Remove/install high-pressure fuel pump

AR07.02-P-1028MRO

Remove/install high-pressure fuel pump

05.08.2020

Engine

264 in model 463

1

Shielding

2

Soundproofing

3

Bolts

4

High pressure pump

5

Tappet element

6

Low pressure pipe

7

High pressure pipe

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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

1

Relieve fuel pressure using diagnostic system.



Engine 264 in model 463
as of model year 2020

AD00.00-P-2000-04B

 To do so, select following menu items:
ME-SFI [ME] control unit 
Actuation 
Actuate the fuel pump .

2

Clamp off ground line of on-board electrical system battery (G1).

Engine 264 in model 463
as of model year 2020

AR54.10-P-0003XG

3

Remove rear engine cover.

AR01.10-P-2408MRO

4

Remove charge air cooler, place toward the front with connected lines, and remove right charge air line.

AR09.41-P-6817MRO

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

6

Remove the cable duct from the cylinder head cover and shielding (1).

7

Unclip the electrical cable from the shielding (1).

8

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

9

Release shielding (1) in reverse order to tightening procedure and remove.

AR07.02-P-0815-01MRH

10

Remove soundproofing (2).

11

Clean the environment around the high-pressure pump (4), high-pressure line (7), and low-pressure line (6).

Assembly cleaner

*BR00.45-Z-1028-04A

12

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

 Box wrench bit

*000589800300

13

Remove high-pressure line (7) and seal connections with suitable stop plugs.

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

 Box wrench bit

*000589800300

 Record plug

*129589009100

14

Remove low-pressure line (6) from cylinder head and high-pressure pump (4).

AR07.03-P-1120MRO

15

Remove screws (3).


Remove screws (3) alternately by half a turn each.
Damage may occur otherwise to the high-pressure pump (4).

16

Remove high-pressure pump (4).

17

Remove the tappet element (5) from the cylinder head cover.



Check

18

Check tappet element (5) for wear and damage.

If damage or wear is present,



replace tappet element (5).

19

Check the high-pressure line (7).

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Replace the high-pressure line (7).

20

Check low-pressure line (6).

AR07.03-P-1120-01MNE

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Replace low-pressure line (6).

AR07.03-P-1120MRO



Clean

21

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

Assembly cleaner

*BR00.45-Z-1028-04A



Install

22

Position the tappet element (5) in the cylinder head cover.


The drive roller of the tappet element (5) must point towards the camshaft.
The camshaft can get damaged otherwise.

23

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

 Assembly tool

*000589936300

24

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

25

Tighten new bolts (3).


Screw in screws (3) alternately by half a turn each.
Damage may occur otherwise to the high-pressure pump (4).


The high-pressure pump (4) must lie flat on the cylinder head cover after screwing in the screws (3).
Leaks can occur otherwise.

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1001-02A

26

Install low-pressure line (6).

AR07.03-P-1120MRO

27

Remove stop plugs and install high-pressure line (7).

AR07.03-P-1010-02MRH

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

*BA07.03-P-1001-01I

 Record plug

*129589009100

 Box wrench bit

*000589800300

28

Install soundproofing (2).

29

Install shielding (1).

Tightening procedure for high-pressure pump shielding

AR07.02-P-0815-01MRH

 Observe tightening procedure.

 Bolt for high-pressure pump shielding

*BA07.02-P-1002-02A

30

Install the cable duct at the cylinder head cover and shielding (1).

 Bolt, engine wiring harness to cylinder head cover

*BA15.18-P-1001-01K

31

Clip in the electrical cables at the shielding (1).

32

Connect electrical connection of high-pressure pump (4) until it is locked.

33

Install right charge air line and attach charge air cooler.

AR09.41-P-6817MRO

34

Clip on ground line of the on-board electrical system battery (G1).

Engine 264 in model 463
as of model year 2020

AR54.10-P-0003XG

35

Switch on ignition.

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

36

Connect diagnostic system and check high-pressure fuel circuit.

AR07.03-P-1010-04MM



Engine 264 in model 463
as of model year 2020

AD00.00-P-2000-04B

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 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 rear engine cover.

AR01.10-P-2408MRO

 Fuel system high pressure pump

Number

Designation

Engine 264

BA07.02-P-1001-02A

Bolt, high-pressure pump to cylinder head cover

Nm

9

 Fuel system high pressure pump

Number

Designation

Engine 264

BA07.02-P-1002-02A

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 264

BA07.03-P-1001-01I

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

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Engine wiring harness

Number

Designation

Engine 264

BA15.18-P-1001-01K

Bolt, engine wiring harness to cylinder head cover

M6

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01