|
Replace high-pressure pump
 Remove
| 2. |
Disconnect battery
| • |
Detach ground connection from ground terminal
|
|
| 3. |
Remove engine cover (1)
| • |
Unclip engine vent hose from bracket (2)
|
| • |
Unscrew oil filler cap (5)
|
| • |
Screw on oil filler cap
Note: Re-attach any
retaining rubbers (3) to the engine cover which may have become
detached
|
|
|
|
| 4. |
Remove air cleaner housing
|
| 5. |
Raise vehicle by its full height
|
| 6. |
Remove lower engine compartment cover and/or right-hand engine
splash guard
|
| 7. |
Place collecting basin underneath.
|
| 8. |
Detach fuel return damping case (2)
| • |
Unclip wiring harness from bracket
|
| • |
Disconnect high-pressure pump wiring harness plug
|
| • |
Unclip 2x fuel lines from bulkhead bracket
|
| • |
Unclip fuel return line from bracket
|
| • |
Remove fuel return line (4) with KM-796-A
|
| • |
Disconnect oil leak line (3)
|
| • |
Unscrew 2x bolts (arrows)
|
|
|
|
| 9. |
Detach high-pressure pump fuel supply line (1)
|
| 10. |
Disconnect high-pressure pump wiring harness plug (2)
|
|
|
| 11. |
Remove high pressure line (1) from high pressure pump to
pressure chamber
Important: When releasing the
union nut, counterhold with open-ended wrench against the
connection for the diesel high pressure fuel pump
|
| • |
Unscrew 2x union nuts
Note: Seal pressure
chamber, high-pressure pump and high-pressure line with sealing cap
from kit (part number 9201697)
|
|
|
|
| 12. |
Remove upper toothed belt cover
| • |
Unscrew 4x bolts (1) with EN-47631
|
|
|
|
| 13. |
Release wiring harness diesel electronics from intake
manifold
| • |
Disconnect wiring harness plug from injector 1
|
|
| 14. |
Detach wiring harness bracket
|
Important: The retaining bolt
must be 40 mm long. The thread may be no more than 10 mm, otherwise
the sliding of the high pressure pump drive gear on the bolts
cannot be guaranteed.
|
| 15. |
Adjust high-pressure pump
| • |
Turn the steering wheel to the right
|
| • |
Rotate the engine at the crankshaft in the direction of engine
rotation until the retaining bolts (1) M6x40 in the high-pressure
pump bracket can be turned
|
|
| 16. |
Release high-pressure pump drive gear
|
|
|
| 17. |
Slacken high pressure pump
| • |
Unscrew 3x nuts (1)
Note: Place cloths
under the high-pressure pump to prevent the loss of nuts
|
|
|
|
Important: Make absolutely
certain that the shaft of the high-pressure pump is not turned.
|
| 18. |
Remove high pressure pump
| • |
Press completely off the high-pressure pump wheel using EN-46790
|
|
|
|
Install
| 19. |
Install high pressure pump
| • |
Tighten 3x new nut 25 Nm
|
|
Important: Slide the
high-pressure pump drive gear onto the high-pressure pump shaft by
hand
|
| 20. |
Fasten the high-pressure pump drive gear
|
| 21. |
Unscrew the retaining bolt from the high-pressure pump drive
gear
|
| 22. |
Install wiring harness bracket
|
| 23. |
Attach wiring harness diesel electronics to intake manifold
| • |
Connect wiring harness plug to injector 1
|
|
Important: Check the
high-pressure pump wheel for fractures and cracks
|
| 24. |
Install upper toothed belt cover
| • |
Tighten 4x bolts with EN-47631
|
|
| 25. |
Install high-pressure line of high-pressure pump to pressure
chamber
Note: Use new high
pressure lines
| • |
Tighten 2x retaining nut
|
|
| 26. |
Connect high-pressure pump wiring harness plugs
|
| 27. |
Attach high-pressure pump fuel supply line
|
| 28. |
Attach fuel return damping case
| • |
Attach fuel return line
Note: Must engage
audibly
|
|
| 29. |
Install air cleaner housing 
|
| 31. |
Raise vehicle by its full height
|
| 32. |
Attach water drain hose of air cleaner housing
|
| 33. |
Install lower engine cover and right engine splash guard
|
| 34. |
Lower vehicle by its full height
|
| 35. |
Connect battery
| • |
Attach ground connection to ground terminal
|
|
| 36. |
Program volatile memories
|
|
