Fuel Pressure Regulator: Service and Repair

WM 246319 Removing and installing high-pressure pump - turbo engine

Tools





Technical values






Preliminary work

1. Disconnect the battery.
=> 2706IN00 Work instructions after disconnecting the battery.
2. Remove air cleaner housing.
=> 242519 Removing and installing air cleaner housing.
3. Drain coolant at the coolant regulator housing.
=> 193817 Draining and filling coolant - turbo engine (includes bleeding the system).
4. Remove rear silencer.
=> 263319 Removing and installing rear silencer - turbo engine.

Removing high-pressure pump

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





Component overview of high-pressure pump on turbo engine





1. Disconnect supply hose for coolant pump.
1.1. Open the spring band clamp -2- and pull off coolant hose -1-.





Coolant hose for coolant pump

2. Remove coolant pipe.
2.1. Unscrew external Torx screws (E10, M6 x 12) -1- and pull off coolant pipe -2-.





Coolant pipe mounting

3. Remove heat protection panel for high-pressure pump.
3.1. Disconnect cable plug for flow control valve -2- and unclip cable -2-.
3.2. Unscrew three external Torx screws (E10, M6 x 12) -3- and remove heat protection panel -4-.





Heat protection panel for high-pressure pump (naturally aspirated engine)

4. Remove cover for high-pressure pump.
4.1. Unscrew external Torx screws (E10) M6 x 25 -1- and (E10) M6 x 40 -2-.
4.2. Guide out cover for high-pressure pump.





High-pressure pump with cover

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

- If the union nuts on the fuel lines at the high-pressure pump cannot be screwed off by hand after loosening them, the relevant line must be replaced.

5. Remove fuel lines for high-pressure pump.
5.1. Loosen union nut on fuel low-pressure line (a/f 17) -1-.





Fuel lines for high-pressure pump (naturally aspirated engine)

5.2. Loosen union nut on fuel high-pressure line (a/f 14) -2-.
5.3. Screw off union nuts by hand. If this is not possible, the relevant fuel line must be replaced.
6. Remove high-pressure pump.
6.1. Unscrew external Torx screws (E10, M6 x 25) -3- used to secure the high-pressure pump.
6.2. Remove high-pressure pump.





High-pressure pump with cover

6.3. Replace O-ring.
7. Clean sealing faces on cylinder head.

Installing high-pressure pump

WARNING

Leaking fuel supply lines

- Emerging fuel
- Risk of fire

-> Perform leak test.

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.

1. Tools for fitting fuel lines:
1.1. Tool set 1:
Torque wrench with 3/8-inch head
Short 3/8-inch extension
Crow foot wrench Nr.195 , a/f 17
Crow foot wrench Nr.195-1 , a/f 14





High-pressure line for fuel pump

1.2. Tool set 2: Position of adapter with joint with respect to torque wrench: 90°





Using tool to tighten union nuts on fuel lines





Tightening sequence for high-pressure pump:





Tightening sequence for high-pressure pump

Information

Before installing the high-pressure pump, check the position of the driver and move it into installation position by hand if necessary.

Information

Always replace gaskets and O-rings.

- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).

2. Fit high-pressure pump.
2.1. Replace sealing ring on high-pressure pump and grease with the prescribed lubricant.
2.2. Position high-pressure pump. Position driver for mounting on the outlet camshaft.
There is no defined driver position required as on naturally aspirated engines!
2.3. Fit external Torx screws (E10, M6 x 25) -1 and 2- and tighten to the prescribed torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)

Information

- Always perform a leak test 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 1710 lubricant (Part No. 000.043.303.27) before being screwed back on again.

- Always allow a drying time of 60 minutes for the lubricant!

- Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation.

- The tightening specifications must be strictly observed.

3. Fit fuel lines on the high-pressure pump using a suitable tool.
3.1. Coat union nuts on fuel lines, cone and high-pressure pump screw sockets with lubricant OKS 1700.
3.2. Screw on union nut for fuel high-pressure line (a/f 14) -2- by hand and then tighten it.=> Tightening torque: 20 Nm (15 ftlb.)





Fuel lines for high-pressure pump

3.3. Screw on union nut for fuel low-pressure line (a/f 17) -1- by hand and tighten it. => Tightening torque: 20 Nm (15 ftlb.)
4. Perform leak test.
=> 200101 Checking fuel system (high-pressure side) for leaks - turbo engine.
5. Fit cover for high-pressure pump.
5.1. Guide in cover for high-pressure pump.
5.2. Screw in external Torx screws (E10) M6 x 40 -3- and (E10) M6 x 25 -4 and 5- and tighten to the prescribed tightening torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)
6. Fit heat protection panel for high-pressure pump.
6.1. Position heat protection panel -4- , screw in three external Torx screws (E10, M6 x 12) -3- and tighten to the prescribed torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)
6.2. Insert cable plug for flow control valve -2- and clip in cable -1-.





Heat protection panel for high-pressure pump (naturally aspirated engine)

Information

- Grease O-rings, hoses and lines in the cooling system with Kluber plus Gel (Part No. 000.043.205.93).

7. Fit coolant pipe.
7.1. Replace sealing ring on coolant pipe and grease with the prescribed lubricant.
7.2. Position coolant pipe -2- , screw in external Torx screws (E10, M6 x 12) -1- and tighten to the prescribed tightening torque.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Securing coolant pipe

8. Fit supply hose for coolant pump.
8.1. Push on coolant hose -1- and fit the spring band clamp -2-.





Coolant hose for coolant pump

Subsequent work

1. Install rear silencer.
=> 263319 Removing and installing rear silencer - turbo engine.
2. Fill in coolant.
=> 193817 Draining and filling coolant - turbo engine (includes bleeding the system).
3. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing.
4. Connect the battery.
=> 2706IN00 Work instructions after disconnecting the battery.
5. Start the system for the first time.
=> 2001IN Bleeding fuel system high-pressure side (First Start function).
6. If the high-pressure pump was replaced, a high-pressure adaptation is required.
=> 247019 Removing and installing DME (DFI) control unit.