Special tool
 | Hand vacuum/pressure pump 23-036A (416-D001) |
 | High pressure fuel pump pulley puller 310-095 (23-067) |
Withdrawal
All cars
1.
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.
Remove the timing belt. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
2.
CAUTION: Protect generator from contamination. Failure to follow this instruction may result in premature generator failure.
Cover the generator with lint-free material to prevent contamination.
3. Disconnect the high pressure fuel lines.
4. Remove the high pressure fuel lines and discard them as no longer needed.
5. Raise and support the vehicle.
6. Remove the generator plug cover.
7. Disunite shtekerny sockets of the generator.
Vehicles with an air conditioning system.
8. Disconnect the air conditioning compressor and secure it to the side.
All cars
9. Remove the generator.
10. Remove the alternator support bracket.
11. Remove the high pressure fuel pump bracket. Turn out four bolts and remove one nut.
12. Lower the car.
13.
NOTE: The high pressure fuel pump pulley seals against the fuel pump sprocket.
Turn out bolts of fastening of a pulley of the fuel pump of a high pressure.
14. Remove the high pressure fuel pump pulley.
- Insert the special tool into the bolt hole in the high pressure fuel pump pulley.
- Press the special tool in the direction of the high pressure fuel pump and at the same time screw in the pin of the special tool until the high pressure fuel pump pulley is released.
15. Remove and discard high pressure fuel pump seal.
16.
NOTE: Fuel line connectors are painted white or identified by a white rim. Fuel return line connectors are colored red or identified by a red rim.
Disconnect the supply and return fuel lines.
- 1. Pull on the clip to release the latch.
- 2. Lift the connector to free the line.
17. Disconnect the plug connector of the high pressure fuel pump control unit.
- 1. Pull on the clip to release the latch.
- 2. Remove the plug.
18. Turn out bolts of an asterisk of the fuel pump of a high pressure.
19.
NOTE: Access to bolts is provided through holes. The high pressure fuel pump bolts cannot be completely removed.
Remove the high pressure fuel pump.
20. Remove and discard the high pressure fuel pump gasket as unnecessary.
Installation
All cars
1.
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.
NOTE: Install new high pressure fuel lines.
NOTE: Install a new high pressure fuel pump seal.
NOTE: Install a new high pressure fuel pump gasket.
NOTE: A new high pressure fuel pump may be shipped locked or unlocked. This can be determined by inspecting the injection pump drive shaft lock bolt. The blocked high pressure fuel pump is equipped with a hex bolt and comes with a spacer. The unlocked high pressure fuel pump is fitted with a hex socket bolt and does not have any spacer. A blocked fuel pump drive shaft must not be rotated.
NOTE: Using a 6mm drill, adjust the position of the high pressure fuel pump relative to the crankshaft.
Install the high pressure fuel pump.
2. Install the high pressure fuel pump sprocket bolts.
3. Remove the drill.
4.
NOTE: If the high pressure fuel pump is shipped unlocked, no spacer is required.
Install the provided spacer between the high pressure fuel pump drive shaft hex lock bolt and the high pressure fuel pump (in the presence of).
5. Install a new high pressure fuel pump seal.
6. Connect the plug connector of the control unit to the high pressure fuel pump.
7. Install the fuel supply line.
- 1. Rotate the clip to lock the latch.
8.
NOTE: Seal the high pressure fuel pump pulley against the pump sprocket with Loctite RTV 5910.
NOTE: Apply Loctite 518 to the outer edges of the injection pump pulley bolt holes.
Install the high pressure fuel pump pulley.
9. Install the high pressure fuel pump bracket.
10. Raise and support the vehicle.
11. Install the generator support bracket.
12. Install the generator.
Vehicles with air conditioning
13. Install the air conditioning compressor.
All cars
14. Install the alternator connectors.
15. Install the generator plug cover.
16. Lower the car.
17.
CAUTION: Protect generator from contamination. Failure to follow this instruction may result in premature generator failure.
Cover the generator with lint-free material to prevent contamination.
18. Install the high pressure fuel lines.
19. Install new high pressure fuel lines and hand tighten.
20.
CAUTION: If the high pressure fuel pump is shipped locked, it should not be rotated until the spacer has been installed.
Put on the timing belt. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
21. Set up the powertrain control module (RSM). See FDS 2000 for more information.
22. Using the special tool, pour fuel into the high pressure fuel pump until clean fuel is seen flowing into the vacuum pump reservoir.
23. Remove the special tool.
24. Install the fuel return line.
- 1. Rotate the clip to lock the latch.
25. Remove lint free material from generator.
26. Switch the ignition switch to position III (engine cranking). Crank the engine until clean fuel comes out of the fuel line nipple.
27. Tighten the high pressure fuel lines.
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