Remove MR/PLD unit pump, install

AR07.15-W-8950S

Remove MR/PLD unit pump, install

24.11.2015

Engine

457.9 in model 949

1

Coolant pipe

B191

Coolant temperature sensor

Y9

Cylinder 4 unit pump

2

Impact extractor

Y6

Cylinder 1 unit pump

Y10

Cylinder 5 unit pump

3

Engine wiring harness

Y7

Cylinder 2 unit pump

Y11

Cylinder 6 unit pump

4

Screw/bolts

Y8

Cylinder 3 unit 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

 Danger !

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



Remove

1

Open engine hood and raise to vertical position

AR88.40-W-1000R

2

Remove front section of front left fender

AR88.10-W-1500RE

3

Remove trim on front end

AR88.30-W-2301S

4

Drain off coolant

AR20.00-W-1142S

5

Remove expansion reservoir with carrier

AR20.30-W-4950-01S

6

Remove left charge air pipe

AR09.41-W-1327S

7

Clean crankcase in the area of the relevant unit pump

8

Remove charge air distributor

AR09.41-W-8683S

9

Remove injection line for the corresponding unit pump

AR07.15-W-9235S


The injection line must not be bent.
Otherwise the coating comes off in the injection line and engine damage occurs.

10

Disconnect electrical engine wiring harness (3) on the corresponding unit pump as well as the unit pumps before and afterwards disconnect and unclip

 Loosen screw/bolts (4) a few turns and lead out eyelets.

11

Mark unit pumps relative to respective cylinder

Only when removing several unit pumps.

12

Detach electrical connection from coolant temperature sensor (B191)

13

Remove coolant pipe (1)

Only if cylinder 1 unit pump(Y6), the cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) is being removed.

 Counterhold connection fitting for banjo bolt.

14

Remove screw/bolts on relevant unit pump and remove by about 4 to 5 mm


Do not unscrew screw/bolts fully.
Otherwise a stationary unit pump springs out of the crankcase due to the lower spring tension and is damaged.


Do not pull a jammed unit pump on the solenoid valve and housing flange.
Otherwise the solenoid valve will be damaged.

15

Attach impact extractor (2) to the relevant unit pump and pull out to the heads of the bolts then remove the impact extractor (2)

Only in the case of a jammed unit pump.

 Impact extractor

*355589016300

16

Remove screw/bolts and take out relevant unit pump



Check

17

Check roller tappet on unit pump for damage

 Check surface of roller tappet. The unit pump can be used again if there are only minimal score marks or scratches on it.

If deep scores, scratches or grinding points are present



Replace relevant unit pump and also check unit pump lobes on the camshaft by means of visual inspection.



Install

18

Carefully remove dirt and paint residues on the crankcase sealing surface

 Close off housing bore.

19

Replace O-rings on the unit pump and lightly coat with high-temperature grease

Only when reinstalling used unit pumps.

AR07.15-W-8950-01G

High-temperature grease

*BR00.45-Z-1051-06A

 Sleeve

*541589011400

20

Slightly coat unit pump body and the hole in the crankcase with high-temperature grease

High-temperature grease

*BR00.45-Z-1051-06A

21

Insert unit pump and tighten screw/bolts

 Do not damage O-rings at unit pump body.
Press the unit pump carefully by hand against the spring force and screw in the screw/bolts.
Then tighten screw/bolts evenly.

 Bolt, unit pump to crankcase

*BA07.15-N-1005-01G

22

Clip in electrical engine wiring harness (3) and connect to unit pumps

23

Install injection line for the corresponding unit pump

AR07.15-W-9235S

24

Install coolant pipe (1)

Only for installation of the cylinder 1 unit pump (Y6), the cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8).

 Install new sealing rings.

25

Connect electrical connection to coolant temperature sensor (B191)

26

Install charge air distributor

AR09.41-W-8683S

27

Install left charge air pipe

AR09.41-W-1327S

28

Install expansion reservoir with carrier

AR20.30-W-4950-01S

29

Pour in coolant

AR20.00-W-1142S

30

Start the engine, bleed fuel system and 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-W-1720S

31

Check coolant pipe (1) for leaktightness through visual inspection

Only for installation of the cylinder 1 unit pump (Y6), the cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8).

32

Connect diagnostic system, start XENTRY and teach in barcode of the unit pump

Only when installing new unit pumps.

33

Install trim at front end

AR88.30-W-2301S

34

Install front section of fender on the left

AR88.10-W-1500RE

35

Close engine hood

AR88.40-W-1000R

 Diesel injection system with unit pumps (MR)

Number

Designation

Engine 457.9

BA07.15-N-1005-01G

Bolt, unit pump to crankcase

Nm

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51