Remove MR/PLD unit pump, install

AR07.15-T-8950CB

Remove MR/PLD unit pump, install

14.2.12

 

Remove/install

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect electric cables at battery

AR54.18-T-0002CB

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

2

Close the shutoff valves of the heating system and drain the coolant

 Position of the shutoff valves, refer the operator's manual.



Drain/fill in coolant

AP20.00-T-2080-01CB



*BF20.00-N-1001-01D



Notes on coolant

All engines

AH20.00-N-2080-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

3

Remove coolant pipe in the area of the unit pumps (1)

AR20.20-T-3865-06CB

4

Attach turning device for engine

AR03.30-T-1600-03BB



*BA01.60-N-1001-01H



*407589006300

5

Remove charge air manifold

AR09.41-T-8681CB

6

Unscrew cap on fuel tank

 The fuel filter housing empties automatically. Fuel flows through the return line back into the fuel tank.

7

First open the cover on the fuel filter then remove with filter insert

 Only remove the cover on the fuel filter completely after the fuel has flowed completely out of the housing.

 Installation: Install new O-ring.



*BA47.25-N-1002-01H

8

Close off fuel tank again with cap

9

Clean engine in the area of the unit pumps (1)

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

10

Remove injection line (5)

 Close of connections on the cylinder head and MR/PLD unit pump (1).

AR07.15-T-9235CB

11

Remove fuel suction line (14) from pressure control valve (15)

 Collect fuel which flows out.

 Installation: Install new sealing rings (13).



*BA47.25-N-1006-01H

12

Remove pressure control valve (15) and remove fuel leak line (17) from crankcase

 Collect fuel which flows out.

 Installation: Install new sealing rings (16).



*BA47.25-N-1010-01H

13

Remove line for fuel feed from crankcase

 Collect fuel which flows out.

The line for the feed is located on the left below the unit pump (1) for cylinder 1.

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

14

Blow out fuel feed channel in crankcase with compressed air

 The fuel remaining in the channel can find its way into the engine oil when removing the unit pump (1) and can cause engine damage during initial startup after installing.

 Collect fuel which flows out.

15

Detach engine cable set (6) from the unit pump (1)

16.1

Mark unit pump (1) relative to corresponding cylinder

 When removing several unit pumps.

17

Loosen bolts (4)

 The unit pump (1) is under spring tension: therefore the bolts must only be unscrewed by about 4 - 5 mm because of the danger of them springing out.

 Installation: Install unit pump (1) by slowly and alternately screwing bolts into the crankcase.



*BA07.15-N-1005-01C

18

Pull out unit pump (1) using the impact extractor to the screw head

 Stuck unit pumps must not be pulled out at the solenoid valve or housing flange because of the danger of damaging them.



*355589016300

19

Completely unscrew screws (4) and pull out the unit pump (1)

 Installation: Coat body of the unit pump (1) as well as surface of the O-rings (2, 3) and bore hole in the crankcase slightly with assembly grease.

*BR00.45-Z-1051-06A

Carefully push in unit pump (1) by hand to a distance of about 4 mm and screw in bolts to the stop on the unit pump (1).

 Do not tilt unit pump when inserting it into the crankcase. If it is not possible to press in the unit pump deep enough due to a cam on the direct injection stranding in the upward condition then keep turning the crankshaft by half a revolution in the direction of rotation.

20

Remove O-rings (2, 3) from unit pump (1)

 Installation: Clean radial groove on unit pump body. Push protective sleeve (9) over the unit pump.

Replace O-rings and coat with assembly grease. First of all roll the black O-ring (2) over the protective sleeve (9) in the groove, then the green O-ring (3). Detach protective sleeve.

*BR00.45-Z-1051-06A

 The O-ring must not be mounted twisted due the risk of tearing.



*541589011400

21

Check roller tappet on unit pump (1) for score mark, scratches and sanding spots

 The unit pump can be used again if there are only a minimal number of score marks or scratches on the roller.
Replace unit pump if the score mark, scratches or sanding spots are too deep.

 Installation: Carefully clean sealing surface on unit pump and on crankcase of dirt and paint residues.

22

Install in the reverse order

23

Read in barcode on unit pump using STAR DIAGNOSIS

 Only when installing new unit pumps.

Number

Designation

Engine 457.9

BA01.60-N-1001-01H

Bolt, inspection hole cap to timing case

Nm

25

Number

Designation

Engine 457.9

BA07.15-N-1005-01C

Bolt, MR/PLD unit pump to crankcase

Nm

60

Number

Designation

Engine 457.9

BA47.25-N-1002-01H

Fuel filter cover on fuel filter housing

Nm

25

BA47.25-N-1006-01H

Banjo bolt, fuel suction line to crankcase

Nm

50

BA47.25-N-1010-01H

Pressure control valve to crankcase

Nm

40

Number

Designation

Engine 402.970, 441.980, 446.938, 457.944

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

75...100

with VOITH retarder

Liters

95...120

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

Number

Designation

Order number

BR00.45-Z-1051-06A

Hot bearing grease

A 000 989 81 51