AR07.15-W-8950C | Remove/install MR/PLD unit pump | 23.2.06 |
ENGINE 457.9 in MODELS 374, 375, 940, 942, 943, 944, 958
W07.15-1406-09
Shown on model 944
1 Coolant pipe
2 Impact extractor
3 Engine wiring harness
Y9 Cylinder 4 unit pump
Y10 Cylinder 5 unit pump
Y11 Cylinder 6 unit pump
Y6 Cylinder 1 plug-in pump
Y7 Cylinder 2 unit pump
Y8 Cylinder 3 unit pump
Modification notes
| Removing | ||
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 contact with fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
1 | Switch off ignition | ||
Danger! | Risk of injury caused by being caught or pinched as cab is tilted | Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut. | |
2 | Tilt cab | ||
| Notes on tilting the cab | ||
3 | Remove soundproofing on frame at the upper left | ||
4 | Clean crankcase in the area of the relevant unit pump | ||
5 | Remove charge air manifold | ||
6 | Remove injection line for the corresponding unit pump | ||
7 | Disconnect and unclip electrical engine wiring harness (3) on the corresponding unit pump | Disconnect electrical engine wiring harness (3) on the corresponding unit pump and unit pump before and afterwards. | |
8 | Mark unit pumps relative to the respective cylinder | Only when removing several unit pumps | |
9 | Partially drain coolant and collect it | Only if the cylinder 1 unit pump (Y6), the cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) must be removed. | |
10 | Remove coolant pipe (1) and lay upwards between the injection lines or push coolant pipe (1) if necessary | Only if the cylinder 1 unit pump (Y6), the cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) must be removed. Collect coolant which flows out. | |
11 | Unscrew bolts 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 (5) are unscrewed completely and get damaged. | |
A firmly attached unit pump must not be pushed out at solenoid valve and housing flange, otherwise solenoid valve damage could occur. | |||
12 | Attach impact extractor (2) to the relevant unit pump and pull out to the heads of the bolts then remove the impact extractor (2) | Only in the case of a jammed unit pump. | |
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13 | Remove bolts and take out relevant unit pump | ||
| Checking | ||
14 | Check roller tappet on unit pump | Check surface of roller tappet. 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 the 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 and lightly coat with hot bearing grease | Only when reinstalling used unit pumps. | |
| |||
17 | Slightly coat unit pump body and the hole in the crankcase with hot bearing grease | ||
18 | Insert unit pump and tighten bolts | Do not damage O-rings on the unit pump body. | |
Press the unit pump carefully by hand against the spring force and screw in the bolts. Then tighten bolts evenly. | |||
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19 | Clip in electrical engine wiring harness (3) and connect to unit pumps | ||
20 | Install injection line for the corresponding unit pump | ||
21 | Attach coolant pipe (1) | Only if cylinder 1 unit pump (Y6), cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) was removed or reinstalled. | |
Install new seals. | |||
22 | Pour in coolant | Only if cylinder 1 unit pump (Y6), cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) was removed or reinstalled. | |
23 | Install charge air manifold | ||
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 running engine | Secure vehicle to prevent it from moving by itself. | |
24 | Start the engine, bleed fuel system and perform engine test run | The fuel system is bled automatically. If the engine fails to start or only runs for a brief period: | |
Bleed fuel system. | |||
25 | Check coolant pipe (1) for leaks through visual inspection | Only necessary if cylinder 1 unit pump (Y6), cylinder 2 unit pump (Y7) or the cylinder 3 unit pump (Y8) was removed or reinstalled. | |
26 | Connect up 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 | |||
27 | Install soundproofing on frame above on the left | ||
Danger! | Risk of injury caused by being caught or pinched as cab is tilted | Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut. | |
28 | Lower cab | ||
| Notes on tilting the cab |
Diesel injection system with unit pumps (MR)
355 589 01 63 00
541 589 01 14 00
Sleeve
Impact extractor
Commercially available tools
Number | Designation | |
WH58.30-Z-1037-13A | Test cable (multiplexer) | 651 100 40 99 |
WH58.30-Z-1039-13A | Adapter cable for 14-pin diagnostic socket | 651 101 40 99 |
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 |