Fuel Pressure Regulator: Service and Repair
WM 246319 Removing and installing high-pressure pump
Tools
Technical values
Preliminary work
1. Disconnect the battery.
-> 2X00IN02 Work instructions after disconnecting the battery Work Instructions After Disconnecting the Battery.
DANGER
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.
2. Lift the vehicle.
-> 4X00IN01 Lifting the vehicle Service and Repair.
WARNING
Hot fluid
- Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
3. Drain coolant.
-> 193817 Draining and filling coolant Service and Repair.
3.1. Pull off two big coolant hoses on the Henn couplings to the engine.
4. Lower the engine.
DANGER
Risk of engine falling down.
- Danger of fatal injury, material damage.
-> Support the engine with the prescribed tool.
-> 1001IN Lower the engine to complete other work 1001IN Lower the engine to complete other work.
4.1. For support, use Master Gear unit elevating platform WE 1206 in combination with retainer plate 9769 , support 9769/1 or support 9769/2.
4.2. Remove the rear axle cross member.
-> 420619 Remove and install rear axle cross member 420619 Removing and installing rear-axle cross member.
4.3. Remove transmission mount.
4.4. Lower the engine approx. 40 to 50 mm and slide to the rear approx. 40 mm with the lifting platform.
5. Remove coolant regulator housing cover.
-> 195519 Remove and install coolant regulator cover 195519 Removing and installing coolant regulator cover.
5.1. The cover can be removed from below, as the engine has now been lowered.
Removing high-pressure pump
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
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
1. Place a warning sign in a clearly visible position or on the vehicle.
Example of warning sign for naked flames
2. Remove structure protection -1-.
2.1. Unscrew three external Torx screws, two M6 x 25 and one M6 x 40, remove structure protection.
Structure protection
3. Release connector on flow control valve and pull it off.
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.
4. Remove fuel lines on high-pressure pump.
4.1. Loosen union nut (a/f 17) on low-pressure line -1- and unscrew by hand.
4.2. Loosen union nut (a/f 14) on high-pressure line -2- and unscrew by hand.
Fuel lines on high-pressure pump
5. Remove high-pressure pump.
5.1. Unscrew two M6 x 25 external Torx screws (E10) -3-.
View of high-pressure pump with structure protection
5.2. Pull high-pressure pump out of the fitting bore.
5.3. Mark position of the higher driver bit on the high-pressure pump with a coloured pen -arrow-. Do not turn driver.
Marking rotor position
6. Replace high-pressure pump O-ring.
Installing high-pressure pump
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
- Always perform a leak test in the high-pressure area after opening the fuel system. Testing and Inspection
- This is particularly important if components are disassembled and replaced.
- The threaded connections of the fuel lines must be coated with OKS 1700 lubricant (Part no. 000.043.207.36) before being screwed back on again.
- 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.
1. Clean sealing surfaces.
1.1. Grease high-pressure pump O-ring with a little Kluber Syntheso Glep (Part No. 000.043.204.68).
Information
Before installing the high-pressure pump, check the position of the driver and move it into installation position by hand if necessary.
Information
- Ensure everything is clean when working on the fuel system.
- Even the smallest particles of dirt can cause problems and damage to the high-pressure system.
2. Fit high-pressure pump.
2.1. Check the clutch position at the outlet sprocket. Check the deeper groove (approx. 13.5 mm) -arrow-.
Deep groove on outlet sprocket, side 1-3
2.2. Position the high-pressure pump driver -1- so that the high driving journal -A- engages in the deeper groove.
Positioning driver
2.3. Insert the high-pressure pump gently in the fitting bore on the cylinder head.
3. Fasten high-pressure pump and place fuel lines.
3.1. Coat fuel line union nuts and high-pressure pump screw sockets with lubricant OKS 1700 using a clean brush.
3.2. After positioning the high-pressure pump, fit the high-pressure line union nut first, then the low-pressure line union nut. Screw union nuts by hand as far as possible.
3.3. Fit and tighten M6 x 25 external Torx screws (E10) -1 and 2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Tightening sequence for high-pressure pump
4. Installing structure protection.
4.1. Position and tighten external Torx screws (E10) M6 x 40 -3- and M6 x 25 -4 and 5-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
5. Tighten union nut (a/f 14) on high-pressure line. Tool: Crow foot wrench Nr.195-1 -1-.
=> Tightening torque: 20 Nm (15 ftlb.)
High-pressure line fuel pump
6. Tighten union nut (a/f 17) on low-pressure line. Tool: Crow foot wrench Nr.195.
=> Tightening torque: 20 Nm (15 ftlb.)
Low-pressure line high-pressure pump
7. Plug in connector for flow control valve.
Subsequent work
1. Install coolant regulator cover. The coolant regulator cover can be installed from below, as the engine has now been lowered.
-> 195519 Remove and install coolant regulator cover 195519 Removing and installing coolant regulator cover.
WARNING
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
-> Perform leak test. Testing and Inspection
2. Checking fuel system for leaks.
-> 200101 Checking fuel system for leaks Testing and Inspection.
3. Lift and secure the engine (engine and transmission mount).
-> 1001IN Lower the engine to complete other work 1001IN Lower the engine to complete other work.
4. Fill in coolant and bleed the system.
-> 193817 Draining and filling coolant Service and Repair.
5. Connect the battery.
-> 2X00IN02 Work instructions after disconnecting the battery Work Instructions After Disconnecting the Battery.
6. Bleed the fuel system using the First Start function in the PIWIS Tester 9718.
-> 2001IN Bleed fuel system (First start function) Service and Repair.
7. If the high-pressure pump was replaced, a high-pressure adaptation is required.
-> 247019 Removing and installing DME (DFI) control unit Service and Repair.