Remove/install high-pressure fuel pump

AR07.02-P-1028MRD

Remove/install high-pressure fuel pump

06.03.2020

Engine

274.9 in model 213

Engine

274.9 in model 238

Shown on engine 274.9 in model 213 (except 213.050)

1

Cable duct

2

Shielding

4

High pressure pump

4s

Bolts

5

Soundproofing

6

High pressure pipe

7

Tappet element

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 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 threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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

1

Remove center and rear sections of lower engine compartment lining.

AR61.20-P-1105LWE

2

Remove fuel pressure via the service connection.

AR07.03-P-1460-01MR

 Dust cap at service connection

*BA07.03-P-1003-01F

 Pressure hose

*119589046300

3

Disconnect ground line from battery.

Engine 274.9 in model 238

AR54.10-P-0003LWO

Engine 274.9 in model 213

AR54.10-P-0003LW

4

Remove upper engine cover.

5

Remove soundproofing.

Engine 274.9 in model 213
except code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
except code 920 (Direct petrol injection with stratified charging)

AR94.30-P-5410MRD

6

Remove engine air intake duct upstream of air filter.

7

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

 Socket wrench bit

*001589650900

8

Remove cable duct (1).

9

Release and disconnect electrical connection of high-pressure pump (4).

10

Remove shielding (2).

Tightening procedure

AR07.02-P-0815-01MR

 Unfasten shielding (2) counter to the tightening procedure.

11

Remove soundproofing(5).

12

Clean area around the high-pressure pump (4) and high-pressure line (6).

Assembly cleaner

*BR00.45-Z-1028-04A

13

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

14

Remove low-pressure line from the high-pressure pump (4) and seal connections with suitable stop plugs.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

15

Remove high-pressure line (6) and seal connections with suitable stop plugs.


Do not kink or bend high-pressure line (6).
Otherwise leaks and damage can occur.

 Record plug

*129589009100

 Box wrench bit

*000589800300

16

Remove screws (4s).


Remove screw/bolt (4s) alternately respectively by half a revolution.
Damage may occur otherwise to the high-pressure pump (4).

17

Remove high-pressure pump (4).

18

Pull tappet element (7) out of the cylinder head cover.



Check

19

Check tappet element (7) for wear and damage.

If damage or wear is present,



replace tappet element (7).

20

Check high-pressure line (6).

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Replace the high-pressure line (6).



Clean

21

Clean mount for high-pressure pump (4) in the cylinder head cover.



Install

22

Position the tappet element (7) in the cylinder head cover.


The drive roller of the tappet element (7) must sit on the camshaft.
The camshaft can get damaged otherwise.

23

Replace sealing ring of the high-pressure pump (4).

24

Position high-pressure pump (4) in cylinder head cover.

25

Screw in new screws (4s).


Screw in screw/bolts (4s) alternately each by half a revolution.
Damage may occur otherwise to the high-pressure pump (4).


The high-pressure pump (4) must lie flat on the cylinder head cover () after tightening the screw/bolts (4s).
Otherwise leaks and damage can occur to the high-pressure pump (4).

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1003-01D

26

Install the high-pressure line (6).

AR07.03-P-1010-02MR

 Union nut, fuel line to high-pressure pump

*BA07.03-P-1002-01F

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01F

 Box wrench bit

*000589800300

27

Attach low-pressure line with new clamp to the high-pressure pump (4).

 Pliers for click clamps

*171589003700

28

Install soundproofing (5).

29

Install shielding (2).

Tightening procedure

AR07.02-P-0815-01MR

 Bolt for high-pressure pump shielding

*BA07.02-P-1004-01D

30

Attach cable duct (1).

 M61

*BA00.10-P-1002-04A

31

Connect electrical connector of the high-pressure pump (4).

32

Install engine air intake duct upstream of air filter.

33

Connect ground line to the battery.

Engine 274.9 in model 238

AR54.10-P-0003LWO

Engine 274.9 in model 213

AR54.10-P-0003LW

34

Install soundproofing.

Engine 274.9 in model 213
except code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
except code 920 (Direct petrol injection with stratified charging)

AR94.30-P-5410MRD

35

Switch on ignition.


Switch on ignition for 5 s before engine start to fill high-pressure pump (4) with fuel.
Damage may occur otherwise to the high-pressure pump (4).

36

Check the fuel high-pressure circuit.

AR07.03-P-1010-04MM



Engine 274.9 in model 238

AD00.00-P-2000-06LWO



Engine 274.9 in model 213

AD00.00-P-2000-04B

 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

37

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

38

Install center and rear lower engine compartment lining.

AR61.20-P-1105LWE

39

Install upper engine cover.

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 High pressure pump

Number

Designation

Engine 274

BA07.02-P-1003-01D

Bolt, high-pressure pump to cylinder head cover

Nm

14

 High pressure pump

Number

Designation

Engine 274

BA07.02-P-1004-01D

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

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 274

BA07.03-P-1002-01F

Union nut, fuel line to high-pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1003-01F

Dust cap at service connection

Plastic

Nm

2

Metal

Nm

15

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01