AR07.15-D-8950AD | Remove/ install MR/PLD unit pump | 16.8.06 |
ENGINE 900.917 /918 /919 in MODEL 668, 670
D07.15-0009-04
2 Engine cover
D07.15-0008-09
1 Injection line
3 Engine wiring harness
4 Bolt
9 Unit pump (cylinder 1)
10 Engine stop switch
11 Engine start switch
12 Impact extractor
5 Roller tappet.
6 Unit pump (cylinder 4)
7 Unit pump (cylinder 3)
8 Unit pump (cylinder 2)
| 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. Wear protective clothing when handling fuel. | |
1 | Remove service cover | ||
2 | Remove engine trim panel (2) | ||
3 | Clean crankcase in the area of relevant unit pumps (6, 7, 8, 9) | ||
4 | Remove injection line (1) of relevant unit pumps (6, 7, 8, 9) | ||
5 | Mark unit pumps (6, 7, 8, 9) relative to respective cylinder | Only for reinstalling worn unit pumps (6, 7, 8, 9). | |
6 | Remove mounting strip for engine wiring harness (3) with Engine stop switch (10) and Engine start switch (11) on crankcase | Only for removing worn unit pumps (7, 8, 9). | |
7 | Disconnect engine wiring harness (3) on relevant unit pumps (6, 7, 8, 9) | ||
8 | Loosen bolts (4) of relevant unit pumps (6, 7, 8, 9) and unscrew by about 4 to 5 mm | Unit pumps (6, 7, 8, 9) are under spring force and can suddenly spring out of the crankcase if bolts (4) are unscrewed completely and get damaged. | |
9 | Attach impact extractor (12) to relevant unit pumps (6, 7, 8, 9) | | |
10 | Pull out relevant unit pumps (6, 7, 8, 9) using extractor (12) up to heads of serrated bolts (4) | A jammed unit pump (6, 7, 8, 9) must not be pushed out on unit pump solenoid valve or on housing flange, otherwise the respective unit pump solenoid valve will be damaged. | |
| |||
11 | Remove impact extractor (12) | | |
12 | Remove bolt (4) and relevant unit pumps (6, 7, 8, 9) | ||
| Checking | ||
13 | Check user interface of roller tappet (5) on relevant unit pumps (6, 7, 8, 9) | The unit pumps (6, 7, 8, 9) can be used again if there are only a minimal number of score marks or scratches on it. In the case of deep score marks, scratches or sanding spots replace relevant unit pumps (6, 7, 8, 9) and also check unit pump cams at camshaft by means of visual inspection. | |
| Install | ||
14 | Carefully remove dirt and paint residues on crankcase sealing surface | Close of bore in crankcase using clean rags. | |
15 | Replace O-rings on relevant unit pumps (6, 7, 8, 9) | Only for reinstalling worn unit pumps (6, 7, 8, 9). | |
| |||
Hot bearing grease | |||
16 | Slightly coat unit pump body and the hole in crankcase with hot bearing grease | Hot bearing grease | |
17 | Screw both assembly pins into crankcase and insert relevant unit pumps (6, 7, 8, 9) | Do not damage the O-rings at the unit pump body. Observe installation position and carefully press in unit pumps (6, 7, 8, 9) by hand against the spring force. | |
If it is not possible to press in the unit pumps (6, 7, 8, 9) to a sufficient depth, turn engine further by approx. one half revolution (in direction of rotation). | |||
| Assembly pins for installing unit pump | ||
18 | Replace assembly pins by bolts (4) and tighten unit pumps (6, 7, 8, 9) | | |
| Assembly pins for installing unit pump | ||
19 | Attach mounting strip for engine wiring harness (3) with Engine stop switch (10) and Engine start switch (11) on crankcase | Only if unit pumps (7, 8, 9) were removed. | |
20 | Attach wiring harness (3) to relevant unit pumps (6, 7, 8, 9) | ||
21 | Install injection line (1) on relevant unit pumps (6, 7, 8, 9) | ||
22 | Teach in barcode for unit pumps (6, 7, 8, 9) and read out fault memory; delete if necessary | Only when replacing unit pumps (6, 7, 8, 9). | |
| Connect STAR DIAGNOSIS and read out fault memory | ||
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. | |
23 | Conduct engine test run, stop engine and check in the area of relevant unit pumps (6, 7, 8, 9) for leaks | Crank engine with starter for maximum 90 seconds. Wait at least for about 2 minutes before repeating attempt at starting. The fuel system is bled automatically. | |
24 | Install engine cover (2) | ||
25 | Install service cover |
Diesel injection system with unit pumps (MR/PLD)
Number | Designation | Engine Engine | ||
BA07.15-N-1001-01A | Bolt, unit pump to crankcase | Nm | 65 | |
355 589 01 63 00
904 589 03 14 00
Sleeve
Impact extractor
Commercially available tools
Number | Designation | |
WH58.30-Z-1049-13A | STAR DIAGNOSIS Compact diagnostic system for commercial vehicles | 651 131 10 00 |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1051-06A | Hot bearing grease | A 000 989 81 51 |
Referenced documents
- ad0000l200004a Connect STAR DIAGNOSIS and read out fault memory
- ar0715d895001ad Replace O-rings on the unit pump
- ar0715d9235ad Remove/install MR/PLD injection lines
- as0000z000501a 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.
- as4700z000101a 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.
- wf5850w071501a Assembly pins for installing unit pump