Remove/install high-pressure pump - AR07.02-P-1020MT

ENGINE 270 in MODEL 117, 156, 176, 242, 246.2

Fig 1: Identifying High-Pressure Pump Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove/install
1	Clean area around the fuel high pressure circuit	Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system. Failure of the fuel injection system can occur otherwise.
2	Detach ground line from battery		AR54.10-P-0003NKB
2	Detach ground line from battery	The ground line on the battery must always be detached before beginning work on the fuel system otherwise the system pressure will be built up in the fuel system through opening a vehicle door or the trunk lid.
3	Lift vehicle on vehicle lift		AR00.60-P-1000AK
4	Open service flap on fender liner in right front fender
5	Rotate engine at crankshaft center bolt in direction of engine rotation to a 79° crank angle (CKA) after top dead center (ignition TDC) on cylinder 1	The 79° marking on belt pulley/vibration damper must be aligned with positioning edge on timing case cover.
6	Remove engine cover
7	Remove insulation (2) on high-pressure pump (1)
8	Disconnect electrical connection at quantity control valve (Y94)
9	Detach engine wiring harness at cylinder head cover and place to one side		AR01.00-P-2410-02MT
		Nut, circuit B+ to alternator	*BA15.40-P-1002-01F
		Nut, connection for terminal designation 30	*BA15.30-P-1001-01J
10	Detach low-pressure line at high-pressure pump (1)
11	Remove fuel pressure in fuel high-pressure circuit		AR07.03-P-1460-02MM
12	Remove high-pressure line (3) between rail (5) and high-pressure pump (1)	Mount high-pressure line (3).	AR07.03-P-1010-02MT
		Check high-pressure line (3)	AR07.03-P-1010-03MM
			AD00.00-P-2000-04A
		Do not kink or bend high-pressure line (3). Leaks or damage can occur otherwise. The sealing cone for the high-pressure lines (3) must be checked before assembly. The work instructions absolutely must be observed for assembly work.
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01F
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01F
		Assembly cleaner Checking of fuel high-pressure circuit must be carried out after repair: ↓	*BR00.45-Z-1028-04A
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
13	Remove screw/bolts (1s) for high-pressure pump (1)	The screw/bolts (1s) must screwed in and out by half a revolution alternately for removal or installation of the high-pressure pump (1). Damage could occur to the high-pressure pump (1) otherwise. Replace screw/bolts (1s) with new ones. The high-pressure pump (1) must lie flat on the cylinder head cover (6) after tightening the screw/bolts (1s).
13	Remove screw/bolts (1s) for high-pressure pump (1)	Bolt, high-pressure pump to cylinder head cover	*BA07.02-P-1003-01D
14	Remove high-pressure pump (1)	Replace sealing ring of the high-pressure pump (1). The sealing ring must not come into contact with the oil before inserting the high-pressure pump (1) in the cylinder head cover (6). The sealing ring will swell otherwise and leaks will occur. Clean mount for high-pressure pump (1) in cylinder head cover (6) and wet with silicone-free engine oil.
15	Pull tappet element (4) out of cylinder head cover (6)	The tappet element (4) must be installed in such a way that the drive roller for the tappet element (4) sits on the camshaft. Damage can occur to the camshaft otherwise.
	Check
16	Check tappet element (4) for wear, check for damage and replace if necessary
17	Install in the reverse order
18	Switch on ignition	The ignition must be switched on for 5 s before the engine start in order to fill the high-pressure pump (1) with fuel. Damage could occur to the high-pressure pump (1) otherwise.
	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
19	Perform an engine test run and check fuel system for proper operation and leaktightness

HIGH PRESSURE PUMP

Number	Designation		ENGINE 270
BA07.02-P-1003-01D	Bolt, high-pressure pump to cylinder head cover	Nm	14

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation			ENGINE 270
BA07.03-P-1001-01F	Union nut, fuel line to fuel distributor	Stage 1	Nm	15
		Stage 2	∠°	75
		Stage 3	∠°	25

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation			ENGINE 270
BA07.03-P-1002-01F	Union nut, fuel line to high-pressure pump	Stage 1	Nm	15
		Stage 2	∠°	75
		Stage 3	∠°	25

STARTER

Number	Designation		ENGINE 270
BA15.30-P-1001-01J	Nut, connection for terminal designation 30	Nm	15

ALTERNATOR

Number	Designation		ENGINE 270
BA15.40-P-1002-01F	Nut, circuit B+ to alternator	Nm	16

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG