W07.16-1090-09
1 | Fuel system high pressure pump | 5 | Coolant line | 9 | Power steering pump | ||
2 | Electrical connector | 6 | Compressor | Y642 | Quantity control valve | ||
3 | Bracket | 7 | Bracket | ||||
4 | Engine wiring harness | 8 | High pressure pipe |
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. | |
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. | |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. | |
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. | |
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
| Remove | ||
1 | Drain off coolant | ||
2 | Clean engine in the area of fuel system high pressure pump (1) and the fuel filter module | ||
3 | Remove resonator | ||
4 | Remove air intake duct on compressor (6) and place to one side | ||
5 | Remove high-pressure line (8) to rail | ||
6 | Remove power steering pump (9) and place to one side |
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Do not disconnect the lines of the power steering pump (9) in the process. | |||
7 | Remove fuel filter module | ||
8 | Attach turning device to timing case | ||
Bolt, turning device to timing case | |||
Turning device | |||
9 | Set engine to TDC for cylinder 1 and lock in place | ||
Drift | |||
Turning device | |||
10 | Remove coolant line (5) from compressor (6) and from crankcase | Collect escaping coolant using suitable vessel. | |
11 | Disconnect electrical connector (2) at quantity control valve (Y642) | ||
12 | Expose engine wiring harness (4) on holder (3) | ||
13 | Remove bracket (3) | ||
14 | Remove fuel system high pressure pump (1) | To lift out the engine wiring harness, press (4) with holder (7) to the side. | |
15 | Check gear of the fuel system high pressure pump (1) for damage | For damage | |
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Also check the mating gear in crankcase for damage and if necessary install a new one. | |||
16 | Pull out drift for locking the engine on timing case | Only if the gear of the fuel system high pressure pump (1) is damaged. | |
17 | Turn engine with the attached turning device through exactly two full revolutions (2 x 360°) and check the counter gear wheel for fuel system high pressure pump (1) in the process | Only if the gear of the fuel system high pressure pump (1) is damaged. | |
18 | Engine in the TDC of cylinder 1 with a drift | Only if the gear of the fuel system high pressure pump (1) is damaged. | |
The engine is again in TDC for cylinder 1 after exactly two full revolutions (2 x 360°). | |||
Drift | |||
19 | Remove gear of fuel system high pressure pump (1) | Only if the fuel system high pressure pump (1) or the gear is renewed. | |
| Clean | ||
20 | Clean all sealing surfaces on the fuel system high pressure pump (1) and on crankcase | ||
| Install | ||
21 | Install gear of fuel system high pressure pump (1) | Only if gear was removed. | |
22 | Install fuel system high pressure pump (1) | ||
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Push bracket (7) and engine wiring harness (4) to the side. | |||
Screw, fuel high-pressure pump to crankcase | |||
23 | Install bracket (3) | Lead in a new cable tie before installing bracket (3). | |
Screw/nut, holder to fuel high-pressure pump | |||
Screw, fuel high-pressure pump holder to crankcase | |||
24 | Attach engine wiring harness (4) at bracket (3) | ||
25 | Connect electrical connection (2) to quantity control valve (Y642) | ||
26 | Attach coolant line (5) to compressor (6) and crankcase | ||
27 | Remove turning device from timing case | ||
Screw/bolt, cap of TDC inspection hole to timing case | |||
28 | Pull out drift for locking the engine on timing case | ||
29 | Install crankshaft position sensor with new O-ring and connect electrical connector | Bolt, crankshaft position sensor to timing case | |
30 | Install fuel filter module | ||
31 | Attach power steering pump (9) |
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Screw/bolt, power steering pump to control housing | |||
32 | Install high-pressure line (8) to rail | ||
33 | Attach air intake duct on compressor (6) | ||
34 | Install resonator | ||
35 | Pour in coolant | ||
36 | Fill fuel low-pressure circuit on engine | ||
37 | Connect diagnostic system and perform quick test | Only if the fuel system high pressure pump (1) was replaced. | |
See information from body manufacturer. | |||
38 | Reset "Adaptation area for quantity control valve" (Y642) | Only if the fuel system high pressure pump (1) was replaced. | |
The process is completely menu-assisted under: | |||
39 | Remove diagnostic system | Only if the fuel system high pressure pump (1) was replaced. | |
40 | Start engine and perform an engine test run | Allow engine to run at a higher rotational speed. | |
If engine fails to start or only runs for a brief period. | |||
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Fill fuel low-pressure circuit again. | |||
41 | Shut off engine and check area around fuel system high pressure pump (1), the fuel filter module and the coolant line (5) for leaktightness | Visual inspection. |
470 589 00 15 00
Drift
904 589 04 63 00
Turning device