Remove MR/PLD unit pump, install

AR07.15-W-8950R

Remove MR/PLD unit pump, install

1.7.10



Removing

 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

1

Switch off ignition

2

Open engine hood and raise to vertical position

AR88.40-W-1000R

3

Remove charge air pipe from charge air cooler to charge air manifold

 Only if cylinder unit pump 1 (Y6) is removed

AR09.41-W-1311RA

4

Take off bracket (2) at cylinder head

 Only if cylinder unit pump 1 (Y6) is removed

5

Remove clamp (arrow) for compressor air intake line (4) from engine cover (3)

6

Remove engine cover (3)

7

Remove injection line (1) for the corresponding unit pump

AR07.15-W-9235R

8

Mark the unit pumps relative to the cylinder concerned or note down the barcode

 Only when removing several unit pumps

9

Disconnect electrical engine wiring harness (5) on the corresponding unit pump

10

Detach mounting strip (6) from the cylinder crankcase and press off

 Only if cylinder 3 unit pump(Y8), cylinder 4 unit pump (Y9) or cylinder 5 unit pump (Y10) is being removed.

11.1

Disconnect the engine electrical wiring harness (5) from engine start button (S10) and engine stop button (S11)

Up to engine end no. 733509
 Only if cylinder unit pump 3 (Y8), cylinder unit pump 4 (Y9) or cylinder unit pump 5 (Y10) is removed.

11.2

Disconnect electrical engine wiring harness (5) from engine start/engine stop button (S10.1)

As of engine end no. 733510
 Only if cylinder unit pump 3 (Y8), cylinder unit pump 4 (Y9) or cylinder unit pump 5 (Y10) is removed.

12

Loosen bolts (7) on corresponding unit pump and unscrew approx. 4 ...5 mm.

 The unit pump is under spring force and can suddenly spring out of the crankcase if the bolts (7) are unscrewed completely and get damaged.

13

Attach removal tool (8) to the related unit pump and pull out the unit pump with removal tool (8) up to the bolt heads (7).

 Only in the case of a jammed unit pump.

 If the unit pump is stuck, it should not be pushed out at the solenoid valve or housing flange, otherwise the solenoid valve will be damaged.



*949589006300

14

Remove removal tool (8)

 Only if the unit pump is stuck.

15

Remove bolts (7) and take out relevant unit pump

16

Check roller tappet (9) at respective unit pump

 Inspect surface of the roller tappet; if there are only minimal scores or scratches, the MR/PLD unit pump (9) can still be used. If deep scoring, scratches or sanding spots are present:



Replace corresponding unit pumps and additionally check unit pump cams on camshaft by inspecting visually with cylinder illumination unit endoscope.



Install

17

Carefully remove dirt and paint residues on the crankcase sealing surface

 Seal off hole in crankcase.

18

Replace O-rings on the unit pump

 Only if reinstalling a used unit pump.

AR07.15-W-8950-01J



*904589031400

Lubricate the O-rings with high-temperature grease.

*BR00.45-Z-1051-06A

19

Lubricate the unit pump body and the hole in the cylinder crankcase with high-temperature grease

*BR00.45-Z-1051-06A

20

Insert unit pump in cylinder crankcase and tighten evenly

 Note the marking or barcode on the unit pumps, if more than one unit pumps are being removed. Do not damage O-rings at unit pump body. Press unit pump carefully by hand against the spring force and screw in the bolts (7) at the same time



*BA07.15-N-1001-01A

21.1

Tighten the mounting strip (6) and connect engine electrical wiring harness (5) to engine start button (S10) and engine stop button (S11)

Up to engine end no. 733509
 Only if cylinder unit pump 3 (Y8), cylinder unit pump 4 (Y9) or cylinder unit pump 5 (Y10) is removed.

21.2

Connect electrical engine wiring harness (5) to engine start/stop button (S10.1) and tighten mounting strip (6)

As of engine end no. 733510
 Only if cylinder unit pump 3 (Y8), cylinder unit pump 4 (Y9) or cylinder unit pump 5 (Y10) is removed.

22

Connect electrical wiring harness (5) at respective unit pump

23

Install injection line (1) for the corresponding unit pump

 Do not close hood yet.

AR07.15-W-9235R

24

Install bracket (2) on cylinder head

 Only if cylinder unit pump 1 (Y6) is removed.

25

Install charge air pipe from charge air cooler to charge air manifold

 Only if cylinder unit pump 1 (Y6) is removed.

AR09.41-W-1311RA

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

26

Start the engine and run it at varying speeds

 Crank engine with the starter for not more than 90 seconds. The fuel system is ventilated automatically. If the engine stops or does not start, repeat starting procedure after a break of 2 minutes.

27

Switch off the engine and check around the unit pumps for leaktightness

28

Install engine cover (3)

29

Install clamp (arrow) on compressor air intake duct (4) at engine cover (3)

30

Close engine hood

AR88.40-W-1000R

31

Connect STAR DIAGNOSIS and teach in bar code of unit pump

 Only when installing new unit pumps.

Number

Designation

Engine 924.9, 925.9, 926.9

BA07.15-N-1001-01A

Bolt, unit pump to crankcase

Nm

65

Number

Designation

Order number

BR00.45-Z-1051-06A

Hot bearing grease

A 000 989 81 51