Removing and Installing High-Pressure Pump

Removing And Installing High-pressure Pump

Tools

Part 1:

Part 2:

Technical values







Preliminary work
1. Relieve the fuel pressure.
1.1. Pull out the fuse for the fuel pump in the fuse carrier (passenger compartment at the bottom left, row D, first retainer from the left).
1.2. Start the engine and allow to run until it cuts out.
1.3. Re-insert the fuse.

2. Disconnect the battery.

DANGER:
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.

3. Lift the vehicle.

WARNING:
Hot fluid
- Danger of scalding
- Let the fluid cool down.
- Wear personal protective gear.

4. Drain coolant.
4.1. Pull off the two big coolant hoses on the Henn couplings to the engine.

5. Lower the engine.

DANGER:
Risk of engine falling down.
- Danger of fatal injury, material damage.
- Support the engine with the prescribed tool.

5.1. For support, use Master Gear unit elevating platform WE 1206 in combination with retainer plate 9769, support 9769/1 or support 9769/2.
5.2. Remove the rear axle cross member.
5.3. Remove transmission mount.
5.4. Lower the engine approx. 40 to 50 mm and slide to the rear approx. 40 mm with the lifting platform.

6. Remove coolant regulator housing cover.
6.1. The cover can be removed from below, as the engine has now been lowered.

Removal

Removing high-pressure pump

WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.

INFORMATION:
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E..) for external Torx, (T..) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

Component overview












1. Place a warning sign in a clearly visible position or on the vehicle.
2. Remove structure protection -1-.







2.1. Unscrew three external Torx screws, two M6 x 25 and one M6 x 40, remove structure protection.

3. Release connector on flow control valve and pull it off.
4. Remove fuel lines on high-pressure pump.
4.1. Unscrew union nut (A/f 17) of low-pressure line -1-.







4.2. Unscrew union nut (A/f 14) of high-pressure line -2-.

5. Remove high-pressure pump.







5.1. Unscrew two M6 x 25 outer Torx screws (E10) -3-.
5.2. Pull high-pressure pump out of the fitting bore.







5.3. Mark position of the higher driver bit on the high-pressure pump with a coloured pen -arrow-. Do not turn driver.

6. Replace high-pressure pump O-ring.

Installation

Installing high-pressure pump

WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.

INFORMATION:
- A leak test must always be performed in the high-pressure area after opening the fuel system.
- This is particularly important if components are disassembled and replaced.
- The threaded connections of the fuel lines must be coated with OKS 1700 lubricant (Part no. 000.043.207.36) before being screwed back on again.
- The tightening specifications must be strictly observed.
- Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation.

1. Clean sealing surfaces.
1.1. Grease high-pressure pump O-ring with a little Kluber Syntheso Glep (Part No. 000.043.204.68).

INFORMATION:
- Before installing the high-pressure pump, check the position of the drivers and move them into installation position by hand if necessary.
- Ensure everything is clean when working on the fuel system.
- Even the smallest particles of dirt can cause problems and damage to the high-pressure system.

2. Fit high-pressure pump.







2.1. Check the clutch position on the exhaust sprocket. Observe deeper groove (15 mm) -arrow-.







2.2. Place the high-pressure pump so that the high pin -arrow- engages in the 15 mm groove.
2.3. Insert the high-pressure pump firmly in the fitting bore on the cylinder head.

3. Fasten high-pressure pump and place fuel lines.
3.1. After positioning the high-pressure pump, fit the high-pressure line union nut first, then the low-pressure line union nut. Screw union nuts by hand as far as possible.
3.2. Coat fuel line union nuts and high-pressure pump screw sockets with lubricant OKS 1700 using a clean brush.







3.3. Fit and tighten M6 x 25 outer Torx screws (E10) -1 and 2-. - Tightening torque: 13 Nm (9.5 ft. lbs.)

4. Installing structure protection.
4.1. Position and tighten M6 x 40 -3- and M6 x 25 -4 and 5- outer Torx screws (E10). - Tightening torque: 13 Nm (9.5 ft. lbs.)







5. Tighten union nut (A/f 14) of high-pressure line. Tool insert: Open-end/ring wrench insert Nr.185 -1-. - Tightening torque: 20 Nm (15 ft. lbs.)







6. Tighten union nut (A/f 17) of low-pressure line. Tool: Open-end/ring wrench insert Nr.196-1. - Tightening torque: 20 Nm (15 ft. lbs.)
7. Plug in connector for flow control valve.

Subsequent work
1. Install coolant regulator cover. The coolant regulator cover can be installed from below, as the engine has now been lowered.

WARNING:
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
- Perform leak test.

2. Checking fuel system for leaks.
3. Lift and fasten engine (engine and transmission mount).
4. Fill in coolant and bleed the system.
5. Connect the battery.