Diesel engine 12V 4000 G73, 16V 4000 G73. Manual - part 19

7.5 Injection Pump / HP Pump

7.5.1 HP pump – Filling with engine oil

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Oils/oil vapors are combustible.

Risk of fire!

• No open flames, no electric sparks. Do not smoke. Avoid ignition sources.

CAUTION

Fuel system high-pressure pump not filled with engine oil.

Damage to components, major material damage!

• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial

operation.

Filling HP pump

1.

Fill fresh engine oil into a clean receptacle.

2.

Fill HP pump (1) at connection (2).

7.6 Injection Valve / Injector

7.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

u

Remove injector and install new injector (→ Page 79).

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7.6.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Installation/removal tool

F6789889

1

Milling cutter

F30452739

1

Torque wrench, 0.5-5 Nm

0015384230

1

Torque wrench, 10-60 Nm

F30452769

1

Torque wrench, 60-320 Nm

F30452768

1

Assembly paste (Optimoly Paste White T)

40477

1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933

1

Engine oil
O-ring

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1.

Shut off fuel supply to engine.

2.

Remove cylinder head cover (→ Page 76).

Removing injector

1.

Disconnect cable connector on injector.

2.

Remove HP fuel line (4).

3.

Remove return line (5).

Note:

The injector accumulator will be emptied

when removing the adapter.

4.

Remove adapter (3).

5.

Remove screw (2) and take off hold-down

clamp (1).

6.

Install installation/removal tool on cylinder

head.

7.

Remove injector with installation/removal

tool.

8.

Remove installation/removal tool.

9.

Remove sealing ring (4) from injector or use

a self-made hook to take it out of the cylin‐

der head.

10.

Remove O-rings (3), O-ring (2) and damper

ring (1) from injector.

11.

Clean all mating and sealing surfaces.

12.

Cover all connections and bores, or seal

with suitable plugs.

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