Installing high pressure pump

NOTE: RISK OF DAMAGE
Damage to the engine.
If the engine is manually rotated in the wrong direction of rotation, the engine can be damaged.

Only rotate the engine manually in the correct direction of rotation: a) clockwise when looking at the damper, or b) counterclockwise when looking at the chain drive. b) applies only if the timing chain is installed in the rear.

NOTE: TECHNICAL INFORMATION
The high pressure pump is preloaded by the piston spring and must be removed by alternately unscrewing the screws without tilting.
Before installing the high pressure pump, the cam of the high pressure pump drive must be turned to bottom dead center.
If necessary, turn the engine in the direction of engine rotation on the central bolt of the crankshaft, otherwise there is a risk of piston breakage of the high pressure pump.

Place the depth gauge (1) flat onto the high pressure pump flange.
Turn the engine at the central bolt in the direction of engine rotation until the camshaft is in the BDC position.
The depth gauge (1) is in the lowest position.

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Turn the engine with the special tool 0 493 380 (11 6 480) in arrow direction until the cam of the high-pressure pump drive is at the BDC position .

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Guide out and remove gasket (1).

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Replace the seal (1).
Parts : Gasket

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NOTE: TECHNICAL INFORMATION
The sealing surfaces must be free of oil, grease and cleaning agents.

Check the threads (1) on the high pressure pump flange for sealing compound residue: Remove sealing compound residue as needed.
Clean the thread (1) with a thread cutter M6 .
Make sure that no contamination gets into the engine.

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Cover opening at the high pressure pump flange with suitable materials.

NOTE: TECHNICAL INFORMATION
The sealing surfaces must be free of oil, grease and cleaning agents.

Clean sealing surface (1).

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Guide in and install the seal (1).
Make sure that the seal (1) is positioned correctly in the marked area.

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NOTE: RISK OF DAMAGE
Damage to the surface.
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage.

Do not use any metal-cutting tools.

NOTE: TECHNICAL INFORMATION
The sealing surfaces must be free of oil, grease and cleaning agents.

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Clean sealing surface (1).
Feed in and install high pressure pump (2).
Replace the bolts (arrows).
Parts : Screws
Position the screws (arrows) on the high pressure pump (2) and alternately in steps of 90° .
Compliance with this specification is imperative to make sure that the piston will not break due to twisting.

TIGHTENING TORQUES SPECIFICATION

High pressure pump to high pressure pump flange
M6x25 Replace screws.	Joining torque	12 Nm
	Angle of rotation	90°

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

Follow-up works

Refer to INSTALL THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
Refer to INSTALL CHARGE AIR LINE .
Refer to INSTALL RESONATOR .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALL THE CYLINDER HEAD COVER ACOUSTIC COVER .
Refer to INSTALL ALL IGNITION COILS .
Refer to INSTALLING ACOUSTIC COVER AT REAR
Refer to INSTALL THE FRONT HOOD SEAL AT THE REAR .
Refer to INSTALLING ACOUSTIC COVER .
Refer to DISCONNECTING ALL BATTERY GROUND LEADS .