AR07.15-W-8950B | Remove MR/PLD unit pump, install | 17.12.09 |
ENGINE 541.9 in MODEL 950, 952, 953, 954
ENGINE 542.9 in MODEL 950, 952, 954
W07.15-1265-09
Shown on engine 542.9
1 Injection line
2 Engine wiring harness
3 Bracket
4 Screw
5 Impact extractor
Y9 Cylinder 4 plug-in pump
Y10 Cylinder 5 plug-in pump
Y11 Cylinder 6 plug-in pump
Y12 Cylinder 7 unit pump (engine 542.9)
Y13 Cylinder 8 unit pump (engine 542.9)
6 Roller tappet
Y6 Cylinder 1 plug-in pump
Y7 Cylinder 2 plug-in pump
Y8 Cylinder 3 plug-in pump
Modification notes
| 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 | Switch off ignition | ||
2 | Remove charge air manifold/charge air housing | ||
3 | Remove charge air pipe | Only on engine 542.9. | |
4 | Clean crankcase in the area of the relevant unit pump | Cover over intake openings at cylinder heads. | |
5 | Remove injection line (1) for the corresponding unit pump | ||
6 | Disconnect electrical engine wiring harness (2) on the respective unit pump and possibly also the electrical engine wiring harness (2) on the bracket (3) | ||
7 | Remove fuel lines and fuel overflow valve | Only necessary if for engine 541.9 the cylinder 3 unit pump (Y8) or for engine 542.9 the cylinder 4 unit pump (Y9) must be removed. | |
8 | Identify unit pump relative to the respective cylinder | Only when removing several unit pumps | |
9 | Loosen bolts (4) on relevant unit pump and unscrew by about 4 to 5 mm | The unit pump is under spring force and can suddenly spring out of the crankcase if the bolts (4) are unscrewed completely and get damaged. | |
10 | Install impact extractor (5) on relevant unit pump | | |
11 | Pull out relevant unit pump using the extractor (5) as far as the heads of the serrated bolts (4) | A firmly attached unit pump must not be pushed out at solenoid valve and housing flange, otherwise solenoid valve damage could occur. | |
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12 | Remove impact extractor (5) | | |
13 | Undo bolts (4) and pull out the respective unit pumps | ||
| Checking | ||
14 | Check roller tappet (6) at unit pump | Check surface of roller tappet (6). 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 visual inspection. | |||
| Install | ||
15 | Carefully remove dirt and paint residues on the crankcase sealing surface | Seal off hole in crankcase. | |
16 | Replace O-rings on the unit pump | Only when reinstalling used unit pumps. | |
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Hot bearing grease | |||
17 | Slightly coat unit pump body and the hole in the crankcase with hot bearing grease | Hot bearing grease | |
18 | Insert unit pump and tighten bolts (4) | Do not damage O-rings on the unit pump body. Press in the unit pump carefully by hand against the spring force in doing so alternately screwing in the bolts (4) by hand. | |
Then tighten the bolts (4). | |||
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19 | Install fuel lines and fuel overflow valve | Only necessary if for engine 541.9 the cylinder 3 unit pump (Y8) or for engine 542.9 the cylinder 4 unit pump (Y9) must be removed and reinstalled. | |
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20 | Connect up electrical engine wiring harness (2) on the respective unit pump and possibly also the electrical engine wiring harness (2) on the bracket (3) | ||
21 | Install injection line (1) for the corresponding unit pump | ||
22 | Install charge air pipe | Only on engine 542.9. | |
23 | Install charge air manifold/charge air housing | ||
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. | |
24 | Start engine and bleed the fuel system | The fuel system is bled automatically. Run the engine for approx. 1 minute. If the engine stops or does not start: | |
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| Bleed fuel system | ||
25 | Turn off engine | ||
26 | Connect STAR DIAGNOSIS and teach in bar code of unit pump | Only when installing new unit pumps. | |
Test cable (multiplexer) | |||
Adapter cable for 14-pin diagnostic socket | |||
STAR DIAGNOSIS Compact diagnostic system for commercial vehicles | |||
Danger! | 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 with the safety strut. | |
27 | Lower cab | ||
| Notes on tilting the cab |
Diesel injection system with unit pumps (MR/PLD)
Fuel pipes/hoses
Number | Designation | Engine | ||
BA47.25-N-1004-01B | Banjo bolt, fuel line to passage in crankcase | M161.5 | Nm | 50 |
BA47.25-N-1005-01B | Banjo bolt, fuel line to fuel overflow valve | M161.5 | Nm | 50 |
541 589 01 14 00
Sleeve
Impact extractor
355 589 01 63 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1051-06A | Hot bearing grease | A 000 989 81 51 |