Remove/install right high-pressure fuel pump

AR07.02-P-1024MNA

06.03.2020

Engine	176 in model 463
	up to model year 2019
Engine	177 in model 205

Modification notes

18.04.2016	Bolt, vacuum pump to cylinder head	Model 463	BA43.05-P-1002-01B
20.05.2016	Union nut, fuel line to fuel distributor/fuel system high pressure pump		BA07.03-P-1001-01H
25.08.2016	Screw/bolt, shield plate to cylinder head	Engine 176	BA07.02-P-1002-01E
25.08.2016	Screw/bolt, shield plate to cylinder head	Engine 177.980	BA07.02-P-1002-01E
30.01.2017	Union nut, fuel line to fuel distributor/fuel system high pressure pump		BA07.03-P-1001-01H

Remove/install right high-pressure fuel pump

Shown on ENGINE 177

1	Plug connections
2	Crash plate
5	Insulation
8	Bolts
9	Fuel line
10	Fuel line

P07.02-2192-06

Shown on ENGINE 177

3	Right fuel system high pressure pump
4	Electrical connector
6	Bolts
7	Vacuum line
8	Screw
11	Rail
12	Ignition coil
13	Heat shield
14	Bolts

P07.02-2196-06

 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	Detach ground line from battery	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205
		Engine 176 in model 463 (except 463.234) as of model year 2013 up to model year 2019	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
3	Remove left and right air filter housing		AR09.10-P-1150MNA
4	Remove side heat shield of left ATL	Engine 177 in model 205
			AR09.40-P-6026MNA
5	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01MNA
		 Dust protection cap to service connection	*BA07.03-P-1005-01H
		 Pressure hose	*119589046300
6.1	Unclip electrical plug connection (1) on crash plate (2)	Engine 177 in model 205
6.2	Unclip electrical lines from crash plate (2)	Engine 176 in model 463 up to model year 2019
7	Disconnect electrical connection (4)
8	Remove insulation (5)
9	Remove bolts (6)
10	Detach vacuum line (7) from vacuum pump and place to one side
11	Remove screws/bolts (8) and place crash plate (2) to one side	 Bolt, shield to cylinder head/cylinder head cover	*BA07.02-P-1002-01E
12	Remove position sensor of camshafts	Engine 176 in model 463 up to model year 2019	AR15.12-P-2144MNF
		Engine 177 in model 205	AR15.12-P-2144MNA
13	Remove lower engine compartment paneling	Engine 176 in model 463 as of model year 2016 up to model year 2019 except code ZQ0 (G 500 4x42)	AR61.20-P-1105GW
		Engine 177 in model 205	AR61.20-P-1105LW
14	Detach front circulation pump for low-temperature water circuit and place with attached lines and hoses to one side	Engine 176 in model 463 up to model year 2019
			AR09.41-P-6925MNF
15	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
16	Detach bracket of fuel lines (9, 10) at right cylinder head cover
17	Detach fuel line (10) at rail (11)	 Thoroughly clean area around fuel line (10) at locations to be separated. Failure can occur otherwise to the fuel system.
		 Do not kink or bend fuel line (10). Otherwise leaks and damage may occur.
		Assembly cleaner	*BR00.45-Z-1028-04A
		 Box wrench bit	*000589800300
18	Detach fuel lines (9, 10) on right fuel system high pressure pump (3) and place to one side	 Thoroughly clean area around fuel lines (9, 10) at locations to be separated. Failure can occur otherwise to the fuel system.
		 Do not kink or bend the fuel lines (9, 10). Otherwise leaks and damage may occur.
		 For pulling out of fuel lines (9, 10) from the right fuel system high pressure pump (3) ensure that the position sensor of the right intake camshaft is not damaged.
		Assembly cleaner	*BR00.45-Z-1028-04A
		 Box wrench bit	*000589800300
19	Remove screws (14) and remove right fuel system high pressure pump (3) upward	 Screw/bolts (14) must be removed alternately each by half a revolution each time when removing the right fuel system high pressure pump (3). Damage could occur otherwise to the right fuel system high pressure pump (3).
		 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
20	Replace sealing ring of the right fuel system high pressure pump (3)
21	Attach right fuel system high pressure pump (3) with screw/bolt (14) on right cylinder head cover	 Screw/bolts (14) must be screwed in alternately each by half a revolution each time when installing the right fuel system high pressure pump (3). Damage could occur otherwise to the right fuel system high pressure pump (3).
		 The right fuel system high pressure pump (3) must lie flat on the right cylinder head cover after tightening the screws (14).
		 Replace screws (14).
		 Bolt, fuel system high pressure pump to cylinder head	*BA07.02-P-1001-01E
	Check
22	Check fuel lines (9, 10) for damage and replace if necessary	Engine 176 in model 463 up to model year 2019	AR07.03-P-1010-03MM
		Engine 177 in model 205	AR07.03-P-1010-03MNA
		 The sealing cones for the fuel lines (9, 10) must be checked before assembly. This prevents leaks and damage.
23	Attach fuel lines (9, 10) to right fuel system high pressure pump (3)		AR07.03-P-1010-02MNA
		 Do not kink or bend the fuel lines (9, 10). 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
24	Attach fuel line (10) to the rail (11)		AR07.03-P-1010-02MNA
		 Do not kink or bend fuel line (10). 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
25	Attach bracket of fuel lines (9, 10) to right cylinder head cover
26	Mount front circulation pump for low-temperature water circuit	Engine 176 in model 463 up to model year 2019
			AR09.41-P-6925MNF
27	Install lower engine compartment paneling	Engine 176 in model 463 as of model year 2016 up to model year 2019 except code ZQ0 (G 500 4x42)	AR61.20-P-1105GW
		Engine 177 in model 205	AR61.20-P-1105LW
28	Install position sensors of camshafts	Engine 176 in model 463 up to model year 2019	AR15.12-P-2144MNF
		Engine 177 in model 205	AR15.12-P-2144MNA
29	Put on crash plate (2) and tighten down screw/bolts (8)	 Bolt, shield to cylinder head/cylinder head cover	*BA07.02-P-1002-01E
30	Attach vacuum line (7) to vacuum pump
31	Screw in screws (6)	 Engine 176 in model 463 up to model year 2019Bolt, vacuum pump to cylinder head	*BA43.05-P-1002-01B
		 Engine 177 in model 205Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump	*BA43.05-P-1002-01O
32	Install insulation (5)
33	Mount electrical connection (4)
34.1	Unclip electrical plug connection (1) on crash plate (2)	Engine 177 in model 205
34.2	Clip in electrical lines of crash plate (2)	Engine 176 in model 463 up to model year 2019
35	Install side heat shield of left ATL	Engine 177 in model 205
			AR09.40-P-6026MNA
36	Install left and right air filter housing		AR09.10-P-1150MNA
37	Attach ground line to battery	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205
		Engine 176 in model 463 (except 463.234) as of model year 2013 up to model year 2019	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
38	Switch on ignition	 The ignition must be switched on for 5 s before the engine start in order to fill the left fuel system high pressure pump with fuel. Damage could occur to the left fuel system high pressure pump otherwise.
	Check
39	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
40	Perform an engine test run and check fuel system for proper operation and leaktightness

 Injection pump, high-pressure fuel pump

Number	Designation		Engine 176	Engine 177
BA07.02-P-1001-01E	Bolt, fuel system high pressure pump to cylinder head	Nm	14	14

 Injection pump, high-pressure fuel pump

Number	Designation		Engine 176	Engine 177
BA07.02-P-1002-01E	Bolt, shield to cylinder head/cylinder head cover	Nm	10	10

 Injection nozzles, injection valves, lines

Number	Designation				Engine 176	Engine 177
BA07.03-P-1001-01H	Union nut, fuel line to fuel distributor/fuel system high-pressure pump	In case of reusability		Nm	22	22
		For new lines	Stage 1	Nm	15	15
			Stage 2	°	90	90

 Injection nozzles, injection valves, lines

Number	Designation		Engine 176	Engine 177
BA07.03-P-1005-01H	Dust protection cap to service connection	Nm	1	1

 Vacuum pump

Number	Designation		Model 463 up to model year 2019
BA43.05-P-1002-01B	Bolt, vacuum pump to cylinder head	Nm	10

 Vacuum pump

Number	Designation		Engine 177
BA43.05-P-1002-01O	Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump	Nm	9

177 589 00 15 00

Drift

000 589 80 03 00

Box wrench bit

119 589 04 63 00

Pressure hose

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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