Remove/install high-pressure fuel pump

AR07.02-D-1028TSC

Remove/install high-pressure fuel pump

18.10.2018

Engine

274 in model 907

1

Fuel system high pressure pump

5

Electrical connector

9

Bolts

2

Cable duct

6

Shielding

10

Sealing ring

3

Bolts

7

Soundproofing

11

Tappet element

4

Electrical wiring harness

8

Fuel hose

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 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

 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

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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A



Remove

1

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

AR54.10-D-0029TS

2

Remove cover of cylinder head cover.

AR01.20-D-5015TSC

3

Raise vehicle.

AR00.60-D-1000-04TS

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS

4

To relieve the tappet element (11), turn engine at the center bolt of the crankshaft in the direction of engine rotation to a crank angle (CKA) of 79° after ignition TDC at cylinder 1.

 Observe marking on the belt pulley.

 Socket wrench bit

*001589650900

5

Remove fuel pressure via the service connection.

AR07.03-S-1460-04EG

 Dust protection cap to service connection

*BA07.03-N-1001-01H

 Pressure hose

*119589046300

6

Lower vehicle.

7

Remove screws (3) and remove cable duct (2).

8

Unclip electrical wiring harness (4) from the shielding (6).

9

Release and disconnect electrical connector (5).

10

Remove screws of the shielding (6) in reverse order of the tightening procedure.

AR07.02-S-0815-01EG

11

Remove shielding (6).

12

Remove soundproofing (7).

13

Remove fuel hose (8) and seal exposed connections with suitable stop plugs.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

14

Remove fuel high-pressure line and seal exposed connections with suitable stop plugs.



000 589 10 99 00 Tool kit

WS00.00-P-0030Z

 Collect escaping fuel using suitable means.

 Installation: Install new fuel high-pressure line.

 Record plug

*129589009100

15

Remove screws/bolts (9).


Remove screws (9) alternately by half a revolution each.
This prevents damage to the fuel system high pressure pump (1).

16

Remove fuel system high pressure pump (1) with tappet element (11).



Check

17

Check tappet element (11) for wear and damage.

If wear or damage is present:



Replace tappet element (11).



Install

18

Install tappet element (11) in the cylinder head cover.

 Pay attention to installation position.

19

Install fuel high-pressure pump(1).

 Replace sealing ring (10).

20

Tighten screws (9).


Screw in screws (9) alternately by half a revolution each.
This prevents damage to the fuel system high pressure pump (1).

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-N-1001-01F

21

Install new fuel high-pressure line.

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



000 589 10 99 00 Tool kit

WS00.00-P-0030Z

AR07.03-S-1010-02EG


Do not kink or bend fuel high-pressure line.
This prevents leaks or damage.

 Union nut, high-pressure line to high pressure pump

*BA07.03-N-1003-01H

 Union nut, high-pressure line to rail

*BA07.03-N-1002-01H

22

Attach fuel hose (8).

 Replace clamp.

 Pliers for click clamps

*171589003700

23

Install soundproofing (7).

24

Install shielding (6).

25

Tighten screws of the shielding (6) as per the tightening procedure.

AR07.02-S-0815-01EG

 Bolt for high-pressure pump shielding

*BA07.02-N-1002-01F

26

Connect electrical connector (5).

27

Check retaining clamp and electrical wiring harness (4) on the shielding (6).

If the retaining clamp is damaged,



Replace retaining clip.

28

Attach cable duct (2) and tighten screws (3).

 M6

*BA00.10-N-1002-01A

29

Install cover of cylinder head cover.

AR01.20-D-5015TSC

30

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

AR54.10-D-0029TS

31

Switch on ignition.

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



Check

32

Check fuel high-pressure circuit.

AR07.03-S-1010-04EG

 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

33

Perform engine test run; while doing so, check fuel system high pressure pump (1) and fuel high-pressure lines for proper operation and leak tightness.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 High pressure pump

Number

Designation

Engine 274 in model 907

BA07.02-N-1001-01F

Bolt, high-pressure pump to cylinder head cover

Nm

14

 High pressure pump

Number

Designation

Engine 274 in model 907

BA07.02-N-1002-01F

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1001-01H

Dust protection cap to service connection

Plastic

Nm

2

Metal

Nm

15

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1002-01H

Union nut, high-pressure line to rail

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1003-01H

Union nut, high-pressure line to high pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25