AR07.15-W-8950G | Remove MR/PLD unit pump, install | 5.11.02 |
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
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 unit pump
Y10 Cylinder 5 unit pump
Y11 Cylinder 6 unit pump
Y12 Unit pump cylinder 7 (engine 542.9)
Y13 Unit pump cylinder 8 (engine 542.9)
6 Roller tappet.
Y6 Cylinder 1 unit pump
Y7 Cylinder 2 unit pump
Y8 Cylinder 3 unit pump
Modification notes
| Remove | ||
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 | ||
2 | Remove 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 respective unit pump | ||
6 | Separate electrical engine wiring harness (2) at the relevant unit pump | ||
7 | Remove electrical engine wiring harness (2) at bracket (3). | ||
8 | Identify unit pump for the respective cylinder | Only when removing several unit pumps | |
9 | Loosen bolts (4) at the relevant unit pump and unscrew by approx. 4 to 5 mm | The unit pump is subjected to spring clamp force and can suddenly spring out of the crankcase when the bolts (4) are fully undone and can therefore be damaged. | |
10 | Install extractor (5) at the relevant unit pump | | |
11 | Pull out relevant unit pump using the extractor (5) as far as the heads of the bolts (4) | A firmly attached unit pump must not be pushed out at solenoid valve and housing flange, otherwise solenoid valve damage could occur. | |
12 | Remove extractor (5) | | |
13 | Unscrew bolts (4) and pull out relevant unit pump | ||
| Check | ||
14 | Check roller tappet (6) at unit pump | Check surface of roller tappet (6) . The unit pump can be reused if scoring and scratching are minimal. If deep scores, scratches or grinding points are present: | |
Replace relevant unit pump and also carry out a visual check of the unit pump cams at the camshaft. | |||
| Install | ||
15 | Carefully remove dirt and paint residue from the sealing surface of the crankcase | Seal hole in crankcase. | |
16 | Replacing O-rings at unit pump | Only when reinstalling used unit pumps. | |
| |||
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 at unit pump body. Carefully press in the unit pump manually against the spring force whilst screwing in each bolt (4) by hand. | |
Then tighten the bolts (4) | |||
| |||
19 | Install electrical engine wiring harness (2) at bracket (3) and connect respective unit pump | ||
20 | Install injection line (1) at the relevant unit pump | ||
21 | Install charge air pipe | Only on engine 542.9. | |
22 | Install 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 when working in engine during starting procedure | Secure vehicle to prevent it from moving. | |
23 | Start engine and bleed fuel system | The fuel system is bled automatically. Allow the engine to run for around 1 minute if the engine is standing or does not start | |
| |||
| Bleed fuel system. | ||
24 | Turn off engine | ||
25 | 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 jammed and crushed when tilting cab | Ensure that no one is within the tilting range of the cab when being tilted. Always tilt the cab all the way to the end position and secure with the safety strut. | |
26 | Lower cab | ||
| Notes on tilting the cab |
Diesel injection system with unit pumps (MR/PLD)
541 589 01 14 00
Sleeve
Impact extractor
355 589 01 63 00
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 |