Remove/install high-pressure fuel pump

AR07.02-P-1028MRM

Remove/install high-pressure fuel pump

06.03.2020

Engine

274.9 in model 167

20

Cover

21

Partition wall

22

Electrical wiring harness

23

Screw

1

Cable duct

5

High pressure pipe

2

Electrical connector

6

Low pressure pipe

3

Shielding

7

Screw

4

Fuel high-pressure pump

8

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 cover for air/water duct.

AR83.10-P-1411ME

2

Unclip cover (20) (arrows) and remove.

3

Unclip line of the inerting system from the partition (21).

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

4

Unclip electrical wiring harness (22) from the partition (21).

5

Remove screws (23) and remove the partition (21) upward.

6

Remove engine compartment lining at rear.

AR61.20-P-1105ME

7

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

8

Disconnect ground line from battery.

AR54.10-P-0003ME

9

Remove upper engine cover.



AP01.10-P-2405-01O

10

Remove engine air intake duct upstream of air filter.

11

Rotate engine using center bolt of crankshaft in direction of engine rotation to a crank angle (CKA) of 790 after top dead center (TDC) at cylinder 1. 

 Socket wrench bit

*001589650900

12

Remove cable duct (1).

13

Release and disconnect the electrical connector (2).

14

Remove shielding (3).

Tightening procedure

AR07.02-P-0815-01MR

 Loosen the shielding (3) in the opposite direction to the tightening procedure.

15

Remove soundproofing from the high-pressure fuel pump (4).

16

Clean area around the high-pressure fuel pump (4) and high-pressure line (5).

Assembly cleaner

*BR00.45-Z-1028-04A

17

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

18

Remove high-pressure line (5) and seal connections with suitable stop plugs.


Do not kink or bend high-pressure line (5).
Otherwise damage and leaks can occur.

 Record plug

*129589009100

 Box wrench bit

*000589800300

19

Remove low-pressure line (6) from the high-pressure fuel pump (4) and seal connections with suitable stop plugs.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

20

Remove bolts_(7).


Remove screws (7) alternately by half a revolution each.
Otherwise, damage to the high-pressure fuel pump (4) will occur.

21

Remove fuel high-pressure pump (4).

22

Pull tappet element (8) out of the cylinder head cover.



Check

23

Check tappet element (8) for wear and damage.

If damage or wear is present,



replace tappet element (8).

24

Check high-pressure line (5).

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Install new high-pressure line(5).



Clean

25

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



Install

26

Position the tappet element (8) in the cylinder head cover.


The drive roller of the tappet element (8) must be seated on the camshaft.
The camshaft can get damaged otherwise.

27

Install new sealing ring of the high-pressure fuel pump (4).

28

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

29

Screw in new screws (7).


Screw in screws (7) alternately by half a revolution each.
Otherwise, damage to the high-pressure fuel pump (4) will occur.


The high-pressure fuel pump (4) must lie flat on the cylinder head cover after the screws (7) are tightened.
Otherwise, leaks and damage to the high-pressure fuel pump (4) will occur.

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1003-01D

30

Install high-pressure line (5).

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

31

Attach low-pressure line (6) with new clamp to the high-pressure fuel pump (4).

 Pliers for click clamps

*171589003700

32

Install soundproofing to the high-pressure fuel pump (4).

33

Install shielding (3).

Tightening procedure

AR07.02-P-0815-01MR

 Bolt for high-pressure pump shielding

*BA07.02-P-1004-01D

34

Connect electrical connection (2).

35

Attach cable duct (1).

 Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

*BA01.20-P-1010-01R

36

Install engine air intake duct upstream of air filter.

37

Connect ground line to the battery.

AR54.10-P-0003ME

38

Switch on ignition.


In order to fill the high-pressure fuel pump (4) with fuel, switch on the ignition for 5 s before the engine start.
Otherwise, damage to the high-pressure fuel pump (4) will occur.

39

Check high-pressure fuel circuit.

AR07.03-P-1010-04MM



AD00.00-P-2000-06ME

 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

40

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

41

Install upper engine cover.



AP01.10-P-2405-01O

42

Install rear engine compartment lining.

AR61.20-P-1105ME

43

Insert partition (21) and screw in screws (23).

 Ensure that the partition (21) is seated correctly in the lower part of the partition.

 Screw, upper engine compartment partition to lower engine compartment partition

*BA62.30-P-1012-02I

44

Clip electrical wiring harness (22) onto the partition (21).

45

Clip line of the inerting system onto the partition (21).

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

46

Clip in cover (20) (arrows).

47

Install cover for air/water duct.

AR83.10-P-1411ME

 Crankcase ventilation system, cylinder head cover, camshaft housing

Number

Designation

Engine 274

BA01.20-P-1010-01R

Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

Nm

8

 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

 Frond end with reinforcement

Number

Designation

Model 167

BA62.30-P-1012-02I

Screw, upper engine compartment partition to lower engine compartment partition

4

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01