Remove/Install High-Pressure Fuel Pump - Ar07.02-D-1028TSC
Engine 274 in model 907
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 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 | |
| Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fue 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 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 | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| 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 | ||
| Remove | |||
| 1 | Clamp off ground line of on-board electrical system battery (G1). | AR54.10-D-0029TS | |
| 2 | Remove cover of cylinder head cover. | AR01.20-D-5015TSC | |
| 3 | Raise vehicle. | AR00.60-D-1000-04TS | |
| Special instructions for lifting and supporting vehicle | AH00.60-N-0100-01IS | ||
| 4 | To relieve the tappet element (11), turn engine at the center bolt of the crankshaft in the direction of engine rotation to a crank angle (CKA) of 79° after ignition TDC at cylinder 1. | ||
| Fig 3 | |||
| 5 | Remove fuel pressure via the service connection. | AR07.03-S-1460-04EG | |
| *BA07.03-N-1001-01H | |||
| Fig 4 | |||
| 6 | Lower vehicle. | ||
| 7 | Remove screws (3) and remove cable duct (2). | ||
| 8 | Unclip electrical wiring harness (4) from the shielding (6). | ||
| 9 | Release and disconnect electrical connector (5). | ||
| 10 | Remove screws of the shielding (6) in reverse order of the tightening procedure. | AR07.02-S-0815-01EG | |
| 11 | Remove shielding (6). | ||
| 12 | Remove soundproofing (7). | ||
| 13 | Remove fuel hose (8) and seal exposed connections with suitable stop plugs. | Fig 1 | |
| Fig 2 | |||
| 14 | Remove fuel high-pressure line and seal exposed connections with suitable stop plugs. | ||
| 000 589 10 99 00 Tool kit | WS00.00-P-0030Z | ||
| Fig 1 | |||
| 15 | Remove screws/bolts (9). | Remove screws (9) alternately by half a revolution each. This prevents damage to the fuel system high pressure pump (1). |
|
| 16 | Remove fuel system high pressure pump (1) with tappet element (11). | ||
| Check | |||
| 17 | Check tappet element (11) for wear and damage. | If wear or damage is present: ↓ Replace tappet element (11). |
|
| Install | |||
| 18 | Install tappet element (11) in the cylinder head cover. | ||
| 19 | Install fuel high-pressure pump (1). | ||
| 20 | Tighten screws (9). | Screw in screws (9) alternately by half a revolution each. This prevents damage to the fuel system high pressure pump (1). |
|
| *BA07.02-N-1001-01F | |||
| 21 | Install new fuel high-pressure line. Notes on threaded connections fastened using a tightening angle-based tightening process |
AH00.00-P-0020-01A | |
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| 000 589 10 99 00 Tool kit | WS00.00-P-0030Z | ||
| AR07.03-S-1010-02EG | |||
Do not kink or bend fuel high-pressure line. This prevents leaks or damage. |
|||
| *BA07.03-N-1003-01H | |||
| *BA07.03-N-1002-01H | |||
| 22 | Attach fuel hose (8). | ||
| Fig 2 | |||
| 23 | Install soundproofing (7). | ||
| 24 | Install shielding (6). | ||
| 25 | Tighten screws of the shielding (6) as per the tightening procedure. | AR07.02-S-0815-01EG | |
| *BA07.02-N-1002-01F | |||
| 26 | Connect electrical connector (5). | ||
| 27 | Check retaining clamp and electrical wiring harness (4) on the shielding (6). | If the retaining clamp is damaged, ↓ Replace retaining clip. |
|
| 28 | Attach cable duct (2) and tighten screws (3). | *BA00.10-N-1002-01A | |
| 29 | Install cover of cylinder head cover. | AR01.20-D-5015TSC | |
| 30 | Clip on ground line of the on-board electrical system battery (G1). | AR54.10-D-0029TS | |
| 31 | Switch on ignition. | The ignition must be switched on for 5 s before the engine start in order to fill the fuel system high pressure pump (1) with fuel. This prevents damage to the fuel system high pressure pump (1). |
|
| Check | |||
| 32 | Check fuel high-pressure circuit. | AR07.03-S-1010-04EG | |
| Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-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 | |
| 33 | Perform engine test run; while doing so, check fuel system high pressure pump (1) and fuel high-pressure lines for proper operation and leak tightness. |
| Number | Designation | 8.8 | 10.9 | ||
|---|---|---|---|---|---|
| BA00.10-N-1002-01A | M6 | Galvanized | Nm | 9 | 13 |
| Phosphated | Nm | 9 | 12 | ||
| Number | Designation | 12.9 | ||
|---|---|---|---|---|
| BA00.10-N-1002-01A | M6 | Galvanized | Nm | 16 |
| Phosphated | Nm | 14 | ||
| Number | Designation | Engine 274 in model 907 | |
|---|---|---|---|
| BA07.02-N-1001-01F | Bolt, high-pressure pump to cylinder head cover | Nm | 14 |
| Number | Designation | Engine 274 in model 907 | |
|---|---|---|---|
| BA07.02-N-1002-01F | Bolt for high-pressure pump shielding | Nm | 20 |
| Number | Designation | Engine 274 in model 907 | ||
|---|---|---|---|---|
| BA07.03-N-1001-01H | Dust protection cap to service connection | Plastic | Nm | 2 |
| Metal | Nm | 15 | ||
| Number | Designation | Engine 274 in model 907 | ||
|---|---|---|---|---|
| BA07.03-N-1002-01H | Union nut, high-pressure line to rail | Stage 1 | Nm | 15 |
| Stage 2 | ∠ ° | 75 | ||
| Stage 3 | ∠ ° | 25 | ||
| Number | Designation | Engine 274 in model 907 | ||
|---|---|---|---|---|
| BA07.03-N-1003-01H | Union nut, high-pressure line to high pressure pump | Stage 1 | Nm | 15 |
| Stage 2 | ∠ ° | 75 | ||
| Stage 3 | ∠ ° | 25 | ||