Remove MR/PLD unit pump, install

AR07.15-B-8950TA

Remove MR/PLD unit pump, install

12.05.2020

Engine

904.9, 906.9 in model 958

Engine

906.9 in model 958

Modification notes

22.03.2004

The document was reviewed and added with work steps

Represented in vehicle 906.9

1

Injection line

5

Impact extractor

Y9

Unit pump 4th cylinder

2

Engine wiring harness

Y6

Unit pump 1st cylinder

Y10

Unit pump 5th cylinder

3

Screws

Y7

Unit pump 2nd cylinder

Y11

Unit pump 6th cylinder

4

Roller tappet

Y8

Unit pump 3rd cylinder

Only in vehicles with code (GS3) hydraulic transmission control

30

Hydraulic line

31

Clamps

32

Holder

33

Screws



Remove

 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

1

Turn off ignition

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

2

Tilt the cabin

3

Remove side acoustic encapsulation on the chassis board

4

Remove engine coating

5

Clean the engine block in the corresponding injecting unit

6

Remove injection line (1) of the respective nozzle unit

AR07.15-B-9235TA

7

Identify nozzle unit for the respective cylinder

 Only when removing several nozzle units.

8

Remove transmission mechanical command holder on the head

 Only in vehicles with code (GS1) "mechanical" gear shift for removal of 1st cylinder nozzle unit (Y6).

9

Remove hydraulic pipe (30) with holder (32) and clamps (31) from engine and place aside

 Only in vehicles with Code (GS3) "hydraulic" gear shift command for removal of 1st cylinder nozzle unit (Y6).

 Do not apart hydraulic pipe (30).

10

Remove the engine harness connector fixation rail (2) with the start and stop from engine block

 Only necessary when, for engine 904.9 the nozzle unit of cylinder 2 (Y7) or the nozzle unit of cylinder 3 (Y8) had been removed, or when for engine 906.9 the nozzle unit of cylinder 4 (Y9) or nozzle unit of cylinder 5 (Y10) had been removed.

11

Apart engine harness connector (2) in the specific nozzle unit

12

Loosen the bolts (3) on the respective nozzle unit and unscrew them approx. 4 to 5 mm

 The nozzle unit is under spring tension and can leap outwards engine block when unscrewing screws (3) thus being damaged.

13

Install the extractor (5) in the respective nozzle unit

 Impact extractor

*355589016300

14

Withdraw respective nozzle unit with the impact extractor (5) until it lays on screw heads (3)

 A stuck nozzle unit cannot be removed from the electromagnet valve or from housing flange because it may damage the electromagnet valve.

15

Remove the extractor (5)

16

Completely remove screws (3), remove nozzle unit

Inspect

17

Verify roller tappets (4) in the nozzle unit

Verify roller tappets surface (4). With minor grooves or scratches the nozzle unit can be reused. In case there are deep grooves, scratches, or sanded areas:



Replace respective nozzle unit and perform visual check of the nozzle unit rebound in the camshaft.



Install

18

carefully remove dirt and residual paint from engine block sealing surface

 Close the drilling in the engine block.

19

Replace O-Rings on nozzle unit and slightly apply heat-resistant grease to the pillow block bearings

.

AR07.15-B-8950-01TJ

 Only when reinstalling nozzle units which have already been serviced.

 Slightly apply pillow block bearings heat-resistant grease to the nozzle unit body and to the engine block

High-temperature grease

*BR00.45-Z-1051-06A

 Sleeve

*904589031400

20

Screw the two assembling pins to the engine block and place nozzle unit



Assembly pins for installing unit pump

WF58.50-B-0715-01A

 Do not damage the rings of the nozzle unit body.
Observe assembling position and carefully push nozzle unit with hands against the elastic resistance.
If it is not possible to push nozzle unit downwards, rotate engine approx. half a functioning turn.

21

Replace assembling pins by screws (3) and tighten nozzle unit with screws (3)

 Engine block injection unit

*BA07.15-B-1001-01A

22

Remove the engine harness connector fixation rail (2) with the start and stop button from engine block

 Only necessary when on engine 904.9 the nozzle unit of cylinder 2 (Y7) or the nozzle unit of cylinder 3 (Y8) had been removed, or when on engine 906.9 the nozzle unit of cylinder 4 (Y9) or nozzle unit of cylinder 5 (Y10) had been removed.

23

install engine harness connector (2) in the specific nozzle unit

24

install transmission mechanical command holder on the head

 Only in vehicles with Code (GS1) "mechanical" gear shift when 1st cylinder nozzle unit (Y6) is installed.

25

Install hydraulic pipe (30) with support (32) and clamps (31) on engine

 Only in vehicles with Code (GS3) "hydraulic" gear shift when 1st cylinder nozzle unit (Y6) is installed.

26

Install injection line (1) of the respective nozzle unit

AR07.15-B-9235TA

 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

27

Actuate the engine start-up and bleed the fuel system

 The fuel system is automatically purged. Run engine for about 1/min. In case the engine stops or does not start, repeat start process after a 2-minute pause.

28

Turn off engine

29

Connect STAR DIAGNOSIS and reset the nozzle unit Barcode

 Only in case of installation of new nozzle units.

30

Install engine coating

31

Install side acoustic encapsulation on the chassis board

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

32

Return the cabin to its position

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

Number

Designation

Engine 904.9, 906.9, 924.9, 926.9

BA07.15-B-1001-01A

Engine block injection unit

Nm

65

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51