246319 Removing and installing DFI high-pressure pump
WM 246319 Removing and installing DFI 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. => 200201 Checking fuel pressure (low pressure) on DFI engines or => 206601 Checking fuel delivery rate (low pressure delivery rate) on DFI engines
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.
1. Remove engine compartment cover at the plenum panel at the middle and left. => 700219 Removing and installing front trim (engine compartment) - section on "Removing"
2. Move bonnet into service position => 553119 Removing and installing front gas spring. While doing this, remove engine compartment rubber seal from the plenum panel => 553319 Removing and installing front lid seal - section on "Removing".
3. Remove cover of plenum panel. => 664419 Removing and installing cowl panel cover - section on "Removing"
4. Pull out the fuses for the two fuel pumps. This stops the fuel pumps from starting up when a door is opened.
5. Remove plenum panel wall on the left.
Plenum panel wall on left
5.1. Release oxygen sensor connector from the bracket on the plenum panel wall -1-. Unclip cable. -2-
5.2. Release PDCC reservoir from plenum panel, if fitted.
5.3. Unscrew three screws on the plenum panel. -3-
5.4. Pull plenum panel up and off.
Information
Component overview
High-pressure pump, Turbo M48/51
High-pressure pump for naturally aspirated engine, M48/01
Removing high-pressure pump
DANGER
Danger of poisoning from fuels.
-> Gasoline is toxic.
-> Inhaling vapours can cause irritation of the mucous membranes and eyes.
-> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
-> Only work on the fuel system in well-ventilated rooms.
-> Wear protective gloves that are fuel-resistant.
-> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
-> Ensure that there is adequate ventilation and extract all fuel vapours.
-> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
-> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
-> Pay attention to cleanliness when working on the fuel system.
DANGER
Danger of fire from fuel.
-> Keep clear of ignition sources.
-> Do not smoke.
-> Disconnect battery.
-> Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
-> Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
-> Secure the vehicle, e.g. with a warning sign.
-> Change any clothing soaked with fuel immediately.
-> In case of fire, use CO2 or dry powder fire extinguishers.
CAUTION
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.
CAUTION
Danger of fire from leaking high-pressure lines.
- Fuel can leak out if high-pressure lines are bent or damaged.
- Fuel can leak out if threaded joints are not fitted correctly.
- Fuel can leak out if the tightening specifications are not observed.
-> Never bend high-pressure lines.
-> The high-pressure distribution pipe (rail) or other fuel feed components in the high-pressure area must always be completely removed.
-> Perform a visual inspection to ensure that connection points are undamaged and perfectly clean.
-> Check that threaded joints at connection points are not seized up or corroded. Make sure the thread is not damaged.
-> Fit union nuts on all connection points by hand before screwing in screws or bolts.
-> Pay attention to cleanliness. Remove dirt on the ball/conical joints.
-> Check or inspect connection points for leaks following assembly.
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 => 24701900 Removing and installing DME (DFI) control unit.
1. Remove low-pressure line for high-pressure pump at 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. Disconnect cable for fuel temperature sensor -1- and unclip cable. -2-
Low-pressure temperature sensor
3. 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: The ATL vent line is secured under one screw.
Crash panel with engine removed
4. Undo high-pressure line at union nut on high-pressure pump. => High-pressure line
High-pressure line
5. Turbo: Pull out wire harness at the plenum panel and lay it to one side. Pull off cable plug for hall sender.
6. 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
7. Carefully pull high-pressure pump out of cylinder head.
7.1. 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
7.2. Turn high-pressure pump slightly, pull off cable plug for flow control valve. -arrow-
Cable plug for flow control valve
7.3. 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
8. 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 must be at a distance of 5 to 8 mm from the high-pressure line.
Installing high-pressure pump
DANGER
Danger of poisoning from fuels.
-> Gasoline is toxic.
-> Inhaling vapours can cause irritation of the mucous membranes and eyes.
-> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
-> Only work on the fuel system in well-ventilated rooms.
-> Wear protective gloves that are fuel-resistant.
-> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
-> Ensure that there is adequate ventilation and extract all fuel vapours.
-> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
-> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
-> Pay attention to cleanliness when working on the fuel system.
DANGER
Danger of fire from fuel.
-> Keep clear of ignition sources.
-> Do not smoke.
-> Disconnect battery.
-> Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
-> Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
-> Secure the vehicle, e.g. with a warning sign.
-> Change any clothing soaked with fuel immediately.
-> In case of fire, use CO2 or dry powder fire extinguishers.
CAUTION
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.
CAUTION
Danger of fire from leaking high-pressure lines.
- Fuel can leak out if high-pressure lines are bent or damaged.
- Fuel can leak out if threaded joints are not fitted correctly.
- Fuel can leak out if the tightening specifications are not observed.
-> Never bend high-pressure lines.
-> The high-pressure distribution pipe (rail) or other fuel feed components in the high-pressure area must always be completely removed.
-> Perform a visual inspection to ensure that connection points are undamaged and perfectly clean.
-> Check that threaded joints at connection points are not seized up or corroded. Make sure the thread is not damaged.
-> Fit union nuts on all connection points by hand before screwing in screws or bolts.
-> Pay attention to cleanliness. Remove dirt on the ball/conical joints.
-> Check or inspect connection points for leaks following assembly.
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 => 24701900 Removing and installing DME (DFI) control unit.
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. See assembly overview => 246319 Removing and installing high-pressure pump on DFI engines - section on "Information".
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 that can be used 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 on high-pressure pump and grease 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 while 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. => Tightening torque: 10 Nm (7.5 ftlb.)
Union nuts securing high-pressure pump
6. Loosen eyelet on cylinder side 5 to 8 and fold to the side -2-. Eyelet prevents the torque wrench from engaging.
Bar ignition modules and valve cover, cylinder bank 5 to 8
7. Using the leak test equipment, blow the fuel out of the high-pressure pump. => 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks
8. Fit high-pressure line to the adapter for the high-pressure pump. Allow a gap of 5 to 8 mm to the low-pressure line. Tighten high-pressure line in three stages. Open-ended socket ring wrench Nr.185 and torque wrench must be used.=> Tightening torque: 25 Nm (19 ftlb.) , then loosen, => Tightening torque: 25 Nm (19 ftlb.)
High-pressure line
9. Perform leak test on high-pressure pump. => 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks
10. Connect cable plug for temperature sensor -1-. Clip in cable. -2-
Low-pressure temperature sensor
11. 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
12. 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: The ATL vent line is secured under one screw. => Tightening torque: 10 Nm (7.5 ftlb.)
Crash panel with engine removed
13. Turbo: Fit wire harness to plenum panel. Connect cable plug to hall sender.
14. Tighten eyelet. => Tightening torque: 23 Nm (17 ftlb.)
Subsequent work
1. Fit plenum panel wall on the left.
Plenum panel wall on left
1.1. Pre-fit seal for plenum panel on vehicle-side part of bulkhead and spray with silicone spray.
1.2. Press in plenum panel until the screw positions are seated correctly.
1.3. Fit three screws for the plenum panel. -3- => Tightening torque: 9 Nm (6.5 ftlb.)
1.4. Fit oxygen sensor connector to plenum panel wall. Clip in cable. -1 and 2-
1.5. Secure PDCC reservoir to the plenum panel, if this reservoir is to be fitted.
2. Fit cover for plenum panel. => 664419 Removing and installing cowl panel cover - section on "Installing"
3. Fit engine compartment cover at the plenum panel at the middle and left. => 700219 Removing and installing front trim (engine compartment) - section on "Installing"
4. Dismantle service position of bonnet.=> 553119 Removing and installing front gas spring. Fit engine compartment rubber seal onto plenum panel.
5. Fit the fuses for the two fuel pumps.
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.
6. Bleed the fuel high-pressure system. => 2430B1 Filling and bleeding the DFI fuel high-pressure system (includes bleeding fuel distribution pipe)
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 => 24701900 Removing and installing DME (DFI) control unit.
7. Reset the high-pressure adaptation values and then carry out an adaptation drive.