Remove/Install High-Pressure Pump - Ar07.02-D-1020SF

ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig 1: High-Pressure Pump Remove/Install Component Locations

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

20.9.09

Connect Star Diagnosis and teaching in quantity control valve added

Step 12

	Remove/install
	Risk of explosion. Fuel may ignite and explode. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.	Keep all ignition sources out of hazard area. Do not carry out any work on systems when they are under pressure
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01SM
1	Remove fan shroud		AR20.40-D-6800SF
2	Remove coolant hose (9) from bracket (10) and press toward rear	On engine 642.896/898
3	Expose electrical line and disconnect electrical connector (7) from quantity control valve (Y94 or Y94/4)
4	Disconnect electrical connector (4) from fuel temperature sensor (B50 or B50/6)
5	Remove fuel hoses (2, 3) from high-pressure pump (1)	Close off fuel hose (2, 3) using suitable stop plug. Collect escaping fuel. Installation: Check condition of clamps and fuel hoses (2, 3); replace if necessary.
			Fig 2
6	Unscrew pressure line (5) from high-pressure fitting (6) on high-pressure pump (1) and push up slightly	Counterhold high-pressure fitting (6) when loosening pressure line (5) Do not crimp or bend pressure line (5). Plug pressure line (5) and high-pressure fitting (6) in high-pressure pump (1) with suitable stop plug. Installation: Check pressure line (5) sealing cone; replace pressure line (5) if necessary. Ensure correct seating of the pressure line (5).
			BA07.16-N-1008-01B
			Fig 2
7	Unscrew high-pressure fitting (6) from high-pressure pump (1)	Only if high-pressure fitting (6) is loose or leaky Installation: Replace sealing ring and tighten high-pressure fitting (6).
			BA07.16-N-1008-01B
8	Unscrew bolts (8) for high pressure pump (1)		BA07.16-N-1008-01B
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
9	Remove high-pressure pump (1)	Installation: Clean sealing surfaces on high-pressure pump (1), replace sealing ring (11) and moisten with engine oil. Align drive gear (12) to camshaft.
10	Remove drive gear (12) for high-pressure pump ()1	Only when replacing high pressure pump (1).	AR07.02-D-1021SF
11	Install in the reverse order
12	Connect Star Diagnosis and teach in quantity control valve (Y94 or Y94/4)	Only when replacing high pressure pump (1).
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-D-2000-04SD
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
13	Test run engine and check engine for leaks in the area of high-pressure pump (1)	If the high-pressure pump (1) was replaced, fill new high-pressure pump (1) with fuel by switching on the ignition for at least 15 s before starting the engine, otherwise the high-pressure pump (1) can be damaged.

HIGH-PRESSURE PUMP TORQUE SPECIFICATIONS - ENGINE 642.896/898/992/993

Number	Designation				Engine 642.896/898/992/993
BA07.16-N-1004-01B	Bolt, high-pressure pump to cylinder head			Nm	14
BA07.16-N-1008-01B	Pressure line to high-pressure pump	M14x1.5	Stage 1	Nm	20
BA07.16-N-1008-01B			Stage 2	Degrees	60
BA07.16-N-1017-01B	High pressure fitting on the high pressure pump			Nm	55

Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA