Remove/install high-pressure fuel pump

AR07.02-P-1028MFE

Remove/install high-pressure fuel pump

06.03.2020

Engine

608 in model 118, 177, 247

Modification notes

05.08.2019

Document completely revised.

Operation steps 1 to 18

15.11.2019

Operation step added.

Operation step 10

1

Fuel high-pressure pump

4

Bracket

2

Fuel lines

5

Screw

3

Electrical connector

6

Bolts

7

Bracket

8

Bolts

9

Bracket

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

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

Notes about Common-Rail components

AH07.16-P-0002-01TX

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Remove upper engine cover.



AP01.10-P-2405-01B

 Installation: Only install upper engine cover after the leak test.

2

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

AR54.10-P-0003MFA

3

Remove toothed belt.

AR05.00-P-7601MFE

 Installation: Only install lower engine compartment paneling after leak test.

4

Remove top and bottom cylinder head cover trim.

AR01.20-P-5015MFE

5

Remove screws (6) and remove bracket (7).

 Bolt, bracket to high pressure pump

*BA07.16-P-1004-01K

6

Remove fuel lines (2) from the high-pressure fuel pump (1) and seal exposed connections using suitable stop plugs.

 Record plug

*129589009100

7

Remove screw from the bracket (4).

 Bolt, bracket to high pressure pump

*BA07.16-P-1004-01K

8

Release and disconnect electrical connector (3) from quantity control valve (Y94).

9

Remove injection line from the rail to the high-pressure fuel pump (1).

AR07.16-P-1080MFE

10

Remove bolts (8) and remove bracket (9).

11

Remove screws (5) of the high-pressure fuel pump (1).

 Bolt, high-pressure pump to cylinder head

*BA07.16-P-1007-01K

12

Remove fuel high-pressure pump (1).

 Installation: Replace seal.



Clean

13

Clean mount of the high-pressure fuel pump (1).

Assembly cleaner

*BR00.45-Z-1028-04A

14

Remove gearwheel of the high-pressure fuel pump (1).

When replacing fuel high-pressure pump (1).

AR07.16-P-1009MFE

15

Install in the reverse order.

Concluding tasks

 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

16

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

17

Install lower engine compartment lining.

AR61.20-P-1105MFE

18

Install upper engine cover.



AP01.10-P-2405-01B

 Common rail diesel injection (CDI)

Number

Designation

Engine 608

BA07.16-P-1004-01K

Bolt, bracket to high pressure pump

M8

Nm

23

 Common rail diesel injection (CDI)

Number

Designation

Engine 608

BA07.16-P-1007-01K

Bolt, high-pressure pump to cylinder head

M8

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01