Remove/Install High-Pressure Fuel Pump - AR07.02-P-1020MFC

Engine 260 in model 118, 177, 247

MODIFICATION NOTES

13.11.2019

Document completely revised.

Fig 1: High-Pressure Fuel Pump Components Location - Engine 260 In Model 247

Courtesy of MERCEDES-BENZ USA

	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
	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
	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
	Risk of injury . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-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
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove/install
1	Shift transmission to neutral position and secure vehicle against rolling away.
2	Remove upper engine cover.
			AP01.10-P-2405-01C
		Only install upper engine cover after the leak test.
3	Relieve fuel pressure using diagnostic system		AR07.00-P-0003-01MFA
			AD00.00-P-2000-06MFA
4	Release residual fuel pressure.		AR07.03-P-1460-02MM
5	Disconnect ground line of on-board electrical system battery (G1).		AR54.10-P-0003MFA
6	Remove front section of the front right fender liner.		AR88.10-P-1301MFA
7	Use the central bolt of the crankshaft to crank the engine in the engine's direction of rotation to a crank angle (KW) of 79° after the top dead center (ignition OT) at the 1st cylinder.	The 79° marking on the belt pulley and vibration damper must be aligned with the positioning edge on the timing case cover.
		Socket wrench bit	Fig 5
8	Remove damping (2).
9	Clean surrounding area of high-pressure fuel circuit.	Thoroughly clean area around high-pressure fuel circuit so that no dirt can get into fuel injection system. Failure of the fuel injection system can occur otherwise.
		Assembly cleaner	*BR00.45-Z-1028-04A
10	Release and disconnect electrical connector at quantity control valve (Y94).
11	Remove low-pressure line at high-pressure pump (1) and seal exposed connections with suitable stop plugs.	Replace snap clamp. Catch escaping fuel with lint-free rags.
		Record plug	Fig 2
		Pliers for click clamps	Fig 4
12	Remove high-pressure line (3) between fuel distributor (5) and high-pressure pump (1) and seal exposed connections with suitable stop plugs.	Catch escaping fuel with lint-free rags.	AR07.03-P-1010-02MT
		Union nut, fuel line to high-pressure pump/fuel distributor	*BA07.03-P-1001-01I
		Box wrench bit	Fig 3
		Record plug	Fig 2
13	Check the high-pressure line (3).		AR07.03-P-1010-03MM
		Assembly cleaner	*BR00.45-Z-1028-04A
14	Remove bolts (1s).	The screw/bolts (1s) must screwed in and out by half a revolution alternately for removal or installation of the high-pressure pump (1). High-pressure pump (1) will otherwise be damaged. Replace screw/bolts (1s) with new ones. High-pressure pump (1) must lie flat on cylinder head cover (6) after tightening of bolts (1s).
		Bolt, high-pressure pump to cylinder head cover	*BA07.02-P-1003-01D
15	Remove high-pressure pump (1).	Sealing ring must not come into contact with oil before installation of high-pressure pump (1) in cylinder head cover (6). Otherwise, the sealing ring will swell and leaks will occur. Replace sealing ring of high-pressure pump (1).
16	Pull tappet element (4) out of cylinder head cover (6) and cover opening with lint-free rag.	Install the tappet element (4) in such a way that the drive roller of the tappet element (4) sits on the camshaft. Damage can occur to the camshaft otherwise.
17	Check tappet element (4) for wear and damage.	If there are problems, ↓ Replace tappet element (4).
18	Install in the reverse order.
	Check
19	Read out fault memory and delete if necessary.
			AD00.00-P-2000-06MFA
20	Switch on ignition.	Before engine start, switch on ignition for 5 s to fill high-pressure pump (1) with fuel. High-pressure pump (1) will otherwise be damaged.
21	Check high-pressure fuel circuit.		AR07.03-P-1010-04MM
			AD00.00-P-2000-06MFA
22	Perform engine test run. While doing so, check engine for proper operation and leak tightness
23	Install upper engine cover.
			AP01.10-P-2405-01C