Remove/install single injection pump

AR07.15-G-8970CH

Remove/install single injection pump

21.11.2018

Engine

457.9, 458.9 in model 000.001

Modification notes

20.11.2018

Work procedure completely modified.

1

Coolant line

6

Impact extractor

11.4

Cylinder 4 single injection pump

2

Screw

7

O-ring (black)

11.5

Cylinder 5 single injection pump

3

Banjo bolt

8

O-ring (brown)

11.6

Cylinder 6 single injection pump

4

Engine wiring harness

11.1

Cylinder 1 single injection pump

12

Exhaust coolant temperature sensor

4.1

Cover

11.2

Cylinder 2 single injection pump

5

Line lugs

11.3

Cylinder 3 single injection pump

6

Impact extractor

11.1

Cylinder 1 single injection pump

11.4

Cylinder 4 single injection pump

9

Roller tappet

11.2

Cylinder 2 single injection pump

11.5

Cylinder 5 single injection pump

10

Camshaft

11.3

Cylinder 3 single injection pump

11.6

Cylinder 6 single injection pump

 Danger

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 contactwith 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

 Warning

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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Remove

1

Drain off coolant.

Only when removing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).



Coolant specifications

BB00.40-P-0310-01A

 See information from body manufacturer.

2

Remove charge-air distributor.

AR09.41-G-8681CH

3

Clean crankcase in area of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

4

Remove injection line of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

AR07.15-G-8971CH

 When removing single injection pumps for cylinders 1 to 3 (11.1 to 11.3), all injection lines of single injection pumps for cylinders 1 to 3 (11.1 bis 11.3) must be removed.

5

Remove banjo bolt (3) of coolant line (1).

Only when removing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

 Counterhold the connection fitting of the banjo bolt (3).

6

Remove screw (2) and place coolant line (1) to one side.

Only when removing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

7

Open cap (4.1) at engine wiring harness (4) of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

8

Release screws of line lugs (5) by a few turns.

9

Detach line lugs (5) from screws.

10

Unclip housing of engine wiring harness (4) from single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

11

Then disconnect engine wiring harness (4) of single injection pumps for cylinders 1 to 6 (11.1 to 11.6) in same manner before and after this and unclip.

 To facilitate access to affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

12

Mark single injection pumps for cylinders 1 to 6 (11.1 to 11.6) relative to respective cylinder.

Only when removing multiple single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

13

Disconnect electrical connector at exhaust coolant temperature sensor (12).

Only when releasing engine wiring harness (4) in area of single injection pump for cylinder 4 (11.4).

14

Release screws of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6) and unscrew by approx. 5 mm.


Do not pull out a stuck single injection pump for cylinders 1 to 6 (11.1 to 11.6) at solenoid valve and housing flange.
Risk of damage otherwise exists for solenoid valve of corresponding single injection pumps for cylinders 1 to 6 (11.1 to 11.6).


Do not remove the screws completely.
Risk of damage otherwise exists for single injection pumps for cylinders 1 to 6 (11.1 to 11.6) under spring tension.

15

Remove single injection pumps for cylinders 1 to 6 (11.1 to 11.6) using impact extractor (6) up to screw heads and then remove impact extractor (6).

Only in case of a stuck single injection pump for cylinders 1 to 6 (11.1 to 11.6).

 Impact extractor

*355589016300

16

Fully unscrew screws and remove affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

17

Check roller tappet (9) at single injection pumps for cylinders 1 to 6 (11.1 to 11.6) for damage.

 Check the surface of the roller tappet (9) and the camshaft (10).
In the case of minimal score marks or scratches, reuse single injection pumps for cylinders 1 to 6 (11.1 to 11.6) and camshaft (10).

If damage is identifiable



replace affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6) and camshaft (10).

Remove/install camshaft

AR05.20-G-6292CH

18

Carefully remove dirt and paint residues at sealing surface of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

19

Seal bore of affected single injection pump for cylinders 1 to 6 (11.1 to 11.6) in crankcase.



Install

20

Expose bore of affected single injection pump for cylinders 1 to 6 (11.1 to 11.6).

21

Replace O-rings (7, 8) at single injection pumps for cylinders 1 to 6 (11.1 to 11.6) and lightly coat with high-temperature grease.

Only where single injection pumps for cylinders 1 to 6 (11.1 to 11.6) are reused.

AR07.15-G-8970-01CH

High-temperature grease

*BR00.45-Z-1051-06A

 Sleeve

*541589011400

22

Lightly coat single injection pumps for cylinders 1 to 6 (11.1 to 11.6) and housing bore with high-temperature grease.

High-temperature grease

*BR00.45-Z-1051-06A

23

Carefully manually insert single injection pumps for cylinders 1 to 6 (11.1 to 11.6) into bore and push in against spring force; in this connection, screw in screws.

 Observe the marking relative to the corresponding cylinder.
Do not damage the O-rings (7, 8).
Then tighten screw/bolts evenly.

 Bolt, single injection pump to crankcase

*BA07.15-N-1005-01F

24

Clip engine wiring harness (4) into single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

25

Attach all released line lugs (5) to screws and tighten with screws.

26

Close cap (4.1) at engine wiring harness (4) of affected single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

27

Connect electrical connector at exhaust coolant temperature sensor (12).

Only when attaching engine wiring harness (4) in area of single injection pump for cylinder 4 (11.4).

28

Manually screw on coolant line (1) with screw (2).

Only when installing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

29

Tighten coolant line (1) with banjo bolt (3).

Only when installing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

 Counterhold the connection fitting of the banjo bolt (3).
Install new sealing rings of the banjo bolt (3).

30

Tighten screw (2) of coolant line (1).

Only when installing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

31

Install injection line of removed single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

AR07.15-G-8971CH

32

Install charge-air distributor.

AR09.41-G-8681CH

33

Fill in coolant.

Only when installing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).



Coolant specifications

BB00.40-P-0310-01A

 See information from body manufacturer.



Check

34

Perform engine test run.

 The fuel system is bled automatically.

If engine fails to start or only runs for a brief period,



Bleed fuel system.

AR47.00-G-1720CI

35

Check area of single injection pumps for cylinders 1 to 6 (11.1 to 11.6) for leaks.

 Visual inspection.

36

Check coolant line (1) for leaks.

Only when installing single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

 Visual inspection.

37

Connect vehicle diagnosis system and teach in barcode of single injection pumps for cylinders 1 to 6 (11.1 to 11.6).

Only when installing new single injection pumps for cylinders 1 to 3 (11.1 to 11.3).

 See information from body manufacturer.

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA07.15-N-1005-01F

Bolt, single injection pump to crankcase

Nm

65

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51