Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.
Important: When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.
Remove
- 1. Open bonnet
- 2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
- 3. Remove engine cover
- 4. On Z13DTH, detach charge air pipe
- 5. Remove brake force amplifier vacuum line (1) • Disconnect quick-release fitting
- 6. Disconnect vacuum line (2)
- 7. Place collecting pan underneath.
- 8. Detach fuel return damper (1) • Disconnect 2x fuel return line (2) and (4) – Undo 2 clamps • Unscrew bolt (3)
- 9. Disconnect wiring harness plug for exhaust gas recirculation valve (1)
- 10. Remove vacuum pump (1) • Unscrew 2x bolts (2)
Install
- 11. Install vacuum pump • Insert new gasket • Tighten 2x bolts – Tighten bolt (1) 5 Nm – Tighten bolt (2) 5 Nm – Tighten bolt (1) 20 Nm – Tighten bolt (2) 20 Nm
Note. Tightening takes place in 2 steps.
- 12. Connect wiring harness plug for exhaust gas recirculation valve
- 13. Attach fuel return damper • Connect 2x fuel return line – Attach 2x clamps • Tighten bolt 9 Nm
- 14. Connect vacuum line
- 15. Attach vacuum line brake servo • Connect quick release fitting
- 16. On Z13DTH, attach charge air pipe
- 17. Install engine cover
- 18. Connect battery • Attach earth connection to earth terminal – Tighten nut
- 19. Program volatile memories
- 20. Close bonnet
1
) ; protective caps are available in the parts catalogue