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

Engine 651.955/956/957 in model 906 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Shown without code (MS3) Emissions level Euro 3 

Courtesy of MERCEDES-BENZ USA

	Remove/install	-	-
-	Risk of explosion  caused by fuel Igniting. 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 system when it is pressurized.	AS07.16-Z-0001-01A
-	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
-	Notes about Common-Rail components	-	AH07.16-P-0002-01TX
1	Remove engine cover	-	AR01.10-D-2405WE
2	Release engine wiring harness cable duct (23)	-	AR01.00-D-2411-01WE
3	Remove charge air manifold	-	AR09.41-D-8681WE
4	Remove engine charge air duct downstream o charge air cooler	For vehicles without code (MS3) Emissions level Euro 3	AR09.50-D-8680WE
5	Open clips (25), remove fuel filter (27) upwards and place to one side	Do not disconnect fuel hoses (26) and electrical connector of fuel filter heater with water level sensor (R53/1 or R53/3).	-
6	Remove screws (7) and place bracket (8) to one side	Screw/bolt, bracket to mounting plate	*BA09.41-N-1017-01M
7	Unscrew bolts (9) and remove mounting plate (10)	Screw/bolt, charge air pipe mounting plate to engine support	*BA09.41-N-1012-01M
8	Disconnect fuel hose (11) from high-pressure pump (M41/3)	Seal connections after disconnection with stop plugs.	-
-	-	Installation  : Check fuel hose (11) and hose clamps for damage, replace if necessary	-
-	-	Record plug	Fig 3
9	Unscrew bolts (16), remove boost pressure control flap pressure transducer (Y93/1) with connected lines from bracket (18) and place to one side	-	-
10	Remove bolts (17) and remove bracket (18)	For vehicles without code (MS3) Emissions level Euro 3	-
-	-	Bolt, bracket to exhaust gas recirculation valve/bypass flap	*BA14.20-N-1029-01H
-	-	Bolt, exhaust gas recirculation valve/bypass flap bracket to crankcase	*BA14.20-N-1030-01H
11	Disconnect electrical connector at quantity control valve (Y94/3)	-	-
12	Disconnect electrical connector at fuel temperature sensor (B50/5)	-	-
13	Remove screws (2, 3) at brackets of high-pressure line (1)	-	-
14	Unclip retaining clip (21) of electric line (20) of knock sensor 2 (A16/6) at high-pressure line (1)	-	-
15	Unscrew high-pressure line (1) from high-pressure pump (M41/3) and rail (5)	Install high-pressure line (1) free of tension. High-pressure line (1) can otherwise be damaged. Counterhold high-pressure fitting (6). After removal of high-pressure line (1), seal connections at high-pressure pump (M41/3) and rail (5) with stop plugs. Check sealing cone at high-pressure line (1), replace high-pressure line (1) if necessary.	-
-	-	Union nut, pressure line to high-pressure pump/rail	*BA07.16-N-1019-01A
-	-	Box wrench bit	Fig 2
-	-	Record plug	Fig 3
16	Remove leak oil line (19) from high-pressure pump (M41/3)	Check leak oil line (19) for damage, replace if necessary.	-
17	Remove screw/bolts (12)	Bolt, high-pressure pump to crankcase	*BA07.16-N-1018-01A
18	Remove high-pressure pump (M41/3)	Only remove high-pressure pump (M41/3) to extent that fuel hose (24) can be accessed.	-
19	Disconnect fuel hose (24) from high-pressure pump (M41/3) and lift out high-pressure pump (M41/3)	Seal connections after disconnection with stop plugs. Do not disassemble high-pressure pump (M41/3). Clean sealing surfaces, replace sealing ring (13) and grease lightly with special grease. Check fuel hose (24) and hose clamps for damage, replace if necessary. When replacing high-pressure pump (M41/3), coupling flange (14) with nut (22) and driver (15) must basically also be replaced.	-
-	-	Nut, coupling flange to high-pressure pump	*BA07.16-N-1022-01A
-	-	Special grease	*BR00.45-Z-1036-06A
-	-	Record plug	Fig 3
-	-	Counterholder	Fig 1
	Check	-	-
20	Remove driver (15) and check toothing for wear and/or damage, replace if necessary	Only if high-pressure pump (M41/3) is not replaced. Ensure driver (15) is correctly seated.	-
21	Check coupling flange (14) at high-pressure pump (M41/3) for wear and/or damage, replace if necessary	Only if high-pressure pump (M41/3) is not replaced. When replacing coupling flange (14), nut (22) and driver (15) must basically also be replaced.	-
-	-	Nut, coupling flange to high-pressure pump	*BA07.16-N-1022-01A
-	-	Counterholder	Fig 1
22	Install in the reverse order	-	-
	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
23	Perform engine test run and check engine in area of high-pressure pump (M41/3) for leaks	-	-

Fig 1: Counterholder (651 589 04 40 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Box Wrench Bit (000 589 68 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA