engine 176 in model 463
as of model year 2016 up to model year 2019
except code ZQ0 (G 500 4x42)

AR61.20-P-1105GW

Engine 177 in model 205

AR61.20-P-1105LW

14

Detach front circulation pump for low-temperature water circuit and place with attached lines and hoses to one side

Engine 176 in model 463
up to model year 2019

AR09.41-P-6925MNF

15

Rotate engine at crankshaft center bolt in direction of engine rotation to a 40°crank angle (CA) after top dead center (TDC) on cylinder 1 (ignition TDC)

AR05.10-P-7620-04MNA

 Drift

*177589001500

16

Detach bracket of fuel lines (9, 10) at right cylinder head cover

17

Detach fuel line (10) at rail (11)


Thoroughly clean area around fuel line (10) at locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend fuel line (10).
Otherwise leaks and damage may occur.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

18

Detach fuel lines (9, 10) on right fuel system high pressure pump (3) and place to one side


Thoroughly clean area around fuel lines (9, 10) at locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend the fuel lines (9, 10).
Otherwise leaks and damage may occur.

 For pulling out of fuel lines (9, 10) from the right fuel system high pressure pump (3) ensure that the position sensor of the right intake camshaft is not damaged.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

19

Remove screws (14) and remove right fuel system high pressure pump (3) upward


Screw/bolts (14) must be removed alternately each by half a revolution each time when removing the right fuel system high pressure pump (3).
Damage could occur otherwise to the right fuel system high pressure pump (3).


Thoroughly clean area around the fuel high-pressure circuit.
Failure can occur otherwise to the fuel system.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

20

Replace sealing ring of the right fuel system high pressure pump (3)

21

Attach right fuel system high pressure pump (3) with screw/bolt (14) on right cylinder head cover


Screw/bolts (14) must be screwed in alternately each by half a revolution each time when installing the right fuel system high pressure pump (3).
Damage could occur otherwise to the right fuel system high pressure pump (3).

 The right fuel system high pressure pump (3) must lie flat on the right cylinder head cover after tightening the screws (14).

 Replace screws (14).

 Bolt, fuel system high pressure pump to cylinder head

*BA07.02-P-1001-01E



Check

22

Check fuel lines (9, 10) for damage and replace if necessary

Engine 176 in model 463
up to model year 2019

AR07.03-P-1010-03MM

Engine 177 in model 205

AR07.03-P-1010-03MNA


The sealing cones for the fuel lines (9, 10) must be checked before assembly.
This prevents leaks and damage.

23

Attach fuel lines (9, 10) to right fuel system high pressure pump (3)

AR07.03-P-1010-02MNA


Do not kink or bend the fuel lines (9, 10).
Otherwise leaks and damage may occur.

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

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

24

Attach fuel line (10) to the rail (11)

AR07.03-P-1010-02MNA


Do not kink or bend fuel line (10).
Otherwise leaks and damage may occur.

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

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

25

Attach bracket of fuel lines (9, 10) to right cylinder head cover

26

Mount front circulation pump for low-temperature water circuit

Engine 176 in model 463
up to model year 2019

AR09.41-P-6925MNF

27

Install lower engine compartment paneling

Engine 176 in model 463
as of model year 2016 up to model year 2019
except code ZQ0 (G 500 4x42)

AR61.20-P-1105GW

Engine 177 in model 205

AR61.20-P-1105LW

28

Install position sensors of camshafts

Engine 176 in model 463
up to model year 2019

AR15.12-P-2144MNF

Engine 177 in model 205

AR15.12-P-2144MNA

29

Put on crash plate (2) and tighten down screw/bolts (8)

 Bolt, shield to cylinder head/cylinder head cover

*BA07.02-P-1002-01E

30

Attach vacuum line (7) to vacuum pump

31

Screw in screws (6)

 Engine 176 in model 463
up to model year 2019Bolt, vacuum pump to cylinder head

*BA43.05-P-1002-01B

 Engine 177 in model 205Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump

*BA43.05-P-1002-01O

32

Install insulation (5)

33

Mount electrical connection (4)

34.1

Unclip electrical plug connection (1) on crash plate (2)

Engine 177 in model 205

34.2

Clip in electrical lines of crash plate (2)

Engine 176 in model 463
up to model year 2019

35

Install side heat shield of left ATL

Engine 177 in model 205

AR09.40-P-6026MNA

36

Install left and right air filter housing

AR09.10-P-1150MNA

37

Attach ground line to battery

Engine 176 in model 463
up to model year 2019
Engine 177 in model 205

Engine 176 in model 463 (except 463.234)
as of model year 2013 up to model year 2019

AR54.10-P-0003GW

Engine 177 in model 205

AR54.10-P-0003LW

38

Switch on ignition


The ignition must be switched on for 5 s before the engine start in order to fill the left fuel system high pressure pump with fuel.
Damage could occur to the left fuel system high pressure pump otherwise.



Check

39

Check fuel high-pressure circuit

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

40

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

 Injection pump, high-pressure fuel pump

Number

Designation

Engine 176

Engine 177

BA07.02-P-1001-01E

Bolt, fuel system high pressure pump to cylinder head

Nm

14

14

 Injection pump, high-pressure fuel pump

Number

Designation

Engine 176

Engine 177

BA07.02-P-1002-01E

Bolt, shield to cylinder head/cylinder head cover

Nm

10

10

 Injection nozzles, injection valves, lines

Number

Designation

Engine 176

Engine 177

BA07.03-P-1001-01H

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

In case of reusability

Nm

22

22

For new lines

Stage 1

Nm

15

15

Stage 2

°

90

90

 Injection nozzles, injection valves, lines

Number

Designation

Engine 176

Engine 177

BA07.03-P-1005-01H

Dust protection cap to service connection

Nm

1

1

 Vacuum pump

Number

Designation

Model 463
up to model year 2019

BA43.05-P-1002-01B

Bolt, vacuum pump to cylinder head

Nm

10

 Vacuum pump

Number

Designation

Engine 177

BA43.05-P-1002-01O

Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01