Remove/install high-pressure fuel pump

AR07.16-G-1005HA

14.01.2019

Engine

470.9, 471.9## ## as of 032691, 473.9 in model 800.310/320

Modification notes

11.04.2018

Work procedure completely revised.

W47.20-1151-09

1	Bracket	7	Fuel system high pressure pump	13	Sealing rings
2	Electrical connector	8	Fuel line	Y642	Quantity control valve
3	Clip	9	Engine wiring harness	A	Without 2nd generation engine OM470/OM471
4	Fuel lines	10	Electrical connector	B	With 2nd generation engine OM470/OM471
5	Fuel lines	11	High-pressure lines
6	Flange	12	Seal

1	Bracket
7	Fuel system high pressure pump
9	Engine wiring harness
14	Coolant line
15	Coolant line

W07.16-1233-06

 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
 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-0001-01B
 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. Wear protective gloves, protective clothing and safety glasses.	AS20.00-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 self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove
1	Drain off coolant completely.		AR20.00-G-1142H
2	Drain off fuel from fuel filter module.		AR07.03-G-1460-03H
3	Clean engine in the area of the fuel high-pressure pump (7) and the fuel filter module.
4	Remove resonator box.	Only for engine 471.9 as of engine end number 032691, 473.9	AR13.10-G-5840HA
5	Remove air intake line from compressor and place to one side.
6	Remove high-pressure lines (11) to rail.		AR07.16-G-1004HA
7	Remove power-steering pump and place to one side.	Only for engine 470.9, 471.9 as of engine end number 032691, 473.9 with power-steering pump on the timing case	AR46.30-G-0500-02H
		 Do not remove lines of the power-steering pump.
8	Disconnect electrical connector (10) from fuel temperature sensor.
9	Remove fuel lines (5) from fuel filter module.
10	Remove fuel line (8) from metering device.
11	Remove flange (6) with attached fuel lines (5) and attached fuel line (8).
12	Remove fuel lines (4).
13	Mount turning device onto timing case.		AR03.30-G-1600-03N
		 Bolt, turning device to timing case	*BA01.60-N-1002-01N
		 Turning device	*904589046300
14	Place engine on top dead center of cylinder 1 and engage.		AR07.16-W-1005-02H
		 Drift	*470589001500
		 Turning device	*904589046300
15	Disconnect electrical connector (2) from quantity control valve (Y642) and expose engine wiring harness (9).
16	Remove clamp (3) from fuel filter module.	Only for engine 470.9, 471.9 as of engine end number 032691
17	Remove coolant line (14) from engine.	Only for engine 471.9 as of engine end number 032691, 473.9
18	Remove bracket (1).
19	Remove fuel high-pressure pump (7).	 To pry out the coolant line (15) and the engine wiring harness (9), press to one side.
20	Check drive gear of the fuel high-pressure pump (7) for damage.	If the drive gear is damaged,
		
		also check the mating gear in the crankcase for damage and replace if necessary.
		ENGINE 473.9	AR05.10-G-4660HC
		ENGINE 470.9	AR05.10-G-4660HA
		Engine 471.9 as of engine end number 032691	AR05.10-G-4660H
21	Pull out drift for engaging the engine on the timing case.	Only if the gearwheel of the fuel high-pressure pump (7) is damaged.
		 Drift	*470589001500
22	Turn engine with the attached turning device through two full revolutions and check mating gear in crankcase for damage.	Only if the drive gear of the fuel system high pressure pump (7) is damaged.
		 Turning device	*904589046300
23	Re-engage engine in top dead center of cylinder 1 with drift on the timing case.	Only if the gearwheel of the fuel high-pressure pump (7) is damaged.
		 The engine is again in TDC for cylinder 1 after exactly two full revolutions.
		 Drift	*470589001500
24	Remove drive gear of fuel high-pressure pump (7).	Only if the fuel system high pressure pump (7) or the drive gear is replaced.
		Only for engine 470.9 as of engine end number 168338, 471.9 as of engine end number 168338, 473.9 as of engine end number 168338	AR07.16-G-1006HA
		Only for engine 470.9 up to engine end number 168337, 471.9 as of engine end number 032691 up to 168337, 473.9 up to engine end number 168337	AR07.16-G-1006H
	Clean
25	Clean all sealing surfaces on the fuel high-pressure pump (7) and on the crankcase.
	Install
26	Install drive gear of the fuel high-pressure pump (7).	Only if the drive gear was removed.
		Only for engine 470.9 as of engine end number 168338, 471.9 as of engine end number 168338, 473.9 as of engine end number 168338	AR07.16-G-1006HA
		Only for engine 470.9 up to engine end number 168337, 471.9 as of engine end number 032691 up to 168337, 473.9 up to engine end number 168337	AR07.16-G-1006H
27	Insert both inner screws of the fuel high-pressure pump (7).
28	Install fuel high-pressure pump (7).		AR07.16-W-1005-01H
		 The engine must stand or be locked at TDC for cylinder 1 before installation of the fuel system high pressure pump (7). Malfunctions during operation of the engine can occur otherwise.
		 Screw, fuel high-pressure pump to crankcase	*BA07.16-N-1008-03A
29	Thread in new cable tie on the bracket (1).
30	Install bracket (1).	 Screw/nut, holder to fuel high-pressure pump	*BA07.16-N-1009-03A
		 Screw, fuel high-pressure pump holder to crankcase	*BA07.16-N-1010-03A
31	Check sealing ring for coolant line (14) for damage; if necessary.
32	Attach coolant line (14) on the engine.	Only for engine 471.9 as of engine end number 032691, 473.9
		 Replace sealing ring for coolant line (14).
33	Attach clamp (3) with coolant line (15) to fuel filter module.	Only for engine 470.9, 471.9 as of engine end number 032691
		 Bolt, coolant line to fuel filter module	*BA20.00-N-1010-02D
34	Attach engine wiring harness (9) to bracket (1) and connect electrical connector (2) to quantity control valve (Y642).
35	Remove turning device from timing case.		AR03.30-G-1600-03N
		 Screw/bolt, cap of TDC inspection hole to timing case	*BA01.60-N-1001-01N
36	Pull out drift for engaging the engine on the timing case.
37	Replace O-ring on crankshaft position sensor.
38	Install crankshaft position sensor and connect electrical plug.	 Bolt, crankshaft position sensor to timing case	*BA07.04-N-1001-01H
39	Replace O-rings of the fuel lines (4).
40	Install fuel lines (4).	 Flange, low pressure fuel line to fuel high-pressure pump	*BA07.16-N-1014-03A
		 Bolt, flange for fuel line to fuel filter module	*BA07.16-N-1042-03A
41	Replace O-rings of the fuel lines (5).
42.1	Check seal (12) on flange (6); install new flange (6) if necessary.	Only for engine OM470/OM471 without 2nd generation
42.2	Install new seals (13) on flange (6).	Only for engine OM470/OM471 with 2nd generation
43	Install new sealing rings at the fuel line (8).
44	Install flange (6) with attached fuel lines (5) and attached fuel line (8).	 Banjo bolt, fuel line from flange for fuel high-pressure pump to fuel metering device	*BA07.16-N-1026-03A
		 Flange, low pressure fuel line to fuel high-pressure pump	*BA07.16-N-1014-03A
		 Bolt, flange for fuel line to fuel filter module	*BA07.16-N-1042-03A
45	Connect electrical connector (10) to the fuel temperature sensor.
46	Install high-pressure lines (11) to rail.		AR07.16-G-1004HA
47	Attach power-steering pump.	Only for engine 470.9, 471.9 as of engine end number 032691, 473.9 with power-steering pump on the timing case	AR46.30-G-0500-02H
		 Screw/bolt, power steering pump to control housing	*BA01.60-N-1008-01N
48	Attach air intake line to compressor.
49	Install resonator box.	Only for engine 471.9 as of engine end number 032691, 473.9	AR13.10-G-5840HA
50	Fill in coolant.		AR20.00-G-1142H
51	Fill fuel low-pressure circuit on engine.		AR07.16-G-1007H
52	Connect vehicle diagnosis system and carry out quick test.	Only if the fuel system high pressure pump (7) was replaced.
		 See information of engine supplier
53	Reset adaptation area for quantity control valve.	Only if the fuel system high pressure pump (7) was replaced.
		 The process is completely menu-assisted under: MCM - engine management (A4)  Adaptations  Parameterization  Resetting the calibration settings  Adaptation range for quantity control valve
54	Remove vehicle diagnosis system.	Only if the fuel system high pressure pump (7) was replaced.
55	Start engine and carry out engine test run.	 Allow engine to run at a higher rotational speed.
		If the engine does not start or runs for only a short time,
		
		Fill fuel low-pressure circuit again.
			AR07.16-G-1007H
56	Switch off engine.
57	Check area of the fuel high-pressure pump (7), fuel filter module, coolant hoses, and the fuel line (5) for leak tightness.	 Visual inspection.

 Timing case

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA01.60-N-1001-01N	Screw/bolt, cap of TDC inspection hole to timing case	Nm	30	30

 Timing case

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA01.60-N-1002-01N	Bolt, turning device to timing case	Nm	30	30

 Timing case

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA01.60-N-1008-01N	Screw/bolt, power steering pump to control housing	Nm	55	55

 Sensors

Number	Designation		Engine 470.9, 471.9, 473.9
BA07.04-N-1001-01H	Bolt, crankshaft position sensor to timing case	Nm	10