Remove/install high-pressure fuel pump

AR07.02-P-1028MRH

Remove/install high-pressure fuel pump

06.03.2020

Engine

264 in model 213, 238, 257

1

Shielding

2

Soundproofing

3

Bolts

4

High pressure pump

5

Tappet element

6

Low pressure pipe

7

High pressure pipe

 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

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

Relieve fuel pressure using diagnostic system.



Engine 264 in model 238

AD00.00-P-2000-06LWO



Engine 264 in model 213

AD00.00-P-2000-04B



Engine 264 in model 257

AD00.00-P-2000-06FR

 To do so, select following menu items:
ME-SFI [ME] control unit 
Actuation 
Actuate the fuel pump .

2

Disconnect ground line from battery.

Engine 264 in model 238

AR54.10-P-0003LWO

Engine 264 in model 213

AR54.10-P-0003LW

Engine 264 in model 257

AR54.10-P-0003FR

3

Remove rear engine cover.

Engine 264 in model 213, 238, 257

AR01.10-P-2408MRH

4

Remove right charge air line.

AR09.41-P-6817MRH

5

Remove the charge air cooler and place it at the front with the lines connected.

AR09.41-P-6817MRH

6

 Rotate engine at crankshaft center bolt in direction of engine rotation to a 79° crank angle (CKA) after top dead center (ignition TDC) on cylinder 1

 Socket wrench bit

*001589650900

7

Remove the cable duct from the cylinder head cover and shielding (1).

8

Unclip the electrical cable from the shielding (1).

9

Release and disconnect electrical connection of high-pressure pump (4).

10

Remove shielding (1).

Tightening procedure for high-pressure pump shielding

AR07.02-P-0815-01MRH

 Loosen the shielding (1) in the direction in contrary to the tightening procedure.

11

Remove soundproofing (2).

12

Clean the environment around the high-pressure pump (4), high-pressure line (7), and low-pressure line (6).

Assembly cleaner

*BR00.45-Z-1028-04A

13

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

14

Remove high-pressure line (7) and seal connections with suitable stop plugs.


Do not kink or bend high-pressure line (7).
Leaks can occur otherwise.

 Box wrench bit

*000589800300

 Record plug

*129589009100

15

Remove the low-pressure line (6) from the cylinder head cover and high-pressure pump (4) and seal the openings using suitable stop plugs.

 Box wrench bit

*000589800300

 Record plug

*129589009100

16

Remove screw/bolts (3).


Remove screws (3) alternately by half a turn each.
Damage may occur otherwise to the high-pressure pump (4).

17

Remove high-pressure pump (4).

18

Remove the tappet element (5) from the cylinder head cover.



Check

19

Check the tappet element (5) for wear and damage and replace if necessary.

20

Check the high-pressure line (7).

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Replace the high-pressure line (7).

21

Check low-pressure line (6).

AR07.03-P-1120-01MNE

Assembly cleaner

*BR00.45-Z-1028-04A

If damage is present,



Replace low-pressure line (6).

AR07.03-P-1120MRH



Clean

22

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

Assembly cleaner

*BR00.45-Z-1028-04A



Install

23

Position the tappet element (5) in the cylinder head cover.


The drive roller of the tappet element (5) must point towards the camshaft.
The camshaft can get damaged otherwise.

24

Replace sealing ring of the high-pressure pump (4).

25

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

26

Tighten new bolts (3).


Screw in screws (3) alternately by half a turn each.
Damage may occur otherwise to the high-pressure pump (4).


The high-pressure pump (4) must be fully in contact with the cylinder head cover after having tightened the screws (3).
Leaks can occur otherwise.

 Bolt, high-pressure pump to cylinder head cover

*BA07.02-P-1001-02A

27

Install the low-pressure line (6) at the high-pressure pump (4) and cylinder head cover.

 Screw, low-pressure line holder to cylinder head/crankcase/holder

*BA07.03-P-1002-01I

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

*BA07.03-P-1001-01I

 Box wrench bit

*000589800300

28

Install high-pressure line (7).

AR07.03-P-1010-02MRH

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

*BA07.03-P-1001-01I

 Box wrench bit

*000589800300

29

Install soundproofing (2).

30

Install shielding (1).

Tightening procedure for high-pressure pump shielding

AR07.02-P-0815-01MRH

 Bolt for high-pressure pump shielding

*BA07.02-P-1002-02A

31

Install the cable duct at the cylinder head cover and shielding (1).

 M61

*BA00.10-P-1002-04A

32

Clip in the electrical cables at the shielding (1).

33

Connect electrical connection of high-pressure pump (4) until it is locked.

34

Install the charge air cooler.

AR09.41-P-6817MRH

35

Install right charge air pipe.

AR09.41-P-6817MRH

36

Remove the engine cover at the rear.

Engine 264 in model 213, 238, 257

AR01.10-P-2408MRH

37

Connect ground line to battery.

Engine 264 in model 238

AR54.10-P-0003LWO

Engine 264 in model 213

AR54.10-P-0003LW

Engine 264 in model 257

AR54.10-P-0003FR

38

Switch on ignition.


Switch on the ignition for 5 s to fill the high-pressure pump (4) with fuel prior to starting the engine.
Damage may occur otherwise to the high-pressure pump (4).

39

Check the fuel high-pressure circuit.

AR07.03-P-1010-04MM



Engine 264 in model 238

AD00.00-P-2000-06LWO



Engine 264 in model 213

AD00.00-P-2000-04B



Engine 264 in model 257

AD00.00-P-2000-06FR

 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

Carry out engine test run and check engine for proper operation and leak tightness.

41

Install engine cover.

AR01.10-P-2405MRH

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Fuel system high pressure pump

Number

Designation

Engine 264

BA07.02-P-1001-02A

Bolt, high-pressure pump to cylinder head cover

Nm

9

 Fuel system high pressure pump

Number

Designation

Engine 264

BA07.02-P-1002-02A

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 264

BA07.03-P-1001-01I

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

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 264

BA07.03-P-1002-01I

Screw, low-pressure line holder to cylinder head/crankcase/holder

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01