246319 Removing and installing high-pressure pump
WM 246319 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.
2. Remove left cross panel. -> 508119 Removing and installing cross panel - section on "Removing" Service and Repair
Information
Component overview
High-pressure pump, turbo engine
High-pressure pump, naturally aspirated engine
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 vapours.
-> Attach warning sign in a clearly visible position.
NOTICE
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
- 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.
Information
- Do not bend high-pressure lines. Always remove the high-pressure distributor 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.
Information
- 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 depressurised 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. Read the information in the section -> 247019 Removing and installing DME control unit 247019 Removing and installing DME control unit.
1. Remove low-pressure line for the high-pressure pump at the fuel line transfer point -1-. Place cloths underneath. Counter with an open-ended wrench when doing this. Low-pressure line remains attached to the high-pressure pump.
Tank vent and fuel line
2. Remove crash panel for high-pressure pump. Very confined work area between high-pressure pump and plenum panel! For this reason, unscrew the three screws at the crash panel -arrows- using a straight ring wrench and remove with your fingertips. Turbo engine: The ATL vent line is secured under one screw.
Crash panel with engine removed
3. Undo high-pressure line at union nut on high-pressure pump. => High-pressure line
High-pressure line
4. Remove both hexagon-head union nuts -2 and 3- and the fastening screw -1- for the high-pressure pump.
Union nuts securing high-pressure pump
5. To make it easier to remove the high-pressure pump, unscrew the M8 screw socket used to secure the high-pressure line holder.
6. Carefully pull high-pressure pump out of cylinder head.
6.1. 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 twisting it between cylinder head and plenum panel.
Removing high-pressure pump
6.2. Turn high-pressure pump slightly, pull off cable plug for flow control valve. -arrow-
Cable plug for flow control valve
6.3. 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-
Oldham coupling for camshaft
7. In order to replace the high-pressure pump, the low-pressure line that is still fitted must be unscrewed. When re-installing the pump, the low-pressure line on naturally aspirated engines must be 5 to 8 mm away from the high-pressure line. On turbo engines, this gap must be 18 to 22 mm when the pump is installed.
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 vapours.
-> Attach warning sign in a clearly visible position.
NOTICE
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 distributor 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.
Information
- 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 depressurised 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.
Information
- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
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 on a naturally aspirated engine and at least 18 to 22 mm on a turbo engine. 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
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) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease for connection pieces and sealing rings in oily or water-carrying areas.
- Use "Kluber 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.
- "Kluberplus 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 Kluber Syntheso GLEP 1.
4. When installing the high-pressure pump, connect the cable plug for the flow control valve. -arrow-
Cable plug for flow control valve
5. Install high-pressure pump by turning it and position screw and union nut -1, 2 and 3-. When installed, the connecting elements are very difficult to access using a torque wrench. Careful tightening by hand is acceptable.
Union nuts securing high-pressure pump
6. Tighten M8 screw socket used to secure the high-pressure line holder.
7. Using the leak test equipment, blow the fuel out of the high-pressure pump.
8. Fit high-pressure line to the adapter for the high-pressure pump.
9. On naturally aspirated engines:Make sure to leave a gap of 5 to 8 mm -dimension X- to the low-pressure line.
Dimension -X-
10. On turbo engines:Make sure to leave a gap of 18 to 22 mm -dimension Y- to the low-pressure line. The resulting gap between the fuel hose and pressure sensor (in the vehicle) must be nominal 19.5 mm and minimum 15 mm.
Dimension -Y-
11. Tighten high-pressure line in three turns. Open-ended socket ring wrench Nr.185 must be used together with a torque wrench.
High-pressure line
12. Perform leak test on high-pressure pump. -> 243001 Checking fuel distributor pipe (high-pressure system) for leaks Testing and Inspection
13. Fit low-pressure line on adapter for fuel line according to the marking. Counter at the fuel line -1-. => Tightening torque: 35 Nm (26 ftlb.)
Tank vent and fuel line
14. Fit crash panel for high-pressure pump. Very confined work area between high-pressure pump and plenum panel! For this reason, position the three screws on the crash panel using your fingertips and fit using a straight ring wrench -arrows-. Turbo engine: The ATL vent line is secured under one screw.
Crash panel with engine removed
15. Inspect high-pressure system for leaks.
Subsequent work
1. Install left cross panel. -> 508119 Removing and installing cross panel - section on "Installing" Service and Repair
2. Fit the fuse for the fuel pump.
Information
Bleed the high-pressure system.
- Following disassembly work and a subsequent leak test on the high-pressure system, there will be air and gas cushions in the system.
- The bleeding process may take several minutes.
- Faults entries may be recorded in the engine control unit during the bleeding process. The engine switches to emergency operating mode.
- Erase the fault memory of the DME control unit repeatedly if necessary and bleed the system several times.
- The bleeding process is complete when the engine runs smoothly at idle speed and takes in gas in the correct manner.
- A test drive must then be carried out and the fault memory must be read out.
3. Bleed the fuel high-pressure system. -> 2430B1 Filling and bleeding the fuel high-pressure system (includes bleeding fuel distributor pipe) Service and Repair
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. Read the information in the section -> 247019 Removing and installing DME control unit 247019 Removing and installing DME control unit.
4. Reset the high-pressure adaptation values and then carry out an adaptation drive.