High-pressure pump, Z19DT
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High-pressure pump, Z19DT
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Warning
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The work involved in removing the fuel pump requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
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Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
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Absolutely No Smoking!
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Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
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Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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Wear protective goggles.
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Warning
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Diesel under high pressure! So wait for at least one minute after switching off the engine before starting work in the fuel system. Diesel fumes are explosive and can cause severe burn injuries.
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Important
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Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal using 93 161 370 Plug set. Store the components so that contaminants cannot enter.
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4.
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Cut the cable tie and remove the connector of the camshaft position sensor.
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5.
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Remove the bracket and lifting eye (3 bolts).
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6.
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Detach the return fuel line from the return fuel tank using
83 95 261 Fuel line tool
. Have a cloth on hand to catch any spilled fuel.
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7.
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Detach the hoses from the return fuel collector. Remove the return fuel collector.
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8.
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Remove the fuel pressure sensor connector from the pump.
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9.
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Remove the fuel pipe from the pump and the fuel rail.
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10.
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Remove the return fuel hose form the pump.
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11.
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Remove the fuel inlet hose from the pump.
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Important
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Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to
Connectors, handling and inspection
.
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12.
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Remove the injector connectors.
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13.
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Detach the wiring harness from the intake manifold.
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14.
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Remove the delivery lines between the injectors and the fuel rail.
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15.
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Remove the connector on each end of the fuel rail.
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16.
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Remove the fuel rail pipe and place to one side.
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17.
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Remove the nuts and washers using a magnet for the washers.
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1.
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Put the pump in place and fit washers and nuts.
Tightening torque 25 Nm (18 lbf ft).
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2.
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Fit the fuel rail.
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Important
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Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to
Connectors, handling and inspection
.
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3.
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Plug in the connectors on each end of the fuel rail.
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4.
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Check that the fuel pipe sealing surfaces are clean and not damaged. Fit the pipe without tensioning it and mount the nuts by hand. Fit the pipes between the fuel rail and the injectors.
Tightening torque 25 Nm (18 lbf ft)
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5.
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Plug in the connectors to the injectors.
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6.
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Fit the wiring harness to the intake manifold.
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7.
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Fit the fuel inlet hose to the pump.
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8.
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Fit the fuel return hose to the pump.
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9.
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Fit the fuel pressure sensor connector.
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10.
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Fit the fuel pipe between the pump and the fuel rail. Mount the nuts by hand. If the fuel pipe is difficult to get in place, undo the fuel rail retaining bolts slightly.
Tightening torque, fuel pipes 25 Nm (18 lbf ft)
Tightening torque, fuel rail 25 Nm (18 lbf ft).
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11.
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Fit the return fuel collector.
Tightening torque 9 Nm (7 lbf ft).
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12.
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Fit hoses to the return fuel collector.
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13.
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Fit the return fuel line.
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14.
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Fit the lifting eye and bracket.
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15.
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Fit the camshaft position sensor connector with a cable tie.
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18.
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Connect the diagnostic tool and erase any diagnostic trouble codes.
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