Remove/install right high-pressure fuel pump

AR07.02-P-1024MNB

Remove/install right high-pressure fuel pump

06.03.2020

Engine

178 in model 190

Modification notes

20.05.2016

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

BA07.03-P-1001-01H

30.01.2017

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

BA07.03-P-1001-01H

1

Right fuel system high pressure pump

2

Electrical connector

3

Intake air duct

4

Charge air hose

5

Boot

6

Vent line

7

Engine wiring harness

14

Fuel line

15

Fuel line

16

Bolts

8

Wiring harness

12

Nut

9

Sidewall

13

Rubber grommet

10

Vacuum line

34

Seal

11

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

Remove upper engine cover

3

Detach ground line from battery

AR54.10-P-0003RG

4

Remove seal (34)

5

Unclip wiring harness (8) at sidewall (9)

6

Detach vacuum line (10) on brake booster and remove upwards

7

Remove screws/bolts (11)

8

Unscrew nut (12), lift sidewall (9) and remove rubber grommet (13)

9

Take out sidewall (9) in an upward direction

10

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01MNA

 Pressure hose

*119589046300

11

Unclip ME-SFI [ME] control unit and place to one side with connected lines

AR07.08-P-1000MNB

12

Remove insulation of right fuel system high pressure pump (1)

13

Disconnect electrical connection (2)

14

Remove intake air duct (3) downstream of right air filter

15

Remove right upper charge air hose (4)

AR09.41-P-1311-01AL

16

Detach boot (5) at right ATL and place to one side

17

Unclip bleed line (6) at engine wiring harness (7)

18

Detach engine wiring harness (7) at oil separator and crankcase

19

Remove lower engine compartment paneling

AR61.20-P-1105RG

20

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

21

Detach bracket of fuel lines (14, 15) at cylinder head cover

22

Detach bracket of the fuel line (14) at cylinder head

23

Detach fuel line (15) on rail


Thoroughly clean area around fuel line (15) at the locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend fuel line (15).
Otherwise leaks and damage may occur.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

24

Detach fuel line (14, 15) at right fuel system high pressure pump (1) and place to one side


Thoroughly clean area around fuel lines (14, 15) at the locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend the fuel lines (14, 15).
Otherwise leaks and damage may occur.

Assembly cleaner

*BR00.45-Z-1028-04A

 Box wrench bit

*000589800300

25

Remove screw/bolts (16) and remove right fuel system high pressure pump (1) upwards


Screw/bolts (16) must be removed alternately each by half a revolution when removing the right fuel system high pressure pump (1).
Damage could occur to the right fuel system high pressure pump (1) otherwise.


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

26

Replace sealing ring of right fuel system high pressure pump (1)

27

Attach right fuel system high pressure pump (1) with screw/bolts (16) to right cylinder head cover


The screw/bolts (16) must be screwed in for installation if the right fuel system high pressure pump (1) alternately by one half of a revolution respectively.
Damage could occur to the right fuel system high pressure pump (1) otherwise.

 The right fuel system high pressure pump (1) must lie flat on the right cylinder head cover after tightening the screw/bolts (16).

 Replace bolts (16).

 Bolt, fuel system high pressure pump to cylinder head

*BA07.02-P-1001-01E



Check

28

Check fuel lines (14, 15) for damage and replace if necessary

AR07.03-P-1010-03MM


The sealing cone for the fuel lines (14, 15) must be checked before assembly.
Otherwise leaks and damage may occur.

29

Attach fuel lines (14, 15) at right fuel system high pressure pump (1)

AR07.03-P-1010-02MNB


Do not kink or bend the fuel lines (14, 15).
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

30

Attach fuel line (15) to rail

AR07.03-P-1010-02MNB


Do not kink or bend fuel line (15).
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

31

Mount bracket of the fuel line (14) at cylinder head

32

Mount bracket of fuel lines (14, 15) at cylinder head cover

33

Remove stake-out drift from belt pulley/vibration damper

 Drift

*177589001500

34

Mount engine wiring harness (7) at oil separator and crankcase

35

Clip in vent line (6) on engine wiring harness

36

Mount boot (5) on right ATL

 Clamp, boot to exhaust gas turbocharger/air filter

*BA01.20-P-1003-01J

37

Install right upper charge air hose (4)

AR09.41-P-1311-01AL

38

Install intake air duct (3) downstream of right air filter

39

Connect electrical connection (2)

40

Install insulation of right fuel system high pressure pump (1)

41

Clip ME-SFI [ME] control unit with attached lines

AR07.08-P-1000MNB

42

Unscrew pressure hose on diagnostic socket and attach dust cap

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

43

Position sidewall (9) in vehicle

44

Position rubber grommet (13) in sidewall (9)

45

Tighten nut (12)

 Nut, partition wall to body

*BA68.74-P-1002-01D

46

Screw in screws/bolts (11)

 Bolt, partition wall to body

*BA68.74-P-1001-01D

47

Mount vacuum line (10) on the brake booster

48

Clip in wiring harness (8) at sidewall (9)

49

Install seal (34)

50

Mount ground line on battery

AR54.10-P-0003RG



Check

51

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

52

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

53

Install lower engine compartment paneling

AR61.20-P-1105RG

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 178

BA01.20-P-1003-01J

Clamp, boot to exhaust gas turbocharger/air filter

Nm

1,5

 Injection pump, high-pressure fuel pump

Number

Designation

Engine 178

BA07.02-P-1001-01E

Bolt, fuel system high pressure pump to cylinder head

Nm

14

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1001-01H

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

In case of reusability

Nm

22

For new lines

Stage 1

Nm

15

Stage 2

°

90

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1005-01H

Dust protection cap to service connection

Nm

1

 Partition wall

Number

Designation

Model 190

BA68.74-P-1001-01D

Bolt, partition wall to body

Nm

7

 Partition wall

Number

Designation

Model 190

BA68.74-P-1002-01D

Nut, partition wall to body

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01