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Removing and Installing High-Pressure Pump



Removing And Installing High-pressure Pump

Tools







Technical values







Preliminary work

INFORMATION: Before replacing the high-pressure pump if you suspect that it is faulty, check the performance of the fuel pumps in the tank. (Low-pressure test).

1. Pull out the fuse for the fuel pump. This ensures that the fuel pump will not start up when a door is opened. Fuse box at right of dashboard, slot 47.
2. Disassemble the plenum panel (remove cross panel).

Information

Component overview










Removing high-pressure pump

WARNING:
- Toxic substances
- Danger of poisoning or suffocation
- Ventilate the work area well.
- Never ingest or inhale.
- Read specific information on the Hazard Sheet.
- Wear personal protective gear.

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 vapors.
- Attach warning sign in a clearly visible position.

NOTE:
- Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
- Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
- Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
- Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
- Only install clean parts. Do not take spare parts out of the packaging until just before installation.
- Never use compressed air when the system is open. Do not move the vehicle.

INFORMATION:
- High-pressure pumps replaced under warranty must be sent in with protection caps (on the pump connections). Use protection caps from the new pump. Intrusion of dirt must be avoided.
- Possible intrusion of dirt in the pump is not acceptable as the reason for defective high-pressure pumps. The warranty claim will be rejected.
- Do not bend high-pressure lines. Always remove the high-pressure distribution pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.







1. Remove holder for cooling water tube -7-. To do this, remove hexagon-head bolt -6-.










2. Remove crash panel for high-pressure pump. To do this, unscrew the three screws on the crash panel and remove it. Turbo engine -7- or naturally aspirated engine -7-
3. Disconnect low-pressure line and high-pressure line at the high-pressure pump. Turbo engine -2 and 4- or naturally aspirated engine -2 and 4-. Place cloths underneath. Counter with an open-ended wrench when doing this. The tool open-ended socket ring wrench Nr.98-1 Pos.1 with adapter Nr.98-1 Pos.2 can be used if necessary.
4. Remove the three union nuts (Turbo engine -6- or naturally aspirated engine -6- ).
5. Carefully remove the high-pressure pump from the cylinder head.







5.1. To do this, you will need to overcome the resistance of the sealing ring. Carefully lever off high-pressure pump with a screwdriver -> Removing high-pressure pump. Remove high-pressure pump by turning it.







5.2. Turn high-pressure pump slightly and pull off cable plug for flow control valve. -arrow-







5.3. The Oldham coupling between the inlet camshaft and high-pressure pump remains in the camshaft because of a loss preventer -1-. Oldham coupling has symmetrical chamfers for the drivers on the high-pressure pump. -2-

Installing high-pressure pump


WARNING:
- Toxic substances
- Danger of poisoning or suffocation
- Ventilate the work area well.
- Never ingest or inhale.
- Read specific information on the Hazard Sheet.
- Wear personal protective gear.

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 vapors.
- Attach warning sign in a clearly visible position.


NOTE:
- Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
- Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
- Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
- Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
- Only install clean parts. Do not take spare parts out of the packaging until just before installation.
- Never use compressed air when the system is open. Do not move the vehicle.

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

INFORMATION:
- Do not bend high-pressure lines. Always remove the high-pressure distribution pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.

INFORMATION:
- Following replacement of the high-pressure pump and engine, the values for the high-pressure adaptation must be reset using the PIWIS Tester. Then carry out a test and adaptation drive.
- The tightening specifications for the basic engine are stored centrally.
- If the fitting in the high-pressure pump is loosened accidentally, tighten it to -> Tightening torque: 35 Nm (26 ftlb.). When re-installing the low-pressure line on the high-pressure pump, the distance from the high-pressure line must be set to at least 5 to 8 mm. Refer to the component overview above.







1. When re-installing a used high-pressure pump, check the drive coupling and Oldham coupling - using a mirror - for signs of wear. -> Oldham coupling for camshaft
2. Using a mirror, check the position of the Oldham coupling of the inlet camshaft and turn the drive coupling for the high-pressure pump to the correct installation position by hand.

INFORMATION:
- 000 043 204 68 (Status 02/07) "Kl�ber Syntheso GLEP 1" is a neutral-reaction assembly grease that can be used for connection pieces and sealing rings in oily or water-carrying areas.
- Use "Kl�ber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
- "Kl�berplus S06 100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.

3. Replace sealing ring for high-pressure pump and grease lightly using Kl�ber Syntheso GLEP 1.







4. When installing the high-pressure pump, connect the cable plug for the flow control valve. -arrow-










5. Install high-pressure pump while turning it and fit union nut (Turbo engine -6- and naturally aspirated engine -6- ).
6. Screw on low-pressure line. Turbo engine -4- or naturally aspirated engine -4-. The tool open-ended socket ring wrench Nr.98-1 Pos.1 with adapter Nr.98-1 Pos.2 can be used if necessary.
7. Using the leak test equipment, blow the fuel out of the high-pressure pump.







8. Place high-pressure line on adapter for high-pressure pump. Maintain a distance of 5 to 8 mm from the low-pressure line. Tighten high-pressure line in three stages. Open-ended socket ring wrench Nr.185 must be used together with a torque wrench. The tool open-ended socket ring wrench Nr.98-1 Pos.1 with adapter Nr.98-1 Pos.2 can be used if necessary.
9. Perform leak test on high-pressure pump.
10. Fit crash panel for high-pressure pump. To do this, position and fit the three screws on the crash panel.







11. Fit holder for cooling water tube -7-. To do this, fit a hexagon-head bolt -6-. -> Tightening torque: 10 Nm (7.5 ftlb.)

Subsequent work

1. Assemble plenum panel (fit cross panel).
2. Fit the fuse for the fuel pump.
3. Bleed the fuel high-pressure system. Erase the fault memory if necessary.
4. Reset the high-pressure adaptation values and then carry out an adaptation drive. Carry out instructions in the same way as for replacing the DME control unit.
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