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Remove/install high-pressure pump - AR07.02-P-1020RKB

ENGINE 157, 278 in MODEL 231 

MODIFICATION NOTES

08.04.2013 Tightening procedure for housing of the fuel system high pressure pump, added Operation step 25  
04.07.2016 Union nut, Fuel line to fuel distributor   BA07.03-P-1001-01E
04.07.2016 Union nut, Fuel line to high pressure pump   BA07.03-P-1002-01E
Fig 1: High-Pressure Pump Remove/Install Components (1 Of 3)
G11128347Courtesy of MERCEDES-BENZ USA
Fig 2: High-Pressure Pump Remove/Install Components (2 Of 3)
G11128348Courtesy of MERCEDES-BENZ USA
Fig 3: High-Pressure Pump Remove/Install Components (3 Of 3)
G11128349Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
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 contact with 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
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
1 Set DIRECT SELECT gear selector switch to position "N" and release parking brake    
2 Disconnect battery ground line   AR54.10-P-0003RK
IMPORTANT Notes on battery   AH54.10-P-0001-01A
3 Remove both air filter housings    
4 Remove ME-SFI [ME] control unit (N3/10)   AR07.08-P-7008RKB 
5 Remove insulation on rails IMPORTANT Only if fitted.  
6 Remove crankcase breather line (8) and boot (9) IMPORTANT The crankcase breather line (8) and boot (9) not must not be separated from each other.  
7 Remove engine wiring harness on intake manifold and cylinder head covers   AR01.00-P-2410-02RKB
8 Remove bulkhead at firewall    
9 Unclip engine wiring harness on firewall    
10 Disconnect electrical connections on right quantity control valve (Y94/2) and pressure sensor downstream of throttle valve (B287)    
11 Unscrew screw/bolts (12) and remove crash plate (10) TORQUE SPECIFICATION Bolt, shield to high-pressure pump drive housing *BA07.02-P-1003-01C 
12 Remove insulation (11) on left high-pressure pumps (1l) and right high-pressure pump (1r)    
13 Remove lower engine compartment paneling   AR61.20-P-1105RK
14 Turn engine to a 40°CKA after top dead center (TDC) on cylinder 1 (ignition TDC) IMPORTANT To do this turn engine at center bolt of the crankshaft in direction of engine rotation. AR05.10-P-7620-04MM
15 Relieve fuel pressure through service valve IMPORTANT Open tank filler cap for a short time in order to remove the overpressure in the fuel tank. AR07.03-P-1460-01VA
TORQUE SPECIFICATION Protective cap on service valve *BA07.03-P-1007-01E 
SPECIAL TOOL Pressure hose Figure
16 Clean area around the fuel high pressure circuit    
17 Remove high-pressure lines which are mounted on left high-pressure pumps (1l) and right high-pressure pump (1r) NOTES Do not kink or bend high-pressure lines.
Do this to avoid leaks and damage.
The sealing cone for high-pressure lines must be checked before assembly. The work instructions absolutely must be observed for assembly work. Checking of fuel high-pressure circuit must be carried out after assembly: ↓
Check high-pressure lines		 AR07.03-P-1010-03MM
Mount high-pressure lines. AR07.03-P-1010-02MMB
Check fuel high pressure circuit. AR07.03-P-1010-04MM
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01E 
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01E 
TORQUE SPECIFICATION Bolt, fuel line service valve to cylinder head cover *BA07.03-P-1003-01E 
TORQUE SPECIFICATION Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head *BA07.03-P-1004-01E 
TORQUE SPECIFICATION Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase *BA07.03-P-1005-01E 
TORQUE SPECIFICATION Bolt, fuel line clamp to charge air distribution line *BA07.03-P-1006-01E 
Assembly cleaner *BR00.45-Z-1028-04A 
18 Remove screw/bolts (1s) for left high-pressure pump (1l) and right high-pressure pump (1r) NOTES The screw/bolts (1s) each must be unscrewed or screwed in for removal or installation of the left high-pressure pump (1l) and right high-pressure pump (1r) alternately by a half revolution.
Damage can occur otherwise to the left high-pressure pump (1l) and right high-pressure pump (1r).
INSTALLATION IMPORTANT Replace screw/bolts (1s) with new ones.
The left high-pressure pump (1l) and right high-pressure pumps (1r) must  lie flat on the high pressure pump housing (2) after tightening the screw/bolts (1s) under the screw/bolts (1s).
TORQUE SPECIFICATION Bolt, high-pressure pump to high-pressure pump drive housing		 *BA07.02-P-1001-01C 
19 Raise high-pressure pump on the left (1l) somewhat and disconnect electrical connection on left quantity control valve (Y94/1) IMPORTANT When removing left high-pressure pump (1l).  
20 Remove left high-pressure pump (1l) and right high-pressure pump (1r) INSTALLATION NOTESInstallation: 
Dry green sealing ring (3) coated with low-friction paint and insert the black sealing ring (3) wet with oil into the high pressure pump housing (2).
Leakage can occur otherwise.
INSTALLATION IMPORTANT Clean mount(s) for the high-pressure pump(s).
Replace sealing ring (3). There are two variants of the sealing rings (3) which can be differentiated between based on their color.		  
21 Pull tappet elements (4) out of the high-pressure pump housing (2) INSTALLINGInstallation: 
The tappet elements (4) must be installed in such a way that the drive rollers for the tappet elements (4) sit on the camshaft. Damage can occur to the camshaft otherwise.
Damage can occur to the camshaft otherwise.		  
INSPECT Check     
22 Check tappet elements (4) for wear and damage IMPORTANT Replace if necessary.  
  Only perform operation steps 22 to 25 to remove the high-pressure pump housing (2)     
23 Remove centrifuge vacuum line (7) on intake manifold    
24 Remove bracket for high-pressure pump housing (2) on cylinder head cover    
25 Remove screw/bolts (2a) for high-pressure pump housing (2) INSTALLATION NOTES
Observe assembly specification and tightening sequence.
Damage can occur otherwise to the camshaft and cylinder head.		 AR07.02-P-1020-02MM
    TORQUE SPECIFICATION Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover *BA07.02-P-1002-01C 
26 Take out high-pressure pump housing (2) upwards INSTALLATION IMPORTANT Replace seals (5, 6).  
27 Install in the reverse order    
28 Switch on ignition NOTES The ignition must be switched on for 5 s before the engine start in order to fill the left high-pressure pump (1l) and right high-pressure pump (1r) with fuel.
Damage can occur otherwise to the left high-pressure pump (1l) and right high-pressure pump (1r).		  
DANGER 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
29 Perform an engine test run and check fuel system for proper operation and leaktightness AR07.03-P-1010-04MM
HIGH PRESSURE PUMP

Number Designation Engine 157 Engine 278
BA07.02-P-1001-01C Bolt, high-pressure pump to high-pressure pump drive housing Nm 14 14
HIGH PRESSURE PUMP

Number Designation Engine 157 Engine 278
BA07.02-P-1002-01C Bolt, high-pressure pump drive housing to cylinder head/cylinder head cover Stage 1 Nm 1 1
Stage 2 Nm 14 14
HIGH PRESSURE PUMP

Number Designation Engine 157 Engine 278
BA07.02-P-1003-01C Bolt, shield to high-pressure pump drive housing Nm 14 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1001-01E Union nut, fuel line to fuel distributor 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 157 Engine 278
BA07.03-P-1002-01E Union nut, fuel line to 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 157 Engine 278
BA07.03-P-1003-01E Bolt, fuel line service valve to cylinder head cover Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1004-01E Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head Nm 14 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1005-01E Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1006-01E Bolt, fuel line clamp to charge air distribution line Nm 5 5
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1007-01E Protective cap on service valve Plastic Nm 2 2
Metal Nm 15 15
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G07742723Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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