Remove/Install High-Pressure Fuel Pump - AR07.02-P-1020MSA
Engine 256.9 in model 213, 238, 257, 290
MODIFICATION NOTES
| 11.12.2019 | Union nut, high-pressure line to fuel distributor/fuel high-pressure pump | BA07.03-P-1001-01MRT |
| 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 | |
| Topical note | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Topical note | 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 | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove/install | |||
| 1 | Remove fan unit. | AR20.40-P-5050MSA | |
| 2 | Mount protective plate on cooler. | ||
| WF58.50-P-0110-04A | |||
| 3 | Remove charge-air distributor. | AR09.41-P-8683MSA | |
| 4 | Rotate engine in direction of engine rotation to a crank angle of 120° after ignition TDC. | ||
| Fig 4 | |||
| 5 | Remove bolts (5). | *BA07.03-P-1007-01MRT | |
| 6 | Remove screws (3) and remove supporting plate (2). | *BA07.02-P-1006-01MRT | |
| 7 | Remove coolant hose from coolant line (9). | AR20.20-P-7441-01RQ | |
| 8 | Remove screw (8), remove coolant line (9) and seal opening on cylinder head (12). | ||
| *BA20.20-P-1001-02MRT | |||
| Fig 2 | |||
| 9 | Remove noise insulation (6). | ||
| 10 | Clean the environment around the high-pressure pump (1), low-pressure line (7) and high-pressure line (10). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 11 | Release and disconnect electrical connector a quantity control valve (Y94). | ||
| 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 | |
| 12 | Remove high-pressure line (10) from high-pressure pump (1) and catch escaping fuel with a lint-free rag. | Do not bend or kink high-pressure line (10). Leaks can occur otherwise. |
|
| *BA07.03-P-1001-01MRT | |||
| Fig 5 | |||
| Fig 3 | |||
| 13 | Remove screw (13). | *BA07.03-P-1007-01MRT | |
| 14 | Remove low-pressure line (7) from high-pressure pump (1) and seal openings with suitable stop plugs. | Do not bend of kink low-pressure line (7). Leaks can occur otherwise. |
|
| *BA07.03-P-1006-01MRT | |||
| Fig 5 | |||
| Fig 3 | |||
| 15 | Remove screws (11). | Remove screws (11) alternately by one revolution each. The high-pressure pump (1) may otherwise be damaged. |
|
| *BA07.02-P-1001-01MRT | |||
| 16 | Remove high-pressure pump (1). | ||
| Check | |||
| 17 | Check high-pressure line (10). | AR07.03-P-1010-03MRT | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 18 | Check low-pressure line (7). | Assembly cleaner | AR07.03-P-1120-01MRT |
| 19 | Install in the reverse order. | *BR00.45-Z-1028-04A | |
| Check | |||
| 20 | Switch on ignition. | Prior to starting the engine, switch on the ignition for 5 s and fill the high-pressure pump (1) with fuel. The high-pressure pump (1) will be damaged otherwise. |
|
| 21 | Check high-pressure fuel circuit. | ||
| Engine 256.9 in model 213 | AD00.00-P-2000-04B | ||
| Engine 256.9 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 256.9 in model 257, 290 | AD00.00-P-2000-06FR | ||
| AR07.03-P-1010-04MM | |||
| 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 | |
| 22 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 23 | Install lower engine compartment lining. | Engine 256.9 in model 213, 238 | AR61.20-P-1105LWE |
| Engine 256.9 in model 290 | AR61.20-P-1105FRX | ||
| Engine 256.9 in model 257 | AR61.20-P-1105FR | ||
| 24 | Install upper engine cover. | AR01.10-P-2405MSA |
HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.02-P-1001-01MRT | Screw/bolt, high pressure fuel pump to housing | Nm | 8 |
HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.02-P-1006-01MRT | Screw, shield to fuel high-pressure pump housing/support plate | Nm | 8 |
HIGH-PRESSURE LINE, LOW-PRESSURE LINE, FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | |||
|---|---|---|---|---|---|
| BA07.03-P-1001-01MRT | Union nut, high-pressure line to fuel distributor/fuel high-pressure pump | In case of reusability | Nm | 18 | |
| For new lines | Stage 1 | Nm | 15 | ||
| Stage 2 | ∠° | 90 | |||
HIGH-PRESSURE LINE, LOW-PRESSURE LINE, FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | ||
|---|---|---|---|---|
| BA07.03-P-1006-01MRT | Union nut, low-pressure line to fuel high-pressure pump | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
HIGH-PRESSURE LINE, LOW-PRESSURE LINE, FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.03-P-1007-01MRT | Bolt, holder for low-pressure line to shield/supporting plate | Nm | 8 |
ENGINE RADIATOR, COOLANT HOSES AND LINES
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA20.20-P-1001-02MRT | Screw, coolant feed pipe to cylinder head/crankcase | Nm | 8 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |