W07.15-1025-09
1 | Unit pump | 5 | Bolts | |
2 | O-ring | 6 | Injection line | |
3 | O-ring | 7 | Engine wiring harness | |
4 | O-ring | 8 | Impact extractor |
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. | |
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. | |
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
| Remove | ||
1 | Remove engine cover. | Only if installed. | |
2 | Clean the crankcase in the area of the unit pump (1). | ||
3 | Remove injection line (6) from the corresponding unit pump (1). | ||
4 | Mark unit pump (1) relative to corresponding cylinder. | Only when removing several unit pumps (1). | |
5 | Remove the bracket for the gearshift lever from the cylinder head. | Only if installed and only to remove the unit pump (1) from cylinder 1. | |
6 | Remove holder from hydraulic lines. | Only if installed and only to remove the unit pump (1) from cylinder 1. | |
Do not separate hydraulic lines. | |||
7 | Remove mounting strip for the electrical engine wiring harness (7) using the external engine start/stop button on the crankcase. | Only if for engine 900.9, 904.9, 924.9 the unit pump (1) on cylinder 2 or cylinder 3 is removed, or for engine 902.9, 906.9, 925.9, 926.9 the unit pump (1) on cylinder 4 or cylinder 5 is removed. | |
8 | Remove engine wiring harness (7) from unit pump (1). | ||
9 | Loosen screws (5) on the unit pump (1) and unscrew them approx. 4 to 5 mm. | | |
10 | Attach the impact extractor (8) to the unit pump (1). | Impact extractor | |
11 | Unscrew the unit pump (1) with the impact extractor (8) as far as the heads of the screws (5). | | |
12 | Remove impact extractor (8). | ||
13 | Unscrew screws (5) and pull out unit pump (1). | ||
14 | Check the surface of the roller tappet on the unit pump (1). | If deep score marks, scratches, or sanding spots are present, | |
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Replace unit pump (1). | |||
| Install | ||
15 | Carefully remove dirt and paint residues on the crankcase sealing surface. | Close off housing bore. | |
16 | Install new O-rings (2, 3, 4) on the unit pump (1). | Only when reinstalling a used unit pump (1). | |
High-temperature grease | |||
Sleeve | |||
17 | Slightly grease unit pump body and the housing bore. | High-temperature grease | |
18 | Insert unit pump body into the crankcase and tighten down screw/bolts (5) evenly. | Watch out for O-rings (2, 3, 4) on unit pump body. | |
Screw, unit pump (MR/PLD) to crankcase | |||
19 | Attach mounting strip for the electrical engine wiring harness (7) using the external engine start/stop button on the crankcase | Only if for engine 900.9, 904.9, 924.9 the unit pump (1) on cylinder 2 or cylinder 3 has been removed, or for engine 902.9, 906.9, 926.9 the unit pump (1) on cylinder 4 or cylinder 5 has been removed. | |
20 | Install bracket of hydraulic lines. | Only if installed and only to install the unit pump (1) of cylinder 1. | |
21 | Remove the bracket for the gearshift lever from the cylinder head. | Only if installed and only to install the unit pump (1) of cylinder 1. | |
22 | Connect electrical wiring harness (7) at the unit pump (1). | ||
23 | Install injection line (6). | ||
24 | Start engine and perform an engine test run. | See information from body manufacturer. | |
If engine fails to start or only runs for a brief period, | |||
| |||
Repeat starting procedure after a break of 2 minutes. | |||
| Check | ||
25 | Check area around the unit pump (1) for leaktightness. | Visual inspection. | |
26 | Connect diagnostic system and teach in barcode of unit pump (1). | Only when installing a new unit pump (1). | |
See information from body manufacturer. | |||
27 | Disconnect diagnostic system. | Only if the diagnostic system has been connected. | |
See information from body manufacturer. | |||
28 | Install engine cover. | Only if the engine cover has been removed. |
904 589 03 14 00
Sleeve
355 589 01 63 00
Impact extractor